Omron ZFV - 1 User manual

Advanced Industrial Automation
» Scalable and flexible
» Intuitive in use
» Easy colour vision
ZFV VISION SENSOR
Easy vision – Teach & Go

Colour and grey scale versions available
The latest addition to the ZFV family is the ZFV Colour sensor.
Using this instead of the conventional monochrome sensor
widens the choice of applications and increases the stability
of measurement of the inspection. Through its automatic
colour filter function, image contrast is optimised, making
inspections more reliable. There are seven colour filters in
total; the one that obtains the most suitable contrast can be
automatically selected, so there’s no need to worry about
colour setting parameters.
A true “Easy vision –
Teach & Go” vision sensor
Omron’s ZFV is an innovative image-processing
system in a sensor format. What makes this sensor so
special is how easy it is to use; with its ‘Teach & Go’
concept you can configure an inspection routine in just
a few steps using the sensor’s integrated, high-
resolution colour LCD screen and simple menu system.
The screen provides live image display during set-up
and operation, and gives you instant feedback during
the inspection process. And a choice of controllers
gives you the tools to perform everything from simple
presence detection to advanced pattern recognition.

Advanced Industrial Automation
Size and position inspection region
Target - Teach - Go!
Select your inspection toolGo to the menu Teach & Go
Intuitive user interface
The ZFV’s user interface is smart! You can set parameters
using a few buttons and the integrated LCD colour monitor.
Operation menus and icons guide you through a simple set-up
process. During operation, the LCD screen enables you to see
results and images in real-time. There’s no need to connect
an external PC for set-up, maintenance or operation viewing;
the ZFV supplies real-time images all the time. The ZFV provides
instant feedback - on board - exactly when you need it.
Your benefit: No expert knowledge required, minimised
downtime for setup and maintenance.
Set-up in minutes

Width inspection
The Width tool measures an object, in this
case a label, to verify that it is not folded
or cut.
Multiple functions: “One Sensor Fits All” concept
Depending on the controller version, the ZFV contains up to 8 different tools; one can be selected at a time.
These sophisticated tools offer an affordable sensor with a very intuitive user interface. Both the monochrome and
colour version offer basically the same inspection functionality while the ZFV Colour uses the additional colour
information included in the image. The tools include:
Pattern recognition
This tool verifies if a symbol printed on
a package is present and complete using
a taught feature as a reference.
Hue verification
The Hue tool inspects colour differences in
a plain colour work-piece. A false colour cap
will be rejected.
Brightness: verifies objects using density
average and deflection.
Width: measures the width of an object
using Edge Tool.
Character (text): inspects one character and
the presence of a character string.
Hue: checks the difference between the
measured colour and a reference colour
(Colour version only).
Counting (number): uses Edge Count to count
the number of object edges.
Pattern (shape): recognises objects by the
difference of pattern and presence of pattern.
Area (size): verifies an object using size
(pixel count).
Position: verifies the position of an object
using Edge Tool.

Advanced Industrial Automation
Character
This tool verifies if a lot code, date code or
product code is entirely printed on a label.
Colour can be the difference
The monochrome version of the ZFV will be a perfect solution
for all your easy vision tasks - as long as the object colours still
provide enough image contrast. If that is not the case, use the
ZFV Colour. As it acquires a colour image, it uses the colour
information as a “virtual 3rd dimension” - adding security and
reliability to your application.
Get the colours right
Through its automatic colour filter function, the ZFV Colour
is able to see and inspect multi-coloured objects invisible for
a grey scale sensor. Use the seven integrated colour filters and
the colour pickup function to get the right contrast or extract
only the relevant colour from the image– by using colour
information, you simply “get the image good”.
This is what a grey scale sensor sees
That is what a monochrome sensor sees using red light. Depending
on the object colour or object colour mix, the image contrast can
be very weak.
This is what the ZFV Colour sees
The ZFV acquires a colour image, applies a colour filter and processes
the resulting image. Image contrast is significantly increased.

