IFM OPD101 User manual

Operating instructions
Profile detector
OPD101
80297946 / 0102 / 2021
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Contents
1 Preliminary note.............................................................. 4
1.1 Symbols used........................................................... 4
1.2 Warnings used.......................................................... 4
2 Safety instructions............................................................ 5
3 Intended use ................................................................ 6
3.1 General description ...................................................... 6
3.1.1 Teaching and height profile............................................. 6
3.1.2 Normal operation..................................................... 7
3.2 Interpretation of the matching value . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7
3.2.1 Fluctuation of the matching value . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8
3.3 Profile properties ........................................................ 9
3.4 Applications ............................................................ 9
4 Function.................................................................... 10
4.1 Operating modes........................................................ 10
4.1.1 Switching mode...................................................... 10
4.1.2 Operation with IO-Link master........................................... 10
4.1.3 Operation with the “Vision Assistant“ parameter setting software and an IO-Link
master.............................................................
10
5 Installation .................................................................. 12
5.1 Installation conditions..................................................... 12
5.2 Installation instructions.................................................... 12
5.2.1 Lateral inclination .................................................... 12
5.2.2 Front inclination...................................................... 13
5.2.3 Saturation and signal loss.............................................. 13
5.2.4 Avoidance of multiple reflections . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14
5.2.5 Avoidance of soiling and ambient light . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14
6 Electrical connection .......................................................... 15
6.1 Operation with IO-Link master.............................................. 15
7 Operating and display elements.................................................. 16
8 Set-up...................................................................... 17
8.1 “Guided Teach” / teaching of reference profiles . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 18
8.1.1 Language selection................................................... 18
8.1.2 Teaching an object ................................................... 18
8.1.3 Set ROI............................................................ 19
8.1.4 Set the position of the reference profile. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20
8.1.5 Switching threshold................................................... 21
8.1.6 Saving the reference profile............................................. 21
8.1.7 Finishing the teach process............................................. 22
8.1.8 Run mode.......................................................... 22
9 Menu ...................................................................... 23
9.1 Basic functions.......................................................... 23
9.2 Extended functions....................................................... 24
10 Operating modes............................................................. 27
10.1 Continuous mode........................................................ 27
10.2 Triggered mode ......................................................... 27
11 Parameter setting............................................................. 29
11.1 Parameter level basic functions............................................. 29
11.1.1 [Adjust threshold]..................................................... 29
11.1.2 [ROI marking] ....................................................... 29
11.1.3 [Profile properties].................................................... 29
11.1.4 [Profile manager]..................................................... 29
11.1.5 [Extended functions] .................................................. 30
11.1.6 [Back] ............................................................. 30
11.2 Parameter level extended functions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30
11.2.1 [Factory setting]...................................................... 30

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11.2.2 [Device information]................................................... 30
11.2.3 [Configuration]....................................................... 31
11.2.4 [Display] ........................................................... 31
11.2.5 [Back] ............................................................. 31
11.3 Submenu [Configuration].................................................. 31
11.3.1 [Triggered mode]..................................................... 31
11.3.2 [Trigger source]...................................................... 32
11.3.3 [Output mode]....................................................... 32
11.3.4 [Trigger delay]....................................................... 32
11.3.5 [Integration time]..................................................... 32
11.3.6 [Output function] ..................................................... 32
11.3.7 [Output logic]........................................................ 33
11.3.8 [Profile source select] ................................................. 33
11.3.9 [Back] ............................................................. 33
11.4 Submenu [Display]....................................................... 33
11.4.1 [Brightness]......................................................... 33
11.4.2 [Colour]............................................................ 33
11.4.3 [Language] ......................................................... 34
11.4.4 [Back] ............................................................. 34
11.5 IO-Link................................................................ 34
11.5.1 General information................................................... 34
11.5.2 Device-specific information............................................. 34
11.5.3 Parameter setting tools................................................ 34
11.5.4 Functions .......................................................... 34
12 Troubleshooting.............................................................. 36
12.1 Error indications in the display.............................................. 36
12.2 Error indications in the “Vision Assistant” software . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 36
12.3 Other types of incorrect behaviour........................................... 37
13 Maintenance, repair and disposal ................................................ 38
14 Scale drawing................................................................ 39
15 Factory setting............................................................... 40
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1 Preliminary note
You will find instructions, technical data, approvals and further information using the QR code on the
unit / packaging or at www.ifm.com.
