Page 1 Cat. No. Z240-E2-03 ZFV-C Smart Sensor with Ultra-High-Speed Color CCD Cameras User´s Manual...
Page 2 • The ZFV-C Smart Sensor must be operated by personnel knowledgeable in electrical engineering. • To ensure correct use, please read this manual thoroughly to deepen your understanding of the product. • Please keep this manual in a safe place so that it can be referred to whenever necessary.
Page 3 APPLICATION CONSIDERATIONS (Please Read) INTRODUCTION FEATURES SECTION 1 INSTALLATION & CONNECTION SECTION 2 FUNCTIONS AND OPERATIONS TO BE USED SECTION 3 SETTING OF INSPECTION CONDITION SECTION 4 SETTING ADDITIONAL FUNCTIONS SECTION 5 APPENDIX SECTION 6 APPLICATION AND SETTING SECTION 7 User’s Manual...
Page 4 PRODUCTS, WHETHER SUCH CLAIM IS BASED ON CONTRACT, WARRANTY, NEGLIGENCE, OR STRICT LIABILITY. In no event shall responsibility of OMRON for any act exceed the individual price of the product on which liability is asserted. IN NO EVENT SHALL OMRON BE RESPONSIBLE FOR WARRANTY, REPAIR, OR OTHER CLAIMS REGARDING THE PRODUCTS UNLESS OMRON’S ANALYSIS CONFIRMS THAT THE PRODUCTS...
Page 5 The following are some examples of applications for which particular attention must be given. This is not intended to be an exhaustive list of all possible uses of the products, nor is it intended to imply that the uses listed may be suitable for the products: •...
Page 6 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...
Page 7: Meanings Of Signal Words
Indicates the possibility of laser radiation. Alert Statements in This Manual The following alert statements apply to the products in this manual. Each alert statement also appears at the locations needed in this manual to attract your attention. This product is not designed or rated for ensuring safety of persons.
Page 8: Precautions For Safe Use
• During installation, make sure that screws are tightened firmly. (2) Power Supply and Wiring • The supply voltage must be within the rated range (DC24 V + 10 %, –15 %). • Reverse connection of the power supply is not allowed.
Page 9: Precautions For Correct Use
- Immediately after the mode is switched from MENU or ADJ mode to RUN mode - While teaching operation using the parallel signal is in progress Do not turn off the power until the ENABLE signal is turned ON. Failure to do so may initialize the bank data.
Page 10 • Do not use thinner, Alcohol, benzene, acetone or kerosene to clean the Sensor Head and Amplifier Unit. • If large dust particles adhere to the front filter 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.
Page 11: Editor's Note
Movement through menus Copy the settings of other bank numbers to an already selected bank number. up to setting items The following example shows the procedure for copying the settings of BANK 1 to BANK 2. MENU mode-[SYS1]-[BANK SET]-[COPY] Clearing Banks “Clearing”...
Page 12: Meaning Of Symbols
Indicates points that are important to ensure full product performance, such as operational precautions and application procedures. 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-C User’s Manual...
Page 13: Table Of Contents
Introduction CONTENTS CONTENTS Meanings of Signal Words Meanings of Alert Symbols Alert Statements in This Manual Precautions for Safe Use Precautions for Correct Use Editor’s Note Page Format CONTENTS Menu Hierarchy Section 1 FEATURES Features System Configuration Part Names and Functions...
Page 14 Introduction CONTENTS Section 3 FUNCTIONS AND OPERATIONS TO BE USED Switching the Display Content Characters Displayed on the LCD Monitor and Their Meanings Key Operations for RUN Mode Switching to Another Bank Section 4 SETTING OF INSPECTION CONDITION Basic Knowledge for Operation...
Page 15 Setting the Bank Switching Method Setting the System Environment Changing the Measurement Speed Selecting the Measurement Timing Selecting the Teaching Mode from an External Device Setting Screen Display Setting/Cancelling the Eco Mode Changing Image Capture Timing on Teaching Screen I/O Monitor Function...
Page 16 Introduction CONTENTS Setting for Amplifier Unit Gang-Mount Specifying the Amplifier Unit to Input the Trigger Setting the Presence of Sensor Head Setting Output Content Rules of Gang-Mounting Data Route Teaching Process when Gang-Mounting Integrating Judgment Output Restrictions when Gang-Mounting Amplifier Units...
Page 17: User's Manual
Introduction CONTENTS Section 7 APPLICATION AND SETTING Inspecting for the Presence of Electronic Components (Pattern) Detecting Mixed Varieties of Campaign Seals (Area) Inspecting Entry of Workpieces of Wrong Color (HUE) Explanation of Color Related Functions Color Pickup Function Hue Indication Number...
Page 18: Menu Hierarchy
Introduction Menu Hierarchy Menu Hierarchy Items indicated by are displayed only when the EXP menu is selected. MENU mode Settings Default Selection/Setting Range Page p.62 TEACH ITEM PATTERN SEARCH, MATCH p.66 AREA AREA1, AREA2, AREA3 p.70 p.72 WIDTH p.75 POSITION p.78...
Page 19 ECO MODE ON, OFF (*1) Displayed when [ITEM] - [AREA] is selected or when [ITEM] - [WIDTH], [POSITION] or [COUNT] is selected and then [CUSTOM] - [COL MODE] - [PICKCOL ] is selected. (*2) Displayed when [COL JUGE] - [ON] is selected.
