Omron FZ3 Series User manual

User’s Manual
Cat. No. Z290-E1-01
Vision Sensor
FZ3 Series
Vision Sensor FZ3 Series User’s Manual
Authorized Distributor:
In the interest of product improvement,
specifications are subject to change without notice.
Cat. No. Z290-E1-01
OMRON Industrial Automation Global: www.ia.omron.com 1208(I)
OMRON Corporation
Industrial Automation Company
Regional Headquarters
OMRON EUROPE B.V.
Sensor Business Unit
Carl-Benz-Str. 4, D-71154 Nufringen,
Germany
Tel: [phone]/Fax: [phone]
OMRON ELECTRONICS LLC
One Commerce Drive Schaumburg,
IL 60173-5302 U.S.A.
Tel: [phone]/Fax: [phone]
OMRON ASIA PACIFIC PTE. LTD.
No. 438A Alexandra Road # 05-05/08 (Lobby 2),
Alexandra Technopark, Singapore 119967
Tel: [phone]/Fax: [phone]
OMRON (CHINA) CO., LTD.
Room 2211, Bank of China Tower,
200 Yin Cheng Zhong Road,
PuDong New Area, Shanghai, 200120, China
Tel: [phone]/Fax: [phone]
Sensing Devices Division H.Q.
Application Sensors Division
Shiokoji Horikawa, Shimogyo-ku,
Kyoto, 600-8530 Japan
Tel: [phone]/Fax: [phone]
© OMRON Corporation 2008 All Rights Reserved.

Introduction
Thank you for purchasing the FZ3 Series.
This manual provides information regarding functions, performance and operating methods that
are required for using the FZ3 Series.
When using the FZ3 Series, be sure to observe the following:
• The FZ3 Series must be operated by personnel knowledgeable in electrical engineering.
• To ensure correct use, please read this manual thoroughly to deepen your understanding of the
product.
• Please keep this manual in a safe place so that it can be referred to whenever necessary.

FZ3 User's Manual 1
Contents
1. Before Operation…………………………………………………………………………………………7
Operation Flow ………………………………………………………………………………………………8
Layouts of Screens/Windows ………………………………………………………………………………9
Layout of Main Screen (ADJUST Window) ……………………………………………………………9
Layout of Main Screen (RUN Window)…………………………………………………………………12
Layout of Edit Flow Window ……………………………………………………………………………15
Layout of Property Setting Window ……………………………………………………………………17
Checking System Configuration …………………………………………………………………………18
Basic Configuration of FZ3 Series………………………………………………………………………18
Preparing Controllers and Cameras ………………………………………………………………………19
Preparing Controllers ……………………………………………………………………………………19
Adjusting Cameras ………………………………………………………………………………………19
Intelligent Camera (with Lighting Function) ……………………………………………………………20
Input Operations ……………………………………………………………………………………………21
Operation of Touch Pen …………………………………………………………………………………21
Basic Operation of Mouse and Trackball ………………………………………………………………21
Returning Controller to Factory Settings …………………………………………………………………23
Initializing Controller [System Initialization] ……………………………………………………………23
Restarting Controller [System Restart]…………………………………………………………………23
Saving Settings and Turning Power Off …………………………………………………………………24
Turning Off LCD …………………………………………………………………………………………24
2. Setting Scenes (Measurement Flow) …………………………………………………………27
What Is a Scene?……………………………………………………………………………………………28
Scene Examples …………………………………………………………………………………………28
What Is a Scene Group?……………………………………………………………………………………32
Creating a Scene ……………………………………………………………………………………………33
Processing Item Selection Guidelines ……………………………………………………………………35
Selecting Measurement Processing Items Using a Chart ……………………………………………35
Selecting Measurement Processing Items According to the Measurement Method and Purpose
……………………………………………………………………………………………………………………42
Editing Processing Units in Scenes ………………………………………………………………………48
Switching Scenes and Scene Groups ……………………………………………………………………50
Switching Scenes ………………………………………………………………………………………50
Switching Scene Groups ………………………………………………………………………………50
Editing Scenes ………………………………………………………………………………………………52
Copying a Scene …………………………………………………………………………………………52
Clearing a Scene …………………………………………………………………………………………52
Renaming a Scene and Adding a Description…………………………………………………………53
Editing Scene Groups ………………………………………………………………………………………55
Copying a Scene Group …………………………………………………………………………………55
Deleting a Scene Group …………………………………………………………………………………56
Renaming a Scene Group ………………………………………………………………………………56
3. Performing Test Measurement/Starting Operation………………………………………59
ADJUST Window and RUN Window………………………………………………………………………60
Acesst 1.0 6251194

