Cognex In-Sight 5000 Series Instruction Manual

Installing In-Sight®5000 Series Vision Sensors
i
Copyright, Trademarks, Patents
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. 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 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.
This document may not be copied in whole or in part, nor transferred to any other media or
language, without the written permission of Cognex Corporation.
Cognex P/N 597-0027-04
Copyright © 2003-2006 Cognex Corporation. All Rights Reserved.
The hardware and portions of the software described in this document may be covered by
one or more of the following U.S. patents (other U.S. and foreign patents are pending):
Hardware 4,972,359; 5,526,050; 5,657,403; 5,793,899
Vision Tools 5,495,537; 5,548,326; 5,583,954; 5,602,937; 5,640,200; 5,717,785;
5,742,037; 5,751,853;5,768,443; 5,796,868; 5,818,443; 5,825,483;
5,825,913; 5,845,007; 5,859,466; 5,872,870;5,909,504
The following are registered trademarks of Cognex Corporation:
Cognex
Cognex, Vision for Industry
In-Sight "crosshair" logo
In-Sight
The following are trademarks of Cognex Corporation:
The Cognex logo
Other product and company names mentioned herein are the trademarks, or registered
trademarks, of their respective owners.

Regulations/Comformity
ii
Regulations/Comformity
Declaration of Conformity
Manufacturer: Cognex Corporation
One Vision Drive
Natick, MA 01760 USA
Declares this -marked Machine Vision System Product
Product Number: In-Sight 5000: P/N 800-5840-4; P/N 800-5840-4R (RoHS Compliant)
In-Sight 5100/5110: P/N 800-5870-1; P/N 800-5870-1R (RoHS Compliant)
In-Sight 5400/5410: P/N 800-5855-1; P/N 800-5855-1R (RoHS Compliant)
In-Sight 5400S/5410S: P/N 800-5855-3; P/N 800-5855-3R (RoHS Compliant)
In-Sight 5400C: P/N 800-5837-4; P/N 800-5837-4R (RoHS Compliant)
In-Sight 5400CS: P/N 800-5837-6; P/N 800-5837-6R (RoHS Compliant)
In-Sight 5401/5411: P/N 800-5838-4; P/N 800-5838-4R (RoHS Compliant)
Complies With: 89/336/EEC Electromagnetic Compatibility Directive
Compliance Standards EN 55011:1998 + A1:1999 + A2:2002 Class A
EN 61000-3-2:2000 + A2:2005
EN 61000-3-3:1995 +A1:2001
EN 61000-6-2:2001
European Representative: Cognex France
Immeuble le Patio
104 avenue Albert 1er
92563 Rueil Malmaison
France
Safety
LISTED
UL and CUL Certification marks are present on products
FCC FCC Part 15, Class A
This device complies with Part 15 of the FCC Rules. Operation is subject to the
following two conditions: (1) This device may not cause harmful interference,
and (2) this device must accept any interference received, including interference
that may cause undesired operation.
This equipment generates, uses, and can radiate radio frequency energy and, if
not installed and used in accordance with the instruction manual, may cause
harmful interference to radio communications. Operation of this equipment in a
residental area is likely to cause harmful interference in which case the user will
be required to correct the interference at their own expense.

Installing In-Sight®5000 Series Vision Sensors
iii
Declaration of Conformity
Manufacturer:Cognex Corporation
One Vision Drive
Natick, MA 01760 USA
Declares this -marked Machine Vision System Product
Product Number: In-Sight 5400R/5410R: P/N 800-5829-1; P/N 800-5829-1R (RoHS Compliant)
Complies With: 89/336/EEC Electromagnetic Compatibility Directive
Compliance Standards EN 61000-6-4:2001 Class A
EN 61000-3-2:2000 + A2:2005
EN 61000-3-3:1995 + A1:2001
EN 61000-6-2:2001
European Representative: Cognex France
Immeuble le Patio
104 avenue Albert 1er
92563 Rueil Malmaison
France
Safety
LISTED
UL and CUL Certification marks are present on products
FCC FCC Part 15, Class A
This device complies with Part 15 of the FCC Rules. Operation is subject to the
following two conditions: (1) This device may not cause harmful interference,
and (2) this device must accept any interference received, including interference
that may cause undesired operation.
This equipment generates, uses, and can radiate radio frequency energy and, if
not installed and used in accordance with the instruction manual, may cause
harmful interference to radio communications. Operation of this equipment in a
residental area is likely to cause harmful interference in which case the user will
be required to correct the interference at their own expense.

