Cognex DS1000 Series Service manual

DS1000 Series
Displacement Sensors
Reference
2019 October 21
Revision: 9.5.0.SR2.1

Legal Notices
The software described in this document is furnished under license, and may be used or copied only in accordance with
the terms of such license and with the inclusion of the copyright notice shown on this page. Neither the software, this
document, nor any copies thereof may be provided to, or otherwise made available to, anyone other than the licensee.
Title to, and ownership of, this software remains with Cognex Corporation or its licensor. Cognex Corporation assumes
no responsibility for the use or reliability of its software on equipment that is not supplied by Cognex Corporation.
Cognex Corporation makes no warranties, either express or implied, regarding the described software, its
merchantability, non-infringement or its fitness for any particular purpose.
The information in this document is subject to change without notice and should not be construed as a commitment by
Cognex Corporation. Cognex Corporation is not responsible for any errors that may be present in either this document or
the associated software.
Companies, names, and data used in examples herein are fictitious unless otherwise noted. No part of this document
may be reproduced or transmitted in any form or by any means, electronic or mechanical, for any purpose, nor
transferred to any other media or language without the written permission of Cognex Corporation.
2019 October 21 11:49 AM
Revision: 9.5.0.SR2.1
Copyright © 2016. Cognex Corporation. All Rights Reserved.
Portions of the hardware and software provided by Cognex may be covered by one or more U.S. and foreign patents, as
well as pending U.S. and foreign patents listed on the Cognex web site at: cognex.com/patents.
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Cognex, 2DMAX, Advantage, AlignPlus, Assemblyplus, CheckitwithChecker, Checker, CognexVisionforIndustry,
CognexVSOC, CVL, DataMan, DisplayInspect, DVT, EasyBuilder, Hotbars, IDMax, In-Sight, LaserKiller, MVS-8000,
OmniView, PatFind, PatFlex, PatInspect, PatMax, PatQuick, SensorView, SmartView, SmartAdvisor, SmartLearn,
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The following are trademarks of Cognex Corporation:
The Cognex logo, 1DMax, 3D-Locate, 3DMax, BGAII, CheckPoint, CognexVSoC, CVC-1000, FFD, iLearn, In-Sight
(design insignia with cross-hairs), In-Sight2000, InspectEdge, Inspection Designer, MVS, NotchMax, OCRMax,
PatMaxRedLine, ProofRead, SmartSync, ProfilePlus, SmartDisplay, SmartSystem, SMD4, VisiFlex, Xpand
Portions copyright © Microsoft Corporation. All rights reserved.
Portions copyright © MadCap Software, Inc. All rights reserved.
Other product and company trademarks identified herein are the trademarks of their respective owners.
2
Legal Notices

Preface
This document describes the Cognex Displacement DS1000 series sensors.
Symbols
The following symbols indicate safety precautions and supplemental information:
WARNING:This symbol indicates a hazard that could cause death, serious personal injury or electrical shock.
CAUTION:This symbol indicates a hazard that could result in property damage.
Note: This symbol indicates additional information about a subject.
Tip: This symbol indicates suggestions and shortcuts that might not otherwise be apparent.
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Preface

Cognex 3D Displacement Sensors
Cognex 3D displacement sensors combine GigE Vision and laser-stripe illumination to generate information about
three-dimensional objects that cannot easily be generated by cameras that acquire two-dimensional images. Each
sensor projects a triangular laser plane onto an object as it passes within view.
The illumination of the laser plane generates a laser stripe whose shape is determined by the surface of the object.
The integrated camera uses a red long-pass filter to capture an intensity image of the laser stripe:
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Cognex 3D Displacement Sensors

The image of the laser stripe represents a cross-section of the object under inspection. Your application might use this
cross-section data, or you can use a 3D displacement sensor to acquire a series of images while the object moves past
and then combine the height data of each image to generate a synthetic 2D image containing height profile information
in real-world coordinates.
Your Cognex software supports a variety of 3D vision tools for performing tasks such as:
lGenerating information about a planar surface
lGenerating height or volume calculations
lAnalyzing a cross-section of the object
The synthetic image can also be passed to any number of traditional vision tools to perform tasks such as pattern
matching or optical character recognition.
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Cognex 3D Displacement Sensors