Page 20 LOCK OFF LOCK OFF, LOCK ON p.105 PASS NUMBER 0000 0~9999 p.111 LINKSET (*8) OUTPUT EACH ALL, EACH p.111 TRIG I/O, LINK p.111 HEAD USE, NOT USE (*8) This menu is displayed only when Amplifier Units are gang-mounted. ZFV-C User’s Manual...
Page 21: Section 1 Features
Section 1 FEATURES Features System Configuration Part Names and Functions Operation Mode Setting Flow ZFV-C User’s Manual...
Page 22: Features
The ZFV-C also uses 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 by a human, to be executed fast and accurately. Example: Inspection of Campaign Seals...
Page 23: System Configuration
Detects workpieces as images. Used when the amount of light by the built-in type • Narrow view type (Field of vision 5 to 9 mm) ZFV-SC10 lighting device is insufficient or when another lighting • Standard view type (Field of vision 10 to 50 mm) ZFV- method like back lighting is required.
Page 24 In this configuration, multiple sensor heads are used to simultaneously inspect multiple locations on a workpiece. When the TRIG signal is input to an amplifier from a single specified Amplifier Unit, the connected Amplifier Unit starts sensing immediately. The results of sensing are inte- grated on the Amplifier Unit to which the TRIG signal was input, and a total judgment result is output.
Page 25 Personal Computer ZFV-C In addition, up to 128 bank data can be saved in the memory card inserted into the data storage unit. Bank data can be transferred from the data storage unit to ZFV as needed for the device setup.
Page 26: Part Names And Functions
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. ■ Amplifier unit (9) Sensor Head connector (1) OUTPUT indicator OUTPUT (2) RUN indicator...
Page 27: Sensor Head
To connect a programmable controller or personal computer, connect a RS-232C cable to this connector. The following dedicated RS-232C cable shown below must be used. Use of a RS-232C other than the one given below may result in malfunction or damage.
Page 28 This fixture is for mounting the Sensor Head. fixture This fixture can be mounted on all of the four mounting surfaces. Focus adjustment control This control is used for adjusting the focus of the image. Ventilation film This film prevents the front panel from condensation.
Page 29: Operation Mode
Section 1 Operation Mode Operation Mode There are 3 ZFV-C operating modes as follows. Switch to the mode that you meet, before you start operation. To switch the operating mode, use the mode switch. MENU Mode Description MENU mode This mode is for executing teaching or setting up the measurement condi- tions.
Page 30: Setting Flow
“when switched to RUN mode”. When the TEACH key is pressed at the teach- ing screen to teach, conditions that you have set will not be saved unless switched to RUN mode once. Changed contents including teaching results are cleared when switching off without saving.
Page 31: Troubleshooting
Conditions Conditions Section 3 Setting Banks Setting Banks FUNCTIONS AND OPERATIONS TO BE USED Use two or more banks for setup Switching to Another Bank p.58 changes. Section 5 SETTING ADDITIONAL FUNCTIONS Setting Conditions Related to Bank p.94 Setting the System...
Page 32 Section 1 Setting Flow MEMO ZFV-C User’s Manual...
Page 33: Section 2 Installation & Connection
Section 2 INSTALLATION & CONNECTION About Installation and Connection Amplifier Unit Installing the Amplifier Unit Gang-Mounting About the I/O Cable Timing Charts Sensor Head Affixing LED Warning Labels Installing the Mounting Fixture Installing the Sensor Head Connecting the Sensor Head ZFV-C User’s Manual...
Page 34: About Installation And Connection
This section describes installation of Amplifier Unit, and connection of the I/O cable. Before connecting/disconnecting peripheral devices, 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 Installing the Amplifier Unit ■...
Page 35 Push down until you hear it snap into place. 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.
Page 36 Section 2 Amplifier Unit ■ Mounting on a panel The Panel Mount Adapters (sold separately ZS-XPM1) can be used to mount the Amplifier Unit on a panel. Panel Mount Adapters p.128 Push out the Amplifier Unit from the rear Panel of the panel towards the front.
Page 37 Install the Amplifier Unit with Mount Panel Adapters attached onto the panel from the front. Take care not to pinch the I/O cable. Hook the hooks of the mounting bracket Mounting onto the two holes of the smaller Mount bracket Adapters and tighten the screws.
Page 38: Gang-Mounting
Amplifier Unit. Put the cover on the connector of the Amplifier Unit. Pull the hook on the I/O cable end down- wards. Hook on I/O cable Lift up the Amplifier Unit from the I/O cable end, and remove it from the DIN track.
Page 39 Panel Mount Adapters p.128 Install a Amplifier Unit on a DIN track. p.33 When mounting on a panel, be sure to install the DIN track on the rear side of the Amplifier Unit for support. Push out the Amplifier Unit from the rear of the panel towards the front.
Page 40 Amplifier Unit Install the long Mount Adapters on the Panel Mount Adapters two holes on the small Mount Adapter. Install the long Mount Adapters only on both sides of gang-mounted Amplifier Units. Panel Mount Adapters Install the Amplifier Unit with Mount...
Page 41: About The I/O Cable
(4) 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. This lead is interlocked with ERR LED. Error Messages and Corrective Actions p.119 ZFV-C...
Page 42 Selecting the Teaching Mode from an External Device p.97 (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. Selecting the Measurement Timing p.97...
Page 43 Section 2 Amplifier Unit ■ I/O Circuit diagrams ● NPN output type (ZFV-CA40) Brown Power (24 VDC) Load Black OUTPUT Load Orange ENABLE Load Light blue ERROR 24 VDC Blue GND(0V) Yellow TEACH Pink TRIG Gray BANK1 Green BANK2 BANK3 ●...
