F150 Manual 1: SETUP MANUAL Visual Inspection System

F150 Manual 1: SETUP MANUAL Visual Inspection System
Cat.No. Z124-E1-1B
F150
Visual Inspection System
Manual 1:
SETUP MANUAL
F150 Visual Inspection System
Setup Manual
Revised January 2001
Notice:
OMRON products are manufactured for use according to proper procedures
by a qualified operator and only for the purposes described in this manual.
The following conventions are used to indicate and classify precautions in
this manual. Always heed the information provided with them. Failure to
heed precautions can result in injury to people or damage to property.
! DANGER
Indicates an imminently hazardous situation which, if not
avoided, will result in death or serious injury.
! WARNING Indicates a potentially hazardous situation which, if not
avoided, could result in death or serious injury.
! Caution
Indicates a potentially hazardous situation which, if not
avoided, may result in minor or moderate injury, or property
damage.
Electric Shock
Indicates particular circumstances which, if not avoided,
could result in electric shock.
High Temperatures
Indicates particular circumstances which, if not avoided,
could result in heat burns.
Visual Aids
The following headings will help you locate different types of information.
Note Indicates information of particular interest for efficient and convenient operation of the product.
→ Indicates pages where additional information can be found.
1 Indicates a procedure. The step numbers in the procedure
correspond to the numbers in any related illustrations.
 OMRON, 1998
All rights reserved. No part of this publication may be reproduced, stored in a retrieval system, or transmitted,
in any form, or by any means, mechanical, electronic, photocopying, recording, or otherwise, without the prior
written permission of OMRON.
No patent liability is assumed with respect to the use of the information contained herein. Moreover, because
OMRON is constantly striving to improve its high-quality products, the information contained in this manual is
subject to change without notice. Every precaution has been taken in the preparation of this manual. Nevertheless, OMRON assumes no responsibility for errors or omissions. Neither is any liability assumed for damages resulting from the use of the information contained in this publication.
iv
TABLE OF CONTENTS
PRECAUTIONS . . . . . . . . . . . . . . . . . . . . .
ix
1 Safety Precautions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
2 General Precautions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
x
xi
SECTION 1
Before Installing . . . . . . . . . . . . . . . . . . . . .
1
1-1
1-2
1-3
Installation Precautions . . . . . . . . . . . . . . . . . . . . . . .
Confirming Package Contents . . . . . . . . . . . . . . . . . .
Product Availability . . . . . . . . . . . . . . . . . . . . . . . . . .
2
5
5
SECTION 2
Product Introduction . . . . . . . . . . . . . . . . .
7
2-1
2-2
2-3
2-4
2-5
2-6
2-7
2-8
Overview of F150 Application . . . . . . . . . . . . . . . . . .
Component Names and Functions . . . . . . . . . . . . . . .
Connections . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Power Supply and Ground . . . . . . . . . . . . . . . . . . . . .
Cameras . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
CCTV Lens . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Lighting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Mounting the Controller . . . . . . . . . . . . . . . . . . . . . . .
8
9
10
11
12
14
17
20
SECTION 3
Terminal Blocks . . . . . . . . . . . . . . . . . . . . .
23
3-1
3-2
3-3
3-4
Terminal Block Application . . . . . . . . . . . . . . . . . . . .
Crimp Terminals and Cables . . . . . . . . . . . . . . . . . . .
Specifications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Terminals . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
24
24
25
26
SECTION 4
RS-232C Connection . . . . . . . . . . . . . . . . .
29
4-1
4-2
4-3
4-4
RS-232C Port Application . . . . . . . . . . . . . . . . . . . . .
Connector . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Wiring . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Connection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
30
30
31
32
SECTION 5
Troubleshooting . . . . . . . . . . . . . . . . . . . . .
33
5-1
5-2
5-3
5-4
Connection Errors . . . . . . . . . . . . . . . . . . . . . . . . . . .
Errors during Menu Operation . . . . . . . . . . . . . . . . . .
Terminal Block Errors . . . . . . . . . . . . . . . . . . . . . . . .
RS-232C Communications Errors . . . . . . . . . . . . . . .
34
34
34
35
v
TABLE OF CONTENTS
SECTION 6
Maintenance . . . . . . . . . . . . . . . . . . . . . . . .
6-1
6-2
38
39
SECTION 7
Specifications . . . . . . . . . . . . . . . . . . . . . . . .
41
7-1
7-2
7-3
7-4
7-5
7-6
7-7
vi
37
Maintenance Parts and Replacement . . . . . . . . . . . . .
Regular Inspections . . . . . . . . . . . . . . . . . . . . . . . . . .
F150-C10E Vision Mate Controller . . . . . . . . . . . . . .
K150-KP Console . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Cameras . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
F150-LE20/50 Lens . . . . . . . . . . . . . . . . . . . . . . . . . .
F150-LT10 Light . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Cables . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
F300-M09 Video Monitor . . . . . . . . . . . . . . . . . . . . .
42
43
44
46
46
47
48
Revision History . . . . . . . . . . . . . . . . . . . . .
49
About this Manual:
This manual describes the hardware for the F150 Visual Inspection System and how to
install the components, and it includes the sections described below. This is one of three
manuals used to operate the F150. Refer to the following table for the contents of each
manual.
Manual
1: Setup
Manual
Contents
Provides information on system hardware and
installation. Be sure to read this manual first.
Cat. No.
Z124-E1-1B
2: Auto Menu Describes operation of the F150 using the Auto
Operation Menu. The Auto Menu enables the simplest
Manual
operation for OK/NG outputs based on registered
images of acceptable and unacceptable products.
