OMRON ZFX-C20 User Guide
Smart Sensor
Vision Sensor with built-in LCD monitor
ZFX-C20
User's Manual
Cat. No. Z264-E1-02
Introduction
Thank you for purchasing the ZFX-C.
This manual provides information regarding functions, performance and operating methods that
are required for using the ZFX-C.
When using the ZFX-C, be sure to observe the following:
• The ZFX-C must be operated by personnel knowledgeable in electrical engineering.
• To ensure correct use, please read this manual thoroughly to deepen your understanding of the
product.
• Please keep this manual in a safe place so that it can be referred to whenever necessary.
Manuals Provided with this Product
Smart Sensor
Vision Sensor with built-in LCD monitor
ZFX-C20
User's Manual
Smart Sensor
Vision Sensor with built-in LCD monitor
ZFX-C20
Serial Communication
Command Reference
Cat. No. Z264-E1-01
Cat. No. Z265-E1-01
User's Manual (this document)
This manual describes basic operations, such as
installation and connections, and information on settings
and specifications to ensure safe and correct use of this
product.
Serial Communication Command
Reference
This manual provides reference information for when this
product performs communications with an external
device, such as a PC or a programmable controller, via
the serial interface.
APPLICA TION CONSIDERA TIO NS
(Please Read)
1
User's Manual
BEFORE USE
BASIC OPERATIONS
SETTING THE MEASUREMENT
CONDITIONS
FUNCTIONS USED DURING OPERATION
ADDITIONAL FUNCTIONS
PARALLEL INTERFACE
1
2
3
4
5
6
Smart Sensor
Vision Sensor with built-in LCD monitor
ZFX-C20
APPENDICES
7
READ AND UNDERSTAND THIS DOCUMENT
Please read and understand this document before using the products. Please consult your OMRON
representative if you have any questions or comments.
WARRANTY
OMRON’s exclusive w arranty is that the products are f ree from defects in materials a nd workmanship for a
period of one year (or othe r pe ri od if specified) from date of sale by OMRO N .
OMRON MAKES NO WARRANTY OR REPRESENTATION, EXPRESS OR IMPLIED, REGARDING NONINFRINGEMENT, MERCHANTABILITY, OR FITNESS FOR PARTICULAR PURPOSE OF THE PRODU CTS.
ANY BUYER OR USER ACKNOWLEDGES THA T THE BUYER OR USER ALONE HAS DETERMINED THAT
THE PRODUCTS WILL SUITABLY MEET THE REQUIREMENTS OF THEIR INTENDED USE. OMRON
DISCLAIMS ALL OTHER WARRANTIES, EXPRESS OR IMPLIED.
LIMITATIONS OF LIABILITY
OMRON SHALL NOT BE RESPONSIBLE FOR SPECIAL, INDIRECT, OR CONSEQUENTIAL DAMAGES,
LOSS OF PROFITS OR COMMERCIAL LOSS IN ANY WAY CONNECTED WITH THE PRODUCTS,
WHETHER SUCH CLAIM IS BASED ON CONTRACT, WARRANTY, NEGLIGENCE, OR STRICT LIABILITY.
In no event shall responsi bility of OMRON for any act exceed the individual price of the product on which
liability is asserted.
IN NO EVENT SHALL OMRON BE RESPONSIBLE FOR WARRANTY, REPAIR, OR OTHER CLAIMS
REGARDING THE PRODUCTS UNLESS OMRON’S ANALYSIS CONFIRMS THAT THE PRODUCTS WERE
PROPERLY HANDLED, STORED, INSTALLED, AND MAINTAINED AND NOT SUBJECT TO
CONTAMINATION, ABUSE, MISUSE, OR INAPPROPRIATE MODIFICATION OR REPAIR.
SUITABILITY FOR USE
THE PRODUCTS CONTAINED IN THIS DOCUMENT ARE NOT SAFETY RATED. THEY ARE NOT DESIGNED OR
RATED FOR ENSURING SAFETY OF PERSONS, AND SHOULD NOT BE RELIED UPON AS A SAFETY COMPONENT OR PROTECTIVE DEVICE FOR SUCH PURPOSES.
Please refer to separate catalogs for OMRON’s safety rated products.
OMRON shall not be responsible for conform ity with any standards, codes, or regulations that apply to th e
combination of produc ts in the customer’s application or us e of th e pr oduct.
At the customer’s request, OMRON will provide applicable third party certification documents identifying ratings
and limitations of use that apply to the products. This information by itself is not sufficient for a complete
determination of the suitability of the produ cts in comb ination w ith the en d produc t, machi ne, syste m, or other
application or use.
The following are some examples of applications for which particular attention must be given. This is not
intended to be an exhaustive list of all possible uses of the products, nor is it intended to imply that the uses
listed may be suitable for the p ro ducts:
• O utdoor use, uses involving potential chem ical contamination or electrical interference, or conditions or
uses not described in this document.
