Boa
Boa
Boa
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INSTALLATION MANUAL
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Notice
BOA Vision System Installation Manual Document Number 405-00025-00 Revision: 06 Copyright 2011 Teledyne DALSA Corporation. All rights reserved. All copyrights in this manual, and the hardware and software described in it, are the exclusive property of Teledyne DALSA Corporation and its licensors. Claim of copyright does not imply waiver of Teledyne DALSA Corporation or its licensors other rights in the work. See the following Notice of Proprietary Rights. NOTICE OF PROPRIETARY RIGHTS This manual and the related hardware and software are confidential trade secrets and the property of Teledyne DALSA Corporation and its licensors. Use, examination, reproduction, copying, transfer and/or disclosure to others of all or any part of this manual and the related documentation are prohibited except with the express written consent of DALSA Corporation. The information in this document is subject to change without notice. Teledyne DALSA Corporation makes no representations or warranties with respect to the contents of this manual and specifically disclaims any implied warranties of merchantability or fitness for a particular purpose. Teledyne DALSA Corporation assumes no responsibility for errors or omissions in this document. iNspect, Sherlock, and the DALSA logo are trademarks of Teledyne DALSA Corporation. All other trademarks are the property of their respective owners. Teledyne DALSA Industrial Products Information: info.ipd@teledynedalsa.com Support: support.ipd@teledynedalsa.com Web: http://www.teledynedalsa.com/ipd 700 Technology Park Drive Billerica, MA, USA 01821 Tel 1.978.670.2002 Fax 1.978.670.2010
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Certifications
Declaration of Conformity Manufacturer Teledyne DALSA Corporation 605 McMurray Road Waterloo N2V 2E9 Ontario, Canada We declare that this product has been tested to comply with the EC Directive for a class A digital device in accordance with EN55022/CISPR22 We declare that this product has been tested and found to comply with the limits for a class A digital device, pursuant to Part 15 of the FCC rules. These limits are designed to provide reasonable protection against harmful interference in a residential installation. This equipment generates, uses and can radiate radio frequency energy and may cause harmful interference to radio communication.
CE
FCC
Other IP67 This product meets the requirements for industrial applications that require IP67 wash down protection - requires fitted sealing lens cover and sealing plugs on unused connectors This product provides the tools needed for users to implement an auditing program that could be in compliance with CFR 21 Part 11. These tools include: System or software backup and restore System software security (password login and access limits) Protection of system backup files from modification. Record of actions by users with time stamp information Time stamp information on data output.
CFR 21 Part 11
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Handling Precautions
Care should always be exercised when handling and operating your BOA Vision System. Even though the system is encased within a rugged, industrial enclosure, incorrect use or handling can result in damage to your investment. To prevent this, we recommend you avoid the following: Hot-plugging cables and devices. Be sure to shut the system down and remove power before connecting or disconnecting anything to it. Free-standing operation. It is advisable to mount the system properly to prevent it from falling accidentally. Mounting holes are provided on each side of the system. Operating the system in an environment outside of its recommended operating conditions.
Warranty
Teledyne DALSA warrants the BOA Vision System against defects in materials and workmanship for a period of twenty four (24) months from the date of delivery. DALSA and its representatives expressly disclaim any and all other warranties. Your sole remedy shall be repair or replacement of the BOA Vision System product and associated optional components, provided that the defective product is returned within the warranty period. If you need to return the BOA Vision System, you must contact the Teledyne DALSA representative who sold you the product. Do not return your product to Teledyne DALSA without prior authorization. Teledyne DALSA assumes no liability for damages resulting from the use of this manual.