Z125-E1-1
3: Expert
Menu
Operation
Manual
Z126-E1-1A
Describes operation of the F150 using the Expert
Menu. The Expert Menu enables application of all
F150 capabilities, including setting region images
and criteria, and outputting OK/NG terminal
signals or RS-232C measurement values.
Please read the above manuals carefully and be sure you understand the information
provided before attempting to install or operate the F150.
Section 1 Precautions describes the precautions that must be taken when installing
and operating the F150 Visual Inspection System.
Section 2 Product Introduction provides an overview of F150 application and
describes the wiring, Cameras, optical lenses, lighting modes, and light guides used in
the F150 System. It also describes how to mount the Vision Mate Controller to DIN Track
or to a flat surface.
Section 3 Terminal Blocks describes how to connect the terminal blocks.
Section 4 RS-232C Connections describes how to connect the RS-232C port.
Section 5 Troubleshooting lists the errors that may occur, along with their probable
causes and remedies.
Section 6 Maintenance provides information on maintenance and inspection.
Section 7 Specifications provides the specifications of the F150 components.
! WARNING
Failure to read and understand the information provided in this
manual may result in personal injury or death, damage to the
product, or product failure. Please read each section in its
entirety and be sure you understand the information provided
in the section and related sections before attempting any of
the procedures or operations given.
vii
PRECAUTIONS
This section provides general precautions for using the F150 Visual Inspection System.
The information contained in this section is important for the safe and reliable
application of the F150 Visual Inspection System. You must read this section and
understand the information contained before attempting to set up or operate a F150
Visual Inspection System.
1 Safety Precautions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
2 General Precautions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
x
xi
ix
1
PRECAUTIONS
1
Safety Precautions
! WARNING Cover the terminal blocks with the Terminal Block
Protection Covers. Uncovered terminal blocks
can result in electric shock.
! WARNING Use DC power supplies with safe extra
low-voltage circuits on the secondary side for the
main F150 power supply and power supplies for
the terminal blocks. Excessively high voltages
can result in electric shock.
! Caution Do not touch fluorescent or halogen lights while
the power is ON or immediately after the power is
turned OFF. These lights generate heat and can
cause burns.
! Caution Do not use the F150 in environments with flammable or explosive gases.
! Caution Install the F150 away from high-voltage equipment or motors to ensure safety during operation
and maintenance.
! Caution Use the power supply cables and crimp terminals
of specified sizes.
! Caution Use at the power supply voltages specified in this
manual.
! Caution Be sure to securely tighten the screws when
mounting F150 components.
! Caution Do not dismantle, repair or modify any F150 components.
! Caution Dispose of F150 components as industrial waste.
x
2
PRECAUTIONS
! Caution To prevent damage from static electricity, use a
wrist strap or another device for preventing electrostatic charges when touching terminals or connector signal lines.
! Caution Do not turn OFF the power while a message is
being displayed indicating that processing is
being performed. Data in memory will be
destroyed, and the F150 may not operate correctly the next time it is started.
2
General Precautions
The user must operate the product according to the performance
specifications described in the operation manuals.
Before using the product under conditions which are not described in the manual or applying the product to nuclear control
systems, railroad systems, aviation systems, vehicles, combustion systems, medical equipment, amusement machines, safety
equipment, and other systems, machines, and equipment that
may have a serious influence on lives and property if used improperly, consult your OMRON representative.
Make sure that the ratings and performance characteristics of
the product are sufficient for the systems, machines, and equipment, and be sure to provide the systems, machines, and equipment with double safety mechanisms.
xi
SECTION 1
Before Installing
This section describes the precautions that must be taken when installing and operating the
F150 Visual Inspection System.
1-1
1-2
1-3
Installation Precautions . . . . . . . . . . . . . . . . . . . . . . . .
2
1-1-1
1-1-2
1-1-3
1-1-4
1-1-5
1-1-6
F150 Components . . . . . . . . . . . . . . . . . . . . . . . . .
Installation Site . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Cables . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Camera . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Video Monitor . . . . . . . . . . . . . . . . . . . . . . . . . . . .
2
2
2
4
4
4
Confirming Package Contents . . . . . . . . . . . . . . . . . . .
Product Availability . . . . . . . . . . . . . . . . . . . . . . . . . . .
5
5
1
Installation Precautions
1-1
Section 1-1
Installation Precautions
The F150 is highly reliable and resistant to most environmental
factors. The following guidelines, however, must be followed to
ensure reliability and optimum use of the F150.
1-1-1
F150 Components
Be sure to use the Camera, Camera Cable, and Console
designed for the F150.
1 F150-S1 Camera
2 F150-VS Camera Cable
3 F150-KP Console
1-1-2
Installation Site
Do not install the F150 in locations subject to the following conditions:
1 Ambient temperatures outside of 0 to 40°C for the
F300-M09 Video Monitor (recommended monitor)or outside of 0 to 50°C for all other F150 components
2
3
4
5
6
7
8
1-1-3
Condensation due to rapid temperature fluctuations
Relative humidities outside 35% to 85%
Corrosive or flammable gases
Dust, salt, or iron particles
Direct vibration or shock
Direct sunlight
Water, oil, or chemical fumes or spray
Installation
Orientation of Controller
To improve heat dissipation, install the Controller in the following
orientation only:
CORRECT
2
Section 1-1
Installation Precautions
Do not install the Controller in the orientations shown in the following diagram.
INCORRECT
Ambient Temperature
1 Maintain a minimum clearance of 50 mm above and below
F150 components to improve air circulation.
2 Do not install F150 components immediately above strong
heat sources, such as heaters, transformers, or large-capacity resistors.
3 Do not let the ambient operating temperature exceed 50°C.
4 Provide a forced-air fan or air conditioning if the ambient
temperature might exceed 50°C.