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ZFX-C User’s Manual
• Nuclear energy control systems, combustion systems, railroad systems, aviation systems, medical
equipment, amu sem ent ma chi ne s, v eh ic le s, saf et y eq ui pme n t, an d ins t al la t io ns su bj ec t t o separate indus try
or government regulations.
• Systems, machines, and equipment that could present a ris k to lif e or pro per t y.
Please know and obse rv e all p ro hi bi tio ns of use applicable to the products.
NEVER USE THE PRODUCTS FOR AN APPLICATION INVOLVING SERIOUS RISK TO LIFE OR
PROPERTY WITHOUT ENSURING THAT THE SYSTEM AS A WHOLE HAS BEEN DESIGNED TO
ADDRESS THE RISKS, AND THAT THE OMRON PRODUCT IS PROPERLY RATED AND INSTALLED FOR
THE INTENDED USE WITHIN THE OVERALL EQUIPMENT OR SYSTEM.
PERFORMANCE DATA
Performance data given in this document is provided as a guide for the user in determining suitability and does
not constitute a warranty. It may represent the result of OMRON’s test conditions, and the users must correlate
it to actual application requirements. Actual performance i s su bj ect t o th e O M RO N Warranty and Limitations of
Liability.
CHANGE IN SPECIFICATIONS
Product specifications and accessories may be changed at any time based on improvements and other
reasons.
It is our practice to change model numbers when published ratings or features are changed, or when significant
construction chang es are made. However, some specifications o f the product may be changed w ithout any
notice. When in do ubt, special m odel numbe rs may be a ssigned to fix or establish key s pecificat ions for your
application on your request. Please consu lt with your OMRON repres entative at any time to conf irm actual
specifications of purchased products.
DIMENSIONS AND WEIGHTS
Dimensions and weights are nominal and are not to be used for manufacturing purposes, even when
tolerances are shown.
ERRORS AND OMISSIONS
The information in this do cument has been carefully checked and i s believed to be accurate; however, no
responsibility is assum ed for clerical, typographical, or proofreading errors, or omissions.
PROGRAMMABLE PRODUCTS
OMRON shall not be responsible for the user’s prog ra m m in g of a pro gr ammable product, or any conse quence
thereof.
COPYRIGHT AND COPY PERMISSION
This document shall not be copied for sales or promotions w ithout permission.
This document is protected by copyri ght and is inten ded solely for use in conjunc tion with the pr oduct. P lease
notify us before cop ying or reproducing this docum ent in any manner, for any other purpose. I f copying or
transmitting this document to another, please copy or transmit it in its entirety.
ZFX-C User’s Manual
3
Meanings of Signal Words
The following signal words are used in this manual.
Indicates a potentially hazardous situation which, if not avoided, will result in minor or
moderate injury, or may result in serious injury or death. Additionally there may be
significant property damage.
Meanings of Alert Symbols
The following alert symbols are used in this manual
Indicates general proh ib iti ons for which there is no specific sym bo l.
Indicates the possibi lit y of la ser radiation.
Indicates the possibi lit y of explosion under specific cond iti ons .
This produc t is not designed or rated for ensuring safety of pers ons.
Do not use it for such purposes.
The camera with lighting emits visible light, which may adve rs ely affect th e eyes in rare instances.
Do not look direct ly into the light emit ted from the Camer a. When the subject is a specular
reflective object, protect your eyes from reflected light.
A lithium battery is buil t into the Con troller and m ay oc cas ionally comb ust, explod e, or burn if
not treated properly.
Dispose of the Con troller as industrial waste, and nev er disassemble, apply pressure that
would deform, heat to 10 0 °C or hi gher, or incinerate the Controller.
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ZFX-C User’s Manual
Precautions for Safe Use
The following points are important to ensure safety, so make sure that they are strictly observed.
1.Installation Environment
• Do not use the product in environ m ents where it can be exposed to inflamma bl e/ ex pl osive gas.
• To secure the safety of oper ation a nd maint enan ce, d o n ot ins tall the p roduc t cl ose t o high -v oltage de vices
and power devi ces.
• I nstall the product in such a way that its ven tilat io n holes are not blocked.
• Tighten mounting screws at the torque specified in this manual.
2.Power Supply and Wiring
• The voltage and AC power supply must be within the rated range (24 VDC ±10%).
• Reverse connection of the po w er supply is not allowed.
• Use the power supply within the rated load.
• H igh-voltage lines and power lin es must be wired separately from this product. Wiring them toge ther or
placing them in the sam e duct may cause induction, resulting in malfunction or damage.
• Use the product within the power supply voltage specified in this manual .
• U se a DC po wer sup ply with safet y measu res against high-vol tage spikes (sa fety extra lo w-voltage circ uits
on the secondary side).