Scale it to your needs
You can set-up one inspection per controller – but the ZFV
is scalable, so you can simply add controllers as required by
connecting them to a common communication bus to expand
the functionality of your sensor. Up to five controllers can
be connected together through a simple snap-on system to
perform multiple inspections on your work-piece. Other option
modules, like the data storage unit (DSU) for data logging, can
also be added to enhance communication and data storage
functionality. Your benefit: You protect your investment; the
sensor will grow with your requirements.

Advanced Industrial Automation
Easy meets advanced
The sensor keeps all settings for up to 8 configurations in an
internal memory. If that is not enough or if you want to log or
communicate results and settings, simply connect the optional
data storage unit to either the grey scale or colour version.
The ZFV Colour also features USB and RS-232C interfaces for
connection to a personal computer, enabling the easy transfer
of data and results. Remote configuration software will be
available later this year enabling you to remotely set-up and
maintain your sensor.
Large range of sensor heads
Six adjustable sensing heads are available with the ZFV.
A Focus Adjustment function eliminates the need to change
the head for different sizes of work-pieces. The heads come
in a protection rate of IP65 or IP67 allowing installation
in harsh environments.
Light intensity and direction can be adjusted manually
or switched off if an external light source is more appropriate.
The range of detection heads is now larger than ever before,
extending the field of view to 150 mm. This enables you to
inspect even large work-pieces that previously could not be
handled. Your benefit: Minimised investment cost due to the
“one sensor fits all concept”.
ZFV-SR10/SC10
FOV: 5 to 9 mm
ZFV-SR50
FOV: 10 to 50 mm
ZFV-SC50
FOV: 10 to 50 mm
ZFV-SC90
FOV: 50 to 90 mm
ZFV-SC150
FOV: 90 to 150 mm

1ZFV Gray Scale/Colour Series
Smart Vision Sensors
ZFV Gray Scale/Colour Series
Ordering Information
Models ZFV Gray Scale Series
Sets of Sensor Head and Amplifier Unit
Sensor Heads
Models ZFV Colour Series
Sensor Heads
Amplifier Units ZFV Gray Scale Series Amplifier Units ZFV Colour Series
Common Accessories ZFV Gray Scale/Colour Series (order separately)
Data Storage Units
Controller Link Unit
Sensor Head Extension Cable
Panel-mounting Adapter
Type NPN PNP
Narrow View/Single Function ZFV-R1010 ZFV-R1015
Narrow View/Standard ZFV-R1020 ZFV-R1025
Wide View/Single Function ZFV-R5010 ZFV-R5015
Wide View/Standard ZFV-R5020 ZFV-R5025
Appearance Type Setting distance Sensing area Model
Narrow View 34 to 49 mm (variable) 5 x 4.6 mm to 9 x 8.3 mm (variable) ZFV-SR10
Wide View 38 to 194 mm (variable) 10 x 9.2 mm to 50 x 46 mm (variable) ZFV-SR50
Appearance Type Setting distance Sensing area Model
Narrow View 34 to 49 mm (variable) 5 x 4.6 mm to 9 x 8.3 mm (variable) ZFV-SC10
Standard View 31 to 187 mm (variable) 10 x 9.2 mm to 50 x 46 mm (variable) ZFV-SC50
Wide View 66 to 141 mm (variable) 50 x 46 mm to 90 x 83 mm (variable) ZFV-SC90
Ultra-wide View 114 to 226 mm (variable) 90 x 83 mm to 150 x 138 mm (variable) ZFV-SC150
Appearance Type Power supply Output
type
Model
Single
Function
24 VDC NPN ZFV-A10
PNP ZFV-A15
Standard NPN ZFV-A20
PNP ZFV-A25
Appearance Power supply Output type Model
24 VDC
NPN ZFV-CA40
PNP ZFV-CA45
Appearance Power supply Output type Model
24 VDC
NPN ZS-DSU11
PNP ZS-DSU41
Appearance Model
ZS-XCN
Cable length Model
3 m ZFV-XC3B *1
*1. ZFV-XC3BR Robot Cable is also available.
8 m ZFV-XC8B
Appearance
Model ZS-XOM1 ZS-XPM2
First Unit Additional Units
(for expansion)
ZFV Gray Scale/Colour Series8

