Omron F160 Vision Sensor User guide

Manual 1:
SETUP MANUAL
Vision Sensor
F160
Cat. No. Z144-E1-03

F160 Vision Sensor
Manual 1: Setup Manual
Revised January 2004

iv
APPLICATION CONSIDERATIONS
Precautions in using the Product
Read and Understand this Manual
Please read and understand this manual before using the products. Please consult your OMRON
representative if you have any questions or comments.
Warranty, Limitations of Liability
<WARRANTY>
OMRON’s exclusive warranty is that the products are free from defects in materials and
workmanship for a period of one year (or other period if specified) from date of sale by OMRON.
OMRON MAKES NO WARRANTY OR REPRESENTATION, EXPRESS OR IMPLIED,
REGARDING NON-INFRINGEMENT, MERCHANTABILITY, OR FITNESS FOR PARTICULAR
PURPOSE OF THE PRODUCTS. ANY BUYER OR USER ACKNOWLEDGES THAT THE BUYER
OR USER ALONE HAS DETERMINED THAT THE PRODUCTS WILL SUITABLY MEET THE
REQUIREMENTS OF THEIR INTENDED USE. OMRON DISCLAIMS ALL OTHER WARRANTIES,
EXPRESS OR IMPLIED.
<LIMITATIONS OF LIABILITY>
OMRON SHALL NOT BE RESPONSIBLE FOR SPECIAL, INDIRECT, OR CONSEQUENTIAL
DAMAGES, LOSS OF PROFITS OR COMMERCIAL LOSS IN ANY WAY CONNECTED WITH THE
PRODUCTS, WHETHER SUCH CLAIM IS BASED ON CONTRACT, WARRANTY, NEGLIGENCE,
OR STRICT LIABILITY.
In no event shall responsibility of OMRON for any act exceed the individual price of the product on
which liability is asserted.
IN NO EVENT SHALL OMRON BE RESPONSIBLE FOR WARRANTY, REPAIR, OR OTHER
CLAIMS REGARDING THE PRODUCTS UNLESS OMRON’S ANALYSIS CONFIRMS THAT THE
PRODUCTS WERE PROPERLY HANDLED, STORED, INSTALLED, AND MAINTAINED AND NOT
SUBJECT TO CONTAMINATION, ABUSE, MISUSE, OR INAPPROPRIATE MODIFICATION OR
REPAIR.

v
Application Considerations
<SUITABILITY FOR USE>
OMRON shall not be responsible for conformity with any standards, codes, or regulations that apply
to the combination of the products in the customer’s application or use of the product.
Take all necessary steps to determine the suitability of the product for the systems, machines, and
equipment with which it will be used.
Know and observe all prohibitions of use applicable to this product.
NEVER USE THE PRODUCTS FOR AN APPLICATION INVOLVING SERIOUS RISK TO LIFE OR
PROPERTY WITHOUT ENSURING THAT THE SYSTEM AS A WHOLE HAS BEEN DESIGNED
TO ADDRESS THE RISKS, AND THAT THE OMRON PRODUCT IS PROPERLY RATED AND
INSTALLED FOR THE INTENDED USE WITHIN THE OVERALL EQUIPMENT OR SYSTEM.
<PROGRAMMABLE PRODUCTS>
OMRON shall not be responsible for the user’s programming of a programmable product, or any
consequence thereof.
Disclaimers
<PERFORMANCE DATA>
Performance data given in this manual is provided as a guide for the user in determining suitability
and does not constitute a warranty. It may represent the result of OMRON’s test conditions, and the
users must correlate it to actual application requirements. Actual performance is subject to the
OMRON Warranty and Limitations of Liability.
<CHANGE IN SPECIFICATIONS>
Product specifications and accessories may be changed at any time based on improvements and
other reasons.
It is our practice to change model numbers when published ratings or features are changed, or
when significant construction changes are made. However, some specifications of the product may
be changed without any notice. When in doubt, special model numbers may be assigned to fix or
establish key specifications for your application on your request. Please consult with your OMRON
representative at any time to confirm actual specifications of purchased products.
<DIMENSIONS AND WEIGHTS>
Dimensions and weights are nominal and are not to be used for manufacturing purposes, even
when tolerances are shown.
<ERRORS AND OMISSIONS>
The information in this document has been carefully checked and is believed to be accurate;
however, no responsibility is assumed for clerical, typographical, or proofreading errors, or
omissions.