• Tighten mounting screws at the torque specified in this manual.
3.Other
• Do not use this product in safety cir cui ts as sociated with nuclear power and human life.
• Do not disassemble, repair, modify, deform by pressure, or incinerate thi s pr od uct .
• Dispose of this product as indust rial waste.
• Connect the exclusive devices (Camera, Controller, Strobe Controller, Cable). The product might break
down or malfunction i f yo u use a part not included in the exclusive products.
• S hould you notice any abnormalities, imm ediately stop use, turn OFF the power suppl y, and contact your
OMRON representative.
4.Laws and Regulations, Standards
• This product complies with the fo llo w ing EC and EN directives:
EC Directive No.89/336/EEC
EN Standards EN61326: 1997+A1: 1998+A2: 2001+A3: 2003 (EMI: Class A)
ZFX-C User’s Manual
5
Precautions for Correct Use
Observe the following precautions to prevent failure to operate, malfunctions, or undesirable effects on product
performance.
1.Installation Site
Do not install this product in locations subjected to the followin g conditions:
• Ambient temperature outside the rating
• Rapid temperature fluctuati on s (c ausing condensation)
• Relative humidity outside the range of 35 to 85%
• Direct vibration or shock
• Reflection of intense light (such as other laser beams, electric arc- w elding machines, or ultra-violet light )
• Direct sunlight or near heaters
• Strong magnetic or electric field
Also, do not install this product in locations subjected to the following conditions to ensure its protective
performance as described in the specifications:
• Presence of corrosive or flam m abl e gases
• Presence of dust, salt, or iron partic les
• Water, oil, or chemical fumes or spray, or mist atmospheres
2.Power Supply and Wiring
• When using a commercially av ai labl e switching regulator, make sure that the FG terminal is grounded.
• If surge currents are present in the power lines, connect surge absorbers that suit the operating
environment.
• B efore turning ON the power after the product is connected, make su re that the power supply voltage is
correct, there are no incorrect connections (e.g. load short-circuit) and the load current is appropriate.
Incorrect wiring may result in breakdown of the product.
• Before connecting/disc onnecting cables, make sure that the product i s turned OFF. The product may break
down if it is connected/di sc onnected while the power is ON.
• For cables, use only the exclusive products specified in this manual.
p.14, p.15
• Use only combinations of the Camera, Controller and Strobe Controller specified in this manual. Using other
combinations may cause malfunction or damage.
• D o not turn the power OFF in the following instances. Doing so will damage data that is in the process of
being saved.
- While data is being saved on t he Controller
- While data is being saved on the SD card
• T he LCD panel has b een mad e using prec ision tec hnolog y, and sometimes a few pixels a re missing i n the
panel. This is due to the structu re of the LC D panel, and i s not a malfunction.
• Do not remove the base from the Camera.
3.Maintenance and Inspection
Do not use thi nner, benzene, aceto ne or ker osene to clean the Camera and Con troller. If large dust particles
adhere to the Ca mera , us e a b lower brus h (u sed t o cl ean c amer a le nses) to blow them o ff. Do not use br eat h
from your mouth to blow the dust off. To remove dust particles from the Came ra, wipe gently wi th a soft cloth
(for cleaning lenses) moistened with a sma ll amount of alcohol. Do not use excessive force to wi pe off dust
particles. Scratches to the Cam er a m i ght cause error.
4.Ventilation Film
• D o not peel of the ventilation film or pr od it with a sharp-pointed object. Th is might impair its protective
structure.
• Do not cover the ventilation film. Doing so might cause the Came ra's front panel to cloud.
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ZFX-C User’s Manual
5.Optional Lighting Connector
Important
Note
When the optional lighting is not connected, be sure to attach the connector cap. Otherwise, its protective
structure might be impaire d.
6.Camera's Connector Cap
When using only one ca m er a, at tach the connector cap to cameras that are not in use.
Editor's Note
■ Meaning of Symbols
Menu items that ar e displayed on the Controller's LCD screen, and windows, dialog boxes and other GUI
elements displayed on the PC ar e in di cated enclosed by brackets "[ ]".
■ Visual Aids
Indicat es po in t s th at ar e im po rt a n t to ac h iev e t he f u ll pr od uct pe rf or ma nce ,
such as operational precautions.
Indicates application procedures.
Indicates pages where relat ed information can be found.
