Falcon 4M30 User manual

Falcon
4M30 and 4M60
Monochrome and Color Camera Manual
PT-41-04M60-XX-R
PT-42-04M60-XX-R
PT-21-04M30-XX-R
PT-22-04M30-XX-R
4 Megapixel 30/60 fps Area Scan Cameras
3-Jun-11
03-032-20044-03
www.teledynedalsa.com

Falcon 4M Camera Manual
03-032-20044-03 Teledyne DALSA
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© 2011 Teledyne DALSA. All information provided in this manual is believed to be
accurate and reliable. No responsibility is assumed by Teledyne DALSA for its use.
Teledyne DALSA reserves the right to make changes to this information without notice.
Reproduction of this manual in whole or in part, by any means, is prohibited without
prior permission having been obtained from Teledyne DALSA.
About Teledyne Technologies and Teledyne DALSA, Inc.
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inform ation, visit Teled yne Technologies‘ w ebsite at www.teledyne.com.
Teledyne DALSA, a Teledyne Technologies company, is an international leader in high
performance digital imaging and semiconductors with approximately 1,000 employees
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company designs, develops, manufactures and markets digital imaging products and
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visit Teled yne DALSA‘s w ebsite at w w w .teled yned alsa.com.
Support
For further information not included in this manual, or for information on Teledyne
DALSA‘s extensive line of im age sensing prod ucts, p lease contact:
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Falcon 4M Camera Manual
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Contents
Introduction to the 4 Megapixel Falcon Cameras _________________________________ 5
1.1 Camera Highlights.......................................................................................................................................................5
1.2 Camera Performance Specifications.............................................................................................................................6
1.3 Cosmetic Specifications ................................................................................................................................................9
1.4 Image Sensor and Pixel Readout.................................................................................................................................11
1.5 Responsivity.................................................................................................................................................................13
1.6 Shock and Vibration.....................................................................................................................................................15
1.6 Shock and Vibration.....................................................................................................................................................15
Camera Hardware Interface________________________________________________ 17
2.1 Installation Overview...................................................................................................................................................17
2.2 Input/Output Connectors and LED ...............................................................................................................................18
2.2.1 LED Status Indicator...............................................................................................................................18
2.2.2 Camera Link...........................................................................................................................................19
2.2.3 Power Connector ....................................................................................................................................21
Software Interface: How to Control the Camera __________________________________ 23
3.1 First Power Up Camera Settings..................................................................................................................................26
3.2 Saving and Restoring Settings.....................................................................................................................................27
3.3 Camera Output Format................................................................................................................................................27
3.3.1 How to Configure Camera Output..........................................................................................................27
3.3.2 Setting the Camera Link Mode...............................................................................................................29
3.3.3 Setting the Camera Link Strobe Frequency............................................................................................30
3.4 Setting Exposure Mode, Frame Rate and Exposure Time ............................................................................................30
3.4.1 Non-concurrent vs. concurrent modes of operation................................................................................30
3.4.2 Setting the Exposure Mode.....................................................................................................................32
3.4.2 Setting the Frame Rate..........................................................................................................................35
3.4.3 Setting the Exposure Time .....................................................................................................................36
3.4.4 Enabling EXSYNC Debounce Circuit .......................................................................................................37
3.5 Snapshot Modes...........................................................................................................................................................37
3.6 Setting a Vertical Window of Interest...........................................................................................................................42
3.7 Flat Field Correction ....................................................................................................................................................46
3.7.1 Selecting Factory or User Coefficients ....................................................................................................50
3.7.2 Enabling Pixel Coefficients.....................................................................................................................51

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3.7.3 Selecting the Calibration Sample Size...................................................................................................51
3.7.4 Performing FPN Calibration ..................................................................................................................52
3.7.5 Performing PRNU Calibration ...............................................................................................................53
3.7.6 Saving, Loading and Resetting Coefficients...........................................................................................55
3.7.7 Returning Pixel Coefficient Information ................................................................................................56
3.8 Offset and Gain Adjustments .......................................................................................................................................57
3.9 Generating a Test Pattern............................................................................................................................................61
Optical and Mechanical Considerations________________________________________ 65
4.1 Mechanical Interface ....................................................................................................................................................65
4.2 Lens Mounts.................................................................................................................................................................66
4.3 Optical Interface...........................................................................................................................................................66
Troubleshooting________________________________________________________ 69
5.1 Common Solutions.......................................................................................................................................................69
5.2 Troubleshooting Using the Serial Interface.................................................................................................................70
5.3 Specific Solutions .........................................................................................................................................................70
5.4 Product Support...........................................................................................................................................................72
Camera Link™ Reference, Timing, and Configuration Table _________________________ 73
Error Handling and Command List ___________________________________________ 79
B1 All Available Commands ..............................................................................................................................................79
EMC Declaration of Conformity _____________________________________________ 85
Revision History ________________________________________________________ 87
Index _______________________________________________________________ 89