1.1 Symbols used
Requirement
Instructions
Reaction, result
[...] Designation of keys, buttons or indications
Cross-reference
Important note
Non-compliance may result in malfunction or interference.
Information
Supplementary note
1.2 Warnings used
CAUTION
Warning of personal injury
wSlight reversible injuries may result.

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2 Safety instructions
• The unit described is a subcomponent for integration into a system.
– The system architect is responsible for the safety of the system.
– The system creator undertakes to perform a risk assessment and to create documentation in
accordance with legal and normative requirements to be provided to the operator and user of
the system. This documentation must contain all necessary information and safety instructions
for the operator, the user and, if applicable, for any service personnel authorised by the
architect of the system.
• Read this document before setting up the product and keep it during the entire service life.
• The product must be suitable for the corresponding applications and environmental conditions
without any restrictions.
• Only use the product for its intended purpose (Ò Intended use).
• If the operating instructions or the technical data are not adhered to, personal injury and/or damage
to property may occur.
• The manufacturer assumes no liability or warranty for any consequences caused by tampering with
the product or incorrect use by the operator.
• Installation, electrical connection, set-up, operation and maintenance of the product must be
carried out by qualified personnel authorised by the machine operator.
• Protect units and cables against damage.
CAUTION
Exposure to radiation
wInjury due to dangerous exposure to radiation
uOnly use the operating and adjusting devices indicated in the operating instructions.
CAUTION
Visible laser light; LASER CLASS 1.
EN/IEC 60825-1 : 2007 and EN/IEC 60825-1 : 2014 complies with 21 CFR 1040 except for
deviations pursuant to Laser Notice No. 50, dated June 2007.
Position of the product label Warning sign
LASER KLASSE 1
CLASS 1 LASER PRODUCT
APPAREIL Á LASER CLASSE 1
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3 Intended use
3.1 General description
The sensor projects a laser line onto the object and determines the height profile of the object along
the laser line by means of the triangulation principle.
The object to be detected has to be in the sensor's operating range.
The sensor has a trapezoidal operating range with the following dimensions:
• distance to the sensor (Z direction): 150…300mm
• length of the profile (X direction):
– for an object distance of 150 mm: 45mm
– for an object distance of 300mm: 90mm
2
3
4
5
1
0
150
300 90
45
Fig.1: General representation
1: X axis in [mm]
2: Z axis in [mm]
3: transmitter
4: receiver
5: ROI marking
The projected laser line is wider than the operating range. The object to be detected should be
positioned in the centre of the laser line.
During “Guided Teach”, the operating range is indicated in the X direction by two green
projected vertical ROI markers. The ROI markers can also be switched on during operation.
uObject is outside the operating range.
wThe laser line flashes and the message [Object out of range] appears on the display.
3.1.1 Teaching and height profile
In the first step, the sensor is taught (teaching process). The entire height profile covered by the laser
line is captured. The user can then further narrow the ROI.
• The height profile of this ROI is saved as taught reference profile.
• Up to 10 reference profiles, including all associated setting parameters, can be taught and saved. A
reference profile can then be activated from the memory.

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In the next step, the sensor continually detects height profiles, compares them to the activated
reference profile and generates a matching value. Now the user can set a switching threshold.
Interpretation of the matching value (Ò/7).
2
3
4
1
0
150
300
ROI
Fig.2: Height profile
1: X axis in [mm]
2: Z axis in [mm]
3: sensor
4: taught reference profile
3.1.2 Normal operation
In normal operation, the sensor detects height profiles, continually or upon triggering, and compares
them to the activated reference profile in order to generate a matching value.
If the ”Vision Assistant” software is used, high-resolution images of the profiles are transmitted
additionally. Operation with the “Vision Assistant“ parameter setting software and an IO-Link master
(Ò/10). The height profiles are referred to the max. measuring distance = 300 mm (reference
height).
The reference point for the reference height is the optical zero point of the transmitter. It is inside the
sensor.