ZFX-C User’s Manual
7
MEMO
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ZFX-C User’s Manual
CONTENTS
1.BEFORE USE
ZFX-C . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14
System Configuration. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14
Part Names and Functions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16
Mounting and Connecting Devices . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 19
Installing Cameras. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 19
Installing the Controller . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 25
Connecting Devices. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 28
Overview of Settings and Measurement. . . . . . . . . . . . . . . . . . . . . . . . . . 31
Operation Modes . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 31
Outline of MENU mode . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 32
Measurement Items and Banks. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 33
Initializing Controller Settings. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 35
Saving Setup Data. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 36
2.BASIC OPERATIONS
Inspection Setup and Measurement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 38
Setting Measurement Conditions - MENU Mode. . . . . . . . . . . . . . . . . . . . . . . . . 38
Checking the Measurement Status - ADJ Mode . . . . . . . . . . . . . . . . . . . . . . . . . 42
Starting Measurement - RUN Mode. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 42
Troubleshooting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 43
Clear Images Cannot be Obtained . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 43
Measurement Target Cannot be Measured Accurately Due to Movement . . . . . 43
To Output Measurement Values to a PC or PLC. . . . . . . . . . . . . . . . . . . . . . . . . 44
To Output Positi on Information of Measurement Targets as Actual Coordinates
CONTENTS
. . . . . . 44
ZFX-C User’s Manual
9
3.SETTING THE MEASUREMENT CONDITIONS
Setting Measurement Items . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 46
Shape Inspection. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 46
Pattern Search . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 46
Graphic Search . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 51
Flexible Search. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 55
Sensitive Search . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 58
Size Inspection. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 62
Area . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 62
Labeling . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 66
Edge Inspection. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 70
Position. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 70
Width . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 75
Count . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 79
Bright/Color Inspection. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 82
Bright . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 82
HUE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 84
Inspection by Individual Application. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 87
Grouping. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 87
Defect. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 90
Image Adjustment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 94
Cameras/Lighting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 98
Shutter Speed . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 98
Gain Setting. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 98
Partial Function Settings . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 99
Image Rate . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 99
Light Control (Recipe Functions). . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 100
Calibration . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 101
Registering Images. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 106
Position Correction. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 107
Additional Functions. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 109
Calculation. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1 09
Setting Reflection of Individual Results . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 112
Logging Monitor. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 113
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ZFX-C User’s Manual
4.FUNCTIONS USED DURING OPERATION
Monitoring the Measurement Status - RUN Mode . . . . . . . . . . . . . . . . . 116
Displaying Measurement Information . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1 16
Switching the Image Display Method. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 118
Checking/Adjusting the Measurement - ADJ Mode. . . . . . . . . . . . . . . . 119
Checking Measurement Status . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1 19
Switching the Image Display Method. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 121
Using a Saved Image to Perform Re-measurement . . . . . . . . . . . . . . . . . . . . . 121
Adjusting Measurement Conditions. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 122
5.ADDITIONAL FUNCTIONS
Bank Settings . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 126
Bank Data Operations . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1 27
Bank Group Operations. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 127
System Settings . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 128
Camera Specifications. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1 28
Communication Setup . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1 28
Output Settings . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 132
Display Settings. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 134
Operation Settings. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 135
Measurement Control Conditions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 137
Operation Conditions during Startup . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 138
Setting/Changing the Display Language . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 138
Setting/Changing the Date. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 139
Clearing Saved Images . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 139
Tools. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 140
Saving/Loading Data . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1 40
SD Card Operations. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 141
Checking Density Distribution (Profile) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 141
Checking the Communication Status with External Devices . . . . . . . . . . . . . . . 1 42
Displaying the Controller Information. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 143
CONTENTS
ZFX-C User’s Manual
11
6.PARALLEL INTERFACE
Connection. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 146
Parallel Connector Specifications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1 46
Internal Specifications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 150
Signal I/O . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 152
Input Signal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 152
Output Signal. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 153
Timing Charts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 156
Measurement (Handshaking OFF) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1 56
Measurement (Handshaking ON) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 159
Commands Other than for Measurement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 160
Signal Operation in terms of Measurement . . . . . . . . . . . . . . . . . . . . . . . . . . . . 161
7.APPENDICES
Error Messages and Corrective Actions. . . . . . . . . . . . . . . . . . . . . . . . . 166
List of Available Functions for Each Camera. . . . . . . . . . . . . . . . . . . . . 167
AUTO Setting. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 168
AUTO Setting of Measurement Items . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 168
AUTO Setting in Individual Adjustment Screens . . . . . . . . . . . . . . . . . . . . . . . . 169
Specifications and External Dimensions . . . . . . . . . . . . . . . . . . . . . . . . 170
Camera . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 170
Controller . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 176
Accessories & Options. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 178
LED Safety . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 187
Requirements from Regulations and Standards . . . . . . . . . . . . . . . . . . 188
Summary of Requirements to Manufactures. . . . . . . . . . . . . . . . . . . . . . . . . . . 188
Summary of Requirements to User . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 190
Definitions of Laser Classification . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 191
Basic Knowledge for Operation. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 192
Menu List . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 196
INDEX . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 199
How Color Images are Processed . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 201
Color Filter. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 202
Color Pickup. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 204
Hue, Saturation and Brightness Value. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 206
Version Upgrade Information. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 207
Revision History . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 208
12
ZFX-C User’s Manual
BEFORE USE
ZFX-C 14
System Configuration 14
Part Names and Functions 16
Mounting and Connecting Devices 19
Installing Cameras 19
Installing the Controller 25
Connecting Devices 28
Overview of Settings and Measurement 31
Operation Modes 31
Outline of MENU mode 32
Measurement Items and Banks 33
Initializing Controller Settings 35
Saving Setup Data 36
1
BEFORE USE
ZFX-C
3 42
1
The ZFX-C is a series of visi on sens ors th at sen ses obje cts by the ir “surfa ces. “ Obje cts captur ed by a ca mer a
can be checked on the built-in 3.5-inch LCD monitor.