Page 44: Timing Charts
• The minimum ON time width of the TRIG signal is 1 ms. • The OUTPUT signal is held until the measurement result is updated. Note, however, when one-shot output is set, the OUTPUT signal is held for the preset time.
Page 45 Amplifier Unit ■ Teaching ● Workpiece stop teaching Teaching processing is performed according to TRIG signal input after the TEACH sig- nal is input. Measurement is not performed while teaching is being performed. Do not move the workpiece until teaching is completed.
Page 46 ● Workpiece move teaching Use this teaching mode when the object cannot be stopped. Teaching processing is divided up and performed in synchronous with the TRIG signal input after the TEACH signal is input. Teaching must be processed eight times. Measurement is not performed while teach- ing is being performed.
Page 47: Sensor Head
IEC 60825-1:1993+A1:1997 +A2:2001 Installing the Mounting Fixture Attach the mounting fixture (provided with the Smart Sensor) to the side of the Sensor Head. No mounting bracket is needed for the ZFV-SC150/SC150W sensor heads since it is integrated. ■ Installation procedure The mounting fixture can be installed on all of the four mounting surfaces.
Page 48 Make sure that the mounting fixture is firmly fixed on the Sensor Head. ■ Removing a mounting fixture Insert a 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 ZFV-C User’s Manual...
Page 49: Installing The Sensor Head
■ Setting 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 check the model before using these graphs. Workpiece Setting distance L •...
Page 50 Section 2 Sensor Head • ZFV-SC90 Setting distance L (mm) Detection range H (mm) Setting distance L (mm) Detection range H (mm) • ZFV-SC150 Setting distance L (mm) Detection range H (mm) Setting distance L (mm) Detection range H (mm) ZFV-C User’s Manual...
Page 51 MENU SET Key. TEACH Adjust the camera’s setting distance. Refer to the graph and set the camera in a position so that the area to be checked is within the detection area (LCD monitor). Detected distance (L) Detection range (H) ZFV-C User’s Manual...
Page 52 Default is focus set at furthest point. First turn the focus adjustment control slightly to the left and right, to make sure that the Focus adjustment control is not at the upper or lower limit positions. The focus adjustment control is a multi-turn potentiometer.
Page 53: Connecting The Sensor Head
Ferrite core Attach the ferrite cores on the cable of the Sensor Head. Make sure that one ferrite core is attached to the connector side as well as to the body side. ■ Disconnecting the Sensor Head Pull out the Sensor Head connector while pressing the hooks on both sides of the Sen- sor Head connector.
Page 54 Section 2 Sensor Head ■ Connecting the Optional Lighting Unit This optional lighting unit can be mounted to the rear connector of the sensor head (ZFV-SC50/SC50W/SC90/SC90W) with a single motion, and no power supply is required for the unit. Connector of the...
Page 55: Section 3 Functions And Operations To Be Used
Section 3 FUNCTIONS AND OPERATIONS TO BE USED Switching the Display Content Key Operations for RUN Mode Switching to Another Bank ZFV-C User’s Manual...
Page 56: Switching The Display Content
The measurement time differs according to the type of display image. The measurement time for “only image display” is the fastest. The number in parentheses ( ) serves as a guideline when “only image dis- play” is taken as the reference.
Page 57: Characters Displayed On The Lcd Monitor And Their Meanings
Details Characters Judgment result (OK/NG) Judgment threshold value In the case of the upper/lower limits, XX - YY (lower limit - upper limit) is displayed. Average value of measurement result DRANGE Min. and max. of measurement result XX - YY (min. value - max. value)
Page 58 Section 3 Switching the Display Content ● POSITION Display Details Characters Deviation from reference position ● COUNT Display Details Characters Count number ● BRIGHT Display Details Characters DENAVE Density average value DENDEV Density distribution value ● CHARA1 Display Details Characters...
Page 59: Key Operations For Run Mode
A: Switches the image display conditions. B: (Not used) C: Performs measurement again. D: (Not used) ← LEFT key In [BRIGHT], the display content is switched between “average den- → RIGHT key sity value” and “density distribution value”. ↑UP key Not used.
Page 60: Switching To Another Bank
7.BANK7 8.BANK8 ■ Switching to another bank by the external signal A bank can be switched from one to another by combining BANK input signals 1 to 3. This is possible with RUN mode only. Wiring p.39 The setting for the bank switching method must be changed.
Page 61: Section 4 Setting Of Inspection Condition
Section 4 SETTING OF INSPECTION CONDI- TION Basic Knowledge for Operation Displays of MENU/ADJ Mode and Key Operations Teaching Flow Inspecting by Pattern (PATTERN) Inspecting by the Size (Area) Inspecting by Color (HUE) Inspecting by Width (WIDTH) Inspecting by Position (POSITION)
Page 62: Basic Knowledge For Operation
Basic Knowledge for Operation Displays of MENU/ADJ Mode and Key Operations Make setups by the control keys while looking at the menus and the image displayed on the LCD monitor. The details that are displayed differ according to the operating mode.
Page 63: Teaching Flow
MOVE :VOID D : HIST PICK Candidate color * If the EXP menu has been selected, the color selection menu will also appear when [WID], [POSI] or [CNT] is selected. TEACH/SEARCH Press the TEACH key to perform teaching. Executing teaching ITEM REG.
Page 64: Inspecting By Pattern (Pattern)
There are two measurement items for [PATTERN]: [SEARCH] and [MATCH]. ● Search Judgment is performed by whether the registered model is or is not in the inspected area. This item works with workpieces tilted to an angle of ±45°. Example: Inspection of upside down orientation, and color of electronic components...