vi
Notice:
OMRON products are manufactured for use according to proper procedures by a qualified opera-
tor and only for the purposes described in this manual.
The following conventions are used to indicate and classify precautions in this manual. Always
heed the information provided with them. Failure to heed precautions can result in injury to people
or damage to property.
!DANGER Indicates an imminently hazardous situation which, if not avoided, will result in
death or serious injury.
!WARNING Indicates a potentially hazardous situation which, if not avoided, could result in
death or serious injury.
!Caution Indicates a potentially hazardous situation which, if not avoided, may result in
minor or moderate injury, or property damage.
OMRON Product References
All OMRON products are capitalized in this manual. The word “Unit” is also capitalized when it
refers to an OMRON product, regardless of whether or not it appears in the proper name of the
product.
Visual Aids
The following headings appear in the left column of the manual to help you locate different types
of information.
Note Indicates information of particular interest for efficient and convenient opera-
tion of the product.
1,2,3... 1. Indicates lists of one sort or another, such as procedures, checklists, etc.
Precaution Indicates information required to take full advantage of the functions and per-
formance of the product. Incorrect application methods may result in the loss
of damage or damage to the product. Read and follow all precautionary infor-
mation.
CHECK Indicates points that are important in using product functions or in application
procedures.
TwoCamera Indicates information required when using a 2-camera system.
SeeAlso Indicates where to find related information.
HELP Indicates information helpful in operation, such as the definition of terms.
OMRON, 2001
All rights reserved. No part of this publication may be reproduced, stored in a retrieval system, or trans-
mitted, in any form, or by any means, mechanical, electronic, photocopying, recording, or otherwise,
without the prior written permission of OMRON.
No patent liability is assumed with respect to the use of the information contained herein. Moreover,
because OMRON is constantly striving to improve its high-quality products, the information contained
in this manual is subject to change without notice. Every precaution has been taken in the preparation
of this manual. Nevertheless, OMRON assumes no responsibility for errors or omissions. Neither is
any liability assumed for damages resulting from the use of the information contained in this publica-
tion.

vii
TABLE OF CONTENTS
PRECAUTIONS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . xi
1 General Safety Precautions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . xii
2 Special or Critical Applications. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .xiii
3 Regulations and Standards. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . xiv
SECTION 1
Introduction. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
1-1 Installation Precautions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2
1-2 Confirming Package Contents . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5
1-3 Product Availability. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6
SECTION 2
Installation and Connections . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7
2-1 Basic System Configuration . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8
2-2 Component Names and Functions. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10
2-3 Mounting the Controller . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11
2-4 Connecting Peripheral Devices . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15
2-5 Overview of Available Cameras . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16
2-6 Power Supply and Ground. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 18
SECTION 3
Lenses, Lighting, and Memory Cards. . . . . . . . . . . . . . . . . . . . 21
3-1 CCTV Lenses. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 22
3-2 Lighting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 24
3-3 Memory Card. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 26
SECTION 4
Connecting External Devices. . . . . . . . . . . . . . . . . . . . . . . . . . . 29
4-1 Connecting through the Parallel Interface. . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30
4-2 Connecting through the Serial Interface . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 34
SECTION 5
Troubleshooting and Maintenance . . . . . . . . . . . . . . . . . . . . . . 39
5-1 Troubleshooting. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40
5-2 Maintenance. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 41
5-3 Regular Inspections . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 44
5-4 Specifications. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 45
5-5 F200/F300 Camera Parameters . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 63
5-6 Connecting a Strobe Device . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 64
Index. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 67
Revision History . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 69