Control box
Louver
Noise Resistance
Use the following measures to help increase noise resistance.
1 Do not install F150 components in a cabinet containing
high-voltage equipment.
3
Section 1-1
Installation Precautions
2 Do not install the F150 components within 200 mm of power
cables.
Power cable
200 mm min.
200 mm min.
Operation and Maintenance Precautions
1 Keep F150 components away from high-voltage equipment
or motors to ensure safety during operation and maintenance.
2 Install F150 components at a height that allows operation of
the Console while monitoring with the Video Monitor.
1-1-4
Cables
Always turn OFF the power before connecting or disconnecting
cables.
1-1-5
Camera
The Camera’s case is connected to the 0V line in the internal circuits. Heed the following precautions to prevent noise interference.
1 Do not ground the Camera.
2 Do not remove the base attached to the Camera.
3 Do not remove the core attached to the F150-VS Camera
Cable.
1-1-6
Video Monitor
(When using the recommended F300-M09)
Heed the following precautions to prevent noise interference if
the video monitor case is metallic, because it is connected to the
0V line in the internal circuits.
1 Do not ground the video monitor.
2 Do not ground the metallic part of the connector.
3 Secure the video monitor with plastic screws if it is being
mounted to a metallic surface.
4
Section 1-3
Product Availability
1-2
Confirming Package Contents
Check the contents of the package as soon as you receive the
F150. Contact the nearest OMRON representative if any of the
following items are missing.
1
2
3
4
1-3
F150-C10E Vision Mate Controller
Setup Manual (this manual)
Auto Menu Operation Manual
Expert Menu Operation Manual
Product Availability
Some of the products listed may not be available in some countries. Please contact your nearest OMRON sales office by referring to the addresses provided at the back of this manual.
5
SECTION 2
Product Introduction
This section provides an overview of F150 application and describes the wiring, Cameras,
optical lenses, lighting modes, and light guides used in the F150. It also describes how to
mount the Vision Mate Controller to DIN Track or to a flat surface.
2-1
2-2
2-3
2-4
2-5
2-6
2-7
Overview of F150 Application . . . . . . . . . . . . . . . . . . .
Component Names and Functions . . . . . . . . . . . . . . . .
Connections . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Power Supply and Ground . . . . . . . . . . . . . . . . . . . . . .
8
9
10
11
2-4-1
2-4-2
2-4-3
Crimp Terminals and Cables . . . . . . . . . . . . . . . . .
Protective Conductor (Earth) Wiring . . . . . . . . . . .
Wiring the Power Supply . . . . . . . . . . . . . . . . . . . .
11
11
12
Cameras . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
CCTV Lens . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
12
14
2-6-1
2-6-2
2-6-3
Optical Chart . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Lens . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Extension Tubes . . . . . . . . . . . . . . . . . . . . . . . . . . .
14
16
16
Lighting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
17
2-7-1
2-8
Lighting Methods . . . . . . . . . . . . . . . . . . . . . . . . . .
17
Mounting the Controller . . . . . . . . . . . . . . . . . . . . . . . .
20
2-8-1
2-8-2
20
21
Mounting to DIN Track . . . . . . . . . . . . . . . . . . . . .
Mounting on a Flat Surface . . . . . . . . . . . . . . . . . .
7
Section 2-1
Overview of F150 Application
2-1
Overview of F150 Application
The following table shows the basic steps that must be performed to use the F150.
Step
Manual
1: Unit Connections and Wiring
Video
Monitor
Programmable Controller
Setup Manual
Power Supply
Console
Synchronous
sensor
Camera with Light Source
IBM PC/AT or
compatible
computer
2: Setting Measurement Conditions
Video
Monitor
Easy Operation:
Auto Menu
Operation Manual
Advanced Operation:
Expert Menu
Operation Manual
3: Confirming Operation, Measuring
Objects, and Outputting Results
IBM PC/AT or
compatible
computer
Synchronous
sensor
8
Programmable
Controller
Video
Monitor
Section 2-2
Component Names and Functions
2-2
Component Names and Functions
The following diagram shows the terminals, connectors, and
indicators on the F150-C10E Vision Mate Controller.
Ground Power supply Output
terminal terminals
terminals
Input
terminals
POWER
indicator
Monitor
connector
RUN
indicator
ERROR
indicator
Console
connector
RS-232C
connector
Camera
connector
Output
terminals
1 POWER Indicator
Lit while power is ON.
2 RUN Indicator
Lit in measurement mode.
3 ERROR Indicator
Lit when an error occurs.
4 RS-232C Connector
Connects the F150 to a computer,
PLC, or other external device.
5 Camera Connector
Connects to the Camera.
6 Power Supply Terminals
Wired to the power supply.
Do not open.
7 Ground Terminal
Wired to the ground.
8 Input Terminals
Wired to external devices, such as
synchronous sensors or inputs
from a PLC.
9 Output Terminals
Wired to external devices, such as
synchronous sensors or outputs to
a PLC.
10 Monitor Connector
Connects to the video monitor.
11 Console Connector
Connects to the Console.
9
Section 2-3
Connections
2-3
Connections
Connect the basic components as shown in the following diagram. Details are provided later in this section.
! Caution Turn OFF the power to the Controller before connecting or disconnecting cables. Connecting or disconnecting cables with
power turned ON can damage peripheral devices.
Power Supply → p. 12
(OMRON’s S82K-01524 recommended.)
*F150-KP Console
(cable length: 2 m)
F150-VM Monitor
Cable (2 m)
*F150-VS Camera
Cable (3m)
*Camera with Light Source → p. 12
(See note 2.)