System Configuration
Basically, the ZFX-C is configured by the Controller and the camera.
Other external devices can be selected to be used in combination wit h the ZFX-C according to the user’s
specific requireme nts.
Cameras with lighting
(cable built-in)
- Color camera
ZFX-SC10/SC50/SC50W
ZFX-SC90/SC90W
ZFX-SC150/SC150W
- Monochrome camera
ZFX-SR10/SR50
Camera only
- Color camera
ZFX-SC
- Monochrome camera
ZFX-S
A CCTV lens and light
source will be required.
Touch pen
(*1)
Camera cable
ZFX-VS/VSR
Controller
ZFX-C20/C25
Monitor cable
FZ-VM
SD Card (*4)
RS-232C cable
ZFX-XPT2A
RS-422 cable
ZFX-XPT2B
Parallel I/O cable
ZFX-VP
LCD monitor (option)
FZ-M08 (*2)
PC
USB
Ethemet
Console
ZFX-KP
PLC
(*3)
*1: The Touch Pen (ZFX-T P) is su pplied with the Controller.
*2: The same image as in th e C ontroller's LCD monitor can be displayed in the LCD monitor (option).
*3: The console can be us ed instead of the Controller's keys and menu buttons.
*4: Conforms to the SD Card “ P hy si cal layer specifications 1.01.”
File format: FAT16
14
ZFX-C
ZFX-C User’s Manual
Options
Cameras with lighting
2 m
Extension cable
(cable built-in)
ZFX-XC_A/XC_AR
3m/8m
(*1)
5 to 18 m
Extension cable
ZFX-XC_A/XC_AR
3m/8m
(*1,*2)
Camera only
3 m/8 m
Camera cable
ZFX-VS/VSR
8 to 19 m
Extension cable for connecting cameras and the Controller
1
BEFORE USE
*1: Up to two ZFX-XC_A/XC-AR can be connected between the camera cable and the Controller.
*2: Two ZFX-XC8A cannot be connected to each other when used with ZFX-VS (8 m.)
Optional lighting
The following optional light in g ca n be connected to ZFX-SC50/SC50 W /SC90/SC90W.
• Bar lighting ZFV-LTL01
• Bar double-lighting ZFV-LTL02
• Bar low-angle lighting ZFV-LTL04
• Light Source for Through-beam Lighting ZFV-LTF01
ZFX-C User’s Manual
ZFX-C
15
Part Names and Functions
ZFXSC10/SR10/SR50
ZFX-SC50/SC50W
ZFX-SC90/SC90W ZFX-SC150/SC150W
ZFX-S/SC
Cameras
Cameras with lighting
(2)
(2)
(4)
(3)
(2)
(4)
(1)
(3)
(2)
(4)
(3)
(1)
(3)
(4)
(2)
Camera only (C-mount type)
(5)
(6)
(7)
Name. Description
(1)Optional lighting connector This connector is used to connect an optional lighting. (ZFX-SC50/SC50W/SC90/
SC90W)
Important
When no optional lighting is used, make sure that the connector is covered with the
cap. If not, water-resistant performance will be deteriorated.
(2)Ventilation film This film prevents the front panel from condensation.
(3)Focus adjustment control This control is used for adjusting the focus of the image.
(4)Mounting fixture This mounting fixture is used for fastening the camera when installing it. The mount-
(5)Lighting connector This connector is used to connect external lighting (Strobe Controller: 3Z4S-LT
(6)Camera cable connector
(7)Camera mounting base
16
ZFX-C
Important
• Do not peel off or probe the ventilation film with a sharp-pointed object. If you do
that the protective structure rating may no longer be satisfied.
• Do not cover the ventilation film rating. Doing so might cause the front panel to be
condensed.
ing fixture can be installed on all of the four mounting surfaces.
MLEK-C100E1TSX).
This connector is used for connecting to the Con troller via a camera cable (ZFX-VS/ VSR).
This camera mounting base is fastened with screws to hold the camera in place. The camera
mounting base can be installed on all of the four mounting surfaces.