Example: The distance between the sensor and the object is approx. 200mm. In the “Vision Assistant”
software, the height profile has a base height of approx. 100mm.
• Profile heights are referred to the reference height and therefore have positive absolute values.
• All data sheet indications refer to the dimensions of the object profiles and not to the absolute
distances between them and the sensor. The object profiles are displayed with real dimensions
(object profile width/height) regardless of the object profile's position in the operating range.
3.2 Interpretation of the matching value
The measured height profile (in the following also referred to as “profile”) is compared internally to an
activated reference profile. The degree of match is generated as an internal measured value
(matching value).
The measured value determined by the sensor hence describes the degree of match between the
measured profile and the activated reference profile.
Matching value provided in [%] Description
100 There is a 100 % match between the measured profile and
the activated reference profile.
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Matching value provided in [%] Description
50 There is a 50 % match between the measured profile and the
activated reference profile.
The matching value to be tolerated must be determined by the user during set-up and should be
used as switching threshold for the following differentiation:
- good parts
- bad parts
The transition between good parts and bad parts is determined by measurement and used as
switching threshold.
No particular switching threshold is recommended. It has to be determined according to the
respective application.
3.2.1 Fluctuation of the matching value
Natural fluctuations (noise, drift) affect the measured matching value.
As a rule, these measurement fluctuations cause the matching value to be < 100%, even if the taught
object is measured again.
The measurement uncertainty for the detection of height profiles is described using the following
figures:
Gz - accuracy in Z direction (profile height)
Gx - accuracy in X direction (profile width)
2
3
4
5
6
1
Fig.3: Precision
1: sensor
2: measurement uncertainty
3: object profile
4: operating area
5: accuracy in Z direction (Gz)
6: accuracy in X direction (Gx)
This means that Gz/Gx also defines the:
• minimum object height to be detected reliably
• minimum object width to be detected reliably
The height profiles are internally detected by the sensor with a higher resolution than Gz/Gx.
Changes in object height/width can therefore be detected within the measurement uncertainty.

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3.3 Profile properties
The status parameter [Profile properties] specifies the relative proportion of valid measured values in
the height profile. Only the profile range selected by the user will be taken into account. The parameter
can be used as an indicator for the profile quality during operation. Parameter level basic functions
(Ò/29).
Parameter value [%] Description
50 50% of the data points in the measured height profile are
valid and used to determine the matching value. The invalid
values will not be considered.
Ideally, the status parameter [Profile properties] should be recorded and saved directly after
teaching with the taught object (reference object). The profile quality can be checked at any
time during operation using this reference object.
If the value has decreased significantly, e.g. due to changes in the sensor position, it is
advisable to teach the object again.
The status parameter can be continuously monitored via the ifm parameter setting software
“Vision Assistant”. The status parameter can therefore also be used to optimise the sensor
position during teaching.
3.4 Applications
The photoelectric sensor is particularly suitable for process quality assurance, more precisely
monitoring of workpiece shapes and fault detection.
Examples:
• Monitoring of the processing quality, e.g. diameters of drill holes.
• Check of workpieces for faulty processing, e.g. missing drill holes.
During the measurement, the workpiece has to be still.
For static situations, the continuous measurement mode has to be set. The sensor permanently
monitors the workpiece and signals deviations from the activated reference profile. Continuous
mode (Ò/27).
For dynamic situations, the triggered measurement mode has to be set. A higher-level process
control unit decides when the detection takes place and ensures that the workpiece is in the
detection zone and that it does not move. Triggered mode (Ò/27).
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4 Function
The photoelectric sensor detects the height profile of the object in the operating range, continually or
upon triggering, by means of triangulation. Besides, the photoelectric sensor has an IO-Link interface.
The sensor can be used in three different modes of operation:
• Switching mode. Switching mode (Ò/10).
• Operation with an IO-Link master. Operation with IO-Link master (Ò/10).
• Operation with the “Vision Assistant” via the IO-Link interface. Operation with the “Vision Assistant“
parameter setting software and an IO-Link master (Ò/10).
4.1 Operating modes
4.1.1 Switching mode
In switching mode, the sensor is directly connected to the process control unit and transmits
information on good part / bad part via the switching output.
