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ZFV Users Manual

1. 1 4 20 UNC depth 6 Ho 30 1 Mounting hole dimensions 2 M4 _ 33 o Mounting fixture can be attached on each side 20 0 1 Heat resistant PVC shielded cable gt 5 8 mm dia standard length 2 m U U m 12 8 dia 83 5 4 lt a i z 6 36 ZFV User s Manual 95 Section 4 Specifications and External Dimensions ZFV SR10 Narrow View ZFV SR50 Wide View Setting distance L 34 to 49 mm 38 to 194 mm Detection range HxV 5 x 4 6 mm to 9 x 8 3 mm 10 x 9 2 mm to 50 x 46 mm Relation between set ting distance and Setting distance Setting distance detection range L 49mm 34mm 10mm Detection range H Detection range H Guide light Provided center sensing area Built in lens Focus f15 65 Focus f13 47 Object lighting method Pulse lighting Object light source Eight red LEDs Sensing element 1 3 inch CCD partial scan Power supply voltage 15 VDC Supplied from Amplifier Unit Approx 200 mA 1 000 VAC 50 60 Hz for 1 min Current consumption gt a m Z z gt lt Dielectric strength Vibration resistance 10 to 150 Hz 0 35 mm single amplitude 10 times each in X Y and Z directions for 8 destruction min Shock resistance 150 m s2 three times each in six directions up down left ri
2. ECO mode Output signals 1 Control output OUTPUT 2 Enable output ENABLE 3 Error output ERROR Input signals 1 Simultaneous measurement input TRIG or Continuous measurement input TRIG Switched by using menu 2 Bank selection inputs BANK1 to BANK3 3 Workpiece still teaching TEACH or Workpiece moving teaching TEACH Switched by using menu Sensor Head interface Digital interface Image display Compact TFT 1 8 inch LCD Display dots 557 x 234 Indicators e Judgement result indicator OUTPUT Inspection mode indicator RUN Operation interface e Cursor keys up down left right Setting key SET Escape key ESC e Operating mode switching slide switch e Menu switching slide switch e Teaching Display switching key TEACH VIEW Power supply voltage 20 4 to 26 4 VDC including ripple Current consumption 600 mA max with Sensor Head connected Dielectric strength 1 000 VAC 50 60 Hz for 1 min between leads and Amplifier Unit case Noise immunity 1 kV Pulse rise 5 ns Pulse width 50 ns Burst duration 15 ms Cycle 300 ms Vibration resistance Destruction 10 to 150 Hz 0 1 mm single amplitude 10 times each in X Y and Z directions for 8 min Shock resistance Destruction 150 m s2 three times each in six directions up down left right forward backward Ambient temperature Operating 0 to 50 C Storage 25 to 65 C with no icing or condensation ZFV User
3. Please observe the following precautions for safe use of the products 1 2 3 ZFV Installation Environment e Do not use the product in environments where it can be exposed to inflammable explosive gas e Install the Amplifier Unit in such a way that the ventilation holes are not blocked e To secure the safety of operation and maintenance do not install the product close to high voltage devices and power devices e During installation make sure that screws are tightened firmly Power Supply and Wiring e The supply voltage must be within the rated range DC24V 10 e Reverse connection of the power supply is not allowed e Open collector outputs should not be short circuited e Use the power supply within the rated load e High voltage lines and power lines must be wired separately from this product Wiring them together or placing them in the same duct may cause induction resulting in mal function or damage Others e Do not attempt to dismantle repair or modify the product e Dispose of this product as industrial waste e Should you notice any abnormalities immediately stop use turn OFF the power sup ply and contact your OMRON representative User s Manual Introduction Precautions for Correct Use Precautions for Correct Use Please observe the following precautions to prevent failure to operate malfunctions or undesirable effects on product performance 1 2 Installat
4. Take care not to pinch the I O cable zs CHECK 6 Hook the hooks of the mounting fixture onto the two holes of the smaller Mount Adapters and tighten the screws alo Attach two mounting fixtures each on all gang lt mounted Amplifier Units CHECK Make sure that the Amplifier Units are firmly fixed on the panel ZFV User s Manual Section 2 Amplifier Unit About the I O cable The following shows the leads that comprise the I O cable Brown 1 Power supply Blue 2 GND Black 3 OUTPUT Orange 4 ENABLE Light blue 5 ERROR Yellow 6 TEACH Pink 7 TRIG Gra 8 BANK1 Green 9 BANK2 Red 10 BANK3 els Unused LLLE Unused Enabled only in the RUN mode 1 Power supply This connects the power supply Z T j gt m r gt O Z Qo O O Z Z m O O Z Supply power from a DC power supply unit that has a countermeasure safety ultra low voltage circuit built in for preventing high voltages from occurring Z Recommended power supply unit p 16 Wire the power supply separately from other devices Wiring them together or placing them in the same duct may cause induction resulting in malfunction or damage 2 GND The GND terminal is the OV power supply terminal 3 OUTPUT control output This outputs judgment results This lead is interlocked with OUTPUT LED 4
5. E Changing the search area Change the area to search edges or the model in Specify the top left coordinate and bottom left coordinate of the area Search area r Search area 904 09 24 2004 09 24 gt MENU Mode CUSTM MODE DTL SEARCH AREA ae When searching edges S Measurement can be performed only when the search area contains an edge lt Determine the size and position of the area taking the movement range of the workpiece into con CHECK sideration Good Good Bad E E Raising detection stability This item is displayed only when CHARA2 is set gt MENU Mode CUSTM STABLE OFF default value Standard detection method Detailed detection method The process time is longer than OFF ZFV User s Manual 81 dNLAS Reese Section 3 Saving the Set Measurement Conditions Saving the Set Measurement Conditions The set measurement conditions are saved to the amplifier unit when it is switched to RUN mode Saving is done automatically and no confirmation message is displayed If the power is turned off without saving the changed contents including the teaching results will be cleared from memory Kii When external TEACH signal teaching is successful in RUN mode the set measurement condi tions are automatically saved N When the TEACH key is pressed from the teaching screen to teach the contents will not be saved CHECK unless the amplifier unit is switched to RUN mode
6. Whether or not an object is lighter or darker is detected by referring to the den sity during teaching DEVIATION Performs detection using sudden changes density deviation in density Select this to detect the presence of scratches or dirt Teaching image dNLAS fA RAES When AVERAGE is set OK NG NG NG judged when density is different When DEVIATION is set OK OK NG NG OK judged if there is no density NG judged if there is density change even if density is different change ZFV User s Manual 13 Section 3 Customizing Measurement conditions AREA E Reversing black and white images Reverse the currently displayed binary image As white pixels are targeted for measurement select which part of the measured area is to be set to white pixels gt MENU Mode CUSTM COLOR WHITE default value Select which part of the measurement area is to be set as white pixels BLACK E Changing the binarization level Set the level for converting 256 tone contrast image captured from Sensor Head to a binary image dNLAS Reese P MENU Mode CUSTM BINARY 0 to 255 As white pixels are targeted for measurement adjust the binarization level so that the measurement area is converted to white pixels CUSTM BINARY L El H 120 Upper lower Lower Upper limit limit limit LEFT RIGHT keys Select upper limit lower limit UP DOWN keys Change values ZFV 14 User s Manual Section 3 Cu
7. s Manual Section 4 Specifications and External Dimensions Single function Models Standard Models Item ZFV A10 ZFV A15 ZFV A20 ZFV A25 Operating and storage 35 to 85 Accessories Ferrite core 1 Instruction sheet gt a m Z z gt lt ZFV User s Manual 99 Section 4 Specifications and External Dimensions Panel Mount Adapters ZS XPM1 XPM2 When mounting on a panel Unit mm 60x n 12 Panel 8 DIN track Panel Mount 2 _ 37 5 Adaptor Note 1 Note 1 Dimensions are shown for a panel thickness of 2 0 mm Panel cutout dimensions E 60xn 8 gt a m Z z gt lt 1161 n Number of gang mounted controllers 1 to 10 ZS XPM1 for st unit ZS XPM2 for 2nd unit onwards Appearance Vibration resistance 10 to 150 Hz 0 7 mm double amplitude 80 min each in X Y and Z directions destructive Shock resistance destructive 300 m s2 3 times each in six directions up down left right forward backward Weight Approx 50g ZFV 100 User s Manual Section 4 Specifications and External Dimensions Control Link Unit ZS XCN Unit mm gt U v m Z gt lt Item ZS XCN Ambient temperature Operating 0 to 50 C Storage 15 to 60 C with no icing or condensation Ambient humidity Oper
8. 2 dNLAS Reese Switch to ADJ Mode Adjustment of correlation value 1 CHARA2 OK ADJ MENU RUN Measured value Correlation value UP DOWN keys Change values Setting item Details of Adjustment Correlation value O to 100 This is the lower limit of the correlation value with the teaching model This value or above is judged as OK ZFV 58 User s Manual Section 3 Performing Measurement Performing Measurement When the mode is switched to the RUN mode measurement is executed and the measurement result is output to the external device E Switching the display during measurement The display details are switched by pressing the TEACH VIEW key during measure ment The measurement time differs according to the type of display image The measurement time for 5 1 only image display is the fastest The number in parentheses serves as a guideline when only o A image display is taken as the reference Q Sea When the image is switched during measurement the measurement time changes For this rea o son monitor the ENABLE signal wait for the ENABLE signal to turn ON and then input the TRIG oo signal N m Only image display Judgment result Teaching area Teaching area and pa 5 measurement result 1 1 SEARCH 1 SEARCH OK 1 SEARCH a o TEACH VIEW TEACH VIEW ls image only display 5 ms image only display 24 ms image di ETY 30 ms TEACH VIEW TEA
9. HIGH SPEED Note however that image processing becomes rougher and measurement accuracy drops 1 p 61 Switch the screen display during measurement to Display only image The measurement time can be reduced proportionate to the reduction in display time I p 59 Teaching is not going well What should Workpiece move teaching mode do A probable cause is that the workpiece is not properly in the teaching area as intended Change to the workpiece stop teaching mode or teaching by key operation gt a m Z z gt lt A probable cause is that teaching is not successful because an image is too dark or too bright Adjust light emission at CUSTM LIGHT so that the workpiece is projecten clearly and execute teaching again p 71 Does it switch to the teaching area MOVE move screen or SIZE Resize screen Teaching cannot be performed from the MOVE screen or SIZE screen Set the position or size with the SET key go back 1 screen up then press the teaching button At what timing are set measurement condi Set measurement conditions are saved to the amplifier unit when tions saved to the amplifier unit external TEACH signal teaching is successful or when switched to RUN mode When the TEACH key is pressed from the teaching screen to teach contents will not be saved unless switched to RUN mode once Changed contents including teaching results are cleared when switching off without saving Eve
10. Mode Display Item List COUNT Display Characters Meaning COUNT CNT Count CHARA 1 DENDEV DEV Density distribution value gt U v m Z z gt lt ZFV 88 User s Manual Section 4 When Gang mounting Amplifier Units When Gang mounting Amplifier Units Application examples of amplifier unit gang mounting and caution notes are explained Gang mounting example E 1 sensor head multiple amplifier units Example of detection of input image from 1 sensor head with multiple amplifier units eTo detect multiple areas such as a 4 sided POSITION multiple item SEARCH etc eTo detect multiple types such as both SEARCH and AREA judgments o Images are transferred from right side to left side amplifier units gt sas m Z z gt lt ENABLE signal ji TRIG signal v E Multiple sensor heads multiple amplifier units Example of synchronizing and detecting multiple points of the same workpiece and integrating judgments LLLE Measured with images loaded from each sensor head ENABLE signal TRIG signal y ZFV User s Manual 89 Section 4 When Gang mounting Amplifier Units Rules of gang mounting Only host device is enabled Only host device is enabled Enabled at each amplifier unit ENABLE output Only host device is enabled OUTPUT output Depends on the settings Integrated judgment Individual judgment ERROR output Enable