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1
Introduction to the 4
Megapixel Falcon
Cameras
1.1 Camera Highlights
Features
4 mega pixels, 2352 (H) x 1728 (V) resolution, CMOS area camera
Global shutter (non-rolling) for crisp images
60 fps model or 30 fps model
Color and monochrome models
Vertical windowing for faster frame rate
7.4 µm x 7.4 µm pixel pitch
4 x 80 MHz or 2 x 80 MHz data rates
Nominal broadband responsivity of 18.4 DN/ (nJ/ cm2)
Good NIR response
8 or 10 bit selectable output
Dynamic range of 57 dB
Base or Mediu m Cam era Link™ interface
RoHS and CE compliant
Programmability
A simple ASCII protocol controls gain, offset, frame rates, trigger mode, test pattern
output, and camera diagnostics.
The serial interface (ASCII, 9600 baud, adjustable to 19200, 57600, 115200) operates
through Camera Link.

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Description
The 4 mega pixel Falcon cameras are our most advanced high-speed area array cameras.
With data rates up to 320 MHz, these cameras are capable of capturing crisp images at
incredibly fast speeds. Programmable features and diagnostics are accessible through the
Camera Link™ MDR26 connector. Color and monochrome options make the Falcon 4M
camera a very versatile choice.
Applications
The 4M Falcon cameras are ideal for applications requiring high speed, superior image
quality, and high responsivity. Applications include:
PCB inspection
3D solder paste inspection
2D and 3D wafer bump inspection
Semiconductor wafer inspection
Flat panel display inspection
Solar panel inspection
Industrial metrology
Traffic management
General machine vision
Models
The Falcon 4M camera is available in the following models:
Falcon 4M Camera Models Overview
Model Number
Description
PT-21-04M30-XX-R
4M resolution, 2 sensor taps, 30 frames per second, RoHS
compliant, monochrome.
PT-41-04M60-XX-R
4M resolution, 4 sensor taps, 60 frames per second, RoHS
compliant, monochrome.
PT-22-04M30-XX-R
4M resolution, 2 sensor taps, 30 frames per second, RoHS
compliant, color.
PT-42-04M60-XX-R
4M resolution, 4 sensor taps, 60 frames per second, RoHS
compliant, color.
1.2 Camera Performance Specifications
Camera Performance Specifications
Feature / Specification
Notes
Resolution
2352 (H) x 1728 (V) pixels
Pixel Fill Factor
45 %
Effective fill factor
with micro-lenses
60 %
# of Lines per Frame
1728 lines
Output Format (# of taps)
2 (4M30) or 4 (4M60)

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Bayer Filter (color only)
See Fig. 2 for RGB filter location
Optical Interface
Notes
Back Focal Distance
Sensor die to mounting
plate
6.56 mm
5
Sensor Alignment x
y
z
z
±0.10 mm
±0.10 mm
±0.25 mm
±0.3°
Lens Mount
F-mount adapter available
Lens Mount Hole
M42 x 1
Mechanical Interface
Notes
Camera Size
94 x 94 x 48 mm
Mass
<550 g
Connectors
power connector
data connector
6 pin male Hirose
2 x MDR26 female
Electrical Interface
Notes
Input Voltage
+12 to +15 Volts
6
Power Dissipation
10 typ, 14 Watts max
Operating Temperature
0 to 50 °C
1
Data Output Format
8 or 10 user selectable bits
Output Data Configuration
Base or Medium Camera Link
Operating Ranges
Notes
Minimum Frame Rate
1 Hz
Maximum Frame Rate
60.4 Hz (4M60)
30.6 Hz (4M30)
4
Data Rate
80 MHz
Dynamic Range
(10 bits @nominal gain)
682 : 1 typ.
2
Random Noise
1.5 typ, 2.0 max DN rms
Broadband Responsivity (mono)
18.4 typ DN/ (nJ/ cm2)
7
Responsivity
See Figs. 5, 7, and 8
Quantum Efficiency
See Figs. 6
DC Offset
0 DN
7
Antiblooming
>1000x saturation
FPN
0.5 typ, 1.0 max DN rms
PRNU
1.5 typ, 2.6 max DN rms
8
Integral non-linearity
<2% DN
3