Regulations/Comformity
iv
Declaration of Conformity
Manufacturer:Cognex Corporation
One Vision Drive
Natick, MA 01760 USA
Declares this -marked Machine Vision System Product
Product Number: In-Sight 5403/5413: P/N 800-5830-4; P/N 800-5830-4R (RoHS Compliant)
In-Sight 5403S: P/N 800-5830-6; P/N 800-5830-6R (RoHS Compliant)
Complies With: 89/336/EEC Electromagnetic Compatibility Directive
Compliance Standards EN 61000-6-3:2001 + A11:2004 Class B
EN 61000-3-2:2000 + A2:2005
EN 61000-3-3:1995 +A1:2001
EN 61000-6-2:2001
European Representative: Cognex France
Immeuble le Patio
104 avenue Albert 1er
92563 Rueil Malmaison
France
Safety
LISTED
UL and CUL Certification marks are present on products
FCC FCC Part 15, Class B
This device complies with Part 15 of the FCC Rules. Operation is subject to the
following two conditions: (1) This device may not cause harmful interference,
and (2) this device must accept any interference received, including interference
that may cause undesired operation.

Installing In-Sight®5000 Series Vision Sensors
v
Precautions
Observe these precautions when installing In-Sight 5000 series vision sensors to reduce the
risk of injury or equipment damage:
• In-Sight 5000 series vision sensors are intended to be supplied by a Listed, Direct
Plug-In Power Unit with a minimum output rated 24VDC, 500mA and marked Class
2, Limited Power Source (LPS). Any other voltage creates a risk of fire or shock and
can damage the In-Sight components.
• Do not install In-Sight 5000 series vision sensors where they are directly exposed to
environmental hazards such as excessive heat, dust, moisture, humidity, impact,
vibration, corrosive substances, flammable substances, or static electricity.
• To reduce the risk of damage or malfunction due to over-voltage, line noise,
electrostatic discharge (ESD), power surges, or other irregularities in the power
supply, route all cables and wires away from high-voltage power sources.
• Maximize ESD protection by grounding the In-Sight 5000 series sensor case.
• Do not open the In-Sight 5000 series vision sensor or remote head camera. These
devices do not contain user-serviceable parts.
• Do not make electrical or mechanical modifications to In-Sight components.
Unauthorized modifications may violate your warranty.
• Changes or modifications not expressly approved by the party responsible for
regulatory compliance could void the user’s authority to operate the equipment.

Precautions
vi

Installing In-Sight®5000 Series Vision Sensors
vii
Table of Contents
1 Introduction
1.1 In-Sight 5000 Series Vision Sensors Overview................................................................ 1
1.2 In-Sight Support ............................................................................................................... 1
1.3 In-Sight 5000 Series Standard Components.................................................................... 2
1.4 In-Sight 5000 Series Configurations ................................................................................ 3
1.4.1 Standalone Network.............................................................................................. 4
1.4.2 Configurations Using Switches/Routers................................................................ 5
1.4.3 Adding an In-Sight Network to the Factory Network ............................................. 6
2 Setting Up the PC
2.1 Installing the In-Sight Software on a Windows PC........................................................... 7
2.2 Configuring the PC’s Network Settings (Non-DHCP)....................................................... 8
3 Installing the Sensor
3.1 Connecting the In-Sight 5000 Series Vision Sensor...................................................... 11
3.1.1 Connecting the In-Sight 5000 Series Components............................................. 12
3.2 Connecting the Model 1350 Breakout Module............................................................... 16
3.3 Connecting the Model 1460 I/O Expansion Module....................................................... 17
3.4 Connecting the Model 1450 I/O Expansion Module....................................................... 20
4 Configuring the Sensor
4.1 Adding the In-Sight 5000 Series Sensor to a Network................................................... 23
4.2 Installing to a DHCP Network......................................................................................... 23
4.3 Installing to a Non-DHCP Network Using the In-Sight Connection Manager................. 24
4.4 Logging On to the Sensor.............................................................................................. 29
4.5 Logging On Using In-Sight Explorer............................................................................... 29
4.6 Sensor Network Settings................................................................................................ 30
5 Specifications
5.1 General Specifications................................................................................................... 33
5.1.1 Standard Vision Sensor Specifications .............................................................. 34
5.1.2 Stainless Steel Vision Sensor Specifications...................................................... 36
5.1.3 Remote Head Vision Sensor Specifications........................................................ 38
5.2 I/O Specs ....................................................................................................................... 40
5.2.1 Acquisition Trigger Input ..................................................................................... 40
5.2.2 High-Speed Outputs............................................................................................ 41
5.2.3 24VDC Breakout Connector and Cable Specifications....................................... 43
5.2.4 I/O Module Cable................................................................................................ 44
5.2.5 Network Cable Specifications ............................................................................. 45
5.2.6 Camera Cable Specifications.............................................................................. 46
5.3 Dimensional Drawings ................................................................................................... 47
5.3.1 In-Sight 5000, 5100, 5400, 5401, 5400C and 5403 Sensor Dimensions............ 47