Precautions
To reduce the risk of injury or equipment damage, observe the following precautions when you install the Cognex
product:
lRoute cables and wires away from high-current wiring or high-voltage power sources to reduce the risk of
damage or malfunction from the following causes: over-voltage, line noise, electrostatic discharge (ESD), power
surges, or other irregularities in the power supply.
lChanges or modifications not expressly approved by the party responsible for regulatory compliance could void
the user’s authority to operate the equipment.
lEnsure that the cable bend radius begins at least six inches from the connector. Cable shielding can be
degraded or cables can be damaged or wear out faster if a service loop or bend radius is tighter than 10X the
cable diameter.
lThis device is certified for office use only and if used at home, there can be frequency interference problems.
lThis device should be used in accordance with the instructions in this manual.
lAll specifications are for reference purposes only and can change without notice.
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Cognex 3D Displacement Sensors

DS1000 Series Models
The following sensors contain a class 2M laser:
Model Class 2M Laser
DS1050 (821-0116-5R) √
DS1101 (821-0116-3R) √
DS1300 (821-0116-4R) √
Accessories
The following optional components can be purchased separately. For a list of options and accessories, contact your
Cognex sales representative.
Cables
Note: Cables are sold separately.
Power and I/O
For more information, refer to I/O Cable on page26 for the pin-out of the unterminated flying leads.
Length Description Part Number
5m Cable Power and I/O, M12 to flying lead, straight CBL-05P2-S1
20m CBL-20P2-S1
Refer to DB15 Connector on page27 for the pin-out of the DB15 connnector.
Length Description Part Number
5m Cable Power and I/O, M12 to DB15, straight CBL-05P2-S2
20m CBL-20P2-S2
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DS1000 Series Models

Length Description Part Number
5m Cable Power and I/O, M12 to DB15, right-angle CBL-05P2-R2
20m CBL-20P2-R2
Ethernet Cables
Length Description Part Number
0.6m M12 to RJ-45, straight CCB-84901-1001-00
2m CCB-84901-1002-02
5m CCB-84901-1003-05
10m CCB-84901-1004-10
15m CCB-84901-1005-15
30m CCB-84901-1006-30
Length Description Part Number
2m M12 to RJ-45, right-angle CCB-84901-6005-02
5m CCB-84901-6001-05
10m CCB-84901-6002-10
15m CCB-84901-6003-15
30m CCB-84901-6004-30
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DS1000 Series Models

Mounting Hardware
Description Part Number
Mounting bracket and M6 screws. DS-BKT-000
Description Part Number
High-accuracy mounting plate and M6 screws. DS-MPHA-00
Steel Enclosure
Description Part Number
IP69K stainless steel enclosure DS-ENC-SS-00
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DS1000 Series Models

Laser Safety Warnings
DS1050
DS1101
DS1300
LASER LIGHT, DO NOT STARE INTO BEAM:
CLASS 2M LASER PRODUCT
FAILURE TO FOLLOW THESE
INSTRUCTIONS MAY CAUSE SERIOUS
INJURY
Cognex places the following labels on every 3D displacement sensor:
DS1000 Series
If you need more information on the collection, reuse, and recycling systems, please contact your local or regional waste
administration. You may also contact your supplier for more information on the environmental performance of this
product.
Note: AVOID EXPOSURE - LASER RADIATION IS EMITTED FROM THIS APERTURE
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DS1000 Series Models

Label Locations
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DS1000 Series Models

Warnings and Notices
Cognex provides the following warnings and notices:
lDo not stare into the beam.
lDo not view directly with optical instruments (magnifiers).
lDo not place optical components (mirrors) into the beam.
lDesign test fixtures in such a way that unintentional viewing of the beam is prevented.
lSwitch off the laser when not in use.
lAvoid the use of highly reflective materials. If you cannot, try to angle the part so unintentional viewing of the
reflection is prevented.
lTerminate (block) unused beams.
lKeep the laser plane horizontal or pointing downwards.
lReport any issues that may have an impact on laser safety to your supervisor or Laser Safety Officer.
lThere is no scheduled maintenance necessary to keep the product in compliance.
lUnder no circumstances should you operate the sensor if it is defective or the seal damaged. Cognex
Corporation cannot be held responsible for any harm caused by operating a faulty unit.
lUnder no circumstances should you modify in any way the sensor or its housing.
lUse of controls or adjustments or performance of procedures other than those specified herein may result in
hazardous radiation exposure.
lWhen moving the unit from a very hot environment to a cold environment please allow the unit to equalize in a
room temperature environment for 2 hours between temperature extremes.
If you need more information on the collection, reuse, and recycling systems, please contact your local or regional waste
administration. You may also contact your supplier for more information on the environmental performance of this
product.
12
DS1000 Series Models