ix
About this Manual:
This manual describes the hardware for the F160 Vision Sensor and how to install the com-
ponents, and it includes the sections described below. This is one of four manuals used to
operate the F160. Refer to the following table for the contents of each manual.
Please read the above manuals carefully and be sure you understand the information pro-
vided before attempting to install or operate the F160.
Section 1 Introduction describes the precautions that must be taken when installing and
operating the F160 Vision Sensor.
Section 2 Installation and Connections shows a basic F160 system configuration and
explains how to install the F160 and connect it to a power supply and peripheral devices.
Section 3 Lenses, Lighting, and Memory Cards describes how to select and use these
components most effectively.
Section 4 Connecting External Devices describes how to connect external devices
through a parallel interface (the I/O terminals or I/O connector) or serial interface (the RS-
232C/RS-422 connector).
Section 5 Troubleshooting and Maintenance provides tables to help identify and correct
hardware errors that may occur with the F160 as well as information on maintenance and
periodic inspections.
Manual Contents Cat. No.
1:Setup Manual Provides information on system hardware and installation.
Be sure to read this manual first. Z144
2:Conversational
Menu Operation
Manual
Describes operation of the F160 using the Conversational
Menus. The Conversational Menus enable the simplest oper-
ation based on registered images of acceptable and unac-
ceptable products.
Z145
3: Expert Menu
Operation Manual Describes operation of the F160 using the Expert Menus. The Expert Menu enable application of all F160 capabilities,
including setting region images and criteria.
Z147
4:Communications
Reference Man-
ual
Describes the communications settings and communications
protocol used to transfer data through the parallel interface or
serial interface.
Z146
!WARNING Failure to read and understand the information provided in this manual may result in per-
sonal injury or death, damage to the product, or product failure. Please read each section in
its entirety and be sure you understand the information provided in the section and related
sections before attempting any of the procedures or operations given.

xi
PRECAUTIONS
This section provides general precautions for using the F160 Vision Sensor.
The information contained in this section is important for the safe and reliable application of the F160
Vision Sensor. You must read this section and understand the information contained before attempting to
set up or operate an F160 Vision Sensor.
1 General Safety Precautions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . xii
2 Special or Critical Applications. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . xiii
3 Regulations and Standards. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . xiv

xii
General Safety Precautions 1
1 General Safety Precautions
Battery Precautions
!WARNING Do not disassemble the F160, apply pressure to the F160 that would deform
its shape, or incinerate the F160. A lithium battery is built into the F160 and it
may combust, explode, or burn if not treated properly.
!WARNING Do not short circuit, attempt to charge, disassemble, apply pressure that would
deform, or incinerate the lithium battery. The lithium battery may start a fire,
explode, or burn if not treated properly.
Installation Environment Precautions
!Caution Do not use the F160 in environments with flammable or explosive gases.
!Caution Install the F160 away from high-voltage devices and moving machinery to
allow safe access during operation and maintenance.
!Caution Do not block the F160’s cooling vents.
Before the F160 is shipped, a protective label is attached to the top of the
F160 to cover the cooling vents. This label prevents wire strands from falling
into the F160 during wiring, so it must not be removed until wiring is com-
pleted. The label must be removed after wiring to allow proper cooling during
operation.
!Caution Be sure to securely tighten the screws when mounting the F160.
Power Supply and Wiring Precautions
!Caution Use the F160 with the power supply voltages specified in this manual.
!Caution Use the wire and crimp terminals of the proper sizes as specified in this man-
ual. Do not connect the power supply wires by just twisting stranded wire and
connecting directly to the terminals.
!Caution Use a DC power supply with countermeasures against high-voltage spikes
(safe extra low-voltage circuits on the secondary side).
STEP
POWER
RUN
ERROR
RESET
COMIN
RUN
ERROR
BUSY
GATE
OR
DO15
PARALLEL
COMOUT
CONSOLE
CAMERA0
MONITOR
24VDC
1.2A
+
-
RS-232C/422
CAMERA1
F160
VISIONMATE
CONTROLLER
Cooling vents
Cooling vents