2 Smart Vision Sensors
Specifications ZFV Gray Scale Series
Sensor Heads
Amplifier Units
Item ZFV-SR10 (Narrow View) ZFV-SR50 (Wide View)
Setting distance (L) 34 to 49 mm 38 to 194 mm
Detection range (H ×V) 5 ×4.6 mm to 9 ×8.3 mm 10 ×9.2 mm to 50 ×46 mm
Relation between setting distance and
detection range
Guide light Provided (center, sensing area)
Built-in lens Focus: f15.65 Focus: f13.47
Object lighting method Pulse lighting
Object light source Eight red LEDs
Sensing element 1/3-inch CCD, partial scan
Shutter Electronic shutter, shutter time: 1/1,000 to 1/4,000
Power supply voltage 15 VDC (Supplied from Amplifier Unit.)
Current consumption Approx. 200 mA
Vibration resistance (destruction) 10 to 150 Hz, 0.35-mm single amplitude, 10 times each in X, Y, and Z directions for 8 min
Shock resistance (destruction) 150 m/s2, three times each in six directions (up/down, left/right, forward/backward)
Connection method Prewired, Standard cable length: 2 m
Degree of protection IEC60529, IP65
Item Single-function Models Standard Models
ZFV-A10 ZFV-A15 ZFV-A20 ZFV-A25
Output method NPN PNP NPN PNP
Inspection items Pattern (PTRN), Brightness (BRGT) Patterns (PTRN), Brightness (BRGT), Area (AREA),
Width (WID), Position (POSI), Count (CNT),
Characters (CHAR)
Teaching area Rectangular, one area
Teaching area size Pattern (PTRN), Brightness (BRGT): Any rectangular area (256 ×256 max.)
Area (AREA), Width (WID), Position (POSI), Count (CNT), Characters (CHAR): Any rectangular area (full
screen max.)
Sensing area Full screen
Resolution 468 432 (H V) max.
Bank selection Supported for 8 banks.
Response time Pattern (PTRN), Brightness (BRGT): High-speed: 4 ms, Standard: 8 ms, High-precision: 12 ms (not using
partial scan)
Area (AREA), Width (WID), Position (POSI), Count (CNT), Characters (CHAR): 128 128: 15 ms max.
Other functions Control output switching: ON for OK or ON for NG
ON delay/OFF delay, One-shot output, “ECO” mode
Output signals (1) Control output (OUTPUT), (2) Enable output (ENABLE), (3) Error output (ERROR)
Input signals (1) Simultaneous measurement input (TRIG) or Continuous measurement input (TRIG), Switched by using
menu.
(2) Bank selection inputs (BANK1 to BANK3)
(3) Workpiece still teaching (TEACH) or Workpiece moving teaching (TEACH), Switched by using menu.
Sensor Head interface Digital interface
Image display Compact TFT 1.8-inch LCD (Display dots: 557 234)
Indicators Judgement result indicator (OUTPUT) Inspection mode indicator (RUN)
Operation interface Cursor keys (up, down, left, right) Setting key (SET) Escape key (ESC)
Operating mode switching (slide switch) Menu switching (slide switch)
Teaching/Display switching key (TEACH/VIEW)
Power supply voltage 20.4 to 26.4 VDC (including ripple)
Current consumption 600 mA max. (with Sensor Head connected)
Degree of protection IEC60529, IP20
49mm
Setting distance (L)
34 mm
5 mm 9mm Sensing
range(H)
10 mm
187 mm
31 mm
50 mm
Setting distance (L)
Sensing
range (H)
Smart Vision Sensors 9

