Page 1 Smart Sensors with Ultra-High-Speed Color CCD Cameras ZFV-C User’s Manual Cat. No. Z240-E1-04...
Page 2 When using the ZFV-C Smart Sensor, be sure to observe the following: • 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.
Page 3 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 Smart Sensor with Ultra-High-Speed Color CCD Cameras ZFV-C Series...
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 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.
Page 6 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.
Page 7: Meanings Of Signal Words
Since ZFV-SC50 emits a visible light that may have an adverse affect on the eyes, do not stare directly into the light emitted from the sensor head. If a specular object is used, take care not to allow reflected light enter your eyes. ZFV-C User’s Manual...
Page 8: Regulations And Standards
• Do not attempt to dismantle, repair, modify, pressurize or incinerate the product. • Dispose of this product as industrial waste. • Should you notice any abnormalities, immediately stop use, turn OFF the power sup- ply, and contact your OMRON representative. ZFV-C User’s Manual...
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. ZFV-C User’s Manual...
Page 10 Scratches on the filter may cause errors. • Should you notice any abnormalities, immediately stop use, turn OFF the power sup- ply, and contact your OMRON representative. (5) Ventilation Film • Do not peel off or probe the ventilation film with a sharp-pointed object. If you do, the specifications of the protective structure may no longer be satisfied.
Page 11: Editor's Note
Setting Bank Related Conditions Cross-header Setting Bank Related Conditions ZFV-C can hold up to eight sets of settings. These settings can be switched externally Overview of the when changing the device setup. A set of these settings is called a “bank”.
Page 12 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
Setting Flow 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 Installing the Mounting Fixture Installing the Sensor Head Connecting the Sensor Head ZFV-C User’s Manual...
Page 14 Inspecting by Position (POSITION) Basic Setting Procedure CUSTOM Menu Inspecting by Count (COUNT) Basic Setting Procedure CUSTOM Menu Inspecting by Brightness (BRIGHT) Basic Setting Procedure CUSTOM Menu Detecting Presence of Character String (CHARA) Basic Setting Procedure CUSTOM Menu ZFV-C User’s Manual...
Page 15 Restricting Operations (Lock Function) Setting the Lock Function Starting/Cancelling the Lock Function Lock Function during Gang-Mounting Changing OUTPUT Signal Output Conditions Selecting the ON Conditions One-shot Output Setting the ON Delay Time Setting the OFF Delay Time ZFV-C User’s Manual...
Page 16 LED Safety Precautions for Using Laser Equipment Requirements from Regulations and Standards Summary of Requirements to Manufactures Summary of Requirements to User Definitions of Laser Classification Updating the Firmware Flow of Firmware Update Version upgrade information Index ZFV-C User’s Manual...
Page 17 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 Revision History ZFV-C User’s Manual...
Page 18: Menu Hierarchy
DARK, LIGHT p.78 DIRECTION p.66 LIGHT TEACH (*3) OFF, ON [COUNT] p.75 COL MODE FILTER PICKUP, FILTER p.66 AUTO Same as [PATTERN/SEARCH/FILTER] FILTER (*4) p.81 EDGE MODE LIGHT DARK, LIGHT p.81 DIRECTION p.66 LIGHT TEACH (*3) OFF, ON ZFV-C User’s Manual...
Page 19 (*3) Displayed when [COL MODE] - [PICKCOL] is selected. (*4) Displayed when [COL MODE] - [FILTER] is selected. (*5) This menu is not displayed if ZFV-SC150_ is connected. (*6) “1/500” can be set only when the light intensity is set to “0000”. ZFV-C User’s Manual...
Page 20 (*7) This menu is displayed only when Amplifier Units are gang-mounted. (*8) Only when the host device is displayed. (*9) This setting does not display for the host device (the Amplifier Unit that the Sensor Head is connected to). 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.
Page 23: System Configuration
ZS-XPT2 Communication [For connecting a PC] by commands ZS-XRS2 (*1) Recommended OMRON power supply Number of Amplifier Units Sensor Head ZFV-SC10/SC50/SC90/SC150 connected Option Lighting Unit or Option Lighting Unit ZFV-LTL01/LTL02 connected ZFV-LTL04/LTF01 1 or 2 Amplifier Units S8VS-06024 (24 VDC, 2.5 A) S8VS-06024 (24 VDC, 2.5 A)
Page 24 Amplifier Unit to which the TRIG signal was input, and a total judgment result is output. Example) Alignment of products AMP 1 AMP 2 AMP 3 SEARCH SEARCH SEARCH AMP 1 AMP 2 AMP 3 SEARCH SEARCH SEARCH SEARCH SEARCH SEARCH ZFV-C User’s Manual...