11. Select this when there is a characteristics part such as a corner of a text box Model Ta 2004 09 24 EDGE The edge position is used to correct the position Edge 2004 09 24 E Select the content of position compensation Registering models Set this when MODEL is selected to MODE Specify the top left coordinate and bottom left coordinate of the model Model a 2004 09 24 gt MENU Mode CUSTM MODE DTL MODEL ZFV User s Manual 19 dNLAS Reese Section 3 Customizing Measurement conditions Specifying edge detection conditions Set this when EDGE is selected to MODE Set the direction in which edges are searched and the change in density Example To correction position by this edge 2004 09 24 COLOR BLACK EDGE e Selecting the color of edges Select the direction of density change for the edge to be detected dNLAS fA RAES gt MENU Mode CUSTM MODE DTL COLOR WHITE A change from dark to light is judged as an edge BLACK default value A change from light to dark is judged as an edge e Selecting the edge detection direction Select the direction in which edges are searched P MENU Mode CUSTM MODE DTL DIRECTION default value Searches from bottom to top i Searches from top to bottom Searches from left to right Searches from right to left ZFV 80 User s Manual Section 3 Customizing Measurement conditions
12. User s Manual Controller Link Unit Hook on I O cable end Section 2 Amplifier Unit E Mounting on a panel The Panel Mount Adapters sold separately ZS XPM1 XPM2 can be used to mount the Amplifier Unit on a panel I Panel Mount Adapters p 100 1 Install the Amplifier Unit on the DIN track I p 27 Q When mounting on a panel be sure to install the DIN track on the rear side of the Amplifier Unit for Z support 2 Push out the Amplifier Unit from the rear of the panel towards the front 3 Install the small Mount Adapters on the four holes on the Amplifier Unit aloe P l Install the small Mount Adapters on all gang mounted Z ang Amplifier Units hh CHECK apter Panel Mount Adapter ZFV User s Manual Z T j gt m m gt O Z Qo O O Z Z m O Z 29 Z gt m m gt O Z Qo O O Z Z m O O Z 30 Section 2 Amplifier Unit 4 install the long Mount Adapters on the two Panel Mount Adapters holes on the small Mount Adapter alo Install the long Mount Adapters only on both sides of gang mounted Amplifier Units CHECK 5 install the Amplifier Unit with Mount Adapters attached onto the panel from the front alo a E
13. be stopped Teaching processing is divided up and performed in synchronous with the TRIG signal input after the TEACH signal is input from the outside Teaching must be processed six times Measurement is not performed while teaching is being performed Min S OFF eases TEACH an 8 l l OFF T oo TRI 3 4 l F oao o 2 1 5 Re ON ay During teaching processing H ee ae iii OFF ERROR rr O O ON 6 1 Turn the TEACH signal ON from the outside 2 Confirm that the ENABLE signal has turned OFF 3 Input the TRIG signal at the timing for measuring the workpiece to be taught 4 Repeat the input in step 3 six times Trigger inputs from the seventh time onwards are ignored 5 The ENABLE signal turns ON after teaching is completed Check the state of the ERROR signal at this timing 6 When teaching has been completed successfully the ERROR signal stays OFF 7 When teaching fails the ERROR signal turns ON 8 Turn the TEACH signal OFF and end teaching processing When teaching fails the state before teaching was initiated is returned to Perform teaching again If the TEACH signal is turned OFF midway teaching is disabled E Bank switching ZFV The bank No can be switched when BANK1 to BANK3 are connected as follows C fore e fore User s Manual Section 2 Sensor Head This section describes how to install and connect the Sensor Head Attaching the ferrite core Atta
14. connected correctly NECTED SYSDATA Error in the system data The system data will be initialized and ERROR must be reset SYSTEM ERROR Failed to configure FPGA Faulty Amplifier Unit ERROR CODE Failed to initialize LCD Contact your OMRON representative Failed to recognize Amplifier Unit Failed to load data from flash memory Faulty hardware operation Faulty software operation TEACHING The workpiece is not projected correctly Set the area so that the workpiece is FAILED The teaching area is not set at the appro projected in the field of view priate position Make sure that the appropriate teach ing area is set gt v U m Z z gt lt In the following instances error messages are not displayed but the ERROR signal turns ON TRIG was input while ENABLE was OFF Wait until ENABLE is turned ON and then input TRIG Failed to teach from external device Set the area so that the workpiece is projected in the field of view Make sure that the appropriate teaching area is set Make sure that TRIG timing is appropriate in the workpiece move teaching mode ZFV User s Manual 85 Section 4 Q amp A Q amp A Question Answer Can turn LED light emission of the Sensor Yes you can Head OFF CUSTM Set LIGHT to 0000 IE p 71 What should I do to set the measurement There are two ways of setting a shorter measurement time time as short as possible e Set CUSTM IMAGE RATE to
15. currently selected bank z No CHECK P MENU Mode SYS2 ALL CLEAR EXECUTE Initializes the setup data CANCEL Does not initialize the setup data Initializing measurement data Current and past measurement average values measurement count and other measurement data can be cleared without restarting Data to be cleared are the items displayed in the following screen at RUN mode 1 SEARCH OK JG OK SCORE 98 TH 60 AVE 0 DRANGE 0 100 MCONT 2 Lz 2 Meaning of display contents p 87 P MENU Mode SYS2 MEAS CLEAR EXECUTE Initialize measurement data CANCEL Do not initialize measurement data ZFV 62 User s Manual Section 3 Setting the System Environment Checking the version EXP MENU Displays the type of Sensor Head type of Amplifier Unit and system version information of the software P MENU Mode SYS2 VERSION Changing image capture timing on teaching screen EXP MENU Select status of image to be displayed in the teaching screen gt MENU Mode SYS2 TEACH IMAGE THROUGH default value Display the latest raw image being inputted from the sensor head FREEZE Freeze the image and display The still image is displayed when the TRIG signal is input from the teaching screen dNLAS Reese 5 S When amplifier units are gang mounted set all amplifier units to the S teaching screen then input the TRIG signal to the amplifier unit fur CHEcx thest
16. far side e Turn to left Focuses to the near side Default is focus set at furthest point Before turning the focus adjustment control slightly to the left and right make sure that the guide light is not at the upper or lower limit positions The focus adjustment control is a multi turn variable A resistor However the control stops turning at the upper or lower limit positions Do not exert ww CHEeck Unnecessary force to turn the control at the upper or lower limit positions as this might damage the control Connecting the Sensor Head Z gt m m gt O Z Qo O O Z Z m O O Z This section describes how to connect the Amplifier Unit Si e Before connecting disconnecting the Sensor Head make sure that the Amplifier Unit is turned OFF i The Sensor Head may break down if the Sensor Head is connected or disconnected while the power o is ON CHECK Do not touch the terminals inside the connector e Ensure that the connector is secure i e not subject to vibration or impact E Connecting the Sensor Head Insert the Sensor Head connector into the Sensor Head connector of the Amplifier Unit E Disconnecting the Sensor Head Pull out the Sensor Head while pressing in the hooks on both sides of the Sensor Head connector ZFV 40 User s Manual Section 3 SETUP Setting Flow 42 y T a About Setup 44 2 Basic Knowledge for Operation 44 S L
17. is in use gt MENU mode ITEM dNLAS Reese Description Example of Application Select this item to detect the presence of a workpiece This Detection of presence item supports workpieces tilted to an angle of 45 Teach of sales campaign the image pattern to be recognized and register this pattern seals as a model Judgment is performed by whether the regis tered model is or is not in the detected image Recognition of top Example To recognize by the presence of a mark rear side and orienta Non defective item tion of electronic com ponents Model OK NG NG dqoav Ca ED Measurement is unstable when there are two or more of the same pattern Register unique pat terns in the screen or restrict the search range Changing the search area p 81 ZFV User s Manual 51 Section 3 Executing Teaching PATTERN MATCH Description ent objects Judgment is performed by comparing the degree of match vy m PTRN between a registered model and the target workpiece Com pared with SEARCH more detailed detection is possible and larger workpieces can be detected Note however that this item does not support tilted workpieces Non defective item Model NG AFGHIJ Measurement is unstable when there are two or more of the same pattern Register unique pat terns in the screen or restrict the search range dNLAS FAE RAES Changing the search area p 81 BRIGHT S
18. 2 In this configuration multiple Sensor heads are used to simultaneously inspect multiple locations on a workpiece When the TRIG signal is input from a single specified Amplifier Unit the connected Amplifier Unit starts sensing immediately The result of sensing is integrated on the Amplifier Unit to which the TRIG signal was input and is output as a total judgment result Example Alignment of products AMP 1 AMP 2 AMP 3 ZFV User s Manual 17 Section 1 Part Names and Functions Part Names and Functions The following describes the names and functions of parts on the Amplifier Unit and Sensor Head E Amplifier Unit 7 Sensor Head connector i m gt ze m N 6 LCD monitor 3 Control keys 4 Menu selector switch 5 Mode selector switch 8 Coupler I 9 1 0 cable 1 OUTPUT indicator The Output indicator lits when the OUTPUT signal turns ON 2 RUN indicator The RUN indicator turns ON in the RUN mode 3 Control keys The Control Keys are for setting measurement conditions and other information A Displays and Key Operations p 45 4 Menu selector switch This switch selects the setup menu STD Standard menu Select this when setting the minimum required items for measurement EXP Expert menu Select this item when ma
19. CH VIEW Measurement result 3 Enlargement of mea Teaching area and con surement result and trol bar 2 control bar 2 1 SEARCH OK 1 SEARCH OK 1 SEARCH 10 4 TEACH VIEW TEACH VIEW TEACH VIEW AVE 0 DRANGE 0 100 MCONT 2 NG 1 000 TIME 144 image only display image only display image only display 205 ms 55 ms 46 ms 1 In the case of BRIGHT the display can be switched average density value density distribution value by the LEFT RIGHT keys In the case of AREA the display can be switched to binary image by the LEFT RIGHT keys 2 The control bar shows the measurement result and judgment threshold value 3 The measurement time TIME indicated here is the shortest measurement time in only image display avis About meaning of display details in measurement results D ILA p 87 CHECK ZFV User s Manual 59 Section 3 Setting Banks Setting Banks The ZFV Series can hold up to eight sets of settings These settings can be switched externally when changing the device setup A set of these settings is called a bank Switching banks BANK 1 is selected as the default BANK 2 and 8 are also available alo BANKs can also be switched from an external device S oe eo jt Bank switching p 36 gt MENU mode BANK dNLAS Reese BANK 1 to BANK 8 Selects the target bank default value BANK 1 Copying banks Copy the sett
