Sensopart FZS 1024 User manual

Line Sensor
FZS 1024
Manual

SensoPart Industriesensorik GmbH, Am Wiedenbach 1, D-79695 Wieden,
Telphone (0 76 73) 8 21-0, Telefax (0 76 73) 8 21-30
E68-12804 07/00 Printed in Germany
Line Sensor
FZS 1024
Manual

1. Introduction 1-1
1.1 Detection range 1-1
1.2 Dynamic processes 1-2
2. Lens assembly 2-1
3. Equipment assembly 3-1
3.1 For transmitted light mode 3-1
3.2 For incident light mode 3-2
4. Connection 4-1
5. Putting into operation 5-1
5.1 For transmitted light mode 5-1
5.2 For incident ligth mode 5-4
6. If something does not work 6-1
7. Oscillograph intensity profile 7-1
8. Protective tube 8-1
9. Cleaning 9-1
Appendix
A Intermediate ring dimension and working distance A-1
B Operating and adjustment modes B-1
C Exposure time measuring repetition rate C-1
D Function indicator and message output D-1
E Assembly aids E-1
F Technical data F-1
G Connector pin assignment IN/OUT G-1
H Connecting cable D7 H-1
I Ordering data I-1
J Lightings J-1
Contents

14.3mm (1024 pixels x 14µm)
a
b/2
s
tan a/2a/2
a/2a/2
a/2 =
FZS 1024 1. Introduction 1-1
1. Introduction
The line sensor is used for the optical detection of edges for identification and process
monitoring.
The illuminated object level is projected onto a light-sensitive line (CCD line, Charge
Coupled Device) with a camera lens. Detected edges are filtered by the selectable
signal decoding. The position of the selected edge(s) is available as a current or
voltage value at the analog output.
The focal length of the lens and the distance between the device and the object plane
determine the measuring accuracy. The f-stop setting can be used to adapt to lighting
conditions.
On our website www.sensopart.com you can download a program which helps you to
select the right accessories.
1.1 Detection Range
image plane
working distance simage width
detection width b
Detection width:
The range of the object plane projected onto the CCD line. The detection width b
depends on the aperture a of the lens and the working distance s.
Resolution:
In the image plane, the smallest detectable measured value difference is one pixel
(14µm). In the object plane the resolution a 1024th of the detection range. Objects are
therefore resolved with 0.1% of the detection width.
detection range
object plane

1-2 1. Introduction FZS 1024
b1
b2
bt
Uout
Umax
U1
U2
v = 140m/min
v : transport speed
b : detection width
bi : measured length
Idealized time behaviour of the
measuring voltage Uout of the line sensor
20mm
20mm
Line Sensor FZS 1024
1.2 Dynamic Processes
The resolution of objects moving in advance direction is determined by the exposure
time of the line sensor.
The exposure time is the time after which the readout procedure of the CCD line is
repeated.
Example:
As shown in the diagram, a toothing is to be checked for completeness. At a transport
speed of 140 m/min, the tooth and gap can only be detected reliably when the distance
covered during a readout process of the CCD line is smaller than 20 mm. The exposure
time must then be smaller than 8.6 ms.

FZS 1024 2. Lens Assembly 2-1
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Z2 Z3Z1
Z4 Z5
Intermediate ring dimension Z: = Z1 + Z2 + Z3 + Z4 + Z5
2. Lens Assembly
Line sensor, lens and any necessary intermediate rings are packed separately. Make
sure first that you have all the components you require for your application.
Assembly includes the following steps:
1. Pull out the sealing plug from the line sensor.
2. Check that the CCD line is clean and dust-free.
To do this, wipe the glass of the line with a soft, dry cloth or a cotton
wool bud. Make sure no grease film or lint or even scratches are left
behind.
3. Remove the protective cap from the lens on the device side.
Unscrew the intermediate rings with thread if available. Rings without
thread are placed between the screwed rings.
4. Screw the lens onto the line sensor with intermediate rings.

line sensor
detection range
3-1 3. Equipment Assembly FZS 1024
working distance
reading direction
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fluorescent tube
intensity
site
intensity profile
of the CCD line
3. Equipment Assembly
The light-sensitive line is arranged in the direction in which the rear panel labelling can
be read. The position of the equipment and the lighting must therefore be adapted to
the task at hand.
3.1 For Transmitted Light Mode
1. Select the working distance
Maximum working distance:
Given by the required resolution in the detection width
Minimum working distance:
Given by the minimum lens distance of the MOD lens
(including intermediate rings)
2. Pre-assembly of the line sensor at the selected working distance.
detection width

intensity
reading direction
line sensor
FZS 1024 3. Equipment Assembly 3-2
detection width
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fluorescent
tube
!
3. Pre-assembly of the lighting
Maximum distance:
Given by the angle of detection and the maximum useful length of the lighting. This
corresponds to approx. 70% of the tube length for fluorescent tubes on account of the
diminishing intensity towards the end of the tube.
Minimum distance:
Given by the working distance
Please note:
- The lighting must be parallel to the line and ideally symmetrical in the
detection range.
- The tube manufacturer’s labelling must be outside the detection range
or set back.
3.2 For Incident Light Mode
detection range
working distance