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Table Of Contents
Introduction
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6 6 7 8 9 10 10 11 12 13 14 15 16 17 18 19 20 21 22 23 24 25 26
Installation
Connections Cable Pinouts Cable Configurations Panel Link Module Ethernet Only Setup Ethernet and I/O Setup
Software
Getting Started iDiscover Utility BOA Web Server Firmware Updating The BOA Emulator
Specifications
General Specifications Input Specifications Output Specifications Output Control Panel Link Specification Panel link Wiring Serial Port Connection BOA Mechanicals PL-100 Mechanicals
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Introduction
BOA Vision System Overview
BOA is a fully integrated vision system in a compact smart camera format that has been specifically designed for industrial use. Packaged complete with application software embedded, BOA provides an easy-to-deploy automated inspection system for the factory floor. BOA vision systems are configured and monitored remotely using an Ethernet connection to a PC or factory network. An inspection can be quickly setup using a web browser portal into the resident iNspect application. The software interface is fully equipped with a suite of vision tools and capabilities that satisfy a range of inspection needs, from positioning, identification and measuring, to verification and flaw detection. BOA vision systems are small, rugged devices that can be easily integrated into existing production lines, machinery or moving equipment. They are supported by standard industrial M12 cordsets to further simplify and reduce implementation costs. Rated for IP67 deployment when fitted with a compatible lens cover, BOA systems can be mounted in wash down factory environments without the need for additional protective enclosures. For a complete list of specifications, refer to Specifications on page 18.
Product Support
In addition to this installation manual, the following information ships with the product: 1. 2. 3. 4. 5. Online help: Fingertip help is available on every screen (panel) of the iNspect User Interface The iNspect User Manual is included on the CD that ships with the product Self help material and sample job files are included on the CD Factory support is available at support.ipd@teledynedalsa.com Call, fax or email your local representative who sold you the product
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CD including PC emulation software and associated product manuals. M4 screws for mounting the sensor (Qty 4)
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Installation
Connecting the BOA Vision System This section details how to connect the BOA vision system with its associated components and factory environment. Camera Connectors and Indicators
Designator
LAN
Definitions
10/100 BaseT Ethernet connection. Provides the primary interface for configuring the camera, developing the application and monitoring results. NOTE: The camera can be powered from the Ethernet cable directly (Passive Power over Ethernet) Provides access to the camera I/O 2 IN, 2 OUT Opto. Also provides PWR input (12-30V). Provides PWR and strobe control to a local LED light source. NOTE: Lamp PWR is identical to BOA PWR input. The camera should be powered from a 12V PWR source if the light requires a 12V supply (Recommend 24V supply) Red/Green/Yellow = Network activity Blue = Warm Reset Green = Inspection Pass (runtime) Blue blink = Booting (should stop after 20 seconds) Blue = Inspection Recycle (runtime); Red = Inspection Fail (Runtime) Blue Solid = Camera booted, not configured Green blink = Solution loaded, acquisition in process Green Solid = Solution loaded Red = Camera Fault
LED1
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Cable Pinouts
The BOA vision system is compatible with M12 factory cordsets as show below: LAN Connector Pinout and Cordset
Pin 1 2 3 4 5 6 7 8 Name PWR * NC GND * TXDRXD+ TXD+ NC RXDRJ45 Pin 5 7 8 2 3 1 4 6
A-CAB-BVS-E8S-X
A-CAB-BVS-IO8S-X
A-CAB-BVS-L5S-X
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Cable Configurations
The BOA vision system offers flexible cabling options to suit a number of application configurations: 1. For single cable applications, the Ethernet cable can be used to supply power (referred to as Passive Power over Ethernet) and communications between the camera and the control environment. Power is supplied by connecting a DC voltage source between 12-30V to conductors 4 (pwr) and 8 (gnd) on the Ethernet RJ45 connector. Note: The PL-100 module does this automatically. In this configuration, the camera I/O is unavailable. For single cable applications that do not require a runtime Ethernet connection, the I/O-PWR cable provides limited communications and power between the camera and the control environment. Note: Ethernet is still required for setup. For typical applications, both the Ethernet and I/O-PWR cables are connected to provide flexibility between the camera and the control environment. In this configuration, either or both cables can supply power provided they come from the same power source. Do not connect different power sources to the BOA camera connectors. In all configurations, the Lamp cable can be connected between the camera and a compatible LED light source. The BOA vision system supplies power and strobe control to the external light. Power is routed from camera power input to the lamp.