Page 25 Data Storage Unit 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
RUN mode is currently selected. Control keys The Control Keys are for setting measurement conditions and other infor- mation. Key Operations p.57, p.60 LCD monitor The LCD monitor displays setup menus and images captured from the Sensor Head. ZFV-C User’s Manual...
Page 27: Sensor Head
(2) Receiver part (7) Optional lighting connector (4) Sensor Head (3) Connector mounting fixture ZFV-SC90_ (7) Optional lighting connector (1) Lighting part (6) Ventilation film (5) Focus adjustment (3) Connector (4) Sensor Head control (2) Receiver part mounting fixture ZFV-C User’s Manual...
Page 28 This connector is used to connect an optional lighting unit. (ZFV-SC50, ZFV-SC90) When no optional lighting unit is used, make sure that the con- nector is covered with the cap. If not, water-resistant perfor- mance will be deteriorated. ZFV-C User’s Manual...
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 Section 1 Operation Mode Setup Menu Description Top Screen EXP menu This is the expert menu. Switch to this menu to make a more advanced setup. Menu Hierarchy Differences by Menus p.16 ZFV-C User’s Manual...
Page 31: 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. ZFV-C User’s Manual...
Page 32: Switching To Another Bank P
When the Smart Sensor Does Not When an Error Message Appears When an Error Message Appears Operate Correctly Operate Correctly Error Messages and Corrective Actions p.121 Troubleshooting p.120 When You are Not Sure When You are Not Sure Q&A p.122 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 Installing the Mounting Fixture Installing the Sensor Head Connecting the Sensor Head ZFV-C User’s Manual...
Page 34: About Installation And Connection
DIN track (sold separately) PFP-100N (1 m) PFP-50N (0.5 m) PFP-100N2 (1 m) Ferrite core End plate (sold separately) PFP-M Attach the ferrite core (provided with the Smart Sensor) to the I/O cable of the Amplifier Unit. ZFV-C User’s Manual...
Page 35: Installation Procedure
The following describes how to remove the Amplifier Unit from the DIN track. Pull the hook on the I/O cable end of the Amplifier Unit downwards. Lift up the Amplifier Unit from the I/O Hook on I/O cable cable end, and remove it from the DIN track. ZFV-C User’s Manual...
Page 36 Amplifier Unit. Short panel mount adapters Install the long Panel Mount Adapters on Long panel the two holes on the short Panel Mount Mount Adapters Adapter. Long panel Mount Adapters ZFV-C User’s Manual...
Page 37 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. Make sure that the Amplifier Unit are firmly fixed on the panel. ZFV-C User’s Manual...
Page 38: Gang-Mounting
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. ZFV-C User’s Manual...
Page 39 Panel Install the small Mount Adapters on the four holes on the Amplifier Unit. Panel mount adapters Panel Mount Adapter Install the small Mount Adapters on all gang-mounted Amplifier Units. Panel mount adapters ZFV-C User’s Manual...
Page 40 Mount bracket Adapters and tighten the screws. Attach two mounting fixtures each on all gang- mounted Amplifier Units. Make sure that the Amplifier Unit are firmly fixed on the panel. ZFV-C User’s Manual...
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.121 ZFV-C User’s Manual...
Page 42 (9) BANK2 (bank switching input 2) (10) BANK3 (bank switching input 3) The bank No. can be switched when BANK1 to BANK3 are connected as follows. Bank No. BANK1 BANK2 BANK3 BANK1 BANK2 BANK3 BANK4 BANK5 BANK6 BANK7 BANK8 Timing Charts p.42 ZFV-C User’s Manual...
Page 43 Gray BANK1 Green BANK2 BANK3 Blue GND(0 V) Light blue ERROR 24 VDC Orange ENABLE Load Black OUTPUT Load Load Take precautions when choosing to input the TRIG signal using a contact output as chattering may occur. ZFV-C User’s Manual...
Page 44: Timing Charts
• Input the TRIG signal while the ENABLE signal is ON. • 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. One-shot Output p.109 ZFV-C User’s Manual...
Page 45 When teaching fails, the ERROR signal turns ON. Turn the TEACH signal OFF, and end teaching processing. When teaching fails, the state before teaching was initiated is returned to. Per- form teaching again. If the TEACH signal is turned OFF midway, teaching is disabled. ZFV-C User’s Manual...
Page 46 When teaching fails, the ERROR signal turns ON. Turn the TEACH signal OFF, and end teaching processing. When teaching fails, the state before teaching was initiated is returned to. Per- form teaching again. If the TEACH signal is turned OFF midway, teaching is disabled. ZFV-C User’s Manual...
Page 47: Sensor Head
Sensor Head body (light emitting side). Hook Push the other hook. Push down until you hear it snap into place. Make sure that the mounting fixture is firmly fixed on the Sensor Head. ZFV-C User’s Manual...