xiii
Special or Critical Applications 2
Note 1. Keep the power supply wires as short as possible.
2. Ground the F160’s ground terminal to less than 100 Ω.
3. Use a grounding point as close as possible to the F160 and keep the
ground line as short as possible.
4. Wire the F160 to the ground witha separate ground wire. To avoid ground-
ing problems, do not share the ground wiring with any other devices or
ground the F160 to the building’s steel framing/plumbing.
Other Precautions
!Caution Do not attempt to dismantle, repair, or modify the F160.
!Caution Do not touch fluorescent or halogen lights while the power is ON or immedi-
ately after the power is turned OFF. These lights get very hot and can cause
burns.
!Caution If you suspect an error or malfunction, stop using the F160 immediately, turn
OFF the power supply, and consult your OMRON representative.
Note Dispose of the F160 as industrial waste.
2 Special or Critical Applications
When the F160 will be used in one of the conditions or applications listed
below, allow extra safety margins in ratings and functions, add extra safety fea-
tures such as fail-safe systems, and consult your OMRON representative.
• Operating conditions or environments which are not described in the
manual
• Nuclear power control systems, railroad systems, aviation systems, vehi-
cles, combustion systems, medical equipment, amusement equipment, or
safety equipment
• Other systems, machines, and equipment that may have a serious influ-
ence on lives and property and require extra safety features

xiv
Regulations and Standards 3
3 Regulations and Standards
The F160 complies with the international regulations and standards below.
1. EU Regulations
EMC Directive: No. 89/336/EEC
2. EN Standards (European Standards)
EN 61000-6-2: 1999, EN 61326: 1993/Annex A+A1: 1998,
EN 50081-2: 1993/Class A

1
SECTION 1
Introduction
This section describes the precautions that must be taken when installing and operating the F160 Vision Sensor.
1-1 Installation Precautions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2
1-1-1 Controller Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2
1-1-2 Component Installation and Handling. . . . . . . . . . . . . . . . . . . . . . . . 3
1-2 Confirming Package Contents . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5
1-3 Product Availability. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6

2
Installation Precautions Section 1-1
1-1 Installation Precautions
The F160 is highly reliable and resistant to most environmental factors. The
following guidelines, however, must be followed to ensure reliability and opti-
mum use of the F160.
!Caution Read the Precautions section before proceeding with installation or operation.
1-1-1 Controller Installation
Installation Site Do not install the F160 in locations subject to the following conditions:
1,2,3... 1. Ambient temperatures outside of the 0 to 50°C (32 to 122°F) range
2. Rapid temperature fluctuations (likely to cause condensation)
3. Relative humidities outside of the 35% to 85% range
4. Presence of corrosive or flammable gases
5. Presence of dust, salt, or iron particles
6. Direct vibration or shock
7. Direct sunlight
8. Water, oil, or chemical fumes or spray
Orientation of Controller
To improve heat dissipation, install the Controller in the following orientation
only:
Do not install the Controller in the orientations shown in the following diagram.
STEP
POWER
RUN
ERROR
RESET
COMIN
RUN
ERROR
BUSY
GATE
OR
DO15
PARALLEL
COMOUT
CONSOLE
CAMERA0
MONITOR
24VDC
1.2A
+
-
RS-232C/422
CAMERA 1
F160
VISIONMATE
CONTROLLER
CORRECT
STEP
POWER
RUN
ERROR
RESET
COMIN
RUN
ERROR
BUSY
GATE
OR
DO15
PARALLEL
MEMORYCARD
COMOUT
CONSOLE
CAMERA0
MONITOR
24VDC
1.2A
+
-
RS-232C/422
CAMERA1
F160
VISIONMATE
CONTROLLER
INCORRECT

3
Installation Precautions Section 1-1
Ambient Temperature
1,2,3... 1. Maintain a minimum clearance of 50 mm above and below the F160 to im-
prove air circulation.
2. Do not install the F160 immediately above significant heat sources, such
as heaters, transformers, or large-capacity resistors.
3. Do not let the ambient operating temperature exceed 50°C (122°F).
4. Provide a forced-air fan cooling or air conditioning if the ambient tempera-
ture is near 50°C (122°F) so that the ambient temperature never exceeds
50°C (122°F).
Noise Resistance Use the following measures to help increase noise resistance.
1,2,3... 1. Do not install the F160 in a cabinet containing high-voltage equipment.
2. Do not install the F160 within 200 mm of power cables.
1-1-2 Component Installation and Handling
OMRON ComponentsUse a Camera, Camera Cable, and Console designed specifically for the
F160.
Connecting Cables Always turn OFF the F160’s power before connecting or disconnecting a cam-
era or cable.
Handling the CameraThe Camera’s case is connected to the 0V line in the internal circuits. Observe
the following precautions to prevent noise interference.
1,2,3... 1. Do not ground the Camera.
2. Do not remove the base attached to the Camera.
3. Do not remove the core attached to the F150-VS Camera Cable.
Control panel
F160
Louver
F160
200 mm min.
200 mm min.
Power cable