2.
3.
4.
BEWARE: Connecting a voltage on pin 1 of the lamp connector that is lower than the input power voltage to BOA could result in damage to the camera!!
A-BVS-PL-100
NOTE: The BOA vision system does not support the IEEE 802.3af standard Power over Ethernet (PoE) and should not be directly connected to a PoE supported router.
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A-BVS-PL-100 A-BVS-E8S-X
Cat5 Cable
BOA System
LED Lamp
A-BVS-L5S-X
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A-BVS-PL-100
A-BVS-E8S-X A-BVS-IO8S-X
Cat5 Cable
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12
Software Interface
Getting Started
The BOA vision system is supplied with the iNspect vision application embedded. This application offers a suite of vision capabilities to satisfy a diverse range of automated inspection needs. The application interface is accessed through the Ethernet connection using a PC with Microsoft Internet Explorer 6 or higher. You do not need to install software on your host system to setup or operate the BOA system. Take note of the following before attempting to access the application: 1. 2. BOA vision systems are preconfigured with a default static IP address of 192.168.0.100 The PC used to access BOA initially will need to be configured on the same network neighborhood, but with a different address (i.e. 192.168.0.101). Consult your system administrator for instructions on how to do this. The subnet mask should be set automatically to 255.255.255.0 This static IP address can be changed at any time through the BOA web server interface to match your Local Area Network. Click on the Setup Device hot link to change the network address. Remember to keep a record of what the new address is set to. BOA supports both DHCP and Static IP addressing (preferred since the address does not change). NOTE: A power cycle is required before the new address will take effect. 4. If you incorrectly set, or forgot, the new address of your BOA, you can run the iDiscover utility. This program is installed automatically when you click on the iNspect Express or upgrade hot links in the web server interface. This program is also on the iNspect emulator CD that ships with the system. In most cases you will need administrator privileges on your PC to access BOA. It may be necessary to customize the security settings on your browser to download and run ActiveX controls. If for any reason you can not access BOA from your internet browser, you can install the emulator application from the shipping CD and connect to the camera through this interface. This step is explained in more detail later in the manual. BOA is compatible with host computers running the Windows XP operating system. BOA has also been verified on the new Windows 7 O/S. NOTE: See document on CD Configuring Windows for BOA
3.
5.
6.
7.
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iDiscover Utility
The iDiscover utility is provided for discovering BOA cameras connected to the local PC network. iDiscover is installed on the host system when a BOA camera is first connected. It is also installed as part of the emulator installation. The iDiscover program can be launched in one of two ways: 1. If the connecting PC has previously been used to interface a BOA camera, then the iDiscover program resides in the windows System32 directory. To invoke, open the command prompt (Start programs -> Run), type iDiscover and click OK If the connecting PC has not previously been used to interface a BOA camera, you must first install the iNspect software emulator. Once installed, the program can be invoked from the iDiscover shortcut (Start programs -> IPD iNspect -> Discover BOA Cameras).
2.
Once launched the GUI below will be shown. The left panel shows the MAC addresses of all reachable BOA cameras. Click on one of these to populate the associated network configuration on the right. You can then modify the BOA IP address (click Apply) or connect to the associated camera (click Connect To Device).
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4.
The web server provides a quick snapshot of the state of the camera and provides controls for language selection, IP address setup, firmware upgrading and image backup or restore. The web server is the portal into the inspect application and can be set up to prevent unauthorized access. Click on the iNspect Express hot link to launch the application. The camera will automatically install some software components on the host PC when it connects for the first time. These components set up the remote access to the device. Using the iNspect software (refer to the iNspect Express users manual), set up an application and store the solution on the camera. Exit the application and return to the web server interface. The History Log hot link offers a quick and convenient way to view and store inspection results to an Excel spreadsheet on your host PC. This feature is also available from within the iNspect application using the scripting tool.