If the set switching threshold is exceeded/not reached, this is signalled by means of switching
signals on switching output 1/2. The switching outputs act complementary. Electrical connection
(Ò/15).
As an option, the time at which the measurement is taken can be controlled by a process control unit
via the trigger input (pin 5). The sensor signals the successful start of the measurement and the
availability of switching information via switching output 2. The higher-level process control unit
defines the measurement period. Triggered mode (Ò/27).
4.1.2 Operation with IO-Link master
If the sensor is connected to an IO-Link master, parametter setting, triggering and data recording can
be done completely via IO-Link. The cyclic process data include the matching value and the switching
information (good part / bad part).
Additional functions are available via IO-Link:
• detection of the number of trigger processes
• device identification
• When the ROI markers are activated, the two ROIs (regions of interest) are indicated by two pairs
of green markers.
• switching off the laser
• profile heights
• object offset in X / Z direction
• statistical evaluations
More information
www.ifm.com Ò Article number Ò Downloads Ò IODD
4.1.3 Operation with the “Vision Assistant“ parameter setting software and an
IO-Link master
Via the IO-Link protocol, high-resolution profile images are continually transmitted. The image data of
a profile image is split up into several data packages and transmitted in a sequence of IO-Link data
frames.

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The ifm software package “Vision Assistant” includes a corresponding protocol handler that combines
the profile images and visualises them.
This simplifies the teaching process (guided teach), as the detection zone of the sensor and the
assessment of the profiles is visualised base on the profile images.
Requirement:
• IO-Link master
• ifm parameter setting software “ifm Vision Assistant”
(Ò www.ifm.com Ò Article number Ò Downloads Ò Further software)
Using the parameter setting software with an IO-Link master offers the following added value:
• visualisation of the currently measured height profiles and the stored reference profiles
• highly detailed status information: helpful for teaching processes and for difficult measurement
situations
• intuitive user interface for all setting options available via IO-Link
• height profiles can be imported/exported individually
Visualisation of profiles can also be done using a customer-specific software. The required
information can be found in the corresponding document on the ifm website.
www.ifm.com Ò Article number Ò Downloads
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5 Installation
5.1 Installation conditions
uInstall the unit so that the object to be detected is within the sensor's detection zone.
uFor direct installation, fix the unit using two M4 screws.
Further accessories Ò www.ifm.com Ò Data sheet Ò Accessories.
5.2 Installation instructions
5.2.1 Lateral inclination
1
Fig.4: Lateral inclination
1: dead zone due to shadowing
The sensor should be aligned as vertically as possible to the object to be detected. In case of lateral
inclination and vertical object edges, the laser line will be partially interrupted. The profile cannot be
detected in this area. You can avoid this by reducing the inclination angle.

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5.2.2 Front inclination
2
3
1
Fig.5: Front inclination
1: transmitter
2: receiver
3: interrupted laser line
If the sensor is inclined forwards or backwards, make sure that the laser line reflected by the object
can be detected by the receiver.
It can be ensured that the receiver detects the laser line by reducing the inclination angle or rotating
the sensor by 180°.
The use of the “Vision Assistant” software facilitates the detection of such problems.
5.2.3 Saturation and signal loss
The sensor automatically sets the exposure time for the capture of the height profile so that saturation
is avoided.
Highly reflective surfaces lead to extreme contrasts. In some cases, this may lead to individual points
within the ROI not being detected.
Avoid signal losses by slightly changing the sensor position:
• incline the sensor laterally or frontally
• increase or decrease the object distance
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5.2.4 Avoidance of multiple reflections
2
3
1
Fig.6: multiple reflections
1: sensor
2: object
3: multiple reflections
uSlightly change the sensor position – e.g. incline the sensor laterally or frontally, increase/
decrease the distance to the object.
5.2.5 Avoidance of soiling and ambient light
Preferably align photoelectric sensors with the front lens facing downwards or parallel to the earth’s
surface.
Background:
• Photoelectric sensors are sensitive to direct radiation of light sources. Everyday light sources
(lamps, sun) radiate from above.
• Photoelectric sensors react sensitively to soiling, as it reduces the excess gain.