2 FZ3 User's Manual
ADJUST Window …………………………………………………………………………………………60
RUN Window ……………………………………………………………………………………………60
Switching to the RUN Window …………………………………………………………………………62
Switching to the ADJUST Window ……………………………………………………………………62
Performing Test Measurement ……………………………………………………………………………63
Key Points for Adjustment …………………………………………………………………………………65
Stabilizing Measurement ………………………………………………………………………………65
Shortening Processing Time ……………………………………………………………………………67
Arranging the RUN Window ………………………………………………………………………………68
Displaying Multiple Windows Together ………………………………………………………………68
Changing Display Contents ……………………………………………………………………………69
Enlarging Measurement Images [Zoom Images] ……………………………………………………73
Displaying Flow and Detailed Results …………………………………………………………………73
Switching the RUN Window to Fast View Mode [Select RUN Mode] ………………………………74
Changing Display Contents on the RUN Window Measurement Information Display Area ……75
Changing Functions That Can Be Operated from the RUN Window Tool Box ……………………75
Useful Functions for Operation ……………………………………………………………………………76
Remeasuring Saved Images ……………………………………………………………………………76
Improving Adjustment Efficiency ………………………………………………………………………77
Changing Judgement Conditions without Stopping Measurement …………………………………79
Changing Regions as a Batch [Shift area] ……………………………………………………………81
Monitoring Measurement Value Trends ………………………………………………………………82
Logging Measurement Values and Measurement Images …………………………………………82
Analyzing Logging Data …………………………………………………………………………………88
Clearing Measurement Results …………………………………………………………………………90
Clearing Saved Images …………………………………………………………………………………90
Capturing Screens ………………………………………………………………………………………91
4. Saving/Loading Data …………………………………………………………………………………93
Basic Knowledge about Data Saving ……………………………………………………………………94
About Saving Areas………………………………………………………………………………………94
About USB Drive Names ………………………………………………………………………………94
Saving Settings Data to Controller Memory………………………………………………………………96
When Using Scene Group 0 ……………………………………………………………………………96
When Using Scene Groups 1 to 31 ……………………………………………………………………96
Saving Settings Data to RAMDisk/USB Device …………………………………………………………98
Saving Logging Images to RAMDisk/USB Device ……………………………………………………100
Copying/Moving Files ……………………………………………………………………………………101
Loading Settings Data to Controller ……………………………………………………………………103
5. Changing the System Environment …………………………………………………………105
Setting Conditions for Camera Use ……………………………………………………………………106
Checking Camera Connections [Camera Connection] ……………………………………………106
Setting Trigger Delay [Inter-camera Setting]…………………………………………………………106
Setting Conditions Related to Operation during Measurement ………………………………………108
Setting the System Operation Environment ……………………………………………………………110
Setting the Date and Time [Date-time Setting] ………………………………………………………110
Selecting the Language [Language Setting] …………………………………………………………110
Setting the Fan Rotation Speed [Fan Control Setting]………………………………………………111
Acesst 1.0 6251194