Page 48 Secure the base and bracket in place using the included screws (M3×6). Tightening torque: 0.54 N·m Secure the base in its mounted position using screws. Tightening torque M4: 1.2 N·m 1/4"-20 UNC: 2.6 N·m ZFV-C User’s Manual...
Page 49: Installing The Sensor Head
Detection range H Setting distance L (mm) Detection range H (mm) Setting distance L (mm) Detection range H (mm) • ZFV-SC50_ Setting distance L (mm) Detection range H (mm) Setting distance L (mm) 9 10 Detection range H (mm) ZFV-C User’s Manual...
Page 50 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 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 If the workpiece is glossy, install the Sen- sor Head at an angle to prevent mirror reflection light from being picked up by the sensor. Mirror reflection light TEACH/SEARCH TEACH/SEARCH Check the image. ABCDE ABCDE ITEM REG. ITEM REG. ZFV-C User’s Manual...
Page 53: Connecting 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. ZFV-C User’s Manual...
Page 54 This optional lighting unit can be mounted to the rear connector of the sensor head (ZFV-SC50_/-SC90_) with a single motion, and no power supply is required for the unit. Connector of the Remove the cap from the LIGHT connector optional lighting unit on the rear of the sensor head. ZFV-C User’s Manual...
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
(*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”. In the displays showing an image, the image type (color/monochrome) is switched each time the [A] function key is pressed. ZFV-C User’s Manual...
Page 57: Characters Displayed On The Lcd Monitor And Their Meanings
Area value (value obtained by normalizing with area value taken during teaching as 100) ● HUE Display Details Characters DIFF Difference between reference color and measured color Hue Indication Number p.161 ● WIDTH Display Details Characters WIDTH Edge width ZFV-C User’s Manual...
Page 58 ● 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 DENDEV Density distribution value ZFV-C User’s Manual...
Page 59: Key Operations For Run Mode
← LEFT key In [BRIGHT], the display content is switched between “average den- → RIGHT key sity value” and “density distribution value”. ↓ DOWN key Not used. SET key Not used. ESC key Not used. ZFV-C User’s Manual...
Page 60: Switching To Another Bank
Switching to Another Bank Switching to Another Bank ZFV-C can hold up to eight sets of settings. These settings can be switched externally according as inspection condition. A set of these settings is called a “bank”. A bank also contains the threshold value set in ADJ mode.
Page 61: Section 4 Setting Of Inspection Condition
Teaching Flow Inspecting by Pattern (PATTERN) Inspecting by the Size (Area) Inspecting by Color (HUE) Inspecting by Width (WIDTH) Inspecting by Position (POSITION) Inspecting by Count (COUNT) Inspecting by Brightness (BRIGHT) Detecting Presence of Character String (CHARA) ZFV-C User’s Manual...
Page 62: Basic Knowledge For Operation
Returns to the previous menu. Function keys A: Switches the image display conditions. (effective in the displays showing an image) B: (Not used) C: (Not used) D: Sets the detailed color selection conditions (effective in the color pickup screen). ZFV-C User’s Manual...
Page 63: Teaching Flow
* 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. * Teaching cannot be performed with the area adjustment and color selection screens. ZFV-C User’s Manual...
Page 64 Section 4 Basic Knowledge for Operation Do not select an inspection item again after having adjusted the teaching area. If you reselect an inspection item, the registered settings information of the previously selected inspection item will be initialized. ZFV-C User’s Manual...
Page 65: Inspecting By Pattern (Pattern)
Note, however, that this item does not work with tilted workpieces. Example: Inspection of wrong model and color of electronic components MATCH ABCDE MATCH NG due to wrong characters AFGHI MATCH “NG” due to inclina- tion of the workpiece ZFV-C User’s Manual...
Page 66: Basic Setting Procedure
Displayed when [COL JUGE] - [ON] is selected in the CUSTOM menu. “Area of the largest color group” is registered as the reference area when teaching is performed. Set the range for OK judgment with the registered area as “100”. ZFV-C User’s Manual...
Page 67: Custom Menu
Set this item when even a tilted workpiece is to be set as a non-defective item. MENU mode-[TEACH]-[CUSTM]-[ROTATION] Setting Details ±10° (default), ±20°, ±30°, ±45° Set the range of acceptable tilt. The wider the rotation range, the longer the measurement time. ZFV-C User’s Manual...
Page 68 “taught” first can be identified. MENU mode-[TEACH]-[CUSTM]-[LIGHT TEACH] Setting Details ON (default) The brightness/chromaticness range for color selection is changed during teach- ing. The brightness/chromaticness range for color selection is not changed during teaching. ZFV-C User’s Manual...
Page 69: Inspecting By The Size (Area)
NG because the AREA2 p o in t area of the “1 Point” color differs from the point reference area ZFV-C User’s Manual...