Dust deposits can be reduced by downwards or sideways orientation. This allows for longer
cleaning intervals.
Make sure that sensors installed with their front lens facing upwards are not oriented towards
roof windows or ceiling lamps.

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6 Electrical connection
The device must be connected by a qualified electrician.
uThe national and international regulations for the installation of electrical equipment must be
adhered to.
uEnsure voltage supply to EN 50178, SELV, PELV.
OPD101: cULus, Supply Class 2
uDisconnect power.
uConnect the unit as follows:
4
2 1
3
5
L
1
2
4
5
3
OUT2
OUT1
IN1
L+
Fig.7: Wiring diagram (colours to DINEN60947-5-2)
1 = BN (brown)
2 = WH (white)
3 = BU (blue)
4 = BK (black)
5 = GR (grey)
Pin Continuous mode
(factory setting) Triggered mode
1 VDD VDD
2 OUT2 = switching output OUT2 = ready signal (switching output)
3 GND GND
4 OUT1 = switching output / IO-Link OUT1 = switching output / IO-Link
5 Laser ON / OFF* Trigger input of the PLC
*) The function is activated/ deactivated via IO-Link or the ifm parameter setting software.
In the operating mode “Continuous mode”, OUT1 and OUT2 are configured as complementary
switching outputs. Continuous mode (Ò/27).
In the operating mode “Triggered mode”, OUT2 is configured as ready signal. Triggered mode
(Ò/27).
Complementary outputs transmit the same sensor information with oppositional logic levels.
This means that both an NC and NO switching output are available at the same time.
OUT1 can e.g. be used for the detection of good parts, OUT2 for the detection of bad parts.
6.1 Operation with IO-Link master
The unit is compatible with IO-Link master port class A (type A).
For operation with IO-Link master port class B (type B) observe the following:
As a standard, the unit is not compatible with master port class B (type B). Pin 2 and pin 5 are
used for manufacturer-specific functions. That means that the main supply voltage of the unit
and the additional voltage supply (master port class B on pins 2/5) are not electrically isolated.
With the following configuration, the unit can be used with master port class B:
• Connect unit and IO-Link master via 3 wires: Connect pins 1, 3 and 4 of the unit with the IO-Link
master (do not connect pins 2 and 5).
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7 Operating and display elements
2
3
45
6
1
1: 1x yellow LED Switching status OUT1
2: 1X LED green Active LED = power
3: Graphic display Display of the measured matching value
4: Programming button [●] Selection of the parameters and acknowledgement of the parameter values
5: Programming button [▲] Setting of the parameter values (scrolling by holding pressed, incrementally by
pressing once)
6: Programming button [▼] Setting of the parameter values (scrolling by holding pressed, incrementally by
pressing once)
The programming buttons can be locked and unlocked with the following step:
Keep [▲] + [▼] pressed for 10s.
Pressing the [▲] + [▼] buttons at the same time leads back to the menu guide.

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8 Set-up
uAfter installation, electrical connection and programming, check whether the unit operates correctly.
wIf the unit has been correctly set up, the sensor starts with the “Guided Teach”. “Guided Teach” /
teaching of reference profiles (Ò/18). The settings made last are internally stored by the
sensor.
When the sensor is switched on for the first time after a reset, it will also start with the “Guided
Teach” as the taught reference profile is deleted in case of a reset.
Lifetime of a laser diode: 50000 hours.
After successful teaching, the sensor should not be moved again. Any change of the sensor
position will lead to the activated reference profile not being recognised reliably.
The sensor must be taught again if it has been moved.
The sensor needs a warm-up period of ≥ 10 min. The performance parameters specified in the
data sheet only apply after this warm-up period.
The teaching of objects should also be done in the warmed-up state.
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8.1 “Guided Teach” / teaching of reference profiles
Guided Teach
1
[Welcome, choose
your language]
[English]
[Deutsch]
[Français]
[...]
[Floating]
[Fixed]
[Back]
100% 85%
RUN
85%90%
[Conrm]
[Back]
[Save this object
prole?]