Page 65: Basic Setting Procedure
Basic Setting Procedure ■ Teaching The area to be inspected needs to be enclosed by a rectangular box, then teach it. The selected image in the area is registered as the inspection reference (model). Measurement is unstable when there are two or more of the same pattern. Register unique pattern in the screen or restrict the search range.
Page 66: Custom Menu
Teaching brightness p.65 ■ Items related to pattern ● 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 MENU mode-[TEACH] -[CUSTM] -[SEARCH AREA] ●...
Page 67 “Area of color” is not checked. Only “degree of similarity to model shape” is checked. The area of the color is checked, and the correlation value will be “0” if the result is ● Teaching Brightness If this function is set to [ON] (default), even if the brightness changes due to fluctuation of surround lighting, the sensor works well, thereby this function is useful to prevent color pickup problems that may occur due to lighting fluctuation.
Page 68: Inspecting By The Size (Area)
● AREA2 Make a judgment based on the area of each picked-up color (max. 4 colors). The judg- ment will be “OK” if the area of every color is within the specified threshold. This method is suitable when some colors are missing or the colors are different.
Page 69 Measure the area by specifying the measurement target according to brightness, not color, difference. (Binary image) This method is suitable when detecting a glossy metal surface and making a presence/ absence judgment according to the brightness difference, not to the color difference.
Page 70: Basic Setting Procedure
Area value 0 to 999 This is the range for OK when the value at teaching is taken to be 100 %. If AREA2 is selected, the same judgment conditions will be used for all the four colors. Judgment is made based on the color, among the four colors, that has the largest difference from the reference value.
Page 71: Custom Menu
WHITE (default) Select which part of the measurement area is to be set as white pixels. BLACK ● Setting binary levels Set the level for converting the color image captured from Sensor Head to a binary image. MENU mode-[TEACH]-[CUSTM]-[BINARY] Setting...
Page 72: Inspecting By Color (Hue)
Inspecting by Color (HUE) Inspecting by Color (HUE) This item inspects color difference of plain-colored workpieces. If there are two or more colors in the area, the color of the largest area will be the subject of inspection. Example: Cap color inspection...
Page 73 Setting item Range Details of Adjustment Color difference 0 to 509 Threshold for color difference needs to be set. The judgment will be OK if the measured color difference is below the threshold. Hue Indication Number p.159 ZFV-C User’s Manual...
Page 74: Inspecting By Width (Width)
Enclose the area to be inspected using a rectangular box and then perform teaching. Inspection area Teaching setting WIDTH Set so that there are two changes in brightness such as “light to dark” or “dark to light” in the inspec- tion area. ZFV-C User’s Manual...
Page 75: Custom Menu
Details of Adjustment Edge width 0 to 999 This is the range for OK when the width at teaching is taken to be 100 %. Edge level 0 to 100 This is the density level judged to be an edge.
Page 76 FILTER (default) A color filter is used to increase the contrast with the background. When [AUTO] filter is selected, a color filter that increases the contrast in the area will be selected automatically. It is also possible to select a filter that suits the workpiece.
Page 77: Inspecting By Position (Position)
Enclose the area to be inspected using a rectangular box and then perform teaching. Inspection Teaching area setting POSITION Set so that there is one change in brightness such as “light to dark” or “dark to light” in the inspection area. ZFV-C User’s Manual...
Page 78: Custom Menu
Changing edge sensitivity p.77 Items related to Changing the color mode (default: [FILTER]) p.74 color Changing the filter color (only when [FILTER] is selected in [COL MODE]) p.65 Teaching Brightness (only when [PICKUP] is selected in [COL MODE]) p.65 ZFV-C User’s Manual...
Page 79 Section 4 Inspecting by Position (POSITION) ■ Items related to edge detection Set the direction in which edges are searched and the change in density. Example) To detect this position EDGE MODE: DARK DIRECTION: → ● Selecting the color of edges Select the direction of density change for the edge to be detected.
Page 80: Inspecting By Count (Count)
Enclose the area to be inspected using a rectangular box and then perform teaching. Inspection Teaching area setting COUNT A change in brightness such as “light to dark to light” or “dark to light to dark” is counted as “1”. In the above example, the count is 5. ZFV-C User’s Manual...
Page 81: Custom Menu
Items related to Changing the color mode (default: [FILTER]) p.74 color Changing the filter color (only when [FILTER] is selected in [COL MODE]) p.65 Changing Brightness during teaching (only when [PICKUP] is selected in [COL p.65 MODE]) ■ Items related to edge detection Set the direction in which edges are searched and the density level.
Page 82 Section 4 Inspecting by Count (COUNT) ● Selecting the color of edges Select the direction of density change for the edge to be detected. MENU mode-[TEACH]-[CUSTM]-[EDGE MODE] Setting Details DARK Dark areas shown in the filtered monochrome image are assumed to be edges.
Page 83: Inspecting By Brightness (Bright)
Example: Inspection for Dirt on Battery Surface BRIGHT NG due to dirt BRIGHT Basic Setting Procedure ■ Teaching Enclose the area to be inspected using a rectangular box and then perform teaching. Inspection area Teaching setting BRIGHT ZFV-C User’s Manual...
Page 84: Custom Menu
Change values. Setting item Range Details of Adjustment Average 0 to 255 Threshold level for the average density in the teaching area. density value Density devi- 0 to 127 Threshold level for the density deviation in the teaching area. ation value...