4
Installation Precautions Section 1-1
Securing the Video Monitor (When Using the Recommended F150-M09)
Observe the following precautions to prevent noise interference, because the
video monitor case is connected to the 0V line in the internal circuits.
1,2,3... 1. Do not ground the video monitor.
2. Do not ground the metallic part of the connector.
3. Secure the video monitor with plastic screws if it is being mounted to a me-
tallic surface.
Touching Signal Lines
To prevent damage from static electricity, use a wrist strap or another device
for preventing electrostatic discharges when touching terminals or signal lines
in connectors.
Removing the Memory Card
Before removing a Memory Card, stop the power supply to the Card or turn
OFF the F160. The Memory Card or the F160 itself may be damaged if a
Memory Card is removed while power is being supplied.
(Stop the power supply to the Memory Card from the menu.)
Turning OFF the Power
Do not turn OFF the power while a message is being displayed indicating that
processing is being performed. Data in memory will be corrupted, and the
F160 may not operate correctly the next time it is started.
Using the RESET Signal
Do not use the RESET input immediately after power is turned ON. When
using the RESET input to synchronize startup timing, wait at least 1 second
after the F160’s power supply is turned ON before turning ON the RESET sig-
nal.
Saving data.
---- ---ms
0.Scn 0 MON

5
Confirming Package Contents Section 1-2
1-2 Confirming Package Contents
Check the contents of the package as soon as you receive the F160. It is
extremely rare for components to be missing, but contact the nearest OMRON
representative if any of the following items are missing.
1,2,3... 1. F160 Vision Mate Controller Qty.: 1
2. Mounting Bracket (for rear surface mounting)
3. Connector for I/O Terminals Qty.: 1
(Phoenix Contact model MC1.5/10-STF-3.5)
4. Ferrite Core for F150-VM Monitor Cable Qty.: 1
5. Setup Manual (this manual) Qty.: 1
6. Conversational Menu Operation Manual Qty.: 1
7. Expert Menu Operation Manual Qty.: 1
8. Communications Reference Qty.: 1
STEP
POWER
RUN
ERROR
RESET
COMIN
RUN
ERROR
BUSY
GATE
OR
DO15
PARALLEL
COMOUT
CONSOLE
CAMERA0
MONITOR
24VDC
1.2A
+
-
RS-232C/422
CAMERA1
F160
VISIONMATE
CONTROLLER
Bracket: Qty: 1
Screws (M3 x 6): Qty: 4

6
Product Availability Section 1-3
1-3 Product Availability
Some of the products listed may not be available in some countries. Please
contact your nearest OMRON sales office by referring to the addresses pro-
vided at the back of this manual.

7
SECTION 2
Installation and Connections
This section shows a basic F160 system configuration and explains how to install and wire the F160.
2-1 Basic System Configuration . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8
2-2 Component Names and Functions. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10
2-3 Mounting the Controller . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11
2-3-1 DIN Track Mounting. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11
2-3-2 Rear Surface-mounting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12
2-3-3 Side Surface-mounting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14
2-3-4 Bottom Surface-mounting. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15
2-4 Connecting Peripheral Devices . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15
2-4-1 Connecting a Console . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16
2-4-2 Connecting a Monitor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16
2-4-3 Connecting a Camera . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16
2-5 Overview of Available Cameras . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16
2-6 Power Supply and Ground. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 18
2-6-1 Crimp Terminals and Cables. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 18
2-6-2 Ground (Earth) Wiring . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 18
2-6-3 Wiring the Power Supply . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 19