20. ENABLE enable output This turns ON when the sensor is ready for measurement 5 ERROR error output This turns ON when an error is generated E Error Messages and Remedies p 85 ZFV User s Manual 31 Section 2 Amplifier Unit 6 TEACH teaching input There are two teaching modes workpiece stop teaching and workpiece move teaching These teaching modes can be selected in the menu Selecting the teaching mode from an external device p 61 7 TRIG measurement trigger input There are two measurement modes synchronous measurement and continuous measurement Which mode of measurement is to be performed in is selected in the menu I Selecting the measurement timing p 61 8 BANK1 bank switching input 1 9 BANK2 bank switching input 2 10 BANK3 bank switching input 3 IUA Bank switching p 36 z IUA Timing charts p 34 E I O Circuit Diagrams NPN output type ZFV A10 A20 Z gt m m gt O Z Qo O O Z Z m O O Z Se ee ee eae eS gE Brown Power supply 24VDC Q l A Black OUTPUT Load Orange ENABLE Ny d Light blue ERROR I Blue GND 0V 24VDC Internal circuits Yellow TEACH H O Pink TRIG O A Gray BANK1 F n Green BANK2 Red BANK3 Q ZFV 32 User s Manual Section 2 Amplifier Unit PNP output type ZFV A15 A25 I I I I I LI LI I LI I I LI I LI L L
21. I LI I LI I Brown Power supply 24VDC L i Yellow TEACH 6 O O Pink TRIG i 5 i Gray BANK1 i 5 Green BANK2 5 Red BANK3 r GND 0V Internal circuits Light blue ERROR 24VDC Orange ENABLE er er errr rae Z T j gt m r gt O Z Qo O O Z Z m O Z ZFV User s Manual 33 T gt m m gt O Z Qo Q O Z Z m O O Z 34 Section 2 Amplifier Unit Timing charts The following shows the timing charts when communication is performed with external devices E Measurement Continuous measurement Measurement is performed continuously for the duration that the TRIG signal is ON The measurement result is updated and output to external devices at each measure ment cycle OFF TRIG ON ae O a a E OUTPUT ON l The measurement cycle changes depending on the setting ENABLE Er ON Synchronous measurement ZFV Measurement is performed only once in synchronous with the change in TRIG signal state from OFF to ON and the result is output OFF TRIG an Tout Measurement time l OUTPUT OFF X The measurement time changes ON depending on the setting l OFF i ENABLE ON e The minimum ON width of the TRIG signal is 1 ms e The OUTPUT signal is held until the next measurement result is updated Note however that when one shot output is currently set the OUTPUT signal is held for the preset t
22. MENU Set whether to turn the OUTPUT signal ON when OK is judged or when NG is judged P MENU Mode SYS2 OUTPUT ON STATUS OK ON Turns the OUTPUT signal ON when OK is judged NG ON default value Turns the OUTPUT signal ON when NG is judged One shot output dNLAS Reese EXP MENU J OUTPUT turns ON for only the preset output time from when the OUTPUT signal turns ON Synchronous measurement OFF ON TRG Measurement processing OFF OUTPUT ON _ _ ___ _ _ gt Output time Continuous measurement OUTPUT ON at OK judgment Judged as NG Judged as OK Judged as NG OFF i OUTPUT ON eq Output time ZFV User s Manual 65 Section 3 Changing the Input output Conditions E Selecting one shot output ON OFF Set whether or not to enable one shot output on the OUTPUT signal P MENU Mode SYS2 OUTPUT ONE SHOT OFF default value One shot output is not performed One shot output is performed A When one shot output is set to ON the OFF delay time setting is disabled v CHECK E Setting the one shot output time EXP MENU OUTPUT turns ON for the preset time from when the OUTPUT signal turns ON This setting is valid only when ONE SHOT is set to ON dNLAS Keeble P MENU Mode SYS2 OUTPUT OUTPUT TIME 0 to 255 default value 0 Set the time ms that OUTPUT is turned ON Setting the ON delay time EXP MENU Set this item to de
23. N OFF status of ERROR signal 0 OFF 1 ON ule Put the cursor on BANK OUTPUT ENABLE then press the SET button key to switch between 0 and Q 1 The external device operations can be checked by switching output OFF ON when the actural A measurements are not being performed ZFV User s Manual Section 3 Settings During Application Extended Connection Settings During Application Extended Connection These menus are displayed only when Amplifier Units are gang mounted Set to the all gang mounted Amplifier Units Example 1 AMP2 TRIG signal input AMP2 Output of overall ae ricntree tt MENU AMP1 AMP2 HEAD NOTUSE USE AMP1 AMP2 a Example 2 AMP2 TRIG signal input AMP2 Output of overall eomenh ens MENU AMP1 AMP2 dNLAS Reese AMP1 AMP2 i Specifying the Amplifier Unit to input the trigger EXP MENU J Set whether or not to input the TRIG signal to an Amplifier Unit gt MENU Mode SYS2 LINKSET TRIG Setting Description I O default value Set to only the Amplifier Unit to which the TRIG signal is to be input Synchronizes to the TRIG signal from the Amplifier Unit gang mounted on the right side ZFV User s Manual 69 Section 3 Settings During Application Extended Connection Setting the presence of Sensor Head EXP MENU Set whether or not a Sensor Head is connected P MENU Mode SYS2 LINKSET HEAD USE default value Select this for Ampl
24. Smart Sensors USER S MANUAL IN Oey APPLICATION CONSIDERATIONS Searle FEATURES S E HoP INSTALLATION amp CONNECTION Gaok SETUP S E ele 25 APPENDIX User s Manual Smart Sensors with Ultra high Speed CCD Camera ZFV Series Please read first a le tiene je ene Lies r a T Introduction 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 warranty is that the products are free from defects in materials and workmanship for a period of one year or other period if specified from date of sale by OMRON OMRON MAKES NO WARRANTY OR REPRESENTATION EXPRESS OR IMPLIED REGARDING NON INFRINGEMENT MERCHANTABILITY OR FITNESS FOR PARTICULAR PURPOSE OF THE PRODUCTS ANY BUYER OR USER ACKNOWLEDGES THAT 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 responsibility of OMRON for any act exce
25. atch teaching all devices Teaching only clients E External teaching The TEACH signal is input from the host device Input the host device ENABLE signal at ON Teaching is completed when the host device ENABLE signal is set OFF ON after teaching is performed It is ignored even if a TEACH signal is input to the client gt v v m Z z gt lt 92 Tar signal ENABLE signal TEACH signal SS The time required to perform the teaching process increases when gang mounted In particular when 9 performing move teaching raise the TRIG signal input interval to 200ms minimum CHECK ZFV User s Manual Section 4 When Gang mounting Amplifier Units Integrating judgment output Judgment result output OUTPUT of gang mounted amplifier units can be integrated I Setting output content p 70 E When all amplifier unit measurement results are integrated ALL Select ALL to integrate measurement results of all gang mounted amplifier units and output from amplifier units host device where TRIG signals are input Obtain OUTPUT signal after ENABLE signal is set to ON When any amplifier unit is NG the integrated judgment is NG gt U U m Z z gt lt pi OUTPUT signal W A ae signal V ENABLE signal E When judgment results are output by each amplifier unit EACH Select EACH to output judgment results by each amplifier unit The host device ENABLE signal is enabled Obtain OUTPUT
26. ating and storage 35 to 85 with no condensation Vibration resistance 10 to 150 Hz 0 7 mm double amplitude 80 min each in X Y and Z directions destructive Shock resistance destruc 300 m s2 3 times each in six directions up down left right forward backward tive Approx 10g ZFV User s Manual 101 Section 4 Specifications and External Dimensions Extension Cord ZFV XCOIB R V2 Unit mm 13 T5 L Note 1 33 8 5 PVC insulated round cable 6 2 20 pins J AN Mounting holes 2 M3 nm Note 1 For ZFV XCUBV2 L 3m or 8m 0 For ZFV XCLIBRV2 L 3m N Mounting hole dimensions gt a m Z z gt lt ZFV XC3BV2 ZFV XC8BV2 ZFV XC3BRV2 Applicable Amplifier Units ZFV A Series Applicable Sensor Head ZFV S Series Ambient temperature Operating 0 to 40 C Storage 25 C to 65 C with no icing or condensation Operating and storage 35 to 85 with no condensation Case Polycarbonate PC Model Nos appended with R are robot cable types ZFV 102 User s Manual Section 4 Version Up Information Version Up Information Software version upgrade contents are explained E Ver1 00 Ver2 00 necting to the data storage unit type ZS DSU added A function to improve character detection stability added Refer to the data storage unit ZS DSU User s Manual gt sas m Z z gt lt ZFV User s Manual 103 Section 4 Versi
27. ch the ferrite core provided with the Smart Sensor to the connector side of the Sensor Head Ferrite core Installing the mounting fixture Attach the mounting fixture provided with the Smart Sensor to the side of the Sensor Head E Installation procedure The mounting fixture can be installed on all of the four mounting surfaces Z T j gt m m gt O Z Qo O O Z Z m O O Z Mounting fixture 1 Align the two hooks on one side of the mount ing fixture with the two grooves on the Sensor Head body light emitting side Grooves 2 Press in the other hook Push down until you hear it snap into place 3 Make sure that the mounting fixture is firmly fixed on the Sensor Head ZFV User s Manual 37 Section 2 Sensor Head E Removal procedure Insert a regular screwdriver into the gap one of the two gaps between the mounting fixture and the Sensor Head case and remove the mounting fixture Mounting fixture Installing the Sensor Head This section describes how to install the Sensor Head The detection range of the Sensor Head can be confirmed by the guide light Install so that the part to be inspected is inside the frame formed by the guide light WE Installation distance The following graphs show the relationship between detection range and setting dis tance for each model of Sensor Head Values differ according to each model of Sensor Head so fully check the mode
28. characters in the preset teaching area Select the number of characters being within a certain number of characters on one or two lines Selection guidelines 8 characters 1 line 2004 09 24 1LINE NORMAL dNLAS Keeble 8 characters 2 line 2004 09 24 LINE NORMAL 18 25 ADR P MENU Mode CUSTM MDL DIV 1LINE SHORT Select this when the character string is 6 characters or less on 1 line 1LINE NORMAL Select this when the character string is 8 characters or less on 1 line default value 1LINE LONG Select this when the character string is 15 characters or less on 1 line 2LINE SHORT Select this when the character string is 6 characters or less on 2 lines 2LINE NORMAL Select this when the character string is 8 characters or less on 2 lines ST Q The number of characters in the above table are for reference only When there are more characters than the number of reference characters in the selected item measurement accuracy drops CHECK ZFV 78 User s Manual Section 3 Customizing Measurement conditions E Select whether or not to perform Position compensation Set Position compensation for improving detection accuracy in the following instances When there is a pattern in When printed text is out of the detection range position 2004 09 24 2004 09 24 gt MENU Mode CUSTM MODE Setting Description NONE The position is not corrected MODEL The model is used to correct the position
29. d at each amplifier unit MENU ADJ RUN Only host device is enabled STD EXP Enabled at each amplifier unit All key inputs Enabled at each amplifier unit gt a m Z z gt lt Amplifier unit for inputting fur thest right TRIG signal host device A TRIG signal ENABLE signal v Amplifier unit without TRIG signal inputs client device ZFV 90 User s Manual Section 4 When Gang mounting Amplifier Units Data route E Measurement image The measurement image flows from the right side amplifier unit towards the left side Image input timing delays do not occur E I O signal The TRIG signal flows from the right side amplifier unit towards the left side Input tim ing delays do not occur In contrast ENABLE signals and OUTPUT signals combining all amplifying units can be output from the furthest right amplifier unit as ENABLE signals and OUTPUT signals flow from the left side amplifier unit to the right side gt sas m Z z gt lt OUTPUT signal v TRIG signal WV ENABLE signal ZFV User s Manual 901 Section 4 When Gang mounting Amplifier Units Teaching process when gang mounting E Teaching key input from MENU Mode Enter the teaching screen from the host device and press the TEACH key to teach all clients in the teaching screen where the host device is added Enter the teaching screen for the client only and press the TEACH key to teach only this client B