Page 85 Setting Details AVERAGE (default) Inspect by brightness (average density value). Whether an object is lighter or darker is detected by referring to the den- sity at teaching. DEVIATION Inspect by (density deviation) in density. Select this to detect scratches or dirt.
Page 86: Detecting Presence Of Character String (Chara)
There are two measurement items for [CHARA]: [CHARA1] and [CHARA2]. ● CHARA1 Select this item to check for presence of the entire character string printed on plain background. Judgment is performed by monitoring changes in density (brightness) of the registered character string. Errors in characters, missing dots, etc. cannot be detected.
Page 87: Basic Setting Procedure
(Be sure, however, to set to an area having a plain 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.
Page 88 UP/DOWN keys: Change values. Setting item Range Details of Adjustment Density distribution value 0 to 100 This is the value that is judged as OK when the density deviation value during teaching is taken to be 100%. CHARA2 ● ● Switching to ●...
Page 89: Custom Menu
1LINE SHORT Select this when the character string consists of 1 line, 6 characters or less. 1LINE NORMAL (default) Select this when the character string consists of 1 line, 8 characters or less. 1LINE LONG Select this when the character string consists of 1 line, 15 characters or less.
Page 90 Details NONE The position is not corrected. MODEL The model is used to correct the position. Select this when there is a characteristics part such as a corner of a text box. MODEL 2004/09/24 EDGE The edge position is used to correct the position.
Page 91 MENU mode-[CUSTM]-[MODE DTL]-[EDGE MODE] Setting Details DARK (default) Dark areas shown in the filtered monochrome image are assumed to be edges. LIGHT Light areas shown in the filtered monochrome image are assumed to be edges. • Selecting the edge detection direction Select the direction in which edges are searched.
Page 92 MENU mode-[CUSTM]-[MODE DTL]-[SEARCH AREA] When searching edges Measurement can be performed only when the search area contains an edge. Determine the size and position of the area taking the movement range of the workpiece into consideration. ● Raising detection stability This item is displayed only when [CHARA2] is set.
Page 93: Section 5 Setting Additional Functions
Setting the Bank Switching Method Setting the System Environment Changing the Measurement Speed Selecting the Measurement Timing Selecting the Teaching Mode from an External Device 97 Setting Screen Display Setting/Cancelling the Eco Mode Changing Image Capture Timing on Teaching Screen...
Page 94: Setting Image Acquisition Conditions Adjusting Light Intensity And Shutter Speed
Section 5 Setting Image Acquisition Conditions Setting Image Acquisition Conditions Adjusting Light Intensity and Shutter Speed The intensity of the light from Sensor Head and shutter speed can be adjusted. [AUTO] is selected as the default setting. MENU mode-[IMAGE]-[CONTRAST] Setting...
Page 95: Changing The Image Display Position (Partial Function)
Changing the Image Display Position (Partial Function) ZFV-C allows you to increase the processing speed by narrowing the image acquisition area. The image area can be moved, when measurement speed is FAST mode (1/2 screen) or MAX mode (1/4 screen).
Page 96: Setting Conditions Related To Bank
Section 5 Setting Conditions Related to Bank Setting Conditions Related to Bank ZFV-C can hold up to eight sets of settings. These settings can be switched according to inspection conditions. A set of these settings is called a “bank”. Copying Banks Copy the settings of one bank to another bank.
Page 97: Clearing Banks
Description KEY (default) 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. Switching to Another Bank p.58 To switch a bank using a command via USB/RS-232C, select [SWITCH]-[KEY].
Page 98: Setting The System Environment Changing The Measurement Speed
Narrows the image acquisition area to 1/4. This will increase the measurement speed. (5 ms) • If [FAST] or [MAX] is selected, it is possible to select the part of the screen to be inspected. Changing the Image Display Position (Partial Function) p.93 •...
Page 99: Selecting The Measurement Timing
Setting Screen Display The color of characters displayed on the LCD monitor and monitor’s background color can be changed. Change the color when it is difficult to see the character or figure on the image. • Areas whose color can be changed...
Page 100: Setting/Cancelling The Eco Mode
Setting the System Environment Setting/Cancelling the Eco Mode Whether or not to darken the screen when a preset time has passed without any opera- tion. We recommend setting this mode to [ON] to prevent the brightness of the LCD screen from being impaired.
Page 101: I/O Monitor Function
Displays ON/OFF status of ERROR signal. (0: OFF, 1: ON) Put the cursor on OUTPUT, ENABLE and ERROR, then press the SET button key to switch between “0” and “1”. The external device operations can be checked by switching output OFF/ON when the actual measurements are not being performed.
Page 102: Correcting White Balance
Due to influences by sensor head’s surrounding and lighting, the image taken by the cam- era sometimes contains colors even if the object is white. The function to correct the color of a white object so that the object is displayed as white is called white balance.
Page 103: Initializing Measurement Data
Setting the System Environment Initializing Measurement Data Current and past measurement average values, measurement count and other measure- ment data can be cleared without restarting. Data to be cleared are the items displayed in the following screen at RUN mode. SEARCH SCORE DRANGE...
Page 104: Setting Usb/Rs-232C Communication Specifications
For the “Communication Command Reference”, contact OMRON sales staff. Before connecting/disconnecting external devices, make sure that the Amplifier Unit is turned OFF. Breakdown or accidents may occur if this is done with the Amplifier Unit turned ON. USB Connection ■ Connection Install the USB driver to the personal computer.