F150-SL20 (20-mm field of vision)
F150-SL50 (50-mm field of vision)
BNC Jack
(accessory)
*F150-S1 Camera
(See note 3.)
Video Monitor
(OMRON’s F300-M09
recommended; see note 4.)
Note
1. *Components marked with an asterisk are specially
designed for the F150. Other products cannot be used.
2. F150-SL Cameras are the same as F150-S1 Cameras
except that they have a lens and a light attached.
3. If the field of vision is too small, use the F150-S1 Camera
with a normal CCTV lens and light. → p. 14
4. Use an NTSC monitor with an external video input terminal.
10
Section 2-4
Power Supply and Ground
2-4
Power Supply and Ground
Wire the power supply and the ground to the top terminal block,
and tighten the screws to a torque of between 0.5 and 0.6 N⋅m.
! WARNING Cover the terminal blocks with the Terminal Block
Protection Covers. Uncovered terminal blocks
can result in electric shock.
2-4-1
Crimp Terminals and Cables
The terminal block uses M3 terminal screws. Use appropriate
crimp terminals for M3 screws, as shown below.
Forked
Round
6.2 mm max.
6.2 mm max.
Applicable wire size: Insulated wire of 1.31 to 1.65 mm2
(AWG16 to AWG15)
2-4-2
Protective Conductor (Earth) Wiring
Wire the ground as shown in the following diagram.
! Caution Use an appropriate ground. An insufficient ground can affect
F150 operation or result in damage to F150 components.
• To avoid damage to the equipment, do not share the protective
conductor wiring with any other devices nor wire the protective
conductor terminal to the girder. Be sure to wire the protective
conductor of the equipment independently.
• Keep the ground line as short as possible.
×
×
×
× × × × × × × × × ×
× × × × × × × × × ×
Class I
(With protective conductor terminal)
11
Section 2-5
Cameras
2-4-3
Wiring the Power Supply
! WARNING Use a DC power supply with safe extra
low-voltage circuits on the secondary side.
Excessively high voltages can result in electric
shock.
Use a power supply with the following specifications. We recommend using OMRON’s S82K-01524 Power Supply.
Item
Specification
Output current
0.6 A min.
Power supply voltage
24 VDC +10%/-15%
+
–
24 VDC
×
×
×
Note
× × × × × × × × × ×
× × × × × × × × × ×
1. Wire the Power Supply Unit independently of other devices.
In particular, keep the power supply wired separately from
inductive loads.
2. Keep the power supply cable as short as possible.
3. If UL recognition is required, use a UL class II power supply.
2-5
Cameras
The Cameras are designed for the F150. The F150-SL20 and
F150-SL50 Cameras have a lens and light attached. The light
and lens are a single unit and are thus compact and easy to
mount.
Cameras with Light Source
Field of vision
12
Model
20 mm
F150-SL20
50 mm
F150-SL50
Section 2-5
Cameras
Camera
The same Camera is also available without a lens and light so
that other CCTV lenses and lights can be used. Use C-mount
lenses.
Camera
F150 Camera
Model
F150-S1
! Caution The F150 Cameras listed above must be used. Using other
Cameras can damage F150 components or the Camera.
Distance from Measurement Object
Note The Camera’s field of vision is fixed, and the Camera must be
mounted at a distance from the measurement object where it can
correctly view the object.
If the field of vision of the Camera is too small for the object being
measured, use the Camera with a normal CCTV lens and
light. → p. 14
Measurement object
Distance
20-mm lens: 61 to 71 mm
50-mm lens: 66 to 76 mm
Fixed Field of Vision (H × W)
20-mm lens: 20 × 20 mm
50-mm lens: 50 × 50 mm
Note Since the field of vision and focal point vary depending on the
lens, adjust the setting distance whenever the lens or Camera is
replaced.
13
Section 2-6
CCTV Lens
Mounting the Camera
The specified camera distance is only an approximation. Mount
the Camera so that it can be adjusted to either side of the specified distance from the measurement object.
Unit: mm
Camera with Light Source
Two M4 holes with
a depth of 8 mm
Camera
Two M4 holes with
a depth of 8 mm
1/4-20UNC with
a depth of 8 mm
2-6
1/4-20UNC with
a depth of 8 mm
CCTV Lens
When using a F150-S1 Camera (without a light), refer to the following graph to select the appropriate Lens and Extension Tube.
The lens will differ depending on the size of the measurement
object and the distance from the Camera.
2-6-1
Optical Chart
Camera distance A (mm)
The values in the following chart are approximations, and the
Camera must be adjusted after it is mounted.
t: Extension Tube length
Field of vision L (mm)
14
Section 2-6
CCTV Lens
The X axis of the graph shows field of vision L (mm), and the Y
axis shows the camera distance A (mm). The curves on the
graph indicate different lenses, and the “t” values indicates the
lengths of the Extension Tubes.
Camera
Extension Tube tj (mm)
Lens
Camera distance A (mm)
Field of vision L (mm)
15
Section 2-6
CCTV Lens
2-6-2
Lens
Lens
Focal
length
Brightness
Maximum
outer
diameter
Total
length
Filter size
---
3Z4S-LE C418DX
4.8 mm
F1.8
40.5-mm dia.
35.5 mm
3Z4S-LE B618CX
6.5 mm
F1.8
48-mm dia.
42 mm
3Z4S-LE C815B
8.5 mm
F1.5
42-mm dia.
40 mm
3Z4S-LE B1214D-2
12.5 mm
F1.4
42-mm dia.
50 mm
3Z4S-LE C1614A
16.0 mm
F1.4
30-mm dia.
33 mm
3Z4S-LE B2514D
25.0 mm
F1.4
30-mm dia.