3-3 3. Equipment Assembly FZS 1024
diffuse reflection targeted
reflection
1. Select the working distance
Maximum working distance:
Given by the required resolution in the detection width
Minimum working distance:
Given by the minimum lens distance of the MOD lens
(including intermediate rings) and the necessary arrangement with lighting.
2. Pre-assembly of the line sensor and the lighting
For incident light mode, the operational reliability of the setup depends on the
position
of the lighting and line sensor in relation to the object level.
The light-sensitive line must always be parallel to the object plane.
If you are using a fluorescent tube for lighting you will get a targeted reflection. The
proportion of the targeted reflection depends on the surface nature of the object. It is
greater, the stronger the object reflects (e.g. painted surfaces, foils).
Avoid evaluating targeted reflections! Select a setup in which largely diffuse reflection
reaches the line sensor. Although this requires a smaller f-stop number and a longer
exposure time under some circumstances, the setup is less sensitive.
working distance

FZS 1024 4. Connection 4-1
!
4. Connection
Please note:
- The line lengths between the tubes and the ballast may not be longer than 1 m if the
ballast is mounted separately from the fluorescent tube for a tube lighting.
- The connecting cable of the line sensor must be laid separately from the lines to the
fluorescent tubes.

5-1 5. Putting Into Operation FZS 1024
5. Putting Into Operation
If you use a fluorescent tube for lighting, this must have been in operation for at least
three minutes before the line sensor is put into operation. The fluorescent tube reaches
its stable operating state in this time.
5.1 For Transmitted Light Mode
1. Remove the protective cap from the lens.
2. Remove the switch cover on the back of the unit.
3. Set the minimum exposure time by turning the Exposure Time switch to the
0 position (cf. appendix C).
4. Mode 7, „Setting“:
Set mode 7 by turning the mode switch to position 7 or by applying High signal to
the digital input (plug pin 5).
5. Set f-stop 4 on the lens.
S ENSO P ART
modes, exposure time
connection, 7-pole
FZS 1024
Function
Mode ExposureTime
IN/OUT RS485
display, 40 LEDs
switch cover
function indicator

Position of the
CCD line
FZS 1024 5. Putting Into Operation 5-2
6. Aligning the arrangement
The lighting and line sensor are positioned correctly when the free part of the
lighting is shown and indicated on the display. If this is not the case, the lighting
and the light sensitive line are not parallel. The arrangement must be adjusted.
The position of the detection width and the subsequent correction to the lighting or
line sensor can be determined by a test object (any non-transparent object).
Display in mode 7:
The left third of the CCD line
is not lit
If there is no display, you have to increase the exposure time at the smallest
f-number until the function indicator lights up in orange. The maximum possible
exposure time for the application is given by the necessary minimum measuring
repetition rate (cf. Appendix C).
7. Correction of the f-stop until the function indictor changes from orange to green.
8. Check the position of the detection range and mount the arrangement
permanently.
9. Position the object at the working distance if you have not already done so.
10. Mode 6, set „Focussing“
- The digital input (plug pin 5) must be switched to High level here.
- The function indicator must light green. If it is red, no adequate contrast is
available for the focussing mode, the f-stop must be adjusted in mode 7.
- The first body edge detected by the line sensor is checked for focus. The
narrower the display the sharper the edge is projected.

5-3 5. Putting Into Operation FZS 1024
11. Checking the choice of intermediate rings
Intermediate rings are required at a working distance below the minimum object
distance (MOD) specified by the lens. The necessary intermediate ring dimension
and the recommended intermediate rings can be taken from the tables in
appendix A.
Check the intermediate ring dimension given by the available intermediate rings, if
applicable, by turning the focussing ring of the lens from infinite to MOD. Watch
the display:
a) The display lights up along the full length
-> The working distance is not in the focussable working range. The
intermediate ring dimension must be adapted to the working distance
(cf. appendix A).
b) The bar only gets smaller
-> The intermediate ring dimension must be increased
c) The bar only gets bigger
-> The intermediate ring dimension must be reduced
d) The display runs through a minimum
-> The choice of intermediate rings is correct
12. Focus by turning the lens focussing ring to minimum display
13. Check the f-stop setting
In lenses with a long focal length in particular, the aperture ratios of the lens are
influenced by the lens position and the position of the focussing ring. The f-stop
setting therefore needs to be checked after focussing.
Switch to mode 7 (on mode switch or High to input) and check the f-stop setting.
The setting is correct when the function indicator lights green.
14. Set the operating mode (cf. appendix B)
15. Screw on the switch cover