Page 105: Rs-232C Connection
Section 5 Setting USB/RS-232C Communication Specifications RS-232C Connection ■ Connection Insert one end of the RS-232C cable to the RS-232C connector on the Amplifier Unit. Insert the other end of the RS-232C cable to the RS-232C connector of the external device.
Page 106 Node No. indicates a connection group No. viewed from a host device (programmable controller). Not only ZFV-C but also two or more devices can be connected to the pro- grammable controller. Numbers assigned to the devices connected to the programma- ble controller are called node Nos.
Page 107: Restricting Operations (Lock Function) Setting The Lock Function
Description MODE SWITCH Operation of the mode switch (MENU/ADJ/RUN) is restricted. (Lock OFF (default), Lock ON) Operation of keys (SET, ↑ ↓ ← →, TEACH/View, and function keys A through D) is restricted. (Lock OFF (default), Lock ON) TEACH IN TEACH signal input is restricted.
Page 108: Starting/Cancelling The Lock Function
The lock function is cancelled. Lock Function during Gang-Mounting During gang-mounting, the lock function can be started or cancelled only on the host device. With respect to this function, the client is in the same status as the host device. ZFV-C User’s Manual...
Page 109: Changing Output Signal Output Conditions Selecting The On Conditions
Section 5 Changing OUTPUT Signal Output Conditions Changing OUTPUT Signal Output Conditions Selecting the ON Conditions Set whether to turn the OUTPUT signal ON when OK is judged or when NG is judged. MENU mode-[SYS2]-[OUTPUT]-[ON STATUS] Setting Details OK ON Turns the OUTPUT signal ON when OK is judged.
Page 110: Setting The On Delay Time
One-shot output is not performed. One-shot output is performed. When one-shot output is set to [ON], the OFF delay time setting is disabled. ■ Setting the One-Shot output Time OUTPUT turns ON for the preset time from when the OUTPUT signal turns ON.
Page 111: Setting The Off Delay Time
Section 5 Changing OUTPUT Signal Output Conditions Setting the OFF Delay Time Set this item to delay the timing that the OUTPUT signal turns OFF. OUTPUT ON at OK judgment in continuous measurement Judgment NG Judgment OK Judgment NG OUTPUT...
Page 112: Setting For Amplifier Unit Gang-Mount
These settings must be made to each Amplifier Unit. ● Example 1: 1 sensor head + multiple amplifier units Example of detection of input image from 1 sensor head with multiple amplifier units. • To detect multiple areas such as a 4-sided POSITION, multiple item SEARCH, etc.
Page 113: Specifying The Amplifier Unit To Input The Trigger
MENU mode-[SYS2]-[LINKSET]-[TRIG] Setting Details I/O (default) Set to only the Amplifier Unit to which the TRIG signal is to be input. LINK Synchronizes to the TRIG signal from the Amplifier Unit gang-mounted on the right side. All the Amplifier Units except for the rightmost one are set to [LINK] automati- cally.
Page 114: Rules Of Gang-Mounting
Rules of Gang-Mounting Item Rules No. of Amplifier Units connectable 5 or less (power must be supplied to each Amplifier Unit) No. of mounted sensor heads Up to the number of amplifier units TRIG signal input Only host device is enabled...
Page 115: Data Route
Image input timing delays do not occur. ■ 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.
Page 116: Teaching Process When Gang-Mounting
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 after teaching is performed. It is ignored even if a TEACH signal is input to the client. ENABLE signal TRIG signal TEACH signal The time required to perform the teaching process increases when gang-mounted.
Page 117: Integrating Judgment Output
■ 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 signal after ENABLE signal is set to ON. TRIG signal...
Page 118: Restrictions When Gang-Mounting Amplifier Units
■ ZFV-A_ _ Gang-mounting units The ZFV-A_ _ units cannot be gang-mounted. ■ ZFV-CA Gang-mounting multiple units To use two or more ZFV-CA units by gang-mounting them to each other, the following hardware and software are required: Hardware: Amplifier unit with serial number;...
Page 119: Section 6 Appendix
Section 6 APPENDIX Troubleshooting Error Messages and Corrective Actions Q&A Specifications and External Dimensions LED Safety Precautions for Using Laser Equipment Requirements from Regulations and Standards Updating the Firmware Version upgrade information Index ZFV-C User’s Manual...
Page 120: Troubleshooting
Images are not displayed. • Is the Sensor Head connector connected correctly? p.51 • Is the brightness of the LED light set to a dark value? p.92 Screen is not displayed when • Is power turned ON to all the gang-mounted amplifier units simul- p.21...
Page 121: Error Messages And Corrective Actions
High-voltage lines and power lines must be wired separately from this product. In the following instances, error messages are not displayed, but the ERROR and ERR lmap turn ON. Cause Countermeasure Page TRIG was input while ENABLE was OFF.
Page 122: Q&A
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...
Page 123: Specifications And External Dimensions Sensor Head
(Unit: mm) 1/4-20UNC Depth 6 18.7 2-M4 Depth 6 Mounting hole dimensions 20 ± 0.1 2-M4 A fixing bracket can be mounted to each side Focus adjustment control 67.9 17.9 4.5 4.5 6.36 Heat-resistant PVC shielded cable 5.8 Standard length 2 m 23.3...
Page 124 ZFV-SC50/SC50W (Standard View) (Unit: mm) 1/4-20UNC 26.5 Depth 6 2-M4 Depth 6 20 ± 0.1 A fixing jig can be mounted to each side 2-M4 Mounting hole dimensions 35.2 52.5 6.36 26.5 Heat-resistant PVC shielded cable 6.2 Standard 2 m 30.3...