30. djustment details differ according to the currently set teaching mode E SEARCH MATCH Switch to ADJ Mode Adjustment of correlation value 1 SEARCH OK MENU RUN Measured value Correlation value Details of Adjustment This is the lower limit of the correlation value with the teaching model This value or above is judged as OK E BRIGHT Switch to ADJ Mode Adjustment of average density value Adjustment of density deviation value 1 BRIGHT 1 BRIGHT ADJ lt cx MENU RUN TEACH VIEW Measured E Measured L tae te 220 A value L R0 H 60 D value vole Lower Upper Upper lower Lower Upper limit limit limit limit limit limit LEFT RIGHT keys Select upper limit lower limit LEFT RIGHT keys Select upper limit lower limit UP DOWN keys Change values UP DOWN keys Change values Setting item Details of Adjustment Average density value 0 to 255 This is the range of the average density inside the teaching area Density deviation value 0 to 127 This is the range of the density deviation inside the teaching area ZFV User s Manual 55 dNLAS Reese dNLAS Reais 56 Section 3 Adjusting Threshold Values E AREA Switch to ADJ Mode Adjustment of area value Binary image Contrast image Can be set on either image ADJ TEACH VIEW MENU RUN P Measured 80 L B H 120 B value L 3 H 120 G Upper lower Lower Upper limit limit limit LEFT RIGHT keys Selec
31. e Amplifier Unit Additional Functions Checking the Version Confirm the version of the Amplifier Unit When a Problem Occurs The Smart Sensor does not operate correctly An error message has appeared y IU Troubleshooting p 84 jl Missed es nt ee mediee If you have a query ee Q amp A p 86 ZFV User s Manual 43 dNLAS Reese 44 Section 3 About Setup About Setup Basic Knowledge for Operation E Switching Modes There are 3 operating modes as follows Switch to the desired mode before you start operation To switch the operating mode use the mode switch MENU RUN MENU mode This mode is for executing teaching or setting up the measurement conditions ADJ mode This mode is for setting the judgment threshold values RUN mode This mode is for performing actual measurement E Switching Menus There are two setup menus in the MENU mode Switch the menu according to your specific requirements To switch the menu use the menu selector switch STD menu This is the standard menu First set the measurement conditions in this menu EXP menu This is the expert menu Switch to this menu to make a more advanced setup ZFV User s Manual Section 3 About Setup E Displays and Key Operations Make setups using the control keys while viewing the menus and the image displayed on the LCD monitor Display The details that are displayed differ according to th
32. e operating mode e MENU mode e ADJ mode RUN mode Bank No and measurement item TEACH AREA Setting item 1 SEARCH OK Judgment O D O p O te ee H Settings Threshold value or mea 4 The currently selected surement result item is displayed inverted Key Operations U J AO l O Oo Control keys Description lt LEFT key The function of these keys differs according to the operating mode RIGHT key In MENU mode Moves through menus In ADJ mode Changes the adjustment item type of threshold value In RUN mode Changes the display details type of measurement value UP key The function of these keys differs according to the operating mode DOWN key In MENU mode Moves between menus selects parameters and sets numerical values In ADJ mode Changes numerical values TEACH VIEW The function of these keys differs according to the operating mode key In MENU mode Executes teaching In RUN and ADJ modes Switches the screen display e Selects menus e Selects applies items Returns to the previous menu ZFV User s Manual 45 Section 3 About Setup List of Setting Items in MENU mode The following shows the setting items in MENU mode The details that are displayed differ according to the currently selected setup menu STD or EXP Switch the setup menu by the menu selector switch according to your specific requirements MENU Mode Default value Selection item Settin
33. e range of measurement items which means that numerous applications are supported I Types of Teaching p 51 Logging measured images Ver 2 0 and later Measurement images can be logged by connecting to data storage unit ZS DSU Set NG occurrence as a trigger to log before after images and measurement values This is useful for investigating the cause of defectives Logged data is saved to the memory card inserted into the data storage unit and can be easily be loaded to a personal com puter Data Storage Personal Computer jt A Data storage unit ZS DSU User s Manual Enables bank extension Ver 2 0 and later A maximum 128 bank data items can be saved to the memory card mounted to the data storage unit if connected to data storage unit ZS DSU Bank data can be trans ferred from the data storage unit to the ZFV as needed for the device setup E Data storage unit ZS DSU User s Manual ZFV User s Manual 15 Section 1 Basic Configuration Basic Configuration The figure below shows the Basic Configuration of the ZFV Series Sensor Head Detects workpieces as images e Narrow view type ZFV SR10 e Wide view type ZFV SR50 Extension Cord ZFV XC3BV2 3m XC8BV2 8m XC3BRV2 3m Used between a Sensor Head and Amplifier Unit Two ZFV XCLJB R V2 cords can be coupled together to extend the cord length i m gt ze m N Amplifier Unit Used for confirming images and menus performing
34. e the Amplifier Unit from the DIN track ld XS 1 Pull the hook on the I O cable end of the Amplifier Unit downwards 2 Lift up the Amplifier Unit from the I O cable end and remove it from the DIN track Hook on I O cable ZFV User s Manual Section 2 Amplifier Unit E Mounting on a panel The Panel Mount Adapters sold separately ZS XPM1 can be used to mount the Amplifier Unit on a panel Z Panel Mount Adapters p 100 Push out the Amplifier Unit from the rear of the panel towards the front 2 Install the small Mount Adapters on the four holes on the Amplifier Unit 3 Install the long Mount Adapters on the two holes on the small Mount Adapter ZFV User s Manual Z T j gt m m gt O Z Qo O O Z Z m O O Z 25 Panel Mount Adapter Panel Mount Adapter Panel Mount Adapter Section 2 Amplifier Unit 4 Install the Amplifier Unit with Mount Adapters attached onto the panel from the front i vo Take care not to pinch the I O cable 4 CHECK 5 Hook the hooks of the mounting fixture onto the two holes of the smaller Mount Adapters and tighten the screws T gt m m gt O Z Qo Q O Z Z m O O Z Make sure that the Amplifie
35. ed or when significant construction changes are made However some specifications of the product may be changed without any notice When in doubt special model numbers may be assigned to fix or establish key specifications for your application on your request Please consult with your OMRON representative at any time to confirm 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 document has been carefully checked and is believed to be accurate however no responsibility is assumed for clerical typographical or proofreading errors or omissions PROGRAMMABLE PRODUCTS OMRON shall not be responsible for the user s programming of a programmable product or any consequence thereof COPYRIGHT AND COPY PERMISSION This document shall not be copied for sales or promotions without permission This document is protected by copyright and is intended solely for use in conjunction with the product Please notify us before copying or reproducing this document in any manner for any other purpose If copying or transmitting this document to another please copy or transmit it in its entirety ZFV User s Manual r a T a acy a T Introduction Precautions for Safe Use Precautions for Safe Use
36. ed 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 conformity with any standards codes or regulations that apply to the combination of products in the customer s application or use of the product 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 products in combination with the end product machine system 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
37. elect this item to detect brightness density or scratches dirt on plain workpieces Set the teaching area to the desired part of the workpiece to detect brightness in and execute teaching al BRGT Non defective item NG NG Select this item to recognize objects by size area Set the teaching area to the desired part of the workpiece to detect the size area in and execute teaching Teaching area Enclose a restricted area of the workpiece Teaching area Measurement of area at this part ZFV User s Manual 52 Select this item for detecting shapes and recognizing differ Example of Application Recognition of differ ent kind of instruction sheet Detection of scratches dirt in sheets Checking of lighting of indicators Detection of presence of screw threads Inspection of short ages in confectionary Detection of presence of silver paste Section 3 Executing Teaching WIDTH Select this item to detect width or interval Detection of lead Set the teaching area to the part of the workpiece to perform width on capacitors or measurement in and execute teaching other electronic com c ponents Example To measure width Detection of bent leads Detection of out of position labels Set so that there are two changes in brightness in the detection area such as light to dark or dark A to light CHECK POSITION Select this item to detect the position of a w
38. erformed in synchronous with the change in state of the external TRIG signal from OFF to ON CONTINUE Continuous measurement Measurement is repeatedly performed for the duration that the TRIG signal is ON Selecting the teaching mode from an external device There are two teaching modes from an external device gt MENU Mode SYS1 TEACH TYPE STATIONARY default Teaching is performed with the workpiece in a stationary state Input of the exter nal trigger input is required for teaching MOVING The teaching is performed with the moving workpiece Select this teaching mode only when the workpiece cannot be stopped Input of the external trigger is required for teaching W Timing charts p 34 ZFV User s Manual 61 Section 3 Setting the System Environment Setting canceling the Eco mode Whether or not to darken the screen when a preset time has passed without any operation We recommend setting this mode to ON to prevent the brightness of the LCD screen from being impaired gt MENU Mode SYS1 ECO MODE N default value Sets the Eco mode The screen darkens when three minutes continue without any operation Cancels the Eco mode setting T D z a a al al a Initializing setup data m EXP MENU Return all bank settings and system settings to their factory settings alo The settings of all banks and system settings are initialized regardless of the
39. g range aen o o pen ar C a A A GZ Smo a Eo o T cow F O E E 1 These menus are displayed only on standard type Amplifier Unit mwe p p ma je r e y BANK BANK BANK1 BANK1 to BANK8 p 60 pa p p tanm f p o emon fe e fro lese ee Recone pT Mamee _ starionary starionary mono peT how n noe foe cusa C a A ITEM SEARCH LEE ao e a a ROTATION 10 10 20 30 45 ITEM MATCH mmmn fea O o eee METHOD AVERAGE AVERAGE DEVIATION ITEM AREA Usa A COLOR WHITE BLACK WHITE ITEM IWIDTH TEMI l i COLOR WHITE BLACK WHITE dNLAS Reese 2 The display details of items from CUSTOM onwards differ according to the item selected at ITEM ZFV 46 User s Manual Section 3 About Setup 2 2 Setting content Default value Selection item Setting range Pages ITEM POSITION ITEM l F COLOR WHITE BLACK WHITE EDGE SENSE NORMAL SENSITIVE NORMAL ROUGH ITEM COUNT ve l 5 COLOR WHITE BLACK WHITE ITEM CHARACTER1 D N E MODE L NONE MODEL EDGE COLOR BLACK WHITE DIRECTION i SEARCH AREA MDL DIV 1LINE NORMAL 1LINE SHORT 1LINE NORMAL 1LINE LONG 2LINE SHORT 2LINE NORMAL NONE MODEL EDGE MODE DTL To N t p o 3s D7 N Co Co O O ITEM CHARACTER2 2 N co MODE E COLOR BLACK WHITE Horecron th di seancnaneR i A T Listas ore forhon pat Hone
40. ght forward backward destruction Ambient temperature Operating 0 to 40 C Storage 20 to 65 C with no icing or condensation Ambient humidity Operating and storage 35 to 85 with no condensation Ambient atmosphere Must be free of corrosive gas Connection method Prewired Standard cable length 2 m Degree of protection IEC60529 IP65 Materials Case ABS Mounting bracket PBT Weight Approx 200 g including mounting bracket and cord Accessories Mounting bracket 1 Ferrite core 1 Instruction sheet ZFV 96 User s Manual Section 4 Specifications and External Dimensions Amplifier Unit ZFV AOL Unit mm KO enO om E EZ E m 23 2 ii g 4 6 t2 Aff la el J e 90 90 NH o l o p l o o o i 1 U E e 4 U9 f i a 3 9 18 gt U U m z Heat resistant PVC shielded cable g H 5 2 mm dia standard length 2