[Conrm]
[Back] [Back]
[Dene ROI]
[Region of interest]
90%100%
[Save settings]
[Back]
[Position reference
prole]
[Choose slot to save
the current prole]
[Place object and
press conrm]
[Prole 1]
[Prole 2]
[Prole ...]
[Overwrite Prole 1?]
[No]
[Yes]
[Select next step]
[Go to runmode]
[Add new prole]
[Adj. Threshold]
8.1.1 Language selection
uPut the sensor into operation.
wThe available languages are indicated in the display.
uSelect the desired language with [▲] / [▼] and confirm with [●].
8.1.2 Teaching an object
uIn the next step, the profile is taught.

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wThe request [Place object and press confirm] is displayed.
wThe sensor emits a red laser line with two vertical green ROI markings.
uPlace the sensor so that the laser line covers the area to be monitored and the object is within the
operating range of 150...300mm. General representation (Ò/6).
uStart the teaching process by pressing [●].
wThe sensor repeatedly measures the profile of the object/background.
uSelect [Confirm] or [Back] using [▲] / [▼] and press [●].
• [Confirm]: Taught profile is saved.
• [Back]: Teach the profile again.
The object should not be moved during measurement. The end of the measurement is not only
indicated in the display, but also via the laser line flashing twice.
If the object to be detected is outside the operating range (e.g. closer than 150 mm or farther
away than 300 mm), the teaching process is stopped. The message [Object out of range]
appears for three seconds. Afterwards, a new teaching process is started.
8.1.3 Set ROI
The sensor makes it possible to select an ROI from the entire taught height profile. The profile section
included in this ROI is saved as reference profile and used to determine the matching value.
Based on this restriction, the assessment of the height profile can be limited to the relevant
section. Deviations regarding other, irrelevant sections are not taken into account.
When operating with the “Vision Assistant” parameter setting software, it is possible to define up
to two profiles (ROIs).
uIn the next step, the ROI is set.
wThe options [Define ROI] and [Back] are displayed.
uSelect [Define ROI] or [Back]or using [▲] / [▼] and press [●].
• [Define ROI]: Define an ROI from the entire profile taught.
• [Back]: Teach the profile again.
uSelect [Define ROI] using [● ].
w[Set left ROI mark] is displayed.
uMove the green marking line using [▲] / [▼].
wThe left marking line shifts.
uAfter reaching the requested position, confirm with [●].
wThe position of the left marking line is set.
wThe selected section is detected again (new profile).
w[Set right ROI mark] is displayed.
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uMove the green marking line using [▲] / [▼].
wThe left marking line shifts.
uAfter reaching the requested position, confirm with [●].
wThe position of the left marking line is set.
The selected section is detected again (new profile).
Red line indicated in the display: represents the section covered by the laser line.
White marking: represents the fixed marking line.
Green arrow: represents the marking line to be moved. Two vertical ROI markings projected in
green support the setting.
The standard setting for the ROI includes the entire operating range. If the markings are not
moved, but confirmed, the entire profile taught is used for assessment.
8.1.4 Set the position of the reference profile
In the previous step, a reference profile was taught from the ROI. In the next step, you can define the
section in which the measured height profile is to be searched. There are two options:
Fixed:
The reference profile is searched in the ROI defined during teaching. As during teaching, the objects
to be monitored must be positioned very exactly during operation.
Floating:
However, due to mechanical or manual shifting tolerances it is not always possible to position the
object to be monitored correctly.
With the option [Floating], this problem can be avoided. The taught reference profile is searched
across the entire detected height profile. The taught reference profile can be successfully detected
along the X and Z axis despite a change in position.
Marking function:
During teaching, the ROI is indicated via two vertical marking lines projected in green (ROI markings).
This way, the user can see what section of the laser line is defined as ROI. After teaching has been
finished, the marking lines disappear. However, they can be displayed manually. Parameter level
basic functions (Ò/29).
uIn the next step, the position of the ROI is defined.
wThe options [Fixed], [Floating] and [Back] are displayed.
uSelect [Fixed], [Floating] or [Back] using [▲] / [▼] and press [●].
• [Fixed]: No shift of the object is permitted.
• [Floating]: A shift of the object in X direction (along the laser line) and in Z direction is permitted.
• [Back]: Jump back to. Set ROI (Ò/19).