ZFX-C User’s Manual
PULL OPEN
1234
OMRON
ZFX-C10
OUTPUT
RUN
ERROR
ENABLE
MENU RUN
SD
CARD
ADJ
USB
AUTO ESC
SET
ETHERNET
PARALLEL1
CONSOLE
RS-232C
PARALLEL0
CAMERA1
RGB
CAMERA2
(1)
(4)
(2)
(3)
(9)
(5)
(1)
(1)
(4) (5)
(2) (3)
(2)
(6)
(7)
(8)
Operation
panel cover
Front
Top
Bottom
Controller
Front
Name Function
(1) Indicator “Measuring” indicator (RUN): Lights in green when in the RUN mode.
Error indicator (ERROR): Lights in red when an error occurs.
Judgment indicator (OUTPUT): Lights in orange when the judgment res ult is
OK or NG according to the setting. (Note)
Trigger indicator (ENABLE): Lights in blue when the ZFX-C is ready for the
measurement trigger input.
(2) LCD monitor/touch panel The LCD monitor displays setup menus and images captured from the cam-
eras. Various settings can be made on the touch panel by tapping menu but-
tons in the LCD monitor using the touch pen.
(3) Function keys Specific functions are allocated to the Function keys.
(4) Touch pen The touch pen is used to operate the touch panel. This pen can be attached to
the Controller by tying its strap to the strap holder for the touch pen.
(5) USB port This port is for connecting to a personal computer via a USB cable.
(6) SD card slot This slot is for inserting the SD Card.
When the SD Card is inserted, the SD mark is displayed at the top right of the
screen.
Blue SD mark: The SD card is inserted but not being accessed.
Red SD mark: The SD card is being accessed.
(7) Mode switch This switch selects the operation mode.
MENU: Select this mode when setting measurement conditions.
ADJ: Select this mode when adjus ting setting parameters as necessary refer-
encing the image and values displayed on the LCD monitor during con-
(8) Control keys These keys are used to perform operations without the use of the touch pen.
(9) Strap holder for touch pen This holder is for attaching the touch pen.
Note: The judgment result is output to the OR signal via the parallel interface.
ZFX-C User’s Manual
tinuous test measurement (measurement without measurement data
output to external devices).
RUN: Select this mode when performing measurement.
ZFX-C
1
BEFORE USE
17
Top
Name Function
(1) Monitor connector This connector is for connecting to the LCD monitor (option) via a monitor
cable.
(2) Camera connector This connector is for connecting to a camera.
Bottom
Name Function
(1) Ethernet port This port is for connecting to a personal computer via a 100Base-TX/10Base-T
cable.
(2) RS-232C/422 connector This connector is for connecting to a PLC via an RS-232C or an RS-422 cable.
p.14
(3) Console connector
(4) Power connector
(5)Parallel port This port is for connecting to devices such as a PLC using the parallel cable.
This port is for connecting to the Console.
This connector is for connecting to the DC power supply.
p.14
p.28
, p.146
p.14
Important
• Attach the connector caps to connectors that are not in use to prevent dust or dirt from getting inside the connectors
and to prevent the Controller from static electricity.
18
ZFX-C
ZFX-C User’s Manual
Mounting and Connecting Devices
Setting distance (L)
Detection range (H)
Setting distance L (mm)
Detection range H (mm)
9
9.8 49
60
30
38
100
194
300
Setting distance L (mm)
Detection range H (mm)
Setting distance L (mm)
Detection range H (mm)
Setting distance L (mm)
Detection range H (mm)
70
89
10040
40
67
100
142
160
49
Setting distance L (mm)
Detection range H (mm)
Installing Cameras
Camera with Lighting
Optical chart
ZFX-SC10/SR10
60
50
49
34
0
4.9
ZFX-SR50 ZFX-SC50/SC50W
190
187
100
1
BEFORE USE
104
8.9
ZFX-SC90/SC90W ZFX-SC150/SC150W
ZFX-C User’s Manual
31
227
115
30
240
180
100
9.8
12080
89
Mounting and Connecting Devices
49
160
148
19
• The lens has a fixed focal point. The actual detection range and focal point vary from lens to lens, so adjust the
Note
Hooks
Grooves on camera
Mounting
fixture
Mounting fixture
distance to the measurement target after replacing the lens or camera.
• The camera m ounting distance listed in the following tables is an approximate value. Mount the Camera so that
the distance to the measurement target can be adjusted easily.
• If the object size and detection range are incompatible, use a combination of a camera (without lighting), standard
CCTV lens and light source.
Camera Only p.22
Installing the mounting fixture
The mounting fixture can be installed on all of the four mounting surf ac es.
1 Align the two hooks on one side of the mounting fix-
ture with the two grooves on the camera body.
2 Push the other hook down until it is snapped into
place.
Make sure that the mounting fixture is firmly fixed on the
camera.
3 Fasten the mount ing fixtur e at the moun ting locatio n
with screws.
