Cognex DataMan 150 User manual

DataMan®150
Quick Reference Guide
4/24/2015
Version 5.5.0

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.
Copyright © 2015. Cognex Corporation. All Rights Reserved.
Portions of the hardware and software provided by Cognex may be covered Cognex Corporation. All Rights Reserved.
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:
http://www.cognex.com/patents.
The following are registered trademarks of Cognex Corporation:
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,
UltraLight, VisionSolutions, VisionPro, VisionView
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,
ProofRead, SmartSync, ProfilePlus, SmartDisplay, SmartSystem, SMD4, VisiFlex, Xpand, PowerGrid, Hotbars2
Other product and company trademarks identified herein are the trademarks of their respective owners.
2
Legal Notices

Table of Contents
Legal Notices 2
Table of Contents 3
Symbols 4
Getting Started 5
About DataMan 150 5
DataMan 150 Accessories 6
DataMan 150 Systems 7
Communication Modules 9
DataMan 150 Cable Pinouts 9
Reader Layout 10
Dimensions 13
Installing an Optical Filter 15
Installing a Liquid Lens 17
Changing from a 6.2 mm Lens to a 16 mm Lens 19
Changing to an Illumination with a Different Color 22
Setting Up Your DataMan 24
Mounting 24
I/O Cable 25
RS-232 Cable 25
Flying Leads Cable 26
USB Connections 27
RS-232 Connections 28
Wiring the Basic I/O Module 29
Digital Input Wiring Diagrams 30
Digital Output Wiring Diagrams 32
Installing the DataMan Software 34
Setting the Focus Position 35
Field of View and Reading Distances 37
External Triggering and Trigger Modes 38
Training and Trigger Modes 38
Training 38
Incremental Training for Multiple Symbologies 39
Tuning 40
Multi-port Connections 40
DataMan 150 Specifications 43
Imager Specifications 43
Precautions 44
Regulations/Conformity 45
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Table of Contents

Symbols
The following symbols indicate safety precautions and supplemental information.
WARNING:This symbol indicates the presence of a hazard that could result in death, serious personal injury or
electrical shock.
CAUTION:This symbol indicates the presence of a hazard that could result in property damage.
Note: Notes provide supplemental information about a subject.
Tip: Tips provide helpful suggestions and shortcuts that may not otherwise be apparent.
4
Symbols

Getting Started
About DataMan 150
The DataMan 150 readers are best in class ID readers, offering superior performance with the latest ID tools, flexibility to
configure the reader in terms of lighting and optics to optimize the application, and an ease-of-use giving the user the
ability to setup and deploy an application quickly and efficiently all without the need for PC:
lSuperior performance, 1-D and 2-D code reading, including HotBars2™ and patent-pending PowerGrid™
lFlexible optics/lighting, including field upgrades, allowing for the protection of your investment
lEase-of-use, including an auto-tune and trigger button on the reader, the ability to configure the reader in a
straight or right-angle orientation and auto-focus capability utilizing a liquid lens
The DataMan 150 readers provide support for USB and RS-232 communications.
Key highlights:
l1DMax with HotBars2™, best in class 1-D reading, 2DMax with PowerGrid™, best in class 2-D reading. Reading
codes no other ID reader on the market can.
lMultiple options for LED lighting, along with optical filters and polarizing filters. Options for different powered lens,
with autofocus capabilities for each.
lIntelligent tuning and dynamic configuration of the reader combined to make the installation and setup of the
application a snap.
This document provides basic information about how to configure and use DataMan 150 readers. Additional information
is available through the Windows Start menu or the DataMan Setup Tool Help menu after you install the DataMan
software on your PC:
lThe DataMan Communications & Programming Guide shows how to integrate your DataMan reader with your
automation software and factory network.
Cognex->DataMan Software v x.x.x->Documentation->Communications And Programming
lThe DataMan Reader Configuration Codes document provides printable 2-D codes that you can use to
configure the DataMan reader.
Cognex->DataMan Software v x.x.x->Documentation->English->Reader Configuration Codes
lThe DataMan Fixed Mount Readers Reference is a complete online hardware reference for the DataMan fixed-
mount ID readers.
Cognex->DataMan Software v x.x.x->Documentation->English->DM150 ->Fixed Mount Reference Manual
lThe DataMan Questions and Answers document provides context-sensitive information. You can view this help
inside the DataMan Setup Tool or as a stand-alone help file.
Cognex->DataMan Software v x.x.x->Documentation->DM150->Questions and Answers
lThe Release Notes list detailed system requirements and additional information about this DataMan software
release.
Cognex->DataMan Software v x.x.x->Documentation->DataMan v x.x.x Release Notes
5
Getting Started