5.
6.
7.
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When the application is set up and stored on the camera, the Ethernet connection can be disconnected and the inspection will run autonomously. The camera can easily store over 500 solutions in its flash storage memory. These solutions can be switched through network commands, or through established PLC register connections or through the iNspect application interface. The camera administrator can setup user accounts with various levels of access privilege. With password control enabled, the web server will prompt users for a valid login and the application will only expose controls associated with that account.
Firmware Upgrading
BOA firmware may need to be updated occasionally to add new features or fix reported problems. To do this, click on the Upgrade Device hotlink to launch the upgrade control. To upgrade, simply browse to the location of the upgrade binary file (obtain from your DALSA representative) on the connected PC and click the upgrade button. Note: Export your saved solution files before upgrading the firmware. The upgrade control also supports backup and restore of the entire camera image. This is useful for safekeeping and camera replication. We highly recommend exporting solutions after any modification. After a firmware upgrade, it is recommended that the connecting PC be cleaned of old or stale components associated with the previous firmware. To do this, go to the windows command prompt and enter the iAssistant and click go. When the application launches, click the Clean button.
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Note 1: When you access BOA through this interface, it is important that you maintain version compatibility between the camera and the emulator. Note 2: Some shortcuts and programs are only available with versions 1700 or above
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Specifications
General Specifications
This following table lists the specifications of the BOA vision system:
Specification Memory Image Storage Sensor Resolution Type Exposure Acquisition Lens I/O Trigger Definition 256 MB Storage; 256MB Program 1/3 inch CCD; 7.4 m pixel size 640x480 Mono or Color Progressive Scan 22 us to 1000 ms Async Reset, full-frame integration, 60f/s (application dependent) C Mount 1 opto-isolated hardware trigger input Software trigger via Ethernet or internal timer Inputs 1 General purpose opto-isolated. Expandable via Ethernet I/O module Outputs 2 General purpose opto-isolated Expandable via Ethernet I/O module Strobe Status Network Serial Power Ethernet RS232 12-30V Device Lamp Mechanical Material Mounting Size Environment Temp Protection Shock Certification 1 dedicated strobe output for LED light source Network + 2 application assigned LEDs 10/100 BaseT 1 Port flying leads on lamp connector Via Ethernet or IO connectors (not PoE compliant) 150 mA maximum @ 24V (3.6 Watts) 1A maximum (BOA powering light source directly) Machined Aluminum with anodize/paint finish 8 x M4 plus optional mounting block 44mm x 44mm x 56mm (without lens cover) -10C (14F) to 50C (122F) Operating (-60C to 80C) Storage IP67 with cables attached 70 G FCC Class A and EU CE
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Input Specifications
The BOA vision system provides two dedicated opto-isolated, polarity independent inputs. One of the inputs provides the acquisition Trigger function, while the other is general purpose.
Specification Voltage ON OFF Current Protection ON Resistance Isolation Common pin Switch Time Input ON OFF Latency Trigger Definition 12-30 V 0-3 V (12 V nominal threshold) 7.5 mA typ (24 V applied) 3K Ohms 4000 V RMS PWR or GND 10 Microsecond 50 Microseconds 62 Microseconds from trigger input to start of acquisition
The active polarity of each input is configured in the iNspect application. The camera includes a noise filter on the input which is also configurable. To connect with an NPN source, connect the camera trigger input (pin 1) to the NPN source output and the camera common input (pin 5) to PWR. When the source output turns ON, the camera input will be pulled down turning the opto-coupler ON. To connect with an PNP source, connect the camera trigger input (pin 1) to the PNP source output and the camera common input (pin 5) to GND. When the source output turns ON, the camera input will be pulled up turning the opto-coupler ON. Input Diagram
NPN Wiring
PNP Wiring
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Output Specifications
The BOA vision system provides two dedicated opto-isolated, solid state relay outputs and a separate dedicated light strobe (pin 2 of lamp connector).