Dimensions
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DS1000 Series Models

DS1050 Sensor Specifications
Refer to the following sections for DS1050 hardware and laser specifications.
Hardware Specifications
Weight 700 g
Operating
Temperature
0 ºC to 50 ºC (32 ºF to 122 ºF)
Storage
Temperature
-10 ºC to 80 ºC (14 ºF to 176 ºF)
Maximum
Humidity
10% to 85%, non-condensing (Operating and Storage)
Environmental IP65 (with Cognex recommended IP65 Ethernet and Power and I/O cables)
Power Supply
Requirements
Voltage: +24 VDC +/- 10%
Current: 500 mA max
Trigger Input voltage limits: Trig+ - Trig - = - 24VDC to +24VDC
Input ON: > 10 VDC (> 6 mA)
Input OFF: < 2 VDC (< 1.5 mA)
Encoder Input
Specification
Differential: A+/B+: 5-24V (50 kHz max) A-/B-: Inverted (A+/B+)
Single Ended: A+/B+: 5-24V (50 kHz max) A-/B-: VDC = ½ (A+/B+)
Working Distance 87 to 163 mm
Ethernet lGigabit Ethernet interface
lIntegrated link and traffic LEDs
lStandard M12-8 female connector
Shock 50 G’s Half-Sine with a pulse of 11 milliseconds duration. Test conducted while instrumented in a
shipping package dropped from a maximum of 36 inches
Vibration 8 G’s RMS Random Between 10-500 Hz for a duration of 30 minutes.
Certification
Altitude rating 2 km / 6561 ft
Laser Specifications
This laser product is designated as Class 2M.
Wavelength 658 nm
Laser Power for Classification <5 mW
Laser Maximum Total Power <40 mW
Minimum Divergence vertical:<1.5 mrad
horizontal:32 degrees
Laser Line Thickness (FWHM) <0.4 mm
Sensor Size 1024x768 pixels
XResolution Top 0.059 mm
Bottom 0.090 mm
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DS1050 Sensor Specifications

Y Resolution This value depends on Encoder Resolution, the Distance per Cycle and the Steps per Line
settings.
Z Resolution Top 0.005 mm
Bottom 0.014 mm
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DS1050 Sensor Specifications

DS1101 Sensor Specifications
Refer to the following sections for DS1101 hardware and laser specifications.
Hardware Specifications
Weight 700 g
Operating Temperature 0 ºC to 50 ºC (32 ºF to 122 ºF)
Storage Temperature -10 ºC to 80 ºC (14 ºF to 176 ºF)
Maximum Humidity 10% to 85%, non-condensing (Operating and Storage)
Environmental IP65 (with Cognex recommended IP65 Ethernet and Power and I/O cables)
Power Supply Requirements Voltage: +24 VDC +/- 10%
Current: 500 mA max
Trigger Input voltage limits: Trig+ - Trig - = - 24VDC to +24VDC
Input ON: > 10 VDC (> 6 mA)
Input OFF: < 2 VDC (< 1.5 mA)
Encoder Input Specification Differential: A+/B+: 5-24V (50 kHz max) A-/B-: Inverted (A+/B+)
Single Ended: A+/B+: 5-24V (50 kHz max) A-/B-: VDC = ½ (A+/B+)
Working Distance 135 mm to 355 mm
Ethernet lGigabit Ethernet interface
lIntegrated link and traffic LEDs
lStandard M12-8 female connector
Shock 50 G’s Half-Sine with a pulse of 11 milliseconds duration. Test conducted while
instrumented in a shipping package dropped from a maximum of 36 inches
Vibration 8 G’s RMS Random Between 10-500 Hz for a duration of 30 minutes.
Certification
Altitude rating 2 km / 6561 ft
Laser Specifications
This laser product is designated as Class 2M.
Wavelength 658 nm
Laser power for classification <5 mW
Laser maximum total power <40 mW
Minimum Divergence vertical:<1.5 mrad
horizontal:32 degrees
Laser Line Thickness (FWHM) <0.5 mm
Sensor Size 1024x768 pixels
XResolution Top 0.079 mm
Bottom 0.181 mm
Y Resolution This value depends on Encoder Resolution, the Distance per Cycle and the Steps per Line
settings.
Z Resolution Top 0.010 mm
Bottom 0.052 mm
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DS1101 Sensor Specifications