FZ3 User's Manual 3
Setting the Start-up Status [Startup Setting] …………………………………………………………112
Setting the RUN Window Display [RUN mode View Setting] ………………………………………114
Setting the RUN Window Shortcut [Create Shortcut] ………………………………………………115
Setting the Encoder Trigger [Encoder Trigger Setting] ……………………………………………115
Setting the STEP Input Detection Pulse Width [STEP Setting] ……………………………………116
Setting the RUN Window Password [Password Setting]……………………………………………117
Checking System Information [System Information] ………………………………………………119
6. Methods for Connecting and Communicating with External Devices …………121
About Connecting with External Devices ………………………………………………………………122
Communicating through Serial Communication (PLC Link) …………………………………………123
Communication Processing Flow (PLC Link) ………………………………………………………123
Setting Communication Specifications (Ethernet - PLC Link) ……………………………………123
Setting Communication Specifications (RS-232C/422-PLC Link) …………………………………126
Memory Allocation (PLC Link) …………………………………………………………………………129
Command Control (PLC Link) …………………………………………………………………………131
Data Output (PLC Link) ………………………………………………………………………………140
Timing Chart (PLC Link) ………………………………………………………………………………140
Ladder Program Example (PLC Link)…………………………………………………………………144
Controlling/Outputting through Serial Communication (Non-procedure) ……………………………145
Communication Processing Flow (Non-procedure) …………………………………………………145
Setting Communication Specifications (Ethernet - Non-procedure) ………………………………145
Setting Communication Specifications (RS-232C/422 - Non-procedure)…………………………147
Checking Communication Status (Non-procedure) …………………………………………………149
Command Format (Non-procedure) …………………………………………………………………150
Command List (Non-procedure) ………………………………………………………………………151
Output Format (Non-procedure) ………………………………………………………………………176
Controlling/Outputting through Parallel Communication ………………………………………………178
Setting Communication Specifications (Parallel Interface) …………………………………………178
Checking Communication Status (Parallel Interface) ………………………………………………180
I/O Format (Parallel Interface) …………………………………………………………………………181
Timing Chart ……………………………………………………………………………………………183
Externally Outputting Data through FTP ………………………………………………………………192
Setting Communication Specifications ………………………………………………………………192
Communication Example ………………………………………………………………………………193
7. External Reference Tables ………………………………………………………………………195
Input image …………………………………………………………………………………………………198
Measurement Image Switching ………………………………………………………………………198
Measurement ………………………………………………………………………………………………199
Search ……………………………………………………………………………………………………199
Flexible Search …………………………………………………………………………………………200
Sensitive Search ………………………………………………………………………………………201
ECM Search ……………………………………………………………………………………………203
EC Circle Search ………………………………………………………………………………………204
Shape Search+ …………………………………………………………………………………………206
Classification ……………………………………………………………………………………………208
Edge Position ……………………………………………………………………………………………209
Edge Pitch ………………………………………………………………………………………………210
Acesst 1.0 6251194

4 FZ3 User's Manual
Scan Edge Position ……………………………………………………………………………………211
Scan Edge Width ………………………………………………………………………………………212
Color Data ………………………………………………………………………………………………213
Gravity and Area ………………………………………………………………………………………214
Labeling …………………………………………………………………………………………………216
Label Data ………………………………………………………………………………………………217
Labeling+ ………………………………………………………………………………………………218
Defect ……………………………………………………………………………………………………222
Precise Defect …………………………………………………………………………………………222
Fine Matching……………………………………………………………………………………………223
Character Inspection……………………………………………………………………………………224
Date Verification ………………………………………………………………………………………225
Model Dictionary ………………………………………………………………………………………226
Barcode+…………………………………………………………………………………………………227
2D Code+ ………………………………………………………………………………………………228
Circle Angle ……………………………………………………………………………………………230
Compensate image ………………………………………………………………………………………231
Position Compensation…………………………………………………………………………………231
Trapezoidal Correction+ ………………………………………………………………………………231
Filtering …………………………………………………………………………………………………232
Background Suppression ………………………………………………………………………………232
Color Gray Filter…………………………………………………………………………………………233
Extract Color Filter………………………………………………………………………………………234
Anti Color Shading………………………………………………………………………………………235
Stripes Removal Filter+ ………………………………………………………………………………235
Halation Cut+ ……………………………………………………………………………………………236
Panorama+ ………………………………………………………………………………………………236
Polar Transformation …………………………………………………………………………………237
Support measurement ……………………………………………………………………………………238
Calculation ………………………………………………………………………………………………238
Line Regression …………………………………………………………………………………………238
Circle Regression ………………………………………………………………………………………239
Calibration+ ……………………………………………………………………………………………239
Set Unit Data ……………………………………………………………………………………………240
Get Unit Data ……………………………………………………………………………………………240
Set Unit Figure …………………………………………………………………………………………240
Get Unit Figure …………………………………………………………………………………………240
Trend Monitor ……………………………………………………………………………………………241
Image Logging …………………………………………………………………………………………242
Data Logging ……………………………………………………………………………………………242
Elapsed Time ……………………………………………………………………………………………243
Wait ………………………………………………………………………………………………………243
Branch ………………………………………………………………………………………………………244
Conditional Branch ……………………………………………………………………………………244
DI Branch ………………………………………………………………………………………………244
Output result ………………………………………………………………………………………………245
Data Output ……………………………………………………………………………………………245
Parallel Data Output ……………………………………………………………………………………245
Parallel Judgement Output ……………………………………………………………………………246
Acesst 1.0 6251194