37.3 mm
3Z4S-LE B5014A
50.0 mm
F1.4
48-mm dia.
48 mm
M46 × P0.75
3Z4S-LE B7514C
75.0 mm
F1.4
62-mm dia.
79 mm
M58 × P0.75
M40.5 × P0.5
M27 × P0.5
Unit: mm
30 dia.
Max. outer dia.
Total length
2-6-3
Extension Tubes
One or more Extension Tubes are inserted between the lens and
the Camera to focus the Camera image. Use a combination of
one or more of the six sizes of tube to achieve the required
length.
Note
1. Do not use the 0.5-mm and 1.0-mm Extension Tubes
attached to each other. Since these Extension Tubes are
placed over the threaded section of the Lens or other Extension Tube, the connection may loosen when more than one
0.5-mm or 1.0-mm Extension Tube are used together.
2. Reinforcement may be required for combinations of Extension Tubes exceeding 30 mm if the Camera is subject to
vibration.
Extension Tube
16
Section 2-7
Lighting
Model
Maximum outer
diameter
3Z4S-LE EX-C6
31 dia.
Length
Set of 6 tubes
0.5 mm, 1 mm, 5 mm,
10 mm, 20 mm, and
40 mm
Length: 40 mm
2-7
20 mm
10 mm
5 mm 1.0 mm 0.5 mm
Lighting
A stable image must be obtained to ensure accurate inspection.
Use appropriate lighting for the application and the measurement object if using the F150-S1 Camera.
2-7-1
Lighting Methods
Back Lighting
A stable, high-contrast image can be obtained using back lighting.
Applications: Inspection of exterior shape or positioning
inspection
Camera
Measurement object
Light source
17
Section 2-7
Lighting
Reflected Lighting
Ring Lights
Light is shone uniformly on the measurement object.
Applications: Surface inspections
Camera
Light source
Measurement object
Oblique Lighting
Detection can be made utilizing the difference in regular and diffuse reflected light.
Applications: Inspections for surface gloss
Camera
Light source
Measurement object
18
Section 2-7
Lighting
Coaxial Lighting
A stable image can be obtained with few shadows from uneven
surfaces on the measurement object.
Applications: Surface inspections, positioning, and hole
inspections of comparatively small objects
Camera
Light source
Half mirror
Measurement object
19
Section 2-8
Mounting the Controller
2-8
Mounting the Controller
The Vision Mate Controller can be mounted to DIN Track or a flat
surface.
2-8-1
Mounting to DIN Track
The Vision Mate Controller can be easily mounted to or removed
from 35-mm DIN Track.
DIN Track
PFP-M End Plate
(OMRON)
The following DIN Tracks are available from OMRON.
Model
Length
PFP-100N
1m
PFP-50N
50 cm
PFP-100N2
1m
Mounting the Controller
Hook the Controller into the DIN Track as shown in the diagram
and then press in at the bottom until the Controller locks into
place.
20
Section 2-8
Mounting the Controller
Removing the Controller
Use a screwdriver to pull the hook down and then pull out the
Controller from the bottom.
2-8-2
Mounting on a Flat Surface
Mount the Controller using the holes and dimensions shown in
the following diagram.
Unit: mm
Four, M4
100±0.2
120±0.2
! Caution Do not use screw-locking materials that contain ingredients
harmful to ABS or polycarbonate resins. The Controller will be
damaged.
21
SECTION 3
Terminal Blocks
This section describes how to connect the terminal blocks.
3-1
3-2
3-3
3-4
Terminal Block Application . . . . . . . . . . . . . . . . . . . . .
Crimp Terminals and Cables . . . . . . . . . . . . . . . . . . . .
Specifications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Terminals . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
24
24
25
26
23
Section 3-2
Crimp Terminals and Cables
3-1
Terminal Block Application
The following table shows the functions that can be performed by
the F150 using the terminal blocks. Refer to the Auto Menu and
Expert Menu Operation Manuals for communications settings
and I/O formats.
Menu
3-2
Measurement
command
inputs
Overall
evaluation
outputs
Region
evaluation
outputs
Auto Menu
Yes
Yes
No
Expert Menu
Yes
Yes
Yes
Crimp Terminals and Cables
The terminal block uses M3 terminal screws. Use appropriate
crimp terminals for M3 screws, as shown below. Tighten the
screws to a torque of between 0.5 and 0.6 N⋅m.
! WARNING Cover the terminal blocks with the Terminal Block
Protection Covers. Uncovered terminal blocks
can result in electric shock.
Forked
6.2 mm max.
Round
6.2 mm max.
Applicable wire size: Insulated wire of 1.31 to 1.65 mm2
(AWG16 to AWG15)
24
Section 3-3
Specifications
3-3
Specifications
! WARNING Use a DC power supply with safe extra
low-voltage circuits on the secondary side.
Excessively high voltages can result in electric
shock.
Input Specifications
Item
Specification
Input voltage
12 to 24 VDC ±10%
ON current
3 to 15 mA
ON voltage
8.8 V max.
OFF current
0.1 mA max.
OFF voltage
4.5 V min.
ON delay
RESET input: 10 ms max.
Others:
OFF delay
0.5 ms max.
RESET input: 15 ms max.
Others:
Internal circuits
0.7 ms max.
COM IN
Input
terminal
Output Specifications
Item
Specification
Output voltage
12 to 24 VDC ±10%
Load current
45 mA max.
ON residual voltage
2 V max.
OFF leakage current
0.1 mA max.
Internal circuits
Output terminal
Load
COM OUT
Note If UL recognition is required, use a UL class II power supply.
25
Section 3-4
Terminals
3-4
Terminals
The terminals on the terminal blocks are assigned as shown in
the following diagrams and tables.