Tightening torque
M4: 1.2 N•m
1/4”-20 UNC: 2.6 N•m
Removal procedure
20
Mounting and Connecting Devices
1 Insert a screwdriver into the gap (one of the two gaps) be-
tween the mounting fixture and the camera case, and remove the mounting fixture
.
ZFX-C User’s Manual
Adjusting the camera focus
Setting distance (L)
Detection range (H)
Focus
adjustment
control
Note
1 Adjust the distance between the camera and the mea-
surement target and fasten the camera.
Refer to the optical chart and set the camera in a position
so that t he ar ea t o be che cked is with in t he de tect io n ar ea
(LCD monitor).
Optical chart p.19
2 Tu rn the focus ad j ustment control to the left and right
to adjust the focus.
First turn the focus adjustment control slightly to the left and right, to make sure that the Focus adjustment control is
not at the upper or lower limit positions. Do not exert unnecessary force to turn the control at the upper or lower limit
positions as this might damage the control.
(For ZFX-SC90_/SC150_, the control stops turning at the nearest position. It turns free at the farthest position.)
1
BEFORE USE
ZFX-C User’s Manual
Mounting and Connecting Devices
21
40
100
1000
10000
4 10 100 1000
Detection range(mm)
ML-0614
ML-0813
ML-1214
ML-1614
ML-2514
ML-3519
ML-5018
Lens model
3Z4S-LE
Lens model
3Z4S-LE
Camera distance A(mm)Camera distance A(mm)
200
1000
10000
2 10 100 1000
t2
t5
t10
t15
t20
t30
t35
t50
t45
t5
t10
t15
t20
t25
t30
t40
t35
t45
t50
t60
t0
t2
t40
t25
t0
ML-7527
ML-10035
t: Extension tube
Example
t0: Extension tube
is not required.
t5: 5-mm extension
tube is required.
Camera Only
Optical chart
The values in the following chart are approximations, and t he C amera must be adjusted after it is mount ed.
22
Mounting and Connecting Devices
ZFX-C User’s Manual
The X axis of the optical chart shows detection range L (mm), and the Y axis shows the camera distance A
1-32 UNF
(C-mount
thread)
Filter thread
Total length
Max. dia.
(mm). The curves on the optical chart show the relationship between the detection range and camera distance
for each CCTV lens. The values are significantly differen t for each lens, so double-check t he model of the lens
before using the g raph. The “t” value s indicate the l engths of the Extension Tubes. The value “t0” show s the
case where an Extensio n Tube is not required and the value “t5.0” shows the case where a 5-mm Extension
Tube is used.
1
Example
When a 3Z4S-LE ML-5018 CCTV Lens is being used and a detection range of 40 mm is required at the
measurement target, a camera distance of 500 mm and 5-mm Extension Tube are required.
Camera
Extension Tube t_ (mm)
Lens
Camera distance A (mm)
Measurement object
Detection range L (mm)
Lenses and lens diameters
BEFORE USE
Lens Focal length Brightness
3Z4S-LE ML-0614 6 mm F1.4 30 mm dia. 30 mm M27 P0.5
3Z4S-LE ML-0813 8 mm F1.3 30 mm dia. 34.5 mm M25.5 P0.5
3Z4S-LE ML-1214 12 mm F1.4 30 mm dia. 34.5 mm M27 P0.5
3Z4S-LE ML-1614 16 mm F1.4 30 mm dia. 24.5 mm M27 P0.5
3Z4S-LE ML-2514 25 mm F1.4 30 mm dia. 24.5 mm M27 P0.5
3Z4S-LE ML-3519 35 mm F1.9 30 mm dia. 29 mm M27 P0.5
3Z4S-LE ML-5018 50 mm F1.8 32 mm dia. 37 mm M30.5 P0.5
3Z4S-LE ML-7527 75 mm F2.7 32 mm dia. 42.5 mm M30.5 P0.5
3Z4S-LE ML-10035 100 mm F3.5 32 mm dia. 43.9 mm M30.5 P0.5
ZFX-C User’s Manual
Maximum outer diameter
Total len gth Filter size
Mounting and Connecting Devices
23
Extension Tubes
L
m
Camera Mounting Base
One or more Ext ensi on Tubes can be inserte d b etwee n the len s and the Cam era to focus the C am era im age.
Use a combination of on e or mo re of the seven tubes to achieve the required length.
Extension Tube
Model
3Z4S-LE ML-EXR 31 dia. Set of 7 tubes
Important
• Do not use the 0.5-mm, 1.0-mm and 2.0-mm Extension Tubes attached to each other. Since these Extension Tubes
are placed over the threaded section of the Lens or other Extension Tube, the connection may loosen when more
than one 0.5-mm, 1.0-mm or 2.0-mm Extension Tube are used together.
• Reinforcement may be required for combinations of Extension Tubes exceeding 30 mm if the Camera is subject to
vibration.