41. ifier Unit to which a Sensor Head is currently connected Measurement is performed using the input image from the currently connected Sensor Head NOT USE Select this for Amplifier Unit to which a Sensor Head is currently not connected Measurement is performed from the image transferred from the Sensor Head gang mounted on the right side Setting output content dNLAS Reais EXP MENU Set the output content of the measurement result This item is displayed only the Amplifier Unit whose TRIG TRIG setting is set to I O P MENU Mode SYS2 LINKSET OUTPUT Setting Description ALL The measurement results of all gang mounted Amplifier Units are integrated and output as an overall judgment result EACH default value The measurement result of each Amplifier Unit is output from the respective Ampli fier Unit Lz Output image p 93 ZFV 70 User s Manual Section 3 Customizing Measurement conditions Customizing Measurement conditions EXP MENU The display items from CUSTM onwards differ according to the teaching type set at ITEM Common items E Adjusting light emission Adjust the intensity of the light emitted from Sensor Head The light intensity of each adjusted section is displayed as a 4 digit number Top surface model printed surface B View from here f 02 A S siie T D The light intensity can also be adjusted partially A to D Adjust the light intensity b
42. ime Ve One shot output p 65 User s Manual Section 2 Amplifier Unit E Teaching Workpiece stop teaching Teaching processing is performed according to TRIG signal input after the TEACH sig nal is input from the outside Measurement is not performed while teaching is being performed Do not move the workpiece until teaching is completed OFF TEACH c on 8 OFF p A 4 TRIG ON 4 OFF ENABLE 2 6 ON During teaching processing FF ERROR a ON ig 1 Turn the TEACH signal ON 2 Confirm that the ENABLE signal has turned OFF Z T j gt m r gt O Z Qo O O Z Z m O O Z 1 2 3 Make sure that the workpiece to be taught is in the teaching area 4 Input the TRIG signal from the outside 5 5 The ENABLE signal turns ON after teaching is completed At this timing check the state of the ERROR signal 6 When teaching has been completed successfully the ERROR signal stays OFF 7 When teaching fails the ERROR signal turns ON 8 Turn the TEACH signal OFF and end teaching processing When teaching fails the state before teaching was initiated is returned to Perform teaching again If the TEACH signal is turned OFF midway teaching is disabled ZFV User s Manual 35 T gt m m gt O Z Qo Q O Z Z m O O Z 36 Section 2 Amplifier Unit Workpiece move teaching Use this teaching mode when the object cannot
43. ings of other bank numbers to an already selected bank number P MENU Mode SYS81 BANKSET COPY Clearing banks Clearing deletes the settings of the currently selected bank number P MENU Mode SYS1 BANKSET CLEAR aut A SYS1 SYS2 settings and RUN Mode display settings cannot be cleared k zs CHECK Setting the bank switching method Select how to switch banks gt MENU Mode SYS1 BANKSET SWITCH KEY default value Banks are switched by the control keys on Amplifier Unit Banks are switched by the control keys on Amplifier Unit and by external sig nals Switching by external signals is enabled only in the RUN mode ZFV 60 User s Manual Section 3 Setting the System Environment Setting the System Environment Adjusting the measurement speed Set the resolution of the input image Change the resolution according to the required precision and speed of measurement P MENU Mode SYS1 IMAGE RATE FINE Select this when performing measurement by a high precision image Note how ever that it takes longer to perform measurements NORMAL default NORMAL default value Standard a SPEED Select this to _ high speed measurement Note however that images are rougher Selecting the measurement timing dNLAS Reese Set the timing that measurement is executed P MENU Mode SYS1 MEAS TYPE TRIG default value Synchronous measurement Measurement is p
44. ion 22 DIN track 23 ZFV User s Manual gt a m Z z gt lt 105 gt a m Z z gt lt 106 K Section 4 INDEX Gang mounting Panel Installation distance Key Operations LIGHT Logging MDL DIV MEAS CLEAR MEAS TYPE Measurement 45 11 15 Adjusting the measurement speed Measurement time Measurement timing Switching the display during measurement MENU mode Description of MENU mode List of Setting Items Menu selector switch METHOD MODE Mode Mode selector switch MODEL Narrow View NORMAL Number OFF DELAY OFF delay time ON DELAY ON delay time ON STATUS ONE SHOT One shot output User s Manual 61 59 61 96 57 Continuous measurement Output time Synchronous measurement Operating modes OUTPUT 68 OUTPUT TIME Part Names and Functions Amplifier Unit Sensor Head Position Power supply ROTATION Rotation range ROUGH RUN mode Saving the Set Measurement Conditions SEARCH AREA 72 Search area SENSITIVE Sensor Head Attaching the ferrite core Connecting the Sensor Head Installation distance Installing the mounting fixture Specifications and External Dimensions Single function Models STABLE Standard menu Standard Models SWITCH Switching menus Switching the display TEACH IMAGE TEACH TYPE Teaching AREA V W BRIGHT CHARA COUNT PATTERN POSITION Teaching Flow Types of Teaching WIDTH Workpiece m
45. ion H Q Application Sensors Division Shiokoji Horikawa Shimogyo ku Kyoto 600 8530 Japan Tel 81 75 344 7068 Fax 81 75 344 7107 Regional Headquarters OMRON EUROPE B V Sensor Business Unit Carl Benz Str 4 D 71154 Nufringen Germany Tel 49 7032 81 1 0 Fax 49 7032 811 199 OMRON ELECTRONICS LLC 1 East Commerce Drive Schaumburg IL 60173 U S A Tel 1 847 843 7900 Fax 1 847 843 8568 OMRON ASIA PACIFIC PTE LTD 83 Clemenceau Avenue 11 01 UE Square 239920 Singapore Tel 65 6835 301 1 Fax 65 6835 271 1 OMRON CHINA CO LTD Room 2211 Bank of China Tower 200 Yin Cheng Road M Shanghai 200120 China Tel 86 21 5037 2222 Fax 86 21 5037 2200 Authorized Distributor Cat No Z207 E1 03 OMRON Corporation 2004 All Rights Reserved Note Specifications subject to change without notice Printed in Japan 0806 0 5IM 0804 C
46. ion Location Do not install the product in locations subjected to the following conditions e Ambient temperature outside the rating e Rapid temperature fluctuations causing condensation e Relative humidity outside the range of 35 to 85 e Presence of corrosive or flammable gases e Presence of dust salt or iron particles e Direct vibration or shock e Reflection of intense light such as other laser beams or electric arc welding machines e Direct sunlight or near heaters e Water oil or chemical fumes or spray e Strong magnetic or electric field Power Supply and Wiring e When using a commercially available switching regulator make sure that the FG ter minal is grounded e If surge currents are present in the power lines connect surge absorbers that suit the operating environment e Before turning ON the power after the product is connected make sure 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 e Before connecting disconnecting the Sensor Head make sure that the Smart Sensor is turned OFF The Smart Sensor may break down if the Sensor Head is connected or disconnected while the power is ON e Use extension cord ZFV XCLIB R V2 sold separately for extending the cord between the sensor head and amplifier unit 2 ZFV XCLIB R V2 cords can be coupled together to extend the cord
47. ist of Setting Items in MENU mode 46 x Executing Teaching 48 n Teaching Flow 48 Types of Teaching 51 E x Adjusting Threshold Values 55 x Performing Measurement 59 x Setting Banks 60 Setting the System Environment 61 Adjusting the measurement speed 61 Selecting the measurement timing 61 Selecting the teaching mode from an external device 61 Setting canceling the Eco mode 62 Initializing setup data 62 Initializing measurement data 62 Checking the version 63 Changing image capture timing on teaching screen 63 Setting communications environment 64 x Changing the Input output Conditions 65 x I O Monitor Function 68 x Settings During Application Extended Connection 69 Customizing Measurement conditions 71 Common items 71 PATTERN SEARCH MATCH 72 BRIGHT 73 AREA 74 WIDTH 75 POSITION 76 COUNT 77 CHARA CHARA 1 CHARA 2 78 X Saving the Set Measurement Conditions 82 ZFV User s Manual 41 Section 3 Setting Flow Installation and Connection C SECTION 2 Set the Sensor Head and Amplifier Unit IUA INSTALLATION amp CONNECTION p 22 v Power ON Adjusting the Image SECTION 2 Adjust the focus of the image INSTALLATION amp CONNECTION p 38 Preparation for Measurement Only when Amplifier Units are gang mounted Settings in an application extended connection Set the processing details for each Amplifier jt z p 69 Units dNLAS fA RAES Executing Teaching Execute teaching and register the j
48. k number gt MENU Mode SYS1 BANKSET COPY Clearing banks Clearing deletes the settings of the currently selected bank number gt MENU Mode SYS1 BANKSET CLEAR whe A SYS1 SYS2 settings and RUN Mode display settings cannot be cleared CHECK Setting the bank switching method Select how to switch banks gt MENU Mode SYS1 BANKSET SWITCH Setting Description KEY default value Banks are switched by the control keys on Amplifier Unit VO Banks are switched by the control keys on Amplifier Unit and input lead sig nals Switching by input lead signals is enabled only in the RUN mode ZFV User s Manual Helpful information regarding operation and reference pages are introduced here using symbols alo a _ A CHECK ZFV User s Manual T Introduction Editor s Note E Meaning of Symbols Menu items that are displayed on the Amplifier Units LCD screen are indicated enclosed by brackets r a a T E Visual Aids au Indicates points that are important to ensure full product performance such as operational A precautions and application procedures CHECK ME Indicates pages where related information can be found Indicates information helpful in operation Indicates functions that can be set only when the setup menu has been switched to EXP menu ZFV 8 User s Manual Introduc
49. king a more detailed setup ZFV 18 User s Manual 5 6 7 8 9 Section 1 Part Names and Functions Mode selector switch This switch selects the operating mode MENU Select this mode when setting measurement conditions ADJ Select this mode when adjusting the judgment threshold value RUN Select this mode when performing measurement Output is performed only when the RUN mode is currently selected LCD monitor The LCD monitor displays setup menus and images captured from the Sensor Head Sensor Head connector i m gt j C z3 m N This connector connects the Sensor Head Coupler This connector is used to connect two or more Amplifier Units It is located on both sides of the Amplifier Unit I O Cable The I O cable connects the Amplifier Unit to the power supply and external devices such as timing sensors or programmable controllers ZFV User s Manual 19 i m gt ze m N 20 Section 1 Part Names and Functions E Sensor Head 5 Focus adjustment 1 Lighting part poe 2 Receiver part 3 Connector 1 Lighting part This section emits light 2 Receiver part This section captures the image 3 Connector This connector is connected to the Amplifier Unit 4 Sensor Head mounting fixture This fixture is for mounting the Sensor Head This fixture can be mounted on all of the four mounting surfaces 5 Focus adjustment c
50. l before using these graphs T gt m m gt O Z Qo Q O Z Z m O O Z Reading graphs H refers to the following width Detection range Details of detection range LEZ p 96 e ZFV SR10 Setting distance L mm Detection range H Setting distance L mm mm Detection range H mm ZFV 38 User s Manual Section 2 Sensor Head e ZFV SR50 Setting distance L mm 300 Detection range H Setting distance L mm mm Detection range H mm Example When using a ZFV SR50 Sensor Head at a detection range of 25 mm required for the location of the sensing object the set ting distance of Sensor Head becomes I ES 95mm Z T j gt m m gt O Z Qo O O Z Z m O O Z Setting distance L Workpiece Detection range H About installation for reflective workpieces Install the Sensor Head at an angle to prevent mirror reflection light from being picked up by the sensor Mirror reflec tion light Guide light ZFV User s Manual 39 Section 2 Sensor Head E Installation procedure 1 Install the Sensor Head at the installation distance obtained in the above graphs 2 Turn the focus adjustment control to the left and right to adjust the focus Focus adjustment control Focus can be verified by the green guide light Adjust so that the guide light is fine foned e Turn to right Focuses to the