Top terminals
Bottom terminals
Top Terminals
*1
×
×
×
×
×
×
×
×
×
×
×
×
×
×
×
×
×
ERR
BUSY
GATE
×
×
×
Error output
NC
Not connected
COM OUT (*1)
For RUN,
ERR, BUSY,
GATE, and OR
RESET
Resets F150
DSA
Command
i
inputs
t
STEP
DI 0
26
×
×
Name/Application
Name/Application
RUN
OR
×
DI 1
DI 2
DI 3
DI 4
DI 5
DI 6
DI 7
COM IN
---
Command
i
inputs
t
Section 3-4
Terminals
Bottom Terminals
×
×
×
×
×
×
×
×
×
×
×
×
×
×
×
×
*2
DO 3
Measurement
lt output
t t
results
DO 5
×
×
*3
Name/Application
DO 1
×
Name/Application
DO 0
DO 2
Measurement
lt output
t t
results
DO 4
DO 7
DO 6
NC
Not connected
COM OUT
(*2)
For DO 0 to
DO 7
DO 9
Measurement
lt output
t t
results
DO 8
Measurement
lt output
t t
results
DO 11
DO 10
DO 13
DO 12
DO 15
DO 14
---
COM OUT
(*3)
For DO 8 to
DO 15
! Caution Do not reverse the connections of the signal terminals and COM
terminals.
27
SECTION 4
RS-232C Connection
This section describes how to connect the RS-232C port.
4-1
4-2
4-3
4-4
RS-232C Port Application . . . . . . . . . . . . . . . . . . . . . .
Connector . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Wiring . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Connection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
30
30
31
32
29
Section 4-2
Connector
4-1
RS-232C Port Application
The following table shows the functions that can be performed by
the F150 via the RS-232C port. Refer to the Auto Menu and
Expert Menu Operation Manuals for communications settings,
I/O formats, and operating procedures.
Menu
Measurement
command inputs
Menu
Operations
Normal
Host
Link
Measurement
results outputs or
evaluation outputs
Normal
Data
Backup
Host
Link
Auto Menu
Yes
No
No
No
No
Yes
Expert Menu
Yes
Yes
Yes
Yes
Yes
Yes
4-2
Connector
Use an appropriate 9-pin D-SUB female connector. The pin
numbers and names are shown below.
Pin
Signal
Name
1
FG (GND)
Frame ground
2
SD (TXD)
Send Data
3
RD (RXD)
Receive Data
4
RS (RTS)
Request to Send
5
CS (CTS)
Clear to Send
6
NC
Not connected
7
NC
Not connected
8
NC
Not connected
9
SG (GND)
Signal ground
The following plug and hood are recommended and are available from OMRON.
Model
30
Model No.
Plug
XM2A-0901
Hood
XM2S-0911
Section 4-3
Wiring
4-3
Wiring
Use only shielded RS-232C cable.
Standard Connections
F150
Signal name
External device
Pin
Pin
Signal name
*
*
*
*
*
Shield
Connections for RS/CS Control
F150
Signal name
External device
Pin
Pin
Signal name
*
*
*
*
*
Shield
Note Pin numbers on the external device will depend on the device
being connected. Refer to the manual for the device being connected.
31
Section 4-4
Connection
4-4
Connection
Align the connector with the socket and press the connector
straight into place. Tighten the two screws on the edges of the
connector.
! Caution Always turn OFF the power supply before connecting or disconnecting cables. Peripheral devices can be damaged if connected
or disconnected with the power supply turned ON.
Note Always tighten the connector screws.
32
SECTION 5
Troubleshooting
This section lists the errors that may occur, along with their probable causes and remedies.
5-1
5-2
5-3
5-4
Connection Errors . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Errors during Menu Operation . . . . . . . . . . . . . . . . . . .
Terminal Block Errors . . . . . . . . . . . . . . . . . . . . . . . . .
RS-232C Communications Errors . . . . . . . . . . . . . . . .
34
34
34
35
33
Section 5-3
Terminal Block Errors
5-1
Connection Errors
Problem
The POWER indicator is not lit.
Probable cause
The Power Supply is not connected properly.
The supply voltage is not 24 VDC +10%/–15%.
The Video Monitor is blank.
The power to the Video Monitor is not ON.
The Monitor Cable is not connected properly.
The Video Monitor is malfunctioning.
Cannot make key inputs from the
Console.
The Console Cable is not correctly connected.
Camera images
g do not appear on the
screen (for
(f Cameras
C
with
ith Light
Li ht
Source).
The Camera Cable is not correctly connected.
Camera images
g do not appear on the
screen (when
( h a normall CCTV lens
l
and lighting is used).
sed)
The lens cap has not been removed.
The lighting cable is not properly connected to
the Camera.
The Camera Cable is not properly connected.
The lens diaphragm is opened or closed too
far.
The shutter speed is not suitable (for Expert
Menu operation only).
The lighting method is not suitable.
The indicators do not turn ON (for
Cameras
C
e s with Light
g Source).
o ce)
The lighting cable is not correctly connected to
the Camera.
There is no power supply to the F150.
The Video Monitor image is not clear.
There is electrical noise entering from the
power supply or cables.
The Monitor Cable is not correctly connected.
5-2
Errors during Menu Operation
Problem
The measurement results are not
displayed on the Video Monitor.
5-3
Probable cause
The F150 is not in Monitor or
Measurement mode.
Terminal Block Errors
Problem
Trigger
gg signals
g
(input
(
signals)
g
) are not
received.
i d
Probable cause
The cables are not correctly wired.
The signal line is disconnected.
The F150 is not in Monitor or
Measurement mode.
Signals
cannot be output externally.
g
y
The trigger signal has not been input.