Page 70 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. Example: Detection of presence of screw holes AREA3 AREA3 NG due to insuffi- cient black area ZFV-C User’s Manual...
Page 71: Basic Setting Procedure
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. ZFV-C User’s Manual...
Page 72: Custom Menu
0 to 255 Adjust the binary level so that the measuring area is the target color. CUSTM/BINARY L: [ 80] H:[ 120] Lower limit Upper limit Upper/lower limit LEFT/RIGHT keys: Select upper limit/lower limit. UP/DOWN keys: Change values. ZFV-C User’s Manual...
Page 73: Inspecting By Color (Hue)
Example: Cap color inspection NG due to wrong color Basic Setting Procedure ■ Teaching Enclose the area to be inspected using a square box, and then perform teaching. Inspection area Teaching setting TEACH/HUE Application and Setting Examples p.158 ZFV-C User’s Manual...
Page 74 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.161 ZFV-C User’s Manual...
Page 75: 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 76: Custom Menu
Selecting the edge detection direction p.75 Items related to Changing the color mode (default: FILTER) p.75 color Changing the filter color (only when [FILTER] is selected in [COL MODE]) p.66 Teaching Brightness (only when [PICKUP] is selected in [COL MODE]) p.66 ZFV-C User’s Manual...
Page 77 Searches in the vertical direction. ← → (default) Searches in the horizontal direction. ■ Items related to color ● Changing the color mode ZFV-C has two color inspection modes as follows. MENU mode-[TEACH]-[CUSTM]-[COL MODE] Setting Details FILTER (default) A color filter is used to increase the contrast with the background.
Page 78: 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 79: Custom Menu
Changing edge sensitivity p.78 Items related to Changing the color mode (default: [FILTER]) p.75 color Changing the filter color (only when [FILTER] is selected in [COL MODE]) p.66 Teaching Brightness (only when [PICKUP] is selected in [COL MODE]) p.66 ZFV-C User’s Manual...
Page 80 Edge sensitivity is high. Select this when contrast is low and a stable edge cannot be located. NORMAL (default) Standard sensitivity. ROUGH Edge sensitivity is low. Select this when something like dust is mistakenly detected as the edge. ZFV-C User’s Manual...
Page 81: 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 82: Custom Menu
Changing Brightness during teaching (only when [PICKUP] is selected in [COL p.66 MODE]) ■ Items related to edge detection Set the direction in which edges are searched and the density level. Example) To detect this number + + + + + EDGE MODE: DARK DIRECTON: → ZFV-C User’s Manual...
Page 83 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. MENU mode-[TEACH]-[CUSTM]-[DIRECTION] Setting Details ↓ Searches from top to bottom. → (default) Searches from left to right. ZFV-C User’s Manual...
Page 84: 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 85: Custom Menu
Threshold level for the density deviation in the teaching area. ation value CUSTOM Menu Items that can be customized Items that can be customized Page Items related to Changing the detection content p.84 brightness Items related to Changing the filter color p.66 color ZFV-C User’s Manual...
Page 86 Select this to detect scratches or dirt. Teaching image When [AVERAGE] is selected NG judged when density is different When [DEVIATION] is selected OK judged if there is no density NG judged if there is density change even if density is different change ZFV-C User’s Manual...
Page 87: Detecting Presence Of Character String (Chara)
Errors in single characters, missing dots, etc. cannot be detected. This item is suitable for applications such as detection of missing character in character strings such as the best-before date. Example: CHARA2 NG due to absence CHARA2 of a character ZFV-C User’s Manual...
Page 88: Basic Setting Procedure
Any shift of the printing position inside the teaching area is judged as OK. Wrong 04.07.01 04.07.01 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-C User’s Manual...
Page 89 Correlation value UP/DOWN keys: Change values. Setting item Range Details of Adjustment Correlation value 0 to 100 This is the lower limit of the correlation value with the teaching model. This value or above is judged as OK. ZFV-C User’s Manual...
Page 90: Custom Menu
Select this when the character string consists of 2 lines, 8 characters or less. 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. ZFV-C User’s Manual...
Page 91 The edge position is used to correct the position. EDGE 2004/09/24 • Registering models Registration of model is necessary if [MODEL] has been selected for [MODE]. Specify the top left coordinate and bottom left coordinate of the model. MODEL 2004/09/24 MENU mode-[CUSTM]-[MODE DTL]-[MODEL] ZFV-C User’s Manual...
Page 92 Select the direction in which edges are searched. MENU mode-[CUSTM]-[MODE DTL]-[DIRECTION] Setting Details ↑ (default) Searches from bottom to top. ↓ Searches from top to bottom. → Searches from left to right. ← Searches from right to left. ZFV-C User’s Manual...