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Operating Ranges
Notes
Saturation Equivalent Exposure
55 typ nJ/ cm2
Noise Equivalent Exposure
80 typ pJ/ cm2
Saturation Output Amplitude
1023 DN
Test conditions unless otherwise noted:
sem 2(exposure mode 2).
ssf 55 (55 frames per second rate).
set 2000 (2 millisecond exposure time).
sem 2(Exposure mode 2) .
Full frame/ window.
clm 16 (4 tap, 10 bit).
sot 320 (80 MHz camera link strobe).
efd 1(Snapshot mode 1).
snd 1(Number of fast frame dumps = 1).
Light Source: Broadband Quartz Halogen, 3250K (3050 to 3450), with a 750 nm cutoff
filter .
Ambient test temperature 25°C.
Average output 840 DN.
Flat field correction (FFC) turned on.
Notes:
1. Measured at the front plate.
2. Based on output at 1023 DN.
3. Output over 10-90%.
4. Snapshot mode 0 allows for marginally higher frame rates.
5. Optical distance.
6. +12V consumes the least amount of power.
7. With FFC on. Responsivity is not calibrated when FCC is turned off.
8. Measured at half saturation.

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1.3 Cosmetic Specifications
Please note, for this section only, the following values are considered preliminary
information and subject to change without notice.
Monochrome Sensor Cosmetic Specifications
The following table highlights the current cosmetic specifications for the sensor used
inside the Falcon 4M60 and 4M30 cameras. The sensor has 4 megapixels (2352 x 1728),
global shuttering and is capable of 60 fps.
Sensor Cosmetic Specifications
Cosmetic Specification
Maximum Number of Defects
Hot pixel defects
1
Single pixel defects
100
Clusters defects
No limit (refer to the Note below)
Spot defects
1
Column defects
0
Row defects
0
Definition of cosmetic specifications
Hot pixel defect
Pixel whose signal, in dark, deviates by more than 400 DN (10 bits) from the average of all
the pixels.
Single pixel defect
Pixel whose signal, at nominal light (illumination at 50% of saturation), deviates by more
than ±30% from its neighboring pixels.
Cluster defect
A grouping of at most 8 pixel defects within an area of 3 x 3 pixels.
Spot defect
A grouping of 9 pixel defects within an area of 3 x 3 pixels.
Column defect
A column which has 12 pixel defects in a 1*12 kernel.
Row defect
A horizontal grouping of more than 4 pixel defects between at least 2 good pixels on both
sides, where single good pixels between 2 defective pixels are considered defective.
Test conditions
Digital gain –1X.
Nominal light = illumination at 50 % of saturation.
Frame Rate = 60 fps (Falcon 4M60), 30 fps (Falcon 4M30)

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Integration time = 15 ms
Ambient Temperature of 25 °C
Note: While the number of clusters is not limited by a maximum number, the total
number of defective pixels cannot exceed 100. Therefore, you could have 12 clusters of 8
in size (12 x 8 = 96), but you could not have 13 clusters of 8 in size (13 x 8 = 104).
The probability of 12 clusters of 8 is negligible and is only used as an example.
Camera Cosmetic Specification
Beyond sensor cosmetic testing, the camera is placed under additional testing to more
closely examine potential cosmetic defects due to the sensor glass.
Camera Cosmetic Specifications - Glass
Cosmetic Spec
Max. Deviation
from Mean
Cluster Size
Max Number of Defects
Glass defects
5 %
9
0
Definition of blemishes
Glass defects
A group of pixels exceeding the given cluster size and the maximum deviation from the
mean. Images are taken at nominal light (illumination at 50 % of the linear range). A
cluster is defined as a grouping of pixels. A grouping of pixels refers to adjacent pixels or
pixels that touch.
In addition, the camera is examined against the following cosmetic specifications.
Camera Cosmetic Specifications –Sensor & Glass
Cosmetic Specification
Maximum Number of Defects
Dark pixel defects (> 300 DN)
50
Dark pixel defects (> 600 DN)
1
Single pixel defects
100
Definition of cosmetic specifications
Dark pixel defects
Pixel whose signal, in dark, exceeds the given threshold (10 bits).
Single pixel defect
Pixel whose signal, at nominal light (illumination at 50 % of saturation), deviates by more
than ± 30 % from its neighboring pixels.
Test conditions
Digital gain –1X.
Nominal light = illumination at 50 % of saturation.