Specification Voltage (Vin) Current Load GPO[0:1] STRB Protection Common pin Switch Time Fuse Out ON OFF Definition 24V maximum 100mA max (drives to OCMN when active) 100mA max (drives to Vin when active) NOTE: Strobe timing selected in iNspect Sensor Panel PTC fuses to 100mA (GPO) & 100mA (STRB) PWR or GND 10 Microsecond 50 Microseconds
The active polarity of each output is configured in the iNspect application as detailed on the following page. To connect with an NPN input source, connect the camera output (pin 4 or 6) to the NPN source input and the camera common output (pin 8) to GND. When the camera output turns ON, the opto switch closes and OUTX = 0 (current flows through load) To connect with an PNP input source, connect the camera output (pin 4 or 6) to the PNP source input and the camera common output (pin 8) to PWR. When the camera output turns ON, the opto switch closes and OUTX = output common. Output Diagram
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Each BOA output can be configured by an equation in the script tool or a programmable pulse based the inspection result (either Pass, Fail or Recycle): Script Setting: Use the script tool to configure an output to provide a programmable level or a pulse based on the application need (Note: the GUI pulse settings are disabled in this mode shown as dark gray above). Script selection is nondeterministic, meaning the output timing may vary if the processor is heavily loaded. This may occur, for example, when the trigger and inspection times are close and BOA is serving images to a connected PC. Example: A script equation that generates an active high 10ms pulse based on a PASS result would be: If (Result = 1) Global.GPO[0] = pulse( 1, 0 , 10) Pulse Setting: This mode offers a deterministic output with an offset and duration synchronized to the incoming trigger. In this mode, the output will pulse IF the result is TRUE and the total inspection time is less than the pulse offset from the trigger. If the pulse offset is too short, BOA will not generate a pass pulse even if the inspection passes. In this case, BOA will always generate a FAIL pulse if FAIL is selected on the second output. This would result in false rejects if the output is being used to control a directional device. Min Pulse Offset = Exposure Time + Acquisition Time + Inspection Time Example: Pulse 10ms on GPO0 for a PASS result OR pulse 30ms on GPO1 for a FAIL result. Sensor exposure time is 9ms, acquisition time is ~16ms and inspection time is ~35ms. Minimum Pulse Offset = 9+16+35=60ms. IF the minimum offset is satisfied, BOA will output a PASS pulse on a good result, ELSE BOA will output a FAIL pulse instead. The duration of the pulse is not significant in this decision. However, setting the pulse longer than the trigger period is not advised. Max pulse duration is 64ms. Note: Processing overhead can also affect the minimum pulse offset requirement. It is good practice to calibrate this time based on your typical expected usage of the system (i.e. inspection time overhead + system access overhead)
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Definition 24V maximum 100mA max PTC fuses to 100mA (GPO) PWR or GND as wired on respective OPTOs 100 Microsecond (ON or OFF)
GPO[0:1]
Ethernet connection to PC
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To BOA
24V GND NC OUT0 OCMN OUT1
PL-100
IN0TRGGND 24V
24V GND TRG+ TRGIN0+ IN0-
To Control Panel
OU0+
OU0-
OU1+
OU1-
NC
ERTH
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These port settings can be changed through the GUI by configuring the RS232 Stream Settings in the Setup Control panel. Refer to the iNspect Express user manual for details. RS-232 Hardware Configuration Electrically, three (3) signals are required to make a serial port connection between BOA and another device as shown below. RS232 is a point-to-point connection, so the Receive and Transmit lines must be crossed in the cable. BOA LAMP M12-5 Connector
Pin 2 3 5 1,4 Name RS232 RX GND RS232 TX Not required Color White Blue Yellow
Note: It is important to establish a common ground between BOA and the connecting 3rd party device.
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Side View
Bottom View
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Side View
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