The cables are not correctly wired.
The signal line is disconnected.
The F150 is not in Measurement mode.
34
RS-232C Communications Errors
5-4
Section 5-4
RS-232C Communications Errors
Problem
No communications are possible.
Probable cause
The cables are not correctly wired.
The communications specifications do not
match those of the external device.
The communications mode was not
selected under System/Communications
settings.
Select Normal, Host link, or Menu
operations under RS-232C/Operating
mode.
The Unit operates well initially, but after a
while there is no response from the F150.
The reception buffer on the external device
(e.g., computer) is full. Check that settings
allow the data to be properly received.
Cannot perform menu operations via
RS-232C.
The communications mode was not
selected as System/Communications
settings/Menu operations.
35
SECTION 6
Maintenance
This section provides information on maintenance and inspection.
6-1
6-2
Maintenance Parts and Replacement . . . . . . . . . . . . . .
Regular Inspections . . . . . . . . . . . . . . . . . . . . . . . . . . .
38
39
37
Section 6-1
Maintenance Parts and Replacement
6-1
Maintenance Parts and Replacement
Maintenance parts of the F150 are shown in the following table.
Part
Note
Model No.
20-mm Lens (20 mm × 20 mm)
F150-LE20
50-mm Lens (50 mm × 50 mm)
F150-LE50
Light
F150-LT10
1. The Light will gradually lose illumination if used for long periods (approx. 20% loss after 1,500 hours of use). Replace
the Light after approx. 1,500 hours of use.
2. Replace the Light if it is partially damaged or not fully functioning.
Replacing the Lens or Light
Camera base
2
3
1
Hold this section when
removing the Cable.
5
4
Hold this section of the
lens when removing.
Light connector Camera cable
connector
1 Disconnect the light cable from the light connector on the
back of the Camera.
2
3
4
5
Remove the light cable from the slot in the camera base.
Remove the two M3 × 6 screws securing the Light.
Remove the Light from the Camera.
Remove the Lens from the camera mount.
Note Follow these steps in the reverse order to mount the Lens and
Light.
! Caution Do not disassemble the Lens. Disassembly can damage the
Lens.
38
Section 6-2
Regular Inspections
6-2
Regular Inspections
To maintain the F150 in the best condition, perform the following
regularly.
• Lightly wipe off dirt with a soft cloth.
• Clean the Lens and indicators with a special lens cloth or airbrush.
Inspection point
Details
Tools required
Power supply
The voltage measured at
the power supply terminals
on the terminal block must
be 24 VDC +10%/–15%.
Circuit tester
Ambient
temperature
The operating ambient
temperature inside the
cabinet must be between
0 and 50°C.
Thermometer
Ambient humidity
The operating ambient
humidity inside the cabinet
must be between 35% and
85%.
Hygrometer
Installation
Each component must be
firmly secured.
Phillips
screwdriver
Each cable connector must
be correctly inserted and
locked.
The Cameras must be
firmly secured.
The camera lens mounts
must be firmly secured.
Indicators
All indicators must light
when the power is turned
ON.
---
! Caution Turn OFF the power and take safety precautions before conducting inspections. Electrical shock can result from attempting
safety inspections with the power turned ON.
! Caution Do not use thinners or benzene. They will damage F150 components.
39
SECTION 7
Specifications
This section provides the specifications of the F150 components.
7-1
7-2
7-3
7-4
7-5
7-6
7-7
F150-C10E Vision Mate Controller . . . . . . . . . . . . . . .
K150-KP Console . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Cameras . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
F150-LE20/50 Lens . . . . . . . . . . . . . . . . . . . . . . . . . . .
F150-LT10 Light . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Cables . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
F300-M09 Video Monitor . . . . . . . . . . . . . . . . . . . . . .
42
43
44
46
46
47
48
41
Section 7-1
F150-C10E Vision Mate Controller
F150-C10E Vision Mate Controller
4.1
7-1
90
100
Unit: mm
165
Item
Specification
Supply voltage
24 VDC (+10%, –15%)
Current consumption
Approx. 0.5 A
Insulation resistance
20 M Ω min. between all DC external terminals and GR
terminal (at 100 VDC, with internal surge absorber removed)
Dielectric strength
1,000 VAC, 50/60 Hz between all DC external terminals and
GR terminal (with internal surge absorber removed)
Leakage current
10 mA max.
Noise resistance
1500 Vp–p; pulse width: 0.1µs/ 1µs; rising time: 1 ns (pulse)
Vibration resistance
10 to 150 Hz; half-amplitude: 0.5 mm; maximum
acceleration: 70 m/s2, 4 times for 8 minutes each in 3
directions
Shock resistance
200 m/s2, 3 times each in 6 directions
Ambient temperature
0 to 50 °C
Ambient humidity
35% to 85% (with no condensation)
Ambient environment
No corrosive gases
Storage temperature
–25 to 65 °C
Protection class
Class I (with protective conductor terminal)
Degree of protection
IEC60529 IP20 (in-panel)
Weight
Approx. 390 g
42
Section 7-2
K150-KP Console
7-2
K150-KP Console
12.5
12 dia.