Table of Contents
viii
5.3.2 In-Sight 5403S, 5400CS and 5400S Sensor Dimensions...................................48
5.3.3 In-Sight 5400R Sensor Dimensions ....................................................................49
5.3.4 In-Sight Remote Head Camera Dimensions .......................................................50
5.3.5 In-Sight Remote Head Camera Enclosure Dimensions ......................................51
5.3.6 In-Sight Remote Head Camera Mount Dimensions ............................................52
Appendix A
A.1 Configuring the In-Sight Sensor’s I/O Settings...............................................................53
A.1.1 Configuring the I/O Expansion Module Using In-Sight Explorer..........................53
A.1.2 Enabling Hardware Handshaking Using In-Sight Explorer..................................55
Appendix B
B.1 Installing the Remote Head Camera ..............................................................................57
Appendix C
C.1 Cleaning/Maintenance....................................................................................................59
C.1.1 Cleaning the Sensor............................................................................................59
C.1.2 Cleaning the CCD Window..................................................................................59

Installing In-Sight®5000 Series Vision Sensors
ix
List of Figures
Figure 1-1: Standalone Sensor Configuration......................................................................... 4
Figure 1-2: Standalone Configuration with Ethernet Switch/Router....................................... 5
Figure 1-3: Factory Floor Network Installation......................................................................... 6
Figure 2-1: Local Area Connection Properties Dialog ............................................................. 9
Figure 2-2: Select Network Protocol Dialog........................................................................... 10
Figure 3-1: Install the Lens.................................................................................................... 12
Figure 3-2: CAM0 Connection............................................................................................... 13
Figure 3-3: Connect the Network Cable................................................................................ 14
Figure 3-4: Power Connections............................................................................................. 15
Figure 3-5: Breakout Module Connections............................................................................ 16
Figure 3-6: Connecting I/O Wires.......................................................................................... 17
Figure 3-7: Connecting the I/O Cable and Serial Cable........................................................ 18
Figure 3-8: Connecting the Expansion Module to the Sensor............................................... 18
Figure 3-9: Connecting +24VDC and Ground Wires............................................................. 19
Figure 3-10: I/O Expansion Module Connections.................................................................... 20
Figure 4-1: In-Sight Connection Manager Dialog .................................................................. 24
Figure 4-2: Administrative Account Dialog ............................................................................ 25
Figure 4-3: In-Sight Vision Sensor Dialog ............................................................................. 26
Figure 4-4: Set Network Configuration Dialog....................................................................... 27
Figure 4-5: Set New In-Sight Vision Sensor Information Dialog............................................ 28
Figure 4-6: Configure In-Sight Vision Sensors Dialog........................................................... 28
Figure 4-7: Network Settings Dialog...................................................................................... 30
Figure 5-1: Acquisition Trigger Input Schematic.................................................................... 40
Figure 5-2: High-Speed Output Connection Example 1........................................................ 41
Figure 5-3: High-Speed Output Connection Example 2........................................................ 42
Figure 5-4: High-Speed Output Connection Example 3........................................................ 42
Figure 5-5: In-Sight 5000 Series Sensor Dimensions ........................................................... 47
Figure 5-6: In-Sight 5000 Series Stainless Steel Sensor Dimensions................................... 48
Figure 5-7: In-Sight 5400R Sensor Dimensions.................................................................... 49
Figure 5-8: In-Sight 5400R Remote Head Camera Dimensions ........................................... 50
Figure 5-9: In-Sight 5400R Remote Head Camera Enclosure Dimensions .......................... 51
Figure 5-10: In-Sight 5400R Remote Head Camera Mount Dimensions ................................ 52
Figure A-1: Accessing the I/O Output Settings ...................................................................... 53
Figure A-2: Discrete Output Settings Dialog.......................................................................... 54
Figure A-3: Accessing the Serial Port Settings...................................................................... 55
Figure A-4: Serial Port Settings Dialog.................................................................................. 55
Figure B-1: Remote Head Camera Installation Diagram ....................................................... 57