FZ3 User's Manual 5
Display result ………………………………………………………………………………………………247
Result Display …………………………………………………………………………………………247
Display Image File ………………………………………………………………………………………247
Display Last NG Image…………………………………………………………………………………247
8. Appendixes………………………………………………………………………………………………249
About Lenses ………………………………………………………………………………………………250
Error Messages and Troubleshooting …………………………………………………………………256
FAQ …………………………………………………………………………………………………………259
During Start-up …………………………………………………………………………………………259
During Operation ………………………………………………………………………………………259
For Measurement ………………………………………………………………………………………260
About Parallel Interface ………………………………………………………………………………260
About Serial Interface (RS-232C/422 Connection) …………………………………………………261
Measurement Mechanism ………………………………………………………………………………262
Color Processing Mechanism …………………………………………………………………………262
Search Processing Mechanism ………………………………………………………………………262
Edge Detection Measurement …………………………………………………………………………266
Defect Detection Measurement ………………………………………………………………………268
Handling Coordinates …………………………………………………………………………………269
Terminology Explanations ………………………………………………………………………………271
Basic Knowledge about Operations ……………………………………………………………………275
Inputting Values …………………………………………………………………………………………275
Inputting Text ……………………………………………………………………………………………275
Selecting Files and Folders ……………………………………………………………………………276
Available Operations in Select File Window …………………………………………………………278
Using the Zoom Function ………………………………………………………………………………279
Setting Figures ……………………………………………………………………………………………281
Layout of Figure Setting Area …………………………………………………………………………281
Setting Methods…………………………………………………………………………………………282
About OR Setting/NOT Setting ………………………………………………………………………290
About Number of Logging Images ………………………………………………………………………292
About Limits on the Number of Image Input Processing Items Used ………………………………293
About Max. Number of Loading Images during Multiple Image Input ………………………………295
Character Code Table ……………………………………………………………………………………296
Upper Limits of Processing Item Parameters …………………………………………………………297
About Memories Usable with FZ Series…………………………………………………………………298
Index……………………………………………………………………………………………………………299
Acesst 1.0 6251194

6 FZ3 User's Manual
How This Manual Is Organized
This manual includes two manuals: the "User's Manual", which describes basic operations and settings
for vision sensors, and the "Processing Item List Manual", which describes the setting options for each
processing item.
Conventions Used in This Manual
Symbols
The symbols used in this manual have the following meanings.
Indicates relevant operational precautions that must be followed.
Indicates operation-related suggestions from OMRON.
Use of Quotation Marks and Brackets
In this manual, menus and other items are indicated as follows.
[ ] Menu Indicates the menu names or processing items shown in the menu bar.
" " Item name Indicates the item names displayed on the screen.
Version Upgrade Information
The newly added functions are described here
Revision history from Version 2.0 to 2.1
Added Function Note on Newly-Added Function Reference in Manual
Shape Search+
Handling size change
Measurement is now possible even when the size of
measurement objects change.
Reference: "Processing
Item List Manual", " Shape
Search+" (p.94)
2D Code+
Support code colors
Measurement is now possible for white 2D codes on
black backgrounds.
R e fe re n c e : "P ro c e ss in g Ite m
L is t M a n u a l", " 2 D C o d e + " (p .2 6 5 )
Acesst 1.0 6251194

1
Before Operation
FZ3 User's Manual 7
Before Operation
This chapter describes the basic flow and preparations
before beginning operation.
Reference: Operation Flow (p.8)
Reference: Layouts of Screens/Windows (p.9)
Reference: Checking System Configuration (p.18)
Reference: Preparing Controllers and Cameras (p.19)
Reference: Input Operations (p.21)
Reference: Returning Controller to Factory Settings (p.23)
Reference: Saving Settings and Turning Power Off (p.24)
Acesst 1.0 6251194