Page 125 ZFV-SC90/SC90W (Wide View) (Unit: mm) 1/4-20UNC Depth 6 2-M4 Depth 6 20 ± 0.1 Mounting hole dimensions 83.7 35.5 30.25 A mounting bracket can be Heat-resistant PVC shielded cable mounted to each side 6.2 Standard length 2 m 52.5 ZFV-C User’s Manual...
Page 126 Section 6 Specifications and External Dimensions ZFV-SC150/SC150W (Ultra Wide View) (Unit: mm) 110.2 59.5 Heat-resistant PVC shielded cable 6.2 Standard length 2 m Mounting surface 2-M4 20 ± 0.1 Mounting hole dimensions ZFV-C User’s Manual...
Page 127 (Including the current consumed when optional lighting is connected) Dielectric strength 1,000 VAC, 50/60 Hz for 1 min Vibration resis- 10 to 150 Hz, 0.35 mm single amplitude, 10 times each in X, Y, and Z directions for 8 min tance (destructive) Shock resistance 150 m/s...
Page 128: Amplifier Unit
Bank switching Supported for 8 banks. Image input interval 13 ms (Standard), 8 ms (1/2 for partial scan), 5 ms (1/4 for partial scan) Other functions Control output switching: ON for OK /ON for NG, ON delay / OFF delay,...
Page 129 1 kV, Pulse rise: 5 ns, Pulse width: 50 ns, Burst duration: 15 ms Cycle: 300 ms Vibration resistance (destruc- 10 to 150 Hz, 0.1 mm single amplitude, 10 times each in X, Y, and Z directions tive) for 8 min...
Page 130: Panel Mount Adapters
Item ZS-XPM1 (for 1st unit) ZS-XPM2 (for 2nd unit onwards) Appearance Vibration resistance (destructive) 10 to 150 Hz, 0.7 mm double amplitude, 80 min each in X, Y, and Z direc- tions Shock resistance (destructive) 300 m/s 3 times each in six directions (up/down, left/right, forward/back-...
Page 131: Control Link Unit
Ambient humidity Operating and storage: 35 % to 85 % (with no condensation) Vibration resistance (destruc- 10 to 150 Hz, 0.7 mm double amplitude, 80 min each in X, Y, and Z directions tive) Shock resistance (destructive) 300 m/s 3 times each in six directions (up/down, left/right, forward/backward) Material Polycarbonate (PC), etc.
Page 132: Extension Cord
Applicable Sensor Head ZFV-SC10/SC50/SC50W/SC90/SC90W/SC150/ ZFV-SC10/SC50/SC50W SC150W Ambient temperature Operating: 0 to +40 °C, Storage: -25 to +65 °C (with no icing or condensation) Ambient humidity Operating and storage: 35 % to 85 %(with no condensation) Connection type Double-sided connector Material...
Page 133: Rs-232C Cable
1,000 VAC, 50/60 Hz for 1 min Insulation resistance 100 MΩ (at 500 VDC) 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/s 3 times each in six directions (up/down, left/right, forward/backward)
Page 134: Lighting Unit (Option)
Section 6 Specifications and External Dimensions Lighting Unit (Option) ZFV-LTL01 (bar lighting) (Unit: mm) 2 × 3-M3 Depth 5 P5.8 × 9 = 52.2 37.4 8 ± 0.1 20 ± 0.1 Mounting hole dimensions 10.7 69 ± 0.1 2-M3 Depth 5...
Page 135 90° P5.8 × 9 = 52.2 2000 +100 100 ± 0.1 100 ± 0.1 Mounting hole dimensions ZFV-LTF01 (light source for through-beam lighting) (Unit: mm) (Emitting surface) 4-M3 Depth 8 74 ± 0.1 74 ± 0.1 Mounting hole dimensions ZFV-C...
Page 136 Dielectric strength 300 VAC, 50/60 Hz for 1 min Vibration resis- 10 to 150 Hz, 0.35 mm single amplitude, 10 times each in X, Y, and Z directions for 8 min tance (destructive) Shock resistance 150 m/s , 3 times each in six directions (up/down, left/right, forward/backward)
Page 137: Led Safety Precautions For Using Laser Equipment
Class 2 (Exception) (*1) Safety standards vary with the country in which the instrument is to be used (except for Japan, Europe and USA). Refer to the safety regulations and standards for laser devices stipulated in the country in which the instrument is to be used.
Page 138: Requirements From Regulations And Standards
Figures A required wording Aperture label Not required Specified wording required Service entry label Required as appropriate to the class of accessible radiation Override interlock Required under certain conditions as appropriate to the class of laser used label ZFV-C User’s Manual...
Page 139 Promotion brochures must specify product classification; service manuals must contain safety vice information information Note: 1. This table is intended to provide a convenient summary of requirements. See text of this standard for com- plete requirements. 2. For the safety medical laser products, IEC 60601-2-22 applies 3.
Page 140: Summary Of Requirements To User
(see note 2) (see note 3) Note: 1. This table is intended to provide a convenient summary of requirements. See text of this standard for com- plete precautions. 2. Class 1M laser products that failed condition 1 of table10 of the standard. Not required for Class 1M laser products that failed condition 2 of table10 of the standard.
Page 141: Definitions Of Laser Classification
Note: Conditions for safe viewing of diffuse reflections for Class 3B visible lasers are: minimum viewing distance of 13 cm between screen and cornea and a maximum viewing time of 10 s. Other viewing conditions require a comparison of the diffuse reflection exposure with the MPE.