DS1300 Sensor Specifications
Refer to the following sections for DS1300 hardware and laser specifications.
Hardware Specifications
Weight 700 g
Operating Temperature 0 ºC to 50 ºC (32 ºF to 122 ºF)
Storage Temperature -10 ºC to 80 ºC (14 ºF to 176 ºF)
Maximum Humidity 10% to 85%, non-condensing (Operating and Storage)
Environmental IP65 (with Cognex recommended IP65 Ethernet and Power and I/O cables)
Power Supply Requirements Voltage: +24 VDC +/- 10%
Current: 500 mA max
Trigger Input voltage limits: Trig+ - Trig - = - 24VDC to +24VDC
Input ON: > 10 VDC (> 6 mA)
Input OFF: < 2 VDC (< 1.5 mA)
Encoder Input Specification Differential: A+/B+: 5-24V (50 kHz max) A-/B-: Inverted (A+/B+)
Single Ended: A+/B+: 5-24V (50 kHz max) A-/B-: VDC = ½ (A+/B+)
Working Distance 180 mm to 905 mm
Ethernet lGigabit Ethernet interface
lIntegrated link and traffic LEDs
lStandard M12-8 female connector
Shock 50 G’s Half-Sine with a pulse of 11 milliseconds duration. Test conducted while
instrumented in a shipping package dropped from a maximum of 36 inches
Vibration 8 G’s RMS Random Between 10-500 Hz for a duration of 30 minutes.
Certification
Altitude rating 2 km / 6561 ft
Laser Specifications
This laser product is designated as Class 2M.
Wavelength 658 nm
Laser Power for Classification <5 mW
Laser Maximum Total Power <40 mW
Minimum Divergence vertical:<1.5 mrad
horizontal:32 degrees
Laser Line Thickness (FWHM) <0.8 mm
Sensor Size 1024x768 pixels
XResolution Top 0.101 mm
Bottom 0.457 mm
Y Resolution This value depends on Encoder Resolution, the Distance per Cycle and the Steps per Line
settings.
Z Resolution Top 0.016 mm
Bottom 0.265 mm
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DS1300 Sensor Specifications

System Layout
Component Description
1 Status LEDs
2 Ethernet connector
3 24V DC power + I/O + Encoder connector
4 M6 mounting boss
5M4 through-body mounting holes
Safe Handling
lRetain the original packaging supplied by Cognex and re-use it whenever you ship your sensor.
lFollow the instructions in Sensor Maintenance on page20 for details on cleaning the sensor.
lRefer to the topic Safety and Regulatory on page49 for electrical safety information.
lAlways observe the environmental limits. Subjecting the unit to shock, vibration or rough handling in excess of
the specified limits can cause the sensor to fail.
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System Layout

System LEDs
Connector Indicator Description
1 Ethernet Link Blinks when there is Ethernet activity on the link, or is off to indicate
there is no link with the host.
2 Ethernet Link Status Blinks in groups of three when a 1000 Mbps connection is
established with the host.
3 Sensor Status Blinks approximately every 5 seconds when the sensor is running
normally.
4 Laser Enabled Lights while the laser is triggered.
Bottom View
Component Description
1 High-accuracy planar mounting pins
2Laser window
CAUTION:AVOID EXPOSURE - LASER RADIATION IS EMITTED FROM
THIS APERTURE
3 Camera window
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System Layout

Sensor Maintenance
LASER LIGHT, DO NOT STARE INTO BEAM OR VIEW DIRECTLY WITH
OPTICAL INSTRUMENTS: CLASS 2M LASER PRODUCT
Component Description
1Laser window
CAUTION:AVOID EXPOSURE - LASER RADIATION IS
EMITTED FROM THIS APERTURE
2 Camera window
The windows to the camera and laser must be kept clean and free of defects to ensure proper operation. Any scratches,
dust or dirt will impact the accuracy of acquired images.
CAUTION:Use care not to damage the anti-reflective coating on the windows.
Cognex makes the following recommendations for cleaning the laser and camera windows:
lUnplug the unit so the laser cannot be enabled.
lUse lint-free tissue or an optical grade cotton swab ("Q-tip").
lUse reagent-grade isopropyl alcohol.
lUse minimal pressure.
ll Use several tissues or swabs.
lStart at the center of each window and spiral out to the edges.
lRotate the tissue or swab during cleaning so dirt is not dragged across the surface.
Product Service
lBring any performance issues to the attention of your Cognex sales representative.
lThe sensor can only be serviced by a trained Cognex representative. Return the unit to
Cognex for any service or repairs.
lDo not operate the sensor if the enclosure appears damaged.
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Sensor Maintenance