DataMan 150 Accessories
LENS OPTIONS
6.2 mm lens (DM150-LENS-62 )
16 mm lens with extended optics mount (requires the use of
extended front cover) (DM260-LENS-16)
Extended lens cover, used with 16mm lens (DM260-LENS-
16CVR)
Extended lens cover, used with 16mm lens, polarized (DM260-
LENS-16CVR-P)
Liquid Lens used with 6.2 mm lens (DM150-LENS-62LL)
16mm lens with Liquid Lens kit including LED Polarized Cover
(DM260-LENS-16LL)
LIGHTOPTIONS
Red LED illumination (DM150-LED-RED)
White LED illumination (DM150-LED-WHT)
Blue LED illumination (DM150-LED-BLU)
IRLED illumination (DM150-LED-IR)
High Powered red LED illumination (DM260-LED-RED-HP)
CABLES
5-meter extension cable* (DM100-EXTCBL-000)
RS-232/USB adapter for Expansion I/O Module (DM100-PATCH-
000)
USB adapter cable with power tap (DM100-USB-000)
USB adapter cable with power tap (DM100-USB-030)
USB & Flying Leads I/O Cable, 2.0 m (DM-USBIO-00)
RS-232 & Flying Leads I/O Cable, 2.5 m (DM-RS232IO-00)
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Getting Started

RS-232 adapter cable with power tap (DM100-RS232-000)
Flying Leads Connection Cable, 5 m (DM50-PWRIO-05)
Note: *USB/RS-232 extension connection is possible with the following limitations:
1. The USB connection is shorter than 5m.
2. Serial connection is shorter than 15m.
POWERSUPPLIES
Power supply, 6V (DM100-PWR-000)
MOUNTINGBRACKETS
Mounting bracket (DM100-UBRK-000)
Pivot mounting bracket (DM100-PIVOTM-00)
IOMODULES
DataMan Basic I/O Module (DM100-IOBOX-000)
DataMan 150 Systems
Omni-
directional 1-D
Code Reading
1DMax+™ —
Best-In-Class 1-
D Reading
IDQuick™ —
High-Speed 2-D
Reading
2DMax+™ — for
hard to read
DPM and
damaged 2-D
codes
Resolution
DataMan 150S*
(DMR-150S-00) √ √ √ 752x480 Global shutter
DataMan 150QL
(DMR-150QL-00) √ √ 752x480 Global shutter
DataMan 150Q
(DMR-150Q-00) √ √ 752x480 Global shutter
DataMan 150X
(DMR-150X-00) √ √ √ 752x480 Global shutter
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Getting Started

Omni-
directional 1-D
Code Reading
1DMax+™ —
Best-In-Class 1-
D Reading
IDQuick™ —
High-Speed 2-D
Reading
2DMax+™ — for
hard to read
DPM and
damaged 2-D
codes
Resolution
DataMan 152S*
(DMR-152S-00) √ √ √ 1280x960 Global shutter
DataMan 152QL
(DMR-152QL-00) √ √ 1280x960 Global shutter
DataMan 152Q
(DMR-152Q-00) √ √ 1280x960 Global shutter
DataMan 152X
(DMR-152X-00) √ √ √ 1280x960 Global shutter
*Maximum decode rate of 2 codes/sec
8
Getting Started

Communication Modules
The DataMan 150 is available with the following communication options:
lUSB/RS-232
DataMan 150 Cable Pinouts
The I/O module with USB has all signals on a SUB-D 15 connector with the following pinouts:
PIN Color Signal
1 Brown Reserved
2 Green TxD (RS-232)
3 Green/Black RxD (RS-232)
4 Red & Red/Black GND
5 Brown/White DC+ (system power, 5-24 VDC)
6 Blue RTS
7 Blue/White Output-0
8 White Input-0
9 White/Black Input-1
10 Light Blue CTS
11 Light Blue/Black Output-1
12 Light Blue/Yellow Output-Common
13 Light Blue/Green Input-Common
14 Yellow Reserved
15 Yellow/Black Reserved
Note: Pin numbers are shown for cable connector, not I/O module.
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Getting Started

Reader Layout
The following images show the built-in lighting system and other features of the DataMan 150 reader.
1 Illumination LEDs
2 LED aimers
3-4* Mounting holes (M3 x 3.5mm)
5 Trigger button
6 Power
7 Train status/Trigger status
8 Good/bad read
9 Communication
10 Error
11 Tune button
12 Power, I/O and RS-232
Note: *Use only one set of mounting holes (either 3 OR 4) for mounting.
Note: The five status LEDs together also function as a peak meter using an orange light.
Indicator LEDs
Type Signal Color Meaning
Status Power GREEN Power ON
Train status GREEN Trained
YELLOW Untrained
Error RED Error - check
device log
Action Good/bad read GREEN Good read
RED Bad read
Communication YELLOW Link up
blink Data transfer
Peak meter Yellow Tune
Focus
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Getting Started