List of Figures
x

Installing In-Sight®5000 Series Vision Sensors
xi
List of Tables
Table 1-1: In-Sight 5000 Series Sensor Standard Components............................................ 2
Table 1-2: In-Sight 5000 Series Standard Components Descriptions.................................... 3
Table 3-1: In-Sight 5000 Series Vision Sensor Connectors and Indicators ......................... 11
Table 5-1: Standard Sensor Specifications.......................................................................... 34
Table 5-2: Stainless Steel Sensor Specifications................................................................. 36
Table 5-3: In-Sight 5400R Sensor Specifications................................................................. 38
Table 5-4: Remote Head Camera Specifications................................................................. 39
Table 5-5: Remote Head Camera Enclosure Specifications................................................ 39
Table 5-6: Acquisition Trigger Input Specifications.............................................................. 40
Table 5-7: High-Speed Output Specifications...................................................................... 41
Table 5-8: 24VDC Breakout Connector Cable Pin-Out........................................................ 43
Table 5-9: I/O Module Cable Pin-Out................................................................................... 44
Table 5-10: Network Cable Pin-Out ....................................................................................... 45
Table 5-11: Camera Cable Pin-out......................................................................................... 46

List of Tables
xii

1
1 Introduction
In This Section…
1.1 In-Sight 5000 Series Vision Sensors Overview ........................1
1.2 In-Sight Support........................................................................1
1.3 In-Sight 5000 Series Standard Components.............................2
1.4 In-Sight 5000 Series Configurations.........................................3
1.1 In-Sight 5000 Series Vision Sensors Overview
In-Sight®5000 series sensors are compact, network-ready machine vision sensors for
automated inspection, measurement, identification, alignment and robot guidance
applications on the factory floor. For a list of all available sensors, refer to Table 1-1 on
page 2.
All models are configured remotely over a network using an intuitive spreadsheet interface.
This interface also allows remote monitoring of the sensor’s operation during runtime. These
sensors may also be controlled remotely from custom, user-defined applications using
In-Sight Native Mode commands to change settings and retrieve results.
This manual describes how to install In-Sight 5000 series vision sensors. When referring to
the In-Sight 5000 series sensors, the term "standard sensor" refers to all sensors except for
the stainless steel and remote head sensors.
1.2 In-Sight Support
Many information resources are available to assist you in using the In-Sight 5000 series
vision sensors and their spreadsheet interface:
•Getting Started with In-Sight, Cognex P/N 590-6368 (English), 590-6368F (French),
590-6368G (German), or 590-6368J (Japanese).
•In-Sight®Explorer Help, an on-line HTML Help file provided on the In-Sight
CD-ROM (for In-Sight Explorer software).
• In-Sight computer-based tutorials provided on CD-ROM with selected In-Sight
starter accessories kits.
• The In-Sight Online Support and Learning Center at:
www.cognex.com/support/In-Sight.asp.

Introduction
2
1.3 In-Sight 5000 Series Standard Components
In-Sight 5000 series vision sensors are shipped with the components listed in Table 1-1;
component descriptions are given in Table 1-2.
Table 1-1: In-Sight 5000 Series Sensor Standard Components
Vision Sensor 50mm Lens Cover Kit
(P/N 800-5842-x)
IP68 Lens
Cover Kit
(P/N 800-5892-x) Thread Guard
(P/N 370-0361) Remote Head
Camera
(P/N 800-5808-x)
Remote Head
Accessory Kit
(P/N 800-5813-x)
In-Sight 5000
P/N 800-5840-4
P/N 800-5840-4R
X X
In-Sight 5100/
In-Sight 5110
P/N 800-5870-1
P/N 800-5870-1R
X X
In-Sight 5400/
In-Sight 5410
P/N 800-5855-1
P/N 800-5855-1R
X X
In-Sight 5400S/
In-Sight 5410S
P/N 800-5855-3
P/N 800-5855-3R
X X
In-Sight 5400R/
In-Sight 5410R
P/N 800-5829-1
P/N 800-5829-1R
X X
In-Sight 5400C
P/N 800-5837-4
P/N 800-5837-4R
X X
In-Sight 5400CS
P/N 800-5837-6
P/N 800-5837-6R
X X
In-Sight 5401/
In-Sight 5411
P/N 800-5838-4
P/N 800-5838-4R
X X
In-Sight 5403/
In-Sight 5413
P/N 800-5830-4
P/N 800-5830-4R
X X
In-Sight 5403S
P/N 800-5830-6
P/N 800-5830-6R
X X
NOTES: • Part numbers appended by an “R” suffix indicate RoHS compliance.
• The standard components do not include a Breakout cable, Network cable or Camera
cable; these cables must be purchased separately.