51. lay the timing that the OUTPUT signal turns ON OUTPUT ON at OK judgment in continuous measurement Judged as NG Judged as OK Judged as NG OFF OUTPUT i ON i I I 1 Delay time P MENU Mode SYS2 OUTPUT ON DELAY 0 to 255 default value 0 Set the time ms to delay turning ON of the OUTPUT signal ZFV 66 User s Manual Section 3 Changing the Input output Conditions Setting the OFF delay time EXP MENU Set this item to delay the timing that the OUTPUT signal turns OFF OUTPUT ON at OK judgment in continuous measurement Judged as NG Judged as OK Judged as NG l OFF i OUTPUT l ON 1 Delay time P MENU Mode SYS2 OUTPUT OFF DELAY 0 to 255 default value 0 Set the time ms to delay turning OFF of the OUTPUT signal dNLAS Reels ZFV User s Manual 67 dNLAS FAE RAES 68 Section 3 I O Monitor Function I O Monitor Function EXP MENU J This is a function to check the status of I O signals SYS2 I O MON Signal name Signal status 0 OFF 1 0N P MENU Mode SYS2 I O MON TRIG Displays ON OFF status of TRIG signal O OFF 1 ON TEACH Displays ON OFF status of TEACH signal 0 OFF 1 ON BANK Displays ON OFF status of BANK signal 0 OFF 1 ON Expresses BANK1 BANK2 BANK3 sequentially from the right OUTPUT Displays ON OFF status of OUTPUT signal 0 OFF 1 ON ENABLE Displays ON OFF status of ENABLE signal 0 OFF 1 0N ERROR Displays O
52. lay time 66 Setting the OFF delay time 67 I O Monitor Function 68 Settings During Application Extended Connection 69 Specifying the Amplifier Unit to input the trigger 69 Setting the presence of Sensor Head 70 ZFV 10 User s Manual Setting output content Customizing Measurement conditions Common items PATTERN SEARCH MATCH BRIGHT AREA WIDTH POSITION COUNT CHARA CHARA 1 CHARA 2 Saving the Set Measurement Conditions SECTION 4 APPENDIX Introduction CONTENTS 70 71 71 72 13 74 19 76 Tf 78 82 83 Troubleshooting Error Messages and Remedies Q amp A Run Mode Display Item List When Gang mounting Amplifier Units Gang mounting example Rules of gang mounting Data route Teaching process when gang mounting Integrating judgment output Restrictions when gang mounting old and new amplifier units Specifications and External Dimensions sensor Head Amplifier Unit Panel Mount Adapters Control Link Unit Extension Cord Version Up Information INDEX Revision History 84 85 86 87 89 89 90 91 92 93 94 95 95 97 100 101 102 103 105 108 ZFV User s Manual 11 r La a T 5 Introduction CONTENTS 3 MEMO S 2 ZFV 12 User s Manual Section 1 FEATURES ZFV Smart sensor Features Basic Configuration Part Names and Functions 14 16 18 ZFV User s Manual 13 Section 1 ZFV Smart sens
53. lect MOVE or SIZE from screen 3 then A adjust accordingly k BHE MOVE SIZE Move the area to the position for teach Adjust the area size for teaching then ing then press the SET key press the SET key TEACH MOVE TEACH SIZE e MOVE Je SIZE Teaching cannot be performed from the MOVE screen or SIZE screen Set changes with the SET key then return to screen 6 and perform teaching Switch to ADJ mode ADJ MENU RUN 8 Measurement starts 4SEARCH OK ZFV User s Manual 49 dNLAS fA RAES Section 3 Executing Teaching E Teaching Key Operations and Screen Transition FUN mode top screen NA T BANK TEACH SYS1 Teaching execution TEACH VIEW Setting of teaching conditions gt SET 1 1TEM EAs 3 SIZE dNLAS Keeble gt ITEM MOVE SIZE Setting the teaching details Moving the position of the teaching area Changing the size of the teaching area TEACH ITEM v Vilv_y PTRN AREA _ wip vv i POSI NUM BRGT CHAR TEACH MOVE TEACH SIZE PATTERN O 2 2 2 2 m 4 m m 4 ZFV 5O User s Manual Section 3 Executing Teaching Types of Teaching Select the type of teaching according to the detection content The details that are displayed differ according to the model of Amplifier Unit that you are using These items are displayed only when standard type Amplifier Unit
54. length In addition use a robot cable type extension cord ZFV XCLIBRV2 at locations where the cord bends to prevent damage to the cord e Use only combinations of Sensor Heads and Sensor Controllers specified in this man ual e Do not turn the power OFF in the following instances Immediately after the MENU mode or ADJ mode is switched to the RUN mode While teaching with a parallel signal Wait for the ENABLE signal to turn ON before turning the power OFF as the bank data may be initialized ZFV User s Manual mrb a T 5 Introduction Precautions for Correct Use rb acy a T 4 5 6 ZFV 3 Orientation when Installing the Amplifier Unit To improve heat radiation install the Amplifier Unit only in the orientation shown below Maintenance and Inspection e Do not use thinner benzene acetone or kerosene to clean the Sensor Head and Amplifier Unit e If large dust particles adhere to the front Panel of the Sensor Head use a blower brush used to clean camera lenses to blow them off Do not blow the dust particles with your mouth e To remove smaller dust particles wipe gently with a soft cloth Do not use excessive force to wipe off dust particles Scratches on the front Panel may cause errors Optical Axis and Detection Range The center of the guide light and detection range are for reference onl
55. m S lt 0 a il Es l 11 7 dia ZFV User s Manual 97 gt a m Z z gt lt 98 Section 4 Specifications and External Dimensions Single function Models Standard Models Item ZFV A10 ZFV A15 ZFV A20 ZFV A25 Output specifications NPN NPN open collector 30 VDC 50 mA max residual voltage 1 2 V max PNP PNP open collector 50 mA max residual voltage 1 2 V max Input specifications NPN At ON maximum OV short circuit or maximum 1 5V At OFF open circuit Leakage current at maximum 0 1 mA PNP At ON power supply voltage short circuit or power supply voltage within 1 5V At OFF open circuit Leakage current at maximum 0 1 mA Inspection items Pattern PTRN Brightness BRGT Patterns PTRN Brightness BRGT Area AREA Width WID Position POSI Count CNT Characters CHAR Teaching area Rectangular one area Teaching area size e Pattern PTRN Brightness BRGT Any rectangular area 256 x 256 max e Area AREA Width WID Position POSI Count CNT Characters CHAR Any rectangular area full screen max Bank selection Supported for 8 banks Response time Pattern PTRN Brightness BRGT High speed 4 ms Standard 8 ms High precision 12 ms Area AREA Width WID Position POSI Count CNT Characters CHAR 128 x 128 15 ms max Other functions Control output switching ON for OK or ON for NG ON delay OFF delay One shot output
56. measurement processing and outputting the result of processing e Single function type ZFV A10 A15 e Standard type ZFV A20 A25 Power supply Recommended OMRON power supply DC24V 10 15 1 When 1 Amplifier Unit is connected S82K 01524 DC24V 0 6A 2 When 2 or 3 Amplifier Units are connected S82K 05024 DC24V 2 1A 3 When 4 or 5 Amplifier Units are connected Prepare the required number of 1 and 2 power supplies above E Application Expanded Configuration Up to five Amplifier Units can be gang mounted When the Amplifier Unit is gang mounted a wider range of applications can be sup ported as simultaneous processing of multiple areas and measurement items can be combined Me EF a g The image captured by the Sensor Head is transferred to the leftmost Amplifier Unit so connect to the rightmost Amplifier Unit Right Right LE a a l Wrong Wrong ng MEG SH e The maximum number of Amplifier Units that can be connected is five regardless of the number A of connected Sensor Heads Six or more Amplifier Units cannot be connected ae e Provide power to all gang mounted Amplifier Units ZFV 16 User s Manual Section 1 Basic Configuration Example 1 In this configuration multiple parts of an image from a single Sensor Head are mea sured and multiple inspection item are performed Example Inspection of the number of leads AMP 1 AMP 2 i m gt j C 7 m N Example
57. mount Amount Edge level of shift of shift UP DOWN keys Change values e When edge detection direction is gt UP DOWN keys Change values e When edge detection direction is LEFT RIGHT keys Change values Setting item Details of Adjustment 0 to 468 Amount of shift from reference position Edge level O to 100 This is the level of change in density judged to be an edge Adjust this level when measurement is unstable jt A p 56 E COUNT Switch to ADJ Mode Adjustment of number Adjustment of edge level 1 COUNT ADJ lt MENU RUN TEACH VIEW Measured t LEV CHANGE value EDGE LEVI 50 Lower Upper Edge level limit limit UP DOWN keys Change values Setting item Details of Adjustment 0 to 255 This is the number of times that counting is to be performed Edge level O to 100 This is the level of change in density judged to be an edge Adjust this level when measurement is unstable jt A p 56 ZFV User s Manual dNLAS fA RAES 57 Section 3 Adjusting Threshold Values E CHARA 1 Switch to ADJ Mode Adjustment of correlation value 1 CHARA1 ADJ MENU RUN Measured value mm TH 60 UP DOWN keys Change values Density distribution value Setting item Details of Adjustment Density distribution O to 100 This is the value that is judged as OK when the density deviation value value during teaching is taken to be 100 E CHARA
58. n though change the search area for If the CUSTM setting has been changed perform the teaching SEARCH MATCH the search is done out again side the search area ZFV 86 User s Manual Section 4 Run Mode Display Item List Run Mode Display Item List The following tables show the characters that are displayed on the LCD monitor and their meanings Characters in parentheses are the characters that are displayed in the enlarged display mode E items displayed in common at ITEM AVE Average value of measurement result DRANGE Min and max of measurement result XX YY min value max value MCONT Measurement count 1 to 9999999 NG occurrence ratio NG count measurement count Judgment threshold value In the case of the upper lower limits XX YY lower limit upper limit is dis played Measurement time The shortest measurement time when the display image is set to Display only image E items displayed individually SEARCH MATCH CHARA 2 SCORE SCR Correlation values of calculated model BRIGHT DENAVE DAV Density average value DENDEV DEV Density distribution value AREA Ee Display Characters Meaning Area value value obtained by normalizing with area value during teaching taken as 100 POSITION Deviation from reference position WIDTH Edge width ZFV User s Manual gt U v m Z z gt lt 87 Section 4 Run
59. on Up Information gt a m Z z gt lt ZFV 104 User s Manual Section 4 INDEX INDEX A B ADJ mode 44 Adjusting light emission 71 ALL CLEAR 62 Amplifier Unit 23 Attaching the ferrite core 23 Installing the Amplifier Unit 23 restrictions when gang mounting 94 Specifications and External Dimensions Application Expanded Configuration 16 Application extended connection 69 Area value AVERAGE Average density value BANK Bank bank extension Clearing banks Copying banks 56 T3 55 Setting the bank switching method 60 Switching banks 60 Binarization 14 BINARY 74 CLEAR 60 COLOR 74 76 77 80 COM 64 COPY 60 Correlation value 55 58 Coupler 19 Data Storage Unit 15 Density deviation value 55 Density distribution value 58 Detection content 51 Brightness scratches dirt 51 Characters 51 G Number 51 Pattern shape presence 51 Position 51 Size area 51 Width 51 Detection range 38 96 DEVIATION 73 DIRECTION 75 76 77 80 ECO MODE 62 Eco mode 62 Edge 195 Color of edges 75 76 77 detectivity 76 Edge detection direction 75 76 77 Edge level 56 57 EDGE SENSE 76 Edge width 56 Expert menu 44 Extension cord 102 Focus adjustment control 20 FREEZE 63 Gang mounting 27 I O cable 31 I O Circuit Diagrams 32 I O MON 68 IMAGE RATE 61 Initializing measurement data 62 setup data 62 Initializing setup data 62 Input output 65 ON conditions 65 One shot output 65 Installat
60. once dNLAS fi RAES ZFV 82 User s Manual Section 4 APPENDIX Troubleshooting 84 d Error Messages and Remedies 85 BaBa gg d Run Mode Display Item List 0 87 d When Gang mounting Amplifier Units 89 bd Specifications and External Dimensions 95 BA INDEX 105 ZFV User s Manual 83 Section 4 Troubleshooting Troubleshooting This section describes countermeasures for temporary hardware problems Check the malfunction in this section before sending the hardware for repair Problem Probable cause and possible countermeasure Pages OUTPUT indicator does not lit e Check the setting of SYS2 OUTPUT ON STATUS To lit the indicator OUTPUT signal ON when the judgment is OK select OK ON and to lit the indicator OUTPUT signal ON when the judgment is NG select NG ON RUN indicator does not lit e Is the operating mode switch set to RUN Dark LCD screen e Is the Eco mode function set The Eco mode is set if pressing any key automatically returns to the original brightness The brightness is maintained when the Eco mode setting is can celed Note however that the life of the LCD backlight is short ened So we recommend setting the Eco mode Images are not displayed e Is the Sensor Head connector connected correctly p 40 e Is the brightness of the LED light set to a dark value p 71 Nothing is displayed when Ampli Is the power turned ON simultaneously fo