Maximum outer diameter
Length
ength: 40 mm 20 mm 10 mm 5 mm 1 mm2 mm 0.5 m
Installing the Camera Mounting Base
The camera mounting base moun ted on the bot tom of the cam era can be insta lled on all of the four mountin g
surfaces. To change the mounting surface, remove the thr ee mounting screws (M2 x 6) from the cam e ra.
• Tightening torque when fastening the camera mounting base at the mounting location
M4: 1.2 N•m
1/4”-20 UNC: 2.6 N•m
24
Mounting and Connecting Devices
ZFX-C User’s Manual
Installing the Controller
Important
Min.
50 mm
Min.
15 mm
When installing Controller only:
When installing the Controller With the Exhaust Unit
attached:
Min.
50 mm
Min. 15 mm
Installation Precautions
To improve heat radiatio n, in stall the C ont r ol ler only in the orientation show below.
1
Right
Do not install the Controller in the following orientations.
Wrong Wrong
• Install the Controller so that the distance between the Controller and other devices is at least the dimensions shown
in the figure below to improve the ventilation.
BEFORE USE
• Keep the ambient temperature less than 50 °C. If the ambient temperature is higher than 50 °C, install a fan forced
cooling system or an air conditioner to keep the temperature lower than 50 °C.
• Avoid mounting on a panel, in which high-voltage emitting devices are installed to prevent ZFX-C operation from
being affected by noise.
• Allow at least 10 m between the Controller and power lines to keep noise at a low level in the operating environment.
ZFX-C User’s Manual
Mounting and Connecting Devices
25
Installing on the DIN Track
DIN track (sold separately)
End Plate (sold separately)
PFP-M
PFP-100N (1 m)
PFP-50N (0.5 m)
PFP-100N2 (1 m)
Exhaust Unit
1
2
1 Hook the Controller’s upper hook onto the DIN track.
1
2 Push the Control ler down o nto the DIN track until its
lower hook is snapped into place.
2
Important
•Attach the End Plate (sold separately) to both sides of the
Controller on the DIN track.
•Attach the Exhaust Unit (supplied) to the Controller when
installing other devices adjacently on the same DIN track
as the Controller.
OMRON
OUTPUT
ZFX-C10
1234
RUN
p.20
USB
ENABLE
ERROR
ADJ
MENU RUN
AUTO ESC
SET
PULL OPEN
SD
CARD
Removing procedure
1 Pull the Controller’s lower hook downwards.
2 Lift up the Controller from its bottom to remove it from
the DIN track.
26
Mounting and Connecting Devices
ZFX-C User’s Manual
Mounting on a Panel
1
1
2
2
3
Panel mount adapters
Panel
Mounting bracket
1 Install the long Panel Mount Adapters on the four
holes on the Controller.
1
BEFORE USE
2 Install the short Panel Mount Adapters on the two
holes on t he long Panel Mou nt Adapter.
3 Install the Controller with Mount Adapters attached
onto the panel from the front.
4 Hook the hooks of the mounting bracket onto the two
4
holes (two each at top and bottom) of the longer
Mount Adapters and tighten the screws .
Tightening torque: 1.2 N•m.
5 Make sure that the Controller is firmly fixed on the
panel.
ZFX-C User’s Manual
Mounting and Connecting Devices
27
Connecting Devices
24 VDC
-
+
When attaching ferrite cores to the Controller's power
cable, pass the cable once through each ferrite core.
Connecting the Controller to the Power Supply
Use a power supply that meets the following specifications.
Item Specification
Power supply voltage Approx. 24 VDC (21.6 to 26.4 VDC)
Output current 1.5 A min.
Recommended power supply S8VS-06024 (24 VDC, 2.5 A)
Recommended electric wire size 0.14 to 1.5 mm2 (max. 1 m)
Important
Use a DC power supply with countermeasures against high voltages (safe extra low-voltage circuits on the secondary
side). If the system must meet UL standards, use a UL class II power supply.
1 Loosen the t wo screws on the top of the Power con-
nector (male) using a flat-blade screwdriver.
2 Insert the DC power terminal (wire) into the Power
connector (male) and tighten th e two screws on the
top of the Power connector to fasten the power terminal with the screwdriver.
Tightening torque: 0.22 to 0.25 N•m.
3 Plug the Pow er c onne ct or (male) in to the C ont ro ller’s
Power connector (fem ale).
4
Tighten the two screws on the left and right of the Power
connector (male) with the screwdriver to fasten it.
Tightening torque: 0.22 to 0.25 N•m.
Attaching Ferrite Cores
Attach fer rite cores (sup pl ied) to both ends of the c am era's cable and th e Co ntroller's po wer cable, respectively.
Ferrite coreFerrite core
Ferrte core
-
+
DC power
supply
28
Mounting and Connecting Devices
ZFX-C User’s Manual
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