3ZFV Gray Scale/Colour Series
Specifications ZFV Colour Series
Sensor Heads
Note:More colour heads are available. Please contact your OMRON dealer for the full range of ZFV-SC heads.
Amplifier Units
Item ZFV-SC10 (Narrow View) ZFV-SC50 (Wide View)
Setting distance (L) 34 to 49 mm (variable) 31 to 187 mm (variable)
Sensing range (H ×V) 5×4.6 mm to 9 ×8.3 mm (variable) 10 ×9.2 mm to 50 ×46 mm (variable)
Relation between setting
distance and detection range
Built-in lens Focus: f15.65 Focus: f13.47
Object lighting method Pulse lighting
Object light source Eight white LEDs Thirty-six white LEDs
Laser class *1
*1. Applicable standards: IEC 60825-1: 1993, +A1: 1997, +A2: 2001, EN 60825-1: 1994, +A1: 2002, +A2: 2001
Class 1 Class 2
External lighting interface No Yes
Sensing element 1/3-inch CCD
Shutter Electronic shutter, shutter time: 1/500 to 1/8,000
Power supply voltage 15 VDC (Supplied from Amplifier Unit.)
Current consumption Approx. 200 mA Approx. 350 mA (15 V: approx. 150 mA,
48 V: approx. 200 mA, including current
when external light is connected)
Vibration resistance (destruction) 10 to 150 Hz, 0.35 mm single amplitude, 10 times each in X, Y, and Z directions for 8 min
Shock resistance (destruction) 150 m/s2, three times each in six directions (up/down, left/right, forward/backward)
Connection method Prewired, Standard cable length: 2 m
Degree of protection IEC 60529, IP65 IEC 60529, IP65 *2
*2. Consult your OMRON representative if IP67 protection is required.
Item ZFV-CA40 ZFV-CA45
Output method NPN open collector, 30 VDC 50 mA max.,
residual voltage 1.2 V max.
PNP open collector, 50 mA max.,
residual voltage 1.2 V max.
Serial I/O USB2.0 1 port, full-speed (12 Mbps) MINI-B
RS-232C 1 port, 115200 bps max.
Inspection items Patterns (PATTERN), Brightness (BRIGHT), Area (AREA), Width (WIDTH),
Position (POSITION), Count (COUNT), Colour inspection (HUE)
Teaching area size • Patterns (PATTERN), Brightness (BRIGHT): Any rectangular area (256 × 256 max.)
• Area (AREA), Width (WIDTH), Position (POSITION), Count (COUNT),
Colour inspection (HUE): Any rectangular area (full screen max.)
Sensing area Full screen
Resolution 468 x 432 (H x V) max.
Bank selection Supported for 8 banks.
Image input cycle 13 ms (Standard), 8 ms (FAST mode), 5 ms (MAX mode)
Other functions Control output switching: ON for OK or ON for NG, ON delay/OFF delay, One-shot output, "ECO" mode
Connect-
ing to
ZS-DSU
Image logging trigger Stores NG images or all images.
Sampling rate ZFV measurement cycle *1
*1. This is the sampling rate when logging images. To log measurement data only, use the ZS-DSU settings.
Number of logged images Logs up to 128 images in series
Number of connected Units 15 max. (ZFV: 5 Units max.)
External bank function Amplifier Unit setting data can be saved to the memory card as bank data.
Reading bank data enables bank switching.
Output signals (1) Control output (OUTPUT) (2) Enable output (ENABLE) (3) Error output (ERROR)
Input signals (1) Sync measurement input (TRIG)/Continuous measurement input (TRIG); switched from menu
(2) Bank selection input (BANK1-3)
(3) Object stationary teaching (TEACH)/Object motion teaching (TEACH); switched from menu
Sensor Head interface Digital interface
Image display TFT 1.8-inch LCD (Display dots: 557 x 234)
Indicators • Judgment result indicator (OUTPUT, Colour: orange) • Inspection mode indicator (RUN, Colour:
green)
• Error indicator (ERR, Colour: red) • Ready status indicator (READY, Colour: blue)
Operation interface • Cursor keys (up, down, left, right) • Setting key (SET) • Escape key (ESC)
• Operating mode switching (slide switch) • Menu switching (slide switch)
• Teaching/Display switching key (TEACH/VIEW) • Function keys (A to D, 4 inputs)
Power supply voltage 20.4 to 26.4 VDC (including ripple)
Current consumption 800 mA max. (with Sensor Head connected)
Degree of protection IEC 60529, IP20
Sensing range V
H
49mm
Setting distance (L)
34 mm
5 mm 9mm Sensing
range(H) 10 mm
187 mm
31 mm
50 mm
Setting distance (L)
Sensing
range (H)
ZFV Gray Scale/Colour Series10