Installing In-Sight®5000 Series Vision Sensors
3
1.4 In-Sight 5000 Series Configurations
In-Sight 5000 series vision sensors are designed to operate as a host sensor on an In-Sight
Network. For the purposes of the instructions in this manual, an In-Sight Network is an
In-Sight sensor connected over Ethernet to at least one other In-Sight sensor or personal
computer running In-Sight Explorer software.
These configurations may require additional components, such as an Ethernet switch. Many
optional components may be purchased directly from Cognex. A complete catalog of
In-Sight products and accessories is available on the Cognex web sight at:
www.cognex.com/pdf/downloads/In-Sight-brochure.pdf.
These sensors may be used in several possible network configurations. For each
configuration, the sensor is managed using “jobs” in the In-Sight Explorer software, which
also provides a remote display for that sensor. The jobs that can be stored are limited to the
amount of local storage available on the sensor. Jobs that exceed this limit, and all image
files, can be stored on the local PC.
Table 1-2: In-Sight 5000 Series Standard Components Descriptions
Component Description
Vision Sensor Provides image acquisition, vision processing, job storage, serial and
Ethernet connectivity and discrete I/O.
Lens Cover Kit (includes lens
cover and O-Ring) Provides environmental protection for the lens.
Thread Guard Protects the In-Sight sensor lens cover threads when lens cover is
not used. Remove the Thread Guard prior to installing the Lens
Cover.
Remote Head Camera Acquires and sends images to the In-Sight 5400R sensor.
Remote Head Accessory Kit Includes remote head camera mounting hardware and a 5mm
extension ring (for use with C-mount lenses).

Introduction
4
1.4.1 Standalone Network
A standalone In-Sight network configuration includes a connection between an In-Sight
vision sensor and a PC. In this configuration, the In-Sight network is isolated from the factory
network.
The most basic In-Sight network features a sensor connected directly to a PC running
In-Sight Explorer software. In-Sight 5000 series sensors have an Autosense capability,
allowing the sensor to connect directly to a PC using either a straight-pinned Network cable
or a crossover cable.
Figure 1-1 shows a sensor connected directly to a PC using a Network cable. The operator
uses the PC, keyboard and mouse to configure applications and monitor runtime operation.
Figure 1-1: Standalone Sensor Configuration
NOTE:
If the Microsoft "Media Sense" feature, which automatically detects whether or not your
network interface is linked to a network, is enabled when running Microsoft Windows 2000 or
XP, communication with an In-Sight sensor may not be established. It is recommended to
use a hub or switch with a standard Ethernet cable to configure the In-Sight sensor or
configure your PC to disablethe Media Sense feature. See Microsoft Knowledge Base article
239924 for details on this process.

Installing In-Sight®5000 Series Vision Sensors
5
1.4.2 Configurations Using Switches/Routers
An In-Sight network may be extended to include multiple In-Sight sensors by using a
network router or Ethernet switch. The only limit on the size of this type of network is the
number of routers or switches connected and the number of connections they provide.
The standalone In-Sight network shown in Figure 1-2 includes two sensors and a PC
running In-Sight Explorer, connected by a switch/router. In this configuration, any In-Sight
sensor on the network can be configured using In-Sight Explorer. In-Sight Explorer also
provides additional job storage, and image and data archiving for all In-Sight sensors on the
network. The network switch/router may also connect to another network switch/router,
which in turn could have a similar complement of network sensors.
Figure 1-2: Standalone Configuration with Ethernet Switch/Router

Introduction
6
1.4.3 Adding an In-Sight Network to the Factory Network
Multiple In-Sight Networks may be connected to the larger, factory network, combining to
create an In-Sight network of virtually unlimited size. Connecting an In-Sight network to the
factory network allows real-time production data to be accessed remotely from any PC
workstation with network access. For networks that cover large physical areas, a PC running
In-Sight Explorer located on each In-Sight network provides local job configuration and
image display for all In-Sight sensors.
As in the example in section 1.4.1, the In-Sight network shown in Figure 1-3 includes a
sensor and a PC running In-Sight Explorer, connected to the same network
switch/router. However, the switch/router for the In-Sight network is now connected to the
factory network through another switch/router, which in turn may host connections to
additional In-Sight networks.
Figure 1-3: Factory Floor Network Installation