FZS 1024 5. Putting Into Operation 5-4
5.2 For Incident Light Mode
1. Remove the lens cap
2. Remove the switch cover on the back of the unit
3. Set the max. exposure time by turning the Exposure Time switch to position 7
(cf. appendix C)
4. Mode 7, „Setting“:
Set mode 7 by turning the mode switch to position 7 or applying High signal to the
digital input (plug pin 5)
5. Set lens f-stop for green function indicator
6. Align the arrangement
The position of the lighting and the line sensor determine the detectable and
displayable edges. Optimize the arrangement set up in pre-assembly.
7. Secure the position of the line sensor
8. Set mode 6, „Focussing“
- The digital input (plug pin 5) must be switched to Low level here.
In mode 6 the function indicator must light up green. If it is red, the available
contrast is inadequate for displaying the state of focus in the display. You can
improve this by turning the focus ring. If you still do not get a green light we
recommend that you use a test object for the subsequent steps which enables
sufficient contrast thanks to its colour and the nature of its surface.
- When the function indicator is green, the first body edge detected by the line
sensor is examined for focus. The narrower the display, the sharper the edge is
projected.
9. Checking the choice of intermediate rings
Intermediate rings are required at a working distance below the minimum object
distance (MOD) specified by the lens. The necessary intermediate ring dimension
and the recommended intermediate rings can be taken from the tables in
appendix A.
Check the intermediate ring dimension given by the available intermediate rings, if
applicable, by turning the focussing ring of the lens from infinite to MOD. Watch
the display:

5-5 5. Putting Into Operation FZS 1024
a) The display lights up along the full length
-> The working distance is not in the focussable working range. The
intermediate ring dimension must be adapted to the working distance
(cf. appendix A).
b) The bar only gets smaller
-> The intermediate ring dimension must be increased
c) The bar only gets bigger
-> The intermediate ring dimension must be reduced
d) The display runs through a minimum
-> The choice of intermediate rings is correct
12. Focus by turning the lens focussing ring to minimum display.
13. Set mode 7
14. Set the maximum permissible exposure time.
The exposure time to be set is given by the required minimum measuring
repetition rate (cf. appendix C)
15. Correct the f-stop until the function indicator changes from orange to green. If the
intensity is inadequate at the required exposure time (red function indicator) you
will have to make corrections:
- Optimize the arrangement
- Increase the lighting efficiency
- Use a stronger lens
We recommend you to monitor appropriate measures by oscillographing the
intensity profile. The signal of the CCD line is available at pin 2 of the unit plug for
this purpose.
16. Secure the position of the lighting
17. Set the operating mode
18. Screw on the switch cover

FZS 1024 6. If Something Does Not Work 6-1
6. If Something Does Not Work
1. The unit reacts to an edge although there is no object in the detection range:
- dust on the line, clean the line
- inhomogeneities in the lighting
2. Insufficient focus
In transmitted light mode the edge of the body is projected out of focus due to
allround radiation of the object.
- increase the distance of the lighting from the object
- rounded edges (pipes, wire) cannot be set sharper
3. For partially transparent objects (foil, glass) the contrast is inadequate in transmitted
light mode
- use lighting with a higher absorbent wavelength (UV or IR)
4. In mode 7 the function indicator reacts oversensitively to f-stop adjustment
especially in transmitted light mode
- place a diffusor in front of the lighting (e.g. Delrin, 2 mm thick)
- use lens grey filter
- use a weaker lens
5. Modes 1...6 cannot be set
- High level at the digital input switches the unit to mode 7 and locks the „Mode“
switch. Low level releases the switch again.

7-1 6. Oscillographing the Intensity Profile FZS 1024
7. Oscillographing the Intensity Profile
Monitoring of the intensity profile of the CCD line can be of great advantage particularly
for critical tasks in incident light mode. The signal is available at pin 2 of the unit plug
for oscillographing.
Please note:
- The CCD signal may not be carried with the synchronisation signal on one line
- The CCD signal line should be as short as possible
- The synchronisation signal can be used for triggering
- The output is not designed for supplying loads
!

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Screw-on ring
FZS 1024
FZS 1024 8. Protective Tube 8-1
8. Protective Tube
The protective tube protects the tube accoring to protection class IP65.
In addition, it locks the setting on the lens.
It is delivered complete with O-ring for sealing the line sensor housing. The protective
glass is available as a spare part.
Protective tube 55: Tube length 55 mm, for lenses 1.8/12.5 and 1.8/25, incl. any
necessary intermediate rings
Protective tube 75: Tube length 75 mm, for lens 1.8/50, incl. any necessary
intermediate rings
Glass Tube O-ring
Flat seal

9-1 Cleaning FZS 1024
9. Cleaning
Use a cloth soaked in white spirit to clean the housing and the lens. Clean the lens
glass with a damp cotton wool bud only. Make sure you do not scratch the lens or leave
a film of grease on it.
Never clean the unit with organic solvents.
A protective tube is recommended to protect the lens from getting dirty. The plain
surface of the protective glass makes cleaning easier.
We recommend that you blow the protective glass with compressed air in a humid
environment or in the event of spray water.
!