Page 93 ● Raising detection stability This item is displayed only when [CHARA2] is set. MENU mode-[CUSTM]-[STABLE] Setting Details OFF (default) Standard detection method. Detailed detection method. The process time is longer than OFF. ZFV-C User’s Manual...
Page 94 Section 4 Detecting Presence of Character String (CHARA) MEMO ZFV-C User’s Manual...
Page 95: Section 5 Setting Additional Functions
Initializing Measurement Data Switching the Language Checking the Version Setting USB/RS-232C Communication Specifications Restricting Operations (Lock Function) Setting the Lock Function Starting/Cancelling the Lock Function Lock Function during Gang-Mounting Changing OUTPUT Signal Output Conditions Setting for Amplifier Unit Gang-Mount ZFV-C User’s Manual...
Page 96: Setting Image Acquisition Conditions
Select the light intensity by the UP/DOWN keys. IMAGE/LIGHT For partial adjustment • LEFT/RIGHT keys: Select the side that is adjusted. • UP/DOWN keys: Select the light intensity. Press the SET Key to fix the setting. LIGHT 5555 ZFV-C User’s Manual...
Page 97: Changing The Image Display Position (Partial Function)
Setting Image Acquisition Conditions 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 98: 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 99: Clearing Banks
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]. ZFV-C User’s Manual...
Page 100: Setting The System Environment
• 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.95 • If [FAST] or [MAX] is selected, make sure that the inspection area and color selection area are within the displayed image. ZFV-C User’s Manual...
Page 101: Selecting The Measurement Timing
4.DISP BACK NORMAL (color of characters) MENU mode -[SYS1]-[DISP COL] Setting GREEN (default), RED, YELLOW, BLUE, WHITE GREEN, RED (default), YELLOW, BLUE, WHITE NORMAL GREEN, RED, YELLOW, BLUE, WHITE (default) BACK GREEN, RED, YELLOW, BLUE (default), WHITE, BLACK ZFV-C User’s Manual...
Page 102: Setting/Cancelling The Eco Mode
TRIG signal Images are not loaded to the far left amplifier when the far left amplifier is not at the teaching screen. TRIG signal ZFV-C User’s Manual...
Page 103: I/O Monitor Function
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. ZFV-C User’s Manual...
Page 104: Correcting White Balance
The settings of all banks and system settings are initialized regardless of the currently selected bank No. MENU mode-[SYS2]-[ALL CLEAR] Setting Description EXECUTE Used to initialize the settings data. CANCEL Used to cancel initialization of the settings data. ZFV-C User’s Manual...
Page 105: Initializing Measurement Data
Switch the language for displayed messages between Japanese and English. MENU mode-[SYS2]-[LANGUAGE] Setting Description ENGLISH Displays messages in English. JAPANESE Displays messages in Japanese. Checking the Version Displays the type of Sensor Head, type of Amplifier Unit and system version information of the software. MENU mode-[SYS2]-[VERSION] ZFV-C User’s Manual...
Page 106: Setting Usb/Rs-232C Communication Specifications
For details on communication commands, refer to the “Communication Command Reference” (provided separately). 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.
Page 107: Rs-232C Connection
Amplifier unit side PLC side (Note 1) Fitting section Pin No. Signal name Signal name Pin No. SD(TXD) SD(TXD) RD(RXD) RD(RXD) RS(RTS) RS(RTS) CS(CTS) CS(CTS) SG(GND) SG(GND) Note 1: A plug type connector is used for the PLC side. ZFV-C User’s Manual...
Page 108 (Set to "8" (8-bit) when using image acquisition, bank data, system data acquisition, and other XMODEM protocols.) PARITY These settings have no effect on sensor operation and can thus be omitted. STOP BIT BAUDRATE NODE DELIMIT CR (default), LF, CR+LF ZFV-C User’s Manual...
Page 109: Restricting Operations (Lock Function)
TEACH signal input is restricted. (Lock OFF (default), Lock ON) PASS NUMBER The number for cancelling the lock function is set. (Default: 0000) When mode switch operation is enabled, key operation and TEACH signal input cannot be disabled. ZFV-C User’s Manual...
Page 110: 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 111: Changing Output Signal Output Conditions
OUTPUT turns ON for only the preset output time from when the OUTPUT signal turns ● Synchronous measurement Measurement OUTPUT Output time ● Continuous measurement OUTPUT ON at OK judgment Judgment NG Judgment OK Judgment NG OUTPUT Output time ZFV-C User’s Manual...
Page 112: Setting The On Delay Time
OUTPUT ON at OK judgment in continuous measurement Judgment NG Judgment OK Judgment NG OUTPUT Delay time MENU mode-[SYS2]-[OUTPUT]-[ON DELAY] Setting Details 0 to 255 (default: 0) Set the time (ms) to delay turning OFF of the OUTPUT signal. ZFV-C User’s Manual...