61. ontrol This control is used for adjusting the focus of the image 6 Ventilation film This film prevents the front panel from condensation ZFV User s Manual ZFV User s Manual Section 2 INSTALLATION amp CONNECTION x About Installation and Connection x Amplifier Unit Attaching the ferrite core Installing the Amplifier Unit Gang mounting About the I O cable Timing charts a Sensor Head Attaching the ferrite core Installing the mounting fixture Installing the Sensor Head Connecting the Sensor Head 22 23 23 23 2 31 34 37 37 37 38 40 Z e j gt m m gt O Qo O m Q O 21 Section 2 About Installation and Connection About installation and Connection E Checking the installation environment Read Precautions for Safe Use at the beginning of this manual and check the instal lation environment E Checking the installation site Read Precautions for Correct Use at the beginning of this manual and check the installation site E About the power supply Before installing and connecting the Smart Sensor be sure to turn it OFF Also read Precautions for Safe Use and Precautions for Correct Use at the begin ning of this manual and check the power supply and wiring T j gt m m gt O Z Qo Q O Z Z m O a O Z ZFV 22 User s Manual Section 2 Amplifier Unit Amplifier Unit This
62. or Features ZFV Smart sensor Features The ZFV sensor senses objects by its surface How objects are being sensed can be easily set while verifying on the LCD monitor The ZFV also incorporates a 250 000 pixel CCD equivalent to that of a Conventional machine vision sensor This allows presence detection and recognition of different objects which have up till now been performed visually to be executed fast and accurately E Recognition of top rear side and orientation of electronic components i m gt ze m N 1 SEARCH 1 SEARCH 1 Compact Sensor Head The LED light emitting section and lens are built into the compact Sensor Head The Sensor Head takes up little installation space 2 Easy installation and Adjustment The range that can be sensed by Sensor Head can be confirmed by the guide light So the Sensor Head can be installed by viewing the position of the guide light and its focus ZFV 14 User s Manual Section 1 ZFV Smart sensor Features 3 4 5 Business Card size Amplifier Unit e The Amplifier Unit is designed to be compact so that it can be installed at a wide range of sites TE Specifications and External Dimensions p 95 e Outstanding operate ease has been achieved by a 1 8 color LCD motor an industry first icon based menu and simple key layout 1 Basic Knowledge for Operation p 44 i m gt j C 7 m N e The ZFV incorporates an extensiv
63. orkpiece Detection of out of mg Set the teaching area to the part of the workpiece to perform position labels 5 measurement in and execute teaching Posi The edge of the workpiece is detected and judgment is per formed by comparing those edge coordinates against refer ence coordinates Example F Teaching area Set so that there is one change in brightness in the detection area such as light to dark or dark g to light CHECK COUNT Select this item when counting the number of workpieces Detection of the num Set the teaching area to the part of the workpiece to perform ber of leads TM detection in and execute teaching The edges in the teach Count of the number ing area are detected and judgment is performed by com of cables paring the number of edges with a reference value Example To detect the number of leads Bilin A change in brightness such as light to dark to light or dark to light to dark is counted as 1 In zs the above example the count is 4 CHECK ZFV User s Manual 53 dNLAS Reese Section 3 Executing Teaching Description Example of Application Select this item to detect the presence of an entire character Detection of presence string printed on a plain background Judgment is performed of entire character by comparing the changes in density brightness of a regis string such as the tered character string Omission of charac
64. ove teaching Workpiece stop teaching Teaching Key Operations and Screen Transition Threshold Values AREA BRIGHT CHARA 1 CHARA 2 COUNT MATCH POSITION SEARCH WIDTH THROUGH Timing charts Continuous measurement Synchronous measurement TRIG VERSION Version Wide View 63 63 96 Section 4 INDEX ZFV User s Manual gt a m Z z gt lt 107 Section 4 Revision History Revision History A manual revision code appears as a suffix to the catalog number at the bottom of the front and back covers of this manual Cat No 2Z207 E1 03 Revision code 01 August 2004 Original production pra 2005 Functions added as per software version upgrade Ver2 00 Information on extension cord ZFV XCL_ B R added gt a m Z z gt lt August 2006 Change made to the second line of the last bulleted item Third bulleted item added to description of Connecting the Sensor Head Saving the set measurement conditions step added to the Setting Flow Edge level setting item added to table Saving the set measurement conditions item added Question about display problem when Amplifier Units are con nected added to the troubleshooting list BANKDATA ERROR and SYSDATA ERROR added to error messages in table Information on SEARCH MATCH search area added to Q amp A ZFV 108 User s Manual OMRON Corporation Industrial Automation Company Sensing Devices Divis
65. r Unit is firmly fixed on the panel ZFV 26 User s Manual Section 2 Amplifier Unit Gang mounting Up to five Amplifier Units can be gang mounted A Application Expanded Configuration p 16 E Installing on the DIN track Amplifier Units can be easily mounted on the 35 mm DIN track Z j DIN track sold separately D PFP 100N 1 m m PFP 50N 0 5 m p PFP 100N2 1 m z Qo oO O z End plate sold sepa rately 9 PFP M O z Installation procedure 1 Install Amplifier Unit on the DIN track IUA p 24 2 Open the connector cover on the Amplifier Unit Slide the cover to remove Controller Link Unit 3 Insert the Controller Link Unit into the connector on the Amplifier Unit 4 Slide the Amplifier Unit and insert into the connector on the Controller Link Unit ZFV User s Manual 2 T gt m m gt O Z Qo Q O Z Z m O O Z 28 Section 2 Amplifier Unit Removal procedure 1 Slide the Amplifier Unit and remove from the connector on the Controller Link Unit 2 Slide the Controller Link Unit and remove from the connector on the Amplifier Unit 3 Install the cover on the coupler of the Amplifier Unit 4 Pull the hook on the I O cable end downwards 5 Lift up the Amplifier Unit from the I O cable end and remove it from the DIN track ZFV
66. r all of the connected p 16 fier Units are connected Amplifier Units Measurement results are not dis Is the operating mode switch set to RUN p 44 played gt a m Z z gt lt The TRIG signal input signal is Are all cables connected correctly p 31 not accepted e Is the signal line disconnected e Is the operating mode switch set to RUN p 44 The OUTPUT signal is not out e Is the TRIG signal being input p 31 put e Are all cables connected correctly e Is the signal line disconnected p 44 e Is the operating mode switch set to RUN The ENABLE signal does not e Is the operating mode switch set to RUN turn ON The bank is not switched even if Is the bank switching method set to I O the bank switching signal is input When the bank switching method is set to KEY only switching by from the outside key entry is enabled For this reason the external input of the BANK 1 to 3 are not accepted e Is the operating mode switch set to RUN ZFV 84 User s Manual Section 4 Error Messages and Remedies Error Messages and Remedies BANK DATA Error in the bank data The bank data will be initialized and ERROR must be reset HEAD IS NOT The Sensor Head is not connected cor Make sure that the Sensor Head is p 38 CONNECTED rectly connected correctly NEIGHBOR UNIT The Amplifier Units are not coupled cor Make sure that the Amplifier Units are p 27 IS NOT CON
67. s for Joron foo Aono o pes fe Aoroa Jo Joes Soor ourer o oes Soe C a A pe COMPOWAY COMPOWAY NORMAL pen p a mson a p 63 il TUR MODE DTL ojo N O TRIG I O LINK HEAD USE NOT USE p 70 OUTPUT EACH ALL EACH p 70 3 This menu is displayed only when Amplifier Units are gang mounted ZFV User s Manual dNLAS fA RAES 47 Section 3 Executing Teaching Executing Teaching Execute teaching and set the measurement conditions Project the image to be used as the accepted image as the details set in teaching are used as the reference in judgment Teaching Flow There are two ways of executing teaching by key operation and by external signals The following shows a procedure for teaching by key operation 1A For external input teaching p 35 1 Switch to MENU mode ADJ dNLAS Fi RAES MENU RUN 2 Put the cursor on TEACH then press the SET key Ge S 3 Adjust the position to display workpiece to the monitor while checking the image I For still image teaching p 63 iD TEACH SEARCH 4 Put the cursor on 1 ITEM then press the SET key 1 1 TEM BAN TOA SS 3 SIZE 9 Select teaching type A Types of Teaching p 51 ZFV 48 User s Manual Section 3 Executing Teaching 6 Press the TEACH key to perform teaching TEACH SEARCH TEACH VIEW 1 1 TEM BATONS 3 SIZE vt When changing the teaching area positioning or size se
68. section describes installation of the Amplifier Unit and connection of the I O cable Before connecting disconnecting peripheral devices make sure that the Smart Sensor is turned OFF C The Smart Sensor may break down if the Smart Sensor is connected or disconnected while the power check S ON Attaching the ferrite core Attach the ferrite core provided with the Smart Sensor to the I O cable of the Amplifier Unit Z T j gt m m gt O Z Qo O O Z Z m O O Z Ferrite core Installing the Amplifier Unit E Installing on the DIN track Amplifier Units can be easily mounted on the 35 mm DIN track DIN track sold separately PFP 100N 1 m PFP 50N 0 5 m PFP 100N2 1m End plate sold sepa rately PFP M ZFV User s Manual 23 T gt m m gt O Z Qo Q O Z Z m O O Z 24 Section 2 Amplifier Unit Installation procedure 1 Hook the connector end of the Amplifier Unit onto the DIN track Hook on connector end 2 Push the Amplifier Unit down onto the DIN track until the hook on the I O cable side is locked Push down until you hear it snap into place Hook on I O cable vio Q Always hook the connector end of the Amplifier Unit on the DIN track first Hooking the I O cable end on the DIN track first may impair the mounting strength of the DIN track attachment CHECK Removal procedure The following describes how to remov
69. signal after ENABLE signal is set to ON v y v 1 ero signe OUTPUT signal VENABLE signal ZFV User s Manual 93 gt v U m Z z gt lt 94 Section 4 When Gang mounting Amplifier Units Restrictions when gang mounting old and new amplifier units Restrictions on gang mounting between ZFV ALIL units are explained The amplifiers below hereinafter new amplifiers and amplifiers with serial numbers previous to this hereinafter old amplifiers cannot be gang mounted ZFV A10 SER No 0863Y04 or later ZFV A15 SER No 0060Y04 or later ZFV A20 SER No 0834Y04 or later ZFV A25 SER No 0032Y04 or later e Old old amplifiers or new new amplifiers can be gang mounted without problems occurring ve e Old amplifiers and new amplifiers can be distinguished by checking the model notations on the M face plate affixed to the bottom side of the amplifier CHECK i omron_ZFV A10 omron_ZFV A10 Ch Dot SMART SENSOR AMP UNIT SMART SENSOR AMP UNIT SOURCE 24VDC 0 6A SOURCE 24VDC 0 6A SER No SER No OMRON Corporation MADE IN JAPAN OMRON Corporation MADE IN JAPAN Old amplifier New amplifier e Please contact our sales department for more information ZFV User s Manual Section 4 Specifications and External Dimensions Specifications and External Dimensions Sensor Head ZFV SR10 SR50 Unit mm I 2 M4 depth 6