1
Before Operation
8 Operation Flow FZ3 User's Manual
Operation Flow
Operation flow is explained here.
Acesst 1.0 6251194

1
Before Operation
FZ3 User's Manual Layouts of Screens/Windows 9
Layouts of Screens/Windows
Screens vary with the status of the operation being performed. The structure of some typical screens
and the functions for the various buttons are described here.
Layout of Main Screen (ADJUST Window)
This screen is used to check whether measurement is being performed correctly according to the set
conditions.
Acesst 1.0 6251194

1
Before Operation
10 Layouts of Screens/Windows FZ3 User's Manual
a. Menu Bar
Select operations and settings menus related to measurement.
b. Measurement Information Display Area
1. Overall judgement
Displays a scene's overall judgement result ( [OK]/ [NG]).
2. Processing time
Displays the time required for the measurement process.
3. Status display
Displays the scene group number, scene number, external output status, and image mode
for the currently displayed scene.
c. Toolbar
Commonly-used functions appear in the toolbar.
●Edit flow
The Edit Flow window is displayed. Addition and deletion of processing units and switching
of the processing sequence is performed in the Edit Flow window.
●Data save
Setting data is saved into the internal flash memory in the controller. Make sure to save
when settings have been modified.
●Scene switch
To switch a scene group or scene.
●Measure/Stop meas.
Acesst 1.0 6251194

1
Before Operation
FZ3 User's Manual Layouts of Screens/Windows 11
Starts/stops measurement.
●Switch to RUN mode
Switches to the RUN window.
d. Image Display Area
Displays the measured image.
1. Property setting buttons
Displays the name of the currently selected processing item.Moving to the property setting
window can be done by tapping here.
e. Control Area
Displays "Test measurement", "Flow", "Detail result", and "Image display".
●Test measurement
Use when test measurement conditions and images that have been acquired are used for
remeasurement.
●Flow
Displays the judgement results for the flow and each unit.
1. Moves to the top processing unit with an NG error.
2. Moves to the next processing unit with an NG error.
●Detail result
The detailed measurement results of the processing units selected in the measurement
flow are displayed as text.
Acesst 1.0 6251194

1
Before Operation
12 Layouts of Screens/Windows FZ3 User's Manual
●Image display
Sets the display method for the Image Display area.
f. Measurement Manager Bar
1. [Capture]
Saves the content displayed on the monitor as an image.
Reference: Set the save destination for captured images. (p.92)
2. [LCD Off] (Displayed only with LCD-integrated controllers.)
Turns off power to the LCD monitor. Tap the bottom of the monitor screen to turn on power
to the LCD monitor again.
Layout of Main Screen (RUN Window)
This window is used during operation.
Acesst 1.0 6251194

1
Before Operation
FZ3 User's Manual Layouts of Screens/Windows 13
a. Measurement Information Display Area
1. Overall judgement
Displays a scene's overall judgement result ( [OK]/ [NG]).
The judgement results for each processing unit are displayed in the Control area.
2. Processing time
Displays the time required for the measurement process.
3. Scene Group Name, Scene Name
Displays the scene group number and the scene number of the currently displayed scene.
b. Image Display Area
Displays the measured image.
1. Property setting buttons
Displays the name of the currently selected processing item.
Acesst 1.0 6251194

1
Before Operation
14 Layouts of Screens/Windows FZ3 User's Manual
c. Control Area
Displays [Flow], [Detail result], [Image display], and [Tool box].
●Flow
Displays the judgement results for the flow and each unit.
1. Moves to the top processing unit with an NG error.
2. Moves to the next processing unit with an NG error.
Note
●The size of the processing unit buttons can be changed through [View] menu - [Display the enlarged flow] in the
ADJUST Window.
●Detail result
The detailed measurement results of the processing units selected in the measurement
flow are displayed as text.
●Image display
Sets the display method for the Image Display area.
●Tool box
Starts and stops simplified non-stop adjustment, and switches to the ADJUST window.
Items for which operation is performed in the ADJUST window can be allocated to buttons,
and they can then be executed in the RUN window.
Acesst 1.0 6251194