Page 113: Setting The Off Delay Time
OUTPUT ON at OK judgment in continuous measurement Judgment NG Judgment OK Judgment NG OUTPUT Delay time MENU mode-[SYS2]-[OUTPUT]-[OFF DELAY] Setting Details 0 to 255 (default: 0) Set the time (ms) to delay turning OFF of the OUTPUT signal. ZFV-C User’s Manual...
Page 114: Setting For Amplifier Unit Gang-Mount
Example of synchronizing and detecting multiple points of the same workpiece and integrating judgments. AMP3 MENU AMP1/2 (Host device) TRIG LINK (Fixed to I/O) Measured with HEAD (Fixed to USE) images loaded from LINKOUT – each sensor head. AMP1 AMP2 AMP3 ENABLE signal TRIG signal ZFV-C User’s Manual...
Page 115: Specifying The Amplifier Unit To Input The Trigger
Details The measurement results of all gang-mounted Amplifier Units are integrated, and output as an overall judgment result. EACH (default) The measurement result of each Amplifier Unit is output from the respective Amplifier Unit. Output image p.117 ZFV-C User’s Manual...
Page 116: Rules Of Gang-Mounting
Enabled at each amplifier unit All key inputs Enabled at each amplifier unit Amplifier unit for inputting furthest right TRIG signal = host device ENABLE signal TRIG signal Amplifier unit without TRIG signal inputs = client device ZFV-C User’s Manual...
Page 117: Data Route
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. OUTPUT signal TRIG signal ENABLE signal ZFV-C User’s Manual...
Page 118: Teaching Process When Gang-Mounting
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. In particular, when performing move teaching, raise the TRIG signal input interval to 200 ms minimum. ZFV-C User’s Manual...
Page 119: 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 OUTPUT signal ENABLE signal ZFV-C User’s Manual...
Page 120: Restrictions When Gang-Mounting Amplifier Units
Changes to the measurement conditions will not be saved automatically when teaching is executed using the TEACH key on the Teaching menu screen unless the mode is switched to RUN at least temporarily. ZFV-C User’s Manual...
Page 121: 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 122: Troubleshooting
• Are any other applications using the port on the personal com- puter? • Are the same communication conditions are set to both personal computer and Amplifier Unit? • Has the USB driver been installed? • Is the Amplifier Unit operating correctly? ZFV-C User’s Manual...
Page 123: Error Messages And Corrective Actions
SYSTEM ERROR Failed to configure FPGA. Faulty Amplifier Unit Contact your Failed to initialize LCD. OMRON representative. Failed to recognize Amplifier Unit. Failed to load data from flash memory. Faulty hardware operation Faulty software operation TEACHING FAILED...
Page 124: Q&A
Changed contents, including teaching results, are cleared when switching off without saving. Search is performed outside search area If the custom settings have been changed, perform teaching even if search area for [SEARCH]/[MATCH] again. is changed. ZFV-C User’s Manual...
Page 125: Specifications And External Dimensions
(Unit: mm) 18.7 Connector Mounting hole dimensions ±0.1 2-φ4.5 67.9 Focus adjustment control 32.5 17.9 6.36 Heat-resistant PVC shielded cable 5.8 Standard length 2 m 50.5 A fixing bracket can be mounted to each side Optical axis ZFV-C User’s Manual...
Page 126 (Unit: mm) 26.5 Mounting hole dimensions 2- 4.5 30.25 Optical axis Output for external lighting equipment Heat-resistant PVC shielded cable 6.1 Standard length 2 m 52.5 Focus adjustment control A mounting bracket can be mounted to each side ZFV-C User’s Manual...
Page 127: Specifications And External Dimensions
83.7 Output for external lighting equipment 30.25 Light axis Heat-resistant PVC shielded cable 6.1 Standard length 2 m 52.5 Focus adjustment control Mounting hole dimensions ±0.1 2- 4.5 A mounting bracket can be mounted to each side ZFV-C User’s Manual...
Page 128 Section 6 Specifications and External Dimensions ZFV-SC150/-SC150W/-SC150R (Ultra Wide View) (Unit: mm) 110.2 59.5 Heat-resistant PVC shielded cable 6.2 Standard length 2 m Mounting surface 2- 4.5 20 ± 0.1 Mounting hole dimensions ZFV-C User’s Manual...
Page 129 Ferrite core (2), ZFV-XMF (1), Fer- XMF2 (1), Ferrite core XMF2 (1), Ferrite core Instruction sheet rite core (2), Instruc- (2), Instruction sheet (2), Instruction sheet tion sheet LED class *1 Risk Group 1 *1 Applicable standard: IEC62471-2 ZFV-C User’s Manual...