70. stomizing Measurement conditions WIDTH E Specifying edge detection conditions Set the direction in which edges are searched and the change in density Example Teaching area To detect this width COLOR BLACK DIRECTION Selecting the color of edges Select the direction of density change for the edge to be detected dNLAS Reels gt MENU Mode CUSTM COLOR WHITE default value A change from dark to light is judged as an edge A change from light to dark is judged as an edge Selecting the edge detection direction Select the direction in which edges are searched P MENU Mode CUSTM DIRECTION Searches in the vertical direction lt default value Searches in the horizontal direction ZFV User s Manual 15 Section 3 Customizing Measurement conditions POSITION E Specifying edge detection conditions Set the direction in which edges are searched and the change in density Example To detect this position COLOR BLACK DIRECTION Selecting the color of edges Select the direction of density change for the edge to be detected gt MENU Mode CUSTM COLOR dNLAS Reese WHITE default value A change from dark to light is judged as an edge A change from light to dark is judged as an edge Selecting the edge detection direction Select the direction in which edges are searched gt MENU ser alee 5 abc oOo O emee O oO __ feeertome
71. t upper limit lower limit UP DOWN keys Change values Setting item Details of Adjustment Area value 0 to 999 This is the area in which OK is judged when the area value during teaching is taken to be 100 E WIDTH Switch to ADJ Mode Adjustment of edge width Adjustment of edge level 1 WIDTH OK 1 WIDTH ADi i Edge level A gt gt MENU RUN TEACH VIEW m 120 Measured lt LEV gt SELECT L We HH 150 value EDGE LEV 50 Upper lower Lower Upper dge level limit limit limit LEFT RIGHT keys Select upper limit lower limit When edge detection direction is UP DOWN keys Change values LEFT RIGHT keys Switch edge UP DOWN keys Change values e When edge detection direction is UP DOWN keys Switch edge LEFT RIGHT keys Change values Setting item Details of Adjustment Edge width 0 to 999 This is the area in which OK is judged when the width during teaching is taken to be 100 Edge level O to 100 This is the level of change in density judged to be an edge Adjust this level when measurement is unstable Teaching area T ry Max density value Edge level N Min density value ZFV User s Manual Section 3 Adjusting Threshold Values E POSITION Switch to ADJ Mode Adjustment of edge position Adjustment of edge level Edge level 1 POSITION OK al OK ADJ lt MENU RUN TEACH VIEW Measured f LEV CHANGE value EDGE LEV 50 A
72. ters errors miss Best before date ing dots etc cannot be detected 04 07 01 Teaching area Example NG as there is no character string Select this item to detect omission of single characters Detection of missing Errors in characters missing dots etc cannot be detected character in character strings such as the 04 07 01 Teaching area Best before date Example dNLAS fpi RAES NG as 1 is missing This is displayed only when a standard type Amplifier Unit is in use aur About the teaching area for CHARA x A For the teaching area when the printing position is out of position set to an area in which the character string might possibly be printed out of position Be sure however to set to an area having a plain CHECK background If an area very close to the character string without any margin is set the sensor will not be able to track any shift in the printing position Right OK Any shift of the printing position inside the teaching area is judged as OK Wrong NG When the teaching area is set very close to the character without any margin character protrudes from the teaching area and so this is judged as an NG ZFV 54 User s Manual Section 3 Adjusting Threshold Values Adjusting Threshold Values Threshold values are adjusted to determine the range for OK judgments Adjust the threshold values referring to the currently indicated measurement results The a
73. the products e Outdoor use uses involving potential chemical contamination or electrical interference or conditions or uses not described in this document ZFV User s Manual Introduction e Nuclear energy control systems combustion systems railroad systems aviation systems medical equipment amusement machines vehicles safety equipment and installations subject to separate industry or government regulations e Systems machines and equipment that could present a risk to life or property Please know and observe all prohibitions 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 is subject to the OMRON 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 chang
74. tion CONTENTS uononpouyuy CONTENTS Precautions for Safe Use 4 Precautions for Correct Use 5 Editor s Note T Page Format T CONTENTS 9 SECTION 1 FEATURES 13 Basic Configuration 16 Part Names and Functions 18 SECTION 2 INSTALLATION amp CONNECTION 21 Amplifier Unit 23 Attaching the ferrite core 23 Installing the Amplifier Unit 23 Gang mounting 27 About the I O cable 31 Timing charts 34 sensor Head 37 Attaching the ferrite core 37 Installing the mounting fixture 37 Installing the Sensor Head 38 Connecting the Sensor Head 40 ZFV User s Manual 9 a a T Introduction CONTENTS SECTION 3 SETUP 41 About Setup 44 Basic Knowledge for Operation 44 List of Setting Items in MENU mode 46 Executing Teaching 48 Teaching Flow 48 Types of Teaching 51 Adjusting Threshold Values 55 Performing Measurement 59 Setting Banks 60 Switching banks 60 Copying banks 60 Clearing banks 60 Setting the bank switching method 60 Setting the System Environment 61 Adjusting the measurement speed 61 Selecting the measurement timing 61 Selecting the teaching mode from an external device 61 Setting canceling the Eco mode 62 Initializing setup data 62 Initializing measurement data 62 Checking the version 63 Changing image capture timing on teaching screen 63 Setting communications environment 64 Changing the Input output Conditions 65 Selecting the ON conditions 65 One shot output 65 Setting the ON de
75. to the right where the sensor head is connected Images are loaded to all amplifier units when all amplifier units are set to the teaching screen Images are not loaded to all amplifier units when the amplifier where the sensor head is connected is not set to the teaching screen Images are not loaded to the far left amplifier when the far left amplifier is not at the teaching screen TRIG signal ZFV User s Manual 63 Section 3 Setting the System Environment Setting communications environment EXP MENU gt MENU Mode SYS2 COM MODE CompoWay F or no procedures can be set to the communications protocol COMPOWAY default value Use this when gang mounted only with ZFV This allows communications with external devices using the OMRON proprietary communication protocol CompoWay F NORMAL Select when connected to the ZS DSU for communication without external o device procedures O ek _ For details on command formats refer to the ZS DSU manual Communication Command a Reference provided separately aloe cL Set the same communications protocol when gang mounted with ZS DSU I S v CHECK DELMIT A delimiter can be set when there are no communication protocol procedures Setting CR default value CR LF ZFV 64 User s Manual Section 3 Changing the Input output Conditions Changing the Input output Conditions Selecting the ON conditions EXP
76. tte OOOO Searches from right to left Changing edge detectivity Change detectivity when a stable edge cannot be located gt MENU Mode CUSTM EDGE SENSE SENSITIVE Edge detectivity becomes sensitive Select this when there is little background density deviation and a stable edge cannot be located NORMAL default value Standard detectivity Edge detectivity becomes insensitive Select this when debris is mistakenly detected as the edge ZFV 76 User s Manual Section 3 Customizing Measurement conditions COUNT E Specifying edge detection conditions Set the direction in which edges are searched and the change in density Example To detect this number F F COLOR BLACK DIRECTION Selecting the color of edges Select the direction of density change for the edge to be detected P MENU Mode CUSTM COLOR dNLAS Reels WHITE default value A change from dark to light is judged as an edge A change from light to dark is judged as an edge Selecting the edge detection Select the direction in which edges are searched gt MENU Mode CUSTM DIRECTION Searches from top to bottom default value Searches from left to right ZFV User s Manual Tf Section 3 Customizing Measurement conditions CHARA CHARA 1 CHARA 2 E Set the model registration conditions for characters This item is displayed only when CHARA 2 is set Select the number of
77. udgement criteria Key Operation Teaching p 48 External Signal Input Teaching p 35 Setting of Measurement Conditions External I O Set how to output the measurement values Adjusting threshold values Adjust the threshold values for judging the measurement result Saving the set measurement conditions Perform Measurement Applying Settings Performing Measurement aur Set measurement conditions are saved to the amplifier unit when external TEACH signal teaching is suc a a A cessful or when switched to RUN mode When the TEACH key is pressed from the teaching screen to gt teach contents will not be saved unless switched to RUN mode once Changed contents including teach CHECK ing results are cleared when switching off without saving ZFV 4 User s Manual Section 3 Setting Flow Setting Banks Use multiple banks for changeover i justing the measurement speed p Setting Up the System Adjusting th tspeed p 61 Environment Selecting the measurement timing p 61 Selecting the teaching mode from an external device p 61 Setting canceling the Eco mode p 62 V Q prar LL Qe oO r9 Ke A a or lt Changing the Input Output Conditions dNLAS fA RAES Advanced Setup Customizing Measurement Conditions Changing the display image Change the details to display on the LCD monitor during measurement Clearing all data Initialize th
78. y The center of the optical axis sometimes differs according to each Sensor Head Dur ing installation be sure to check the center of the image and the detection range on the LCD monitor of the Amplifier Unit Ventilation Film e Do not peel off or probe the ventilation film with a sharp pointed object If you so the specifications of the protective structure may no longer be satisfied e Do not block the ventilation film Doing so might cause the front panel to be con densed 6 User s Manual Introduction Precautions for Correct Use Editor s Note Page Format uononpouyuy Index label Title of each section Header Section 3 Setting Banks Overview Setting Banks lt c h The ZFV Series can hold up to eight sets of settings These settings can be switched lt G an VOSS ead er Se eee el eee externally when changing the device setup g A set of these settings is called a bank Ove rview of th e Switching banks lt cross h ea der LLL BANK 1 is selected as the default BANK 2 and 8 are also available lt i Movement throu g h z BANKS can also be switched from an external device mMm e n u S u p to setti n g z EA A Setting the bank switching method p 60 a l items MENU mode BANK oa 2 as Seer oe ee Peer o nS een Se eS e e i f Setting f BANK 1 BANK 8 A ER BANK 1 Explanation of options Copying banks Copy the settings of other bank numbers to an already selected ban
79. y the UP DOWN keys Setting Description 0 to 5 default value 5 0 Out 1 to 5 Light intensity increases the larger the number gt MENU Mode CUSTM LIGHT 1 Switch the light intensity by the UP DOWN keys aoe When performing partial adjustment Se 4 e LEFT RIGHT keys Select the adjustment section e UP DOWN keys Select the light intensity TS 2 Press the SET Key to apply the setting LIGHT 5555 ZFV User s Manual TA dNLAS fA RAES Section 3 Customizing Measurement conditions PATTERN SEARCH MATCH E Changing the search area Change the area to search the model in Specify the top left and bottom right of the search area Search area Model ABCDE P MENU Mode CUSTM SEARCH AREA dNLAS FAE RAES E Setting the rotation range of a workpiece This item is displayed only when SEARCH is set Set this item when even a tilted workpiece is to be set as a non defective item gt MENU Mode CUSTM ROTATION 10 default value Set the range of acceptable tilt 10 20 30 The larger the range of acceptable tilt the longer it takes to perform measurement CHECK ZFV 12 User s Manual Section 3 Customizing Measurement conditions BRIGHT E Changing the detection content Select the content whose brightness is to be detected gt MENU Mode CUSTM METHOD AVERAGE default value Performs detection using brightness average density value

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