Page 142: Updating The Firmware
Warp Engine ZS is used to update the firmware. For the file for updating, please contact your OMRON representative. • Never turn OFF the power to the Amplifier Unit during update. Doing so will disable the Amplifier Unit’s ability to start up correctly.
Page 143 Specifications p.102 Turn ON the power supply to the Amplifier Unit. • Make sure that power is supplied to the Amplifier Unit. If power is cut off during update, the Amplifier Unit will be damaged and will not start up correctly.
Page 144 Updating the Firmware Setting the Firmware Information Click the [Controller information] button if necessary. The model and version number of the cur- rently connected Amplifier Unit will be dis- played. Click the [Loading file] button to select the file to be written.
Page 145 (update takes a couple of minutes). • An error may occur with the Amplifier Unit during update, but ignore it. • If the update progress bar stops or update is not completed within 10 minutes, there is a possibility that update has failed.
Page 146 Updating the Firmware ■ Setting the connection port If you have failed to start Warp Engine ZS, a message will appear, followed by the dia- log box shown on the right. Select [Settings]-[Control Panel] from the [Start] menu of the personal com- puter, and then double-click [System].
Page 147: Version Upgrade Information
Changes Page Addition of [COL JUGE] for pattern inspection p.65 Addition of horizontal direction ([DIRECTION] ← → ) for width, position and count inspection p.74, p.77, p.80 Addition of workpiece stop teaching function p.97 Addition of still image teaching function p.98...
Page 148: Index
Focus adjustment control COL JUGE COL MODE GAIN COLOR Gang mounting Color difference Color Pickup Function HEAD Color related items Changing the color mode Changing the filter color Color check I/O Circuit diagrams Light teaching Initialization MEAS CLEAR Connecting Measurement Data RS-232C...
Page 149 Lighting Unit (Option) RUN Mode Lock Function SEARCH AREA MDL DIV Sensor Head MEAS TYPE Affixing LED Warning Labels 45 Measurement Connecting the Sensor Head 51 Measurement time Focus adjustment Speed adjustment Installing the Mounting Fixture 45 Switching the display content 54...
Page 150 Section 6 Index Workpiece move teaching Workpiece stop teaching Threshold AREA AREA1 AREA2 BRIGHT COUNT Match Pattern POSITION Search WIDTH Timing Charts Synchronous measurement Continuous measurement TRIG Ultra Wide View Communication Setting VERSION Warp Engine ZS WHITE BAL Wide View...
Page 151 Section 7 APPLICATION AND SETTING Inspecting for the Presence of Electronic Components (Pattern) Detecting Mixed Varieties of Campaign Seals (Area) Inspecting Entry of Workpieces of Wrong Color (HUE) Explanation of Color Related Functions ZFV-C User’s Manual...
Page 152: Inspecting For The Presence Of Electronic Components (Pattern)
Adjusting the Camera Adjust the camera so that the workpiece is displayed on the monitor. Adjusting the Sensor Head Focus p.49 Setting the Inspection Method Select and press the SET Key.
Page 153 SIZE Adjust the position of the inspection area TEACH/REG. and press the SET Key. Vertical direction Move the green frame so that the target is cen- Horizontal tered in the inspection area. direction MOVE Registering the Reference Workpiece Press the TEACH/VIEW key.
Page 154: Detecting Mixed Varieties Of Campaign Seals (Area)
“1 Point” color differs from point the reference area Adjusting the Camera Adjust the camera so that the workpiece is displayed on the monitor. Adjusting the Sensor Head Focus p.49 Setting the Inspection Method Select and press the SET Key.
Page 155 SIZE Adjust the position of the inspection area TEACH/REG. and press the SET Key. Vertical direction Move the green frame so that the target is cen- point Horizontal tered in the inspection area. direction SIZE Selecting the Color to be Inspected Select [PICK] and press the SET Key.
Page 156 :CHG D :HIST If there are colors that are not to be TEACH/PICK selected, use the ↓ key to add a “x” mark. ← → Left/Right Keys: Move to left/right. point ↓ Key: Switches a currently target object to a...
Page 157 Section 7 Detecting Mixed Varieties of Campaign Seals (Area) Check the measurement results displayed AREA2 on the LCD monitor. point L: [ 80] H:[ 120] G ZFV-C User’s Manual...
Page 158: Inspecting Entry Of Workpieces Of Wrong Color (Hue)
Inspecting Entry of Workpieces of Wrong Color (HUE) NG due to wrong color Adjusting the Camera Adjust the camera so that the workpiece is displayed on the monitor. Adjusting the Sensor Head Focus p.49 Setting the Inspection Method Select and press the SET Key.
Page 159 SIZE Adjust the position of the inspection area TEACH/REG. and press the SET Key. Vertical direction Move the green frame so that the target is cen- Horizontal tered in the inspection area. direction MOVE Registering the Reference Workpiece Press the TEACH/VIEW key.
Page 160: Explanation Of Color Related Functions
Section 7 Explanation of Color Related Functions Explanation of Color Related Functions Color Pickup Function Up to four candidate colors (colors of the four largest areas) are picked up by simply enclosing the area to be measured. TEACH/PICK Color pickup area...
Page 161 ■ When there are four or more inspection target colors Adjustment of the target color range is possible. TEACH/PICK In this example, orange color can also be a target if the upper limit is raised. L[ 5] H[ 40] Upper limit...
Page 162 Section 7 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. Z240-E2-03 Revision code Revision code Date Revised contents 2005.

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