Page 130: Amplifier Unit
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, One-shot output, Eco mode ZFV-C User’s Manual...
Page 131 Must be free of corrosive gas. Connection type Pre-wired, standard cable, length: 2 m Degree of protection IEC60529 IP20 Material Polycarbonate (PC) Weight Approx. 300 g (including cord) (when packaged: approx. 450 g) Accessories Ferrite core (1), Instruction sheet ZFV-C User’s Manual...
Page 132: Panel Mount Adapters
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- ward) Material Polycarbonate (PC), etc. Weight Approx. 50 g ZFV-C User’s Manual...
Page 133: Control Link Unit
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. Weight Approx. 10 g ZFV-C User’s Manual...
Page 134: Extension Cord
L=3 m (ZFV-XC_BRV2) Mounting hole dimensions Item ZFV-XC3BV2 ZFV-XC3BRV2* ZFV-XC8BV2 Applicable Amplifier Units ZFV-C Series Applicable Sensor Head ZFV-SC10_/-SC50_/-SC90_/-SC150_ ZFV-SC10_/-SC50_ 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)
Page 135: Rs-232C Cable
Note 2: Socket type connector Item ZS-XRS2 ZS-XPT2 Applicable Amplifier Units ZFV-C Series Ambient temperature Operating: 0 to +50 °C, Storage: -15 to +60 °C (with no icing or condensation) Ambient humidity Operating and storage: 35 % to 85 % (with no condensation)
Page 136: Lighting Unit (Option)
Mounting hole dimensions 10.7 69 ± 0.1 2-M3 Depth 5 Mounting hole dimensions ZFV-LTL02 (bar double-lighting) (Unit: mm) 4-M4 (Thru) 59.9 90° P5.8 × 9 = 52.2 2000 +100 100 ± 0.1 100 ± 0.1 Mounting hole dimensions ZFV-C User’s Manual...
Page 137 P5.8 × 9 = 52.2 +100 2000 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 User’s Manual...
Page 138 Approx. 250 g Approx. 650 g Approx. 900 g (When packaged: (When packaged: (When packaged: (When packaged: Approx. 550 g) Approx. 300 g) Approx. 900 g) Approx. 1,150 g) LED class Risk Group 1 Applicable standard IEC62471-2 ZFV-C User’s Manual...
Page 139: Led Safety Precautions For Using Laser Equipment
(*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. ZFV-C User’s Manual...
Page 140: 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 141 The maximum accessible emission level permitted within a particular class. For your reference, see ANSI Z136.1-1993, Section 2. Symbol and border: black Background: yellow Figure A Warning label - Hazard symbol Legend and border: black Background: yellow ZFV-C User’s Manual...
Page 142: Summary Of Requirements To User
2 of table10 of the standard. See the text for details. 3. Class 2M laser products that failed condition 1 of table10 of the standard. Not required for Class 2M laser products that failed condition 2 of table10 of the standard. See the text for details. ZFV-C User’s Manual...
Page 143: 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. ZFV-C User’s Manual...
Page 144: Updating The Firmware
Section 6 Updating the Firmware Updating the Firmware This section describes how to update the firmware of the ZFV-C Series Amplifier Unit. Warp Engine ZS is used to update the firmware. For the file for updating, please contact your OMRON representative.
Page 145 Units. If two or more Amplifier Units are connected, Warp Engine ZS will not start. Starting Warp Engine ZS • Do not start Warp Engine ZS unless the Amplifier Unit is recognized by the Personal Computer prop- erly. Select [Programs]-[OMRON]-[ZFV-C]- [WarpEngineZS] From the [Start] menu on the Personal Computer. The [WarpEngineZS] window will appear.
Page 146 [Start upgrade] button is clicked, the cur- rently connected Amplifier Unit does not match the model information registered in the file. In this case, never perform update. Doing so will damage the Amplifier Unit, disabling its ability to start up correctly any more. ZFV-C User’s Manual...
Page 147 • If the update progress bar stops or update is not completed within 10 minutes, there is a possibility that update has failed. In this case, contact OMRON’s sales representative about the firmware version before update and the one in the write file.
Page 148 Open the [Hardware] tab and click [Device Manager]. The [Device Manager] dialog box will appear. Open [Ports (COM&LPT)] and check the COM number in “OMRON Smart Sensor USB COM Drivers (WDM) (COMxx)”. “COMxx” indicates the connection port of the Amplifier Unit.
Page 149: Version Upgrade Information
Addition of introduction of Smart Monitor ZFV Tool for personal computer p.21 ■ Ver1.20 → Ver1.30 Changes Page Addition of restrictions on Gang-Mounting Amplifier units p.118 Addition of Lock function p.107 ■ Ver1.30 → Ver1.37 Changes Page Software update coinciding with changes in hardware component parts ZFV-C User’s Manual...