1
Before Operation
FZ3 User's Manual Layouts of Screens/Windows 15
d. Measurement Manager Bar
1. [Capture]
Saves the content displayed on the monitor as an image.
Reference: Set the save destination for captured images. (p.92)
2. [LCD Off] (Displayed only with LCD-integrated controllers.)
Turns off power to the LCD monitor. Tap the bottom of the monitor screen to turn on power
to the LCD monitor again.
Layout of Edit Flow Window
This window is for compiling the measurement flow.Flow parts are displayed on the right side and the
measurement flow is displayed on the left. If the measurement trigger is activated, processing is
executed in sequence starting from the top of the flow.
a. Unit List
Lists the processing units included in the flow.
You can create a flow for a scene by adding processing items to the unit list.
b. Property Setting Buttons
Displays the property setting window where detailed settings can be performed.
c. End Marker
Indicates the end of the flow.
d. Edit Flow Buttons
●Search up/Search down
Acesst 1.0 6251194

1
Before Operation
16 Layouts of Screens/Windows FZ3 User's Manual
Searching can be performed to find out what position a processing item occupies in the
unit list.
The icon for the processing item to be searched for is selected in the processing item tree
and clicked.
This function is convenient when setting long flows.
●Select top/Select bottom
Selects the processing unit at the top or bottom of the flow.
●Select above/Select below
Selects the processing unit located one above or one below the currently selected
processing unit.
●Rename
Displays a window for renaming the selected processing unit.
●Move up/Move down
Moves the selected processing unit upward or downward.
●Copy
Copies the selected processing unit.
●Paste
Pastes the copied processing unit immediately before the selected processing unit.Pasting
cannot be performed if any operations other than paste are performed after copying.
●Delete
Deletes the selected processing unit.
●Append (Bottom)
Adds a processing unit to the bottom of the flow.
●Insert
Inserts a new processing unit immediately before the selected processing unit.
●New folder
Used when multiple processing units are managed as one group.
●Shift area
Changes related figure data in one batch.
●Multiple selection
Used when processing units are copied or deleted together.
●Set
Displays the processing item setting window for the selected processing unit.
e. Display Options
●Show guide
When checked, explanations for processing items are displayed.
●Enlarge flow
When checked, the "a Unit list" flow is displayed with large icons.
●Enlarge item tree
When checked, the "f Processing item tree" is displayed with large icons.
●Ref. other Scene's flow
When checked, other scene flows within the same scene group can be referred to.
f. Processing Item Tree
This area is for selecting processing items to add to the flow.Processing items are classified by
type and displayed as a tree. Tapping the plus sign "+" of any item displays expanded contents
Acesst 1.0 6251194

1
Before Operation
FZ3 User's Manual Layouts of Screens/Windows 17
below that item. Tapping the minus sign "-" of any item collapses the expanded contents.
When "Ref. other Scene's flow" is checked, the scene select box and other scene flows are
displayed.
g. Guide
Shows an explanation for the processing item selected in the processing item tree.These are
used as reference when selecting processing items. To display guides, check "Show guide" in "e
Display options".
Layout of Property Setting Window
This window is used for detailed setting of measurement parameters and judgement conditions for
processing items.
a. Item Tab Area
Displays the settings items for the processing unit currently being set.Perform settings starting
with the item on the left.
b. Detail Area
Set detailed items.
c. Image Display Area
Displays camera images, figures, and coordinates.
d. Zoom Browser Area
Zooms in and out from the displayed image.
Acesst 1.0 6251194

1
Before Operation
18 Checking System Configuration FZ3 User's Manual
Checking System Configuration
This product is a vision sensor for performing image processing measurement through a controller of
objects photographed using a camera.By connecting an external device such as a PC, measurement
commands can be input and measurement results can be output from the external device.
Basic Configuration of FZ3 Series
*1: The touch pen is an accessory of a controller.
*2: FZ-SC2M and FZ-S2M cannot be connected with the FZ3-3 /FZ3-H3 controllers.
*3: Lenses for small-size cameras are required for small-size 300,000-pixel cameras.
*4: FZ-SC5M and FZ-S5M can only be connected with the FZ3-70 /FZ3-H70 controllers.
Acesst 1.0 6251194