Changing Orientation
Perform the following steps to change between straight and angled configuration.
Note: Switching between straight and right angle configuration is recommended only up to 10 times in the lifetime
of the reader.
Note: Disconnect the DataMan 150 reader from power before changing the orientation.
WARNING:Make sure that no electrostatic charges are applied to the PCB. (E.g. wear ESD shoes.) If the main
module is separated from the I/O module, take care to assemble them correctly. Otherwise, IP rating can be lost.
1. Remove the screw covers and unscrew the screws.
2. Disconnect the main module and the I/O module by firmly pulling
them apart.
3. Change the orientation.
Note: Make sure that the gasket it properly seated on main
module. Ensure that the flat gasket side is facing away from the
module.
WARNING:Do not touch any electrical component.
5. Connect the I/O module to the main module.
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Getting Started

6. Loosely fasten the modules together with the two T10 cap nut
screws until they attach to the housing surface, but do not torque.
7. After each cap nut has been fastened, torque them to 0.12 Nm and
place back the screw covers.
Note: There are unique left and right screw covers. Take care to
attach them correctly.
12
Getting Started

Dimensions
The DataMan 150 consists of three main parts:
1. Optics module (lens including lens mount, illumination and front cover including filter mounting option for a
Diameter (Ø): 12.3mm<Ø<12.7mm, Thickness (t): 1.6mm<t<2mm filter)
2. Main module, including sensor and CPU
3. I/O module
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Getting Started

The size of the DataMan 150 in the straight configuration is shown in the following figure:
The size of the DataMan 150 in the angled configuration is shown in the following figure:
14
Getting Started

Installing an Optical Filter
Perform the following steps to install an optical filter in the optics module of the DataMan 150 reader.
Note: Disconnect the DataMan 150 reader from power before installing an optical filter.
1. First, remove the front cover: unscrew the four screws and take off the LEDcover.
2. Insert the filter at the bottom side of the round opening in the transparent plastic part.
3. Push the top side of the filter firmly until it is sitting flat against the PCB.
Note: Use finger to push the filter in and then a q-tip to clean the filter, or use a q-tip to push the filter into
place.
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Getting Started

4. Attach the front cover. Observing the tightening sequence below, tighten all four screws to 9 Ncm using a torque
wrench.
5. Note: The rib in the front cover must be oriented to the top side.
16
Getting Started

Installing a Liquid Lens
Perform the following steps to install a liquid lens on your DataMan 150 reader.
Note: Disconnect the DataMan 150 reader from power before installing the liquid lens.
1. Remove the front cover: unscrew the four screws and take off the LEDcover.
2. Remove the illumination module.
3. Turn the lens cap to the 105 mm position.
4. Remove the lens cap from the imager lens by pulling it.
Note: Do not rotate the imager lens while the lens cap is removed. Otherwise, focus calibration will be lost.
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Getting Started

5. Attach the liquid lens accessory by aligning the 2x2 connectors of the liquid lens with the 2x2 sockets on the
optics mount.
6. Press the liquid lens onto the imager lens until you reach the stop.
7. Reattach the illumination.
8. Attach the front cover. Observing the tightening sequence below, tighten all four screws to 9 Ncm using a torque
wrench.
Note: The rib in the front cover must be oriented to the top side.
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Getting Started

Changing from a 6.2 mm Lens to a 16 mm Lens
Perform the following steps to change a 6.2 mm lens to a 16 mm lens on your DataMan 150 reader.
Note: Disconnect the DataMan 150 reader from power before changing lenses.
WARNING:This modification must be made in a dust-free and ESD safe area.
1. Remove the front cover: unscrew the four screws and take off the LEDcover.
2. Remove the illumination module.
3. Unscrew the two Phillips head screws and remove the 6.2 mm lens mount.
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Getting Started

4. Attach the 16 mm lens mount.
5. Fasten the two Phillips head screws to 0.06 Nm using a torque wrench.
6. In the case of a manual focus lens, press the 16 mm lens cap onto the lens. The lens has 12 cutouts so it can be
locked in steps of 30 degrees.
In the case of a liquid lens, mount the liquid lens cap onto the 16 mm lens. (See Installing a Liquid Lens.)
7. Attach the illumination board.
Note: Take care to attach the illumination with the right orientation.
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Getting Started