Page 150: Index
Color check I/O Circuit diagrams Light teaching Initialization 104, 106 MEAS CLEAR Connecting Measurement Data RS-232C Setting Data Input cable CONTRAST Input/output Control keys 57, 60 ON conditions COPY One-shot Output Correlation value 64, 87 COUNT Count Coupler ZFV-C User’s Manual...
Page 151 Mode selector switch Dimensions Menu switching Setting distance METHOD SPEED MODE STABLE MODEL Standard menu Standard View STD menu Narrow View SWITCH OFF DELAY TEACH IMAGE OFF delay time TEACH TYPE ON DELAY ON delay time ON STATUS ZFV-C User’s Manual...
Page 152 Threshold AREA AREA1 AREA2 BRIGHT COUNT Match Pattern POSITION Search WIDTH 74, 87 Timing Charts Synchronous measurement Continuous measurement TRIG 113 Ultra Wide View Communication Setting VERSION Warp Engine ZS WHITE BAL Wide View Width Inspection Wiring ZFV-C User’s Manual...
Page 153: Section 7 Application And Setting
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 154: Inspecting For The Presence Of Electronic Components (Pattern)
Adjusting the Sensor Head Focus p.49 Setting the Inspection Method Select and press the SET Key. MENU Select [ITEM] and press the SET Key. TEACH/SEARCH ITEM REG. Select and press the SET Key. TEACH/ITEM PATTERN Select and press the SET Key. TEACH/PATTERN ZFV-C User’s Manual...
Page 155 “+” will begin to blink at the center of the inspection area. Teaching is completed when the “+” mark dis- appears. ITEM REG. Checking Operation Switch the mode switch to “ADJ mode”. MENU Check the measurement results displayed SEARCH on the LCD monitor. [ 60] ZFV-C User’s Manual...
Page 156: Detecting Mixed Varieties Of Campaign Seals (Area)
Setting the Inspection Method Select and press the SET Key. MENU Select [ITEM] and press the SET Key. TEACH/SEARCH point ITEM REG. Select and press the SET Key. TEACH/ITEM AREA Select and press the SET Key. TEACH/AREA ZFV-C User’s Manual...
Page 157 Adjust the size of the color pickup area and TEACH/PICK Zooms in/out press the SET Key. in vertical direction. Enlarge/reduce the window’s red frame of the point Zooms in/out screen so that the color to be selected is horizontal direction. located inside the area. SIZE ZFV-C User’s Manual...
Page 158 Press the TEACH/VIEW key. TEACH/AREA2 “+” mark will appear at the center of the inspection area. point Teaching is completed when the “+” mark dis- appears. ITEM REG. PICK Checking Operation Switch the mode switch to “ADJ mode”. MENU ZFV-C User’s Manual...
Page 159 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 160: Inspecting Entry Of Workpieces Of Wrong Color (Hue)
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. MENU Select [ITEM] and press the SET Key. TEACH/SEARCH ITEM REG. Select and press the SET Key. TEACH/ITEM ZFV-C User’s Manual...
Page 161 “+” mark will appear at the center of the inspection area. Teaching is completed when the “+” mark dis- appears. ITEM REG. Checking Operation Switch the mode switch to “ADJ mode”. MENU Check the measurement results displayed on the LCD monitor. [10] ZFV-C User’s Manual...
Page 162: Explanation Of Color Related Functions
■ When color pickup is unstable If color pickup cannot be performed TEACH/PICK TEACH/PICK properly (e.g. uneven colors), widen the target color range by monitoring the color bar and histogram. L[ 5] H[ 20] L[ 1] H[ 25] Upper limit Lower limit ZFV-C User’s Manual...
Page 163: Hue Indication Number
In this example, orange color can also be a target if the upper limit is raised. L[ 5] H[ 40] Upper limit Hue Indication Number For color inspection threshold values and upper/limit values (in the color pickup histogram screen), color range must be specified using hue indication numbers. ZFV-C User’s Manual...
Page 164: Revision History
• Addition of information for optional lighting unit • Corrections • Functions added as per software version upgrade (Ver1.30) April 2006 • Corrections March 2012 Additions for Notice for Korea Radio Law January 2014 Software update coinciding with changes in hardware component parts ZFV-C User’s Manual...
Page 166 The Netherlands IL 60173-5302 U.S.A. Tel: (31)2356-81-300/Fax: (31)2356-81-388 Tel: (1) 847-843-7900/Fax: (1) 847-843-7787 © OMRON Corporation 2005 All Rights Reserved. OMRON (CHINA) CO., LTD. OMRON ASIA PACIFIC PTE. LTD. In the interest of product improvement, Room 2211, Bank of China Tower, No.

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