87
Unit: mm
Item
Specification
Vibration resistance
10 to 150 Hz; half-amplitude: 0.15 mm
Shock resistance
196 m/s2
Ambient temperature
0 to 50 °C
Ambient humidity
35% to 85% (with no condensation)
Ambient environment
No corrosive gases
Storage temperature
–25 to 65 °C
Degree of protection
IEC60529 IP20 (in-panel)
Length
2m
Minimum bending radius
75 mm
Weight
Approx. 240 g (without cable)
43
Section 7-3
Cameras
7-3
Cameras
F150-SL20/SL50 Camera with Light Source
25.4
(70.5)
44
Unit: mm
Section 7-3
Cameras
F150-S1 Camera
Unit: mm
F150 light
connector
F150-C10E connector
Two M4 holes with
depth of 8 mm
1/4-20UNC with
depth of 8 mm
Item
Specification
Supply voltage
12 VDC
Current consumption
Approx. 160 mA
Vibration resistance
10 to 150 Hz; half-amplitude: 0.5 mm; maximum
acceleration: 70 m/s2, 4 times for 8 minutes each in 3
directions
Shock resistance
200 m/s2, 3 times each in 6 directions
Ambient temperature
0 to 50 °C
Ambient humidity
35% to 85% (with no condensation)
Ambient environment
No corrosive gases
Storage temperature
–25 to 60 °C
Picture element
1/3” Interline CCD (reading all pixels)
Effective pixels
659 × 494 (H × V)
Synchronization
External sync. via horizontal sync signal
Shutter speed
Electronic shutter: 1/100 s, 1/500 s, 1/2,000 s, 1/10,000 s
(Default: 1/2,000 s)
Lens mounting
C mount
Weight
Camera with Light Source: Approx. 135 g
Camera only: Approx. 70 g
45
Section 7-5
F150-LT10 Light
7-4
F150-LE20/50 Lens
Item
Specification
Ambient temperature
0 to 50 °C
Ambient humidity
35% to 85% (with no condensation)
Ambient environment
No corrosive gases
Storage temperature
–25 to 65 °C
System
Fixed focus, fixed diaphragm
Brightness
LE20/50: F2.8
Field of vision
LE20: 20 mm × 20 mm
LE50: 50 mm × 50 mm
Focal distance
LE20: 13 mm
LE50: 6.1 mm
Camera distance
LE20: 61 to 71 mm
LE50: 66 to 76 mm
7-5
F150-LT10 Light
Item
Specification
Supply voltage
12 VDC
Supply voltage fluctuation
10.8 to 13.2 VDC (including ripple)
Current consumption
Approx. 10 mA
Insulation resistance
20 M Ω min. between all DC external terminals and case (at
100 VDC)
Dielectric strength
1,000 VAC, 50/60 Hz between all DC external terminals and
case
Leakage current
10 mA max.
Vibration resistance
10 to 150 Hz; half-amplitude: 0.5 mm; maximum
acceleration: 70 m/s2, 4 times for 8 minutes each in 3
directions
Shock resistance
200 m/s2, 3 times each in 6 directions
Ambient temperature
0 to 50 °C
Ambient humidity
35% to 85% (with no condensation)
Ambient environment
No corrosive gases
Storage temperature
–25 to 65 °C
Light elements
LEDs
Lighting system
Pulse
46
Section 7-6
Cables
7-6
Cables
F150-VS Camera Cable
Item
Specification
Vibration resistance
10 to 150 Hz; half-amplitude: 0.15 mm, 4 times for 8
minutes each in 3 directions
Shock resistance
196 m/s2, 3 times each in 6 directions
Ambient temperature
0 to 50 °C
Ambient humidity
35% to 85% (with no condensation)
Ambient environment
No corrosive gases
Storage temperature
–25 to 65 °C
Length
3m
Minimum bending radius
75 mm
F150VM Monitor Cable
Item
Specification
Vibration resistance
10 to 150 Hz; half-amplitude: 0.15 mm, 4 times for 8
minutes each in 3 directions
Shock resistance
196 m/s2, 3 times each in 6 directions
Ambient temperature
0 to 50 °C
Ambient humidity
35% to 85% (with no condensation)
Ambient environment
No corrosive gases
Storage temperature
–25 to 65 °C
Length
2m
Minimum bending radius
50 mm
47
Section 7-7
F300-M09 Video Monitor
7-7
F300-M09 Video Monitor
This is the recommended monitor and is available from OMRON.
Unit: mm
6
125
215
220
Item
Specification
Supply voltage
100 VAC
Current consumption
Approx. 300 mA
Vibration resistance
10 to 150 Hz; half-amplitude: 0.15 mm, 4 times for 8
minutes each in 3 directions
Shock resistance
196 m/s2, 3 times each in 6 directions
Ambient temperature
0 to 40 °C
Ambient humidity
10% to 90% (with no condensation)
Ambient environment
No corrosive gases
Storage temperature
–25 to 65 °C
System
Number of scanning lines:
525
Horizontal frequency:
15.75 kHz
Field frequency:
60 Hz
I/O impedance
75 Ω, high impedance (selectable)
I/O level and polarity
Image:
0.7 V (peak to peak), positive
Synchronization:
0.3 V (peak to peak), negative
Screen size
123 × 164 (H × W), monochrome (light-holding)
Resolution
700 TV lines min. (at center)
Weight
Approx. 5.8 kg
48
Revision History
A manual revision code appears as a suffix to the catalog number on the front
cover of the manual.
Cat. No. Z124-E1-1B
Revision code
The following table outlines the changes made to the manual during each revision. Page numbers refer to the previous version.
Revision code
Date
1
July 1998
Revised content
1A
January 1999
Pages 20 to 22: 2-7-2 Fluorescent Light Sources
and 2-7-3 Optical Fiber Light Sources removed.
1B
January 2001
Cover: ISO mark removed.
Original production
Page 11 : Grounding indication in the graphic corrected.
Page 25: Graphic in the bottom table corrected.
Page 38: Numbering in the graphic corrected.
Pages 42, 43, 45, 46, 47, 48: “single amplitude”
changed to “half-amplitude”.
Page 44: Camera height corrected from 25.5 to
25.4.
Page 48: Horizontal dimension added to the graphic.
49
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