In-Sight 5000 Series Vision System

Installation Manual

In-Sight 5000 Series Vision System Installation Manual

Legal Notices
The software described in this document is furnished under license, and may be used or copied only in accordance with the terms of such license and with the inclusion of the copyright notice shown on this page. Neither the software, this document, nor any copies thereof may be provided to, or otherwise made available to, anyone other than the licensee. Title to, and ownership of, this software remains with Cognex Corporation or its licensor. Cognex Corporation assumes no responsibility for the use or reliability of its software on equipment that is not supplied by Cognex Corporation. Cognex Corporation makes no warranties, either express or implied, regarding the described software, its merchantability, non-infringement or its fitness for any particular purpose. The information in this document is subject to change without notice and should not be construed as a commitment by Cognex Corporation. Cognex Corporation is not responsible for any errors that may be present in either this document or the associated software. Companies, names, and data used in examples herein are fictitious unless otherwise noted. No part of this document may be reproduced or transmitted in any form or by any means, electronic or mechanical, for any purpose, nor transferred to any other media or language without the written permission of Cognex Corporation. Cognex P/N 597-0027-06 Copyright 2003-2009 Cognex Corporation. All Rights Reserved. Portions of the hardware and software provided by Cognex may be covered by one or more of the U.S. and foreign patents listed below as well as pending U.S. and foreign patents. Such pending U.S. and foreign patents issued after the date of this document are listed on Cognex web site at http://www.cognex.com/patents. 5481712, 5742037, 5751853, 5845007, 5909504, 5943441, 5949905, 5960125, 5978080, 5978081, 6005978, 6137893, 6141033, 6154567, 6215915, 6236769, 6282328, 6301396, 6327393, 6381375, 6408109, 6457032, 6490600, 6563324, 6658145, 6690842, 6771808, 6804416, 6836567, 6850646, 6856698, 6859907, 6920241, 6941026, 6959112, 6963338, 6975764, 6985625, 6993192, 7006712, 7016539, 7043081, 7058225, 7065262, 7069499, 7088862, 7107519, 7164796, 7175090, 7181066, 7251366, JP 3927239 Cognex, In-Sight, VisionView and DVT are registered trademarks of Cognex Corporation. The Cognex logo, SmartLink, EdgeCount, FeatureCount, and ObjectLocate are trademarks of Cognex Corporation. Other product and company trademarks identified herein are the trademarks of their respective owners.

Legal Notices

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In-Sight 5000 Series Vision System Installation Manual

Regulations/Conformity
Note: For the most up-to-date regulations and conformity information, please refer to the In-Sight online support site: http://www.cognexsensors.com/In-Sight Declaration of Conformity
Manufacturer: Cognex Corporation One Vision Drive Natick, MA 01760 USA -marked Machine Vision System Product In-Sight 5100/5110: P/N 800-5870-1R In-Sight 5100C: P/N 800-5837-4R In-Sight 5400/5410: P/N 800-5855-1R In-Sight 5400S/5410S: P/N 800-5855-3R In-Sight 5400C: P/N 800-5837-4R In-Sight 5400CS: P/N 800-5837-6R In-Sight 5401/5411: P/N 800-5838-4R 89/336/EEC Electromagnetic Compatibility Directive EN 55011:1998 + A1:1999 + A2:2002 Class A EN 61000-3-2:2000 + A2:2005 EN 61000-3-3:1995 + A1:2001 EN 61000-6-2:2001 COGNEX INTERNATIONAL Immeuble Le Patio 104 Avenue Albert 1er 92563 Rueil Malmaison Cedex - France

Declares this Product Number:

Complies With: Compliance Standards

European Representative:

Safety and Regulatory

UL and CUL Certification marks are present on products. LISTED FCC FCC Part 15, Class A This device complies with Part 15 of the FCC Rules. Operation is subject to the following two conditions: (1) this device may not cause harmful interference; and (2) this device must accept any interference received, including interference that may cause undesired operation. This equipment generates, uses, and can radiate radio frequency energy and, if not installed and used in accordance with the instruction manual, may cause harmful interference to radio communications. Operation of this equipment in a residential area is likely to cause harmful interference in which case the user will be required to correct the interference at their own expense. RoHS RoHS 6 Compliant.

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Regulations/Conformity

Declaration of Conformity
Manufacturer: Cognex Corporation One Vision Drive Natick, MA 01760 USA -marked Machine Vision System Product In-Sight 5400R/5410R: P/N 800-5829-1R 89/336/EEC Electromagnetic Compatibility Directive EN 61000-6-4:2001 Class A EN 61000-3-2:2000 + A2:2005 EN 61000-3-3:1995 + A1:2001 EN 61000-6-2:2001 COGNEX INTERNATIONAL Immeuble Le Patio 104 Avenue Albert 1er 92563 Rueil Malmaison Cedex - France

Declares this Product Number: Complies With:

Compliance Standards

European Representative:

Safety and Regulatory

UL and CUL Certification marks are present on products. LISTED FCC FCC Part 15, Class A This device complies with Part 15 of the FCC Rules. Operation is subject to the following two conditions: (1) This device may not cause harmful interference, and (2) this device must accept any interference received, including interference that may cause undesired operation. This equipment generates, uses, and can radiate radio frequency energy and, if not installed and used in accordance with the instruction manual, may cause harmful interference to radio communications. Operation of this equipment in a residential area is likely to cause harmful interference in which case the user will be required to correct the interference at their own expense. RoHS RoHS 6 Compliant.

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In-Sight 5000 Series Vision System Installation Manual

Declaration of Conformity
Manufacturer: Cognex Corporation One Vision Drive Natick, MA 01760 USA -marked Machine Vision System Product In-Sight 5403/5413: P/N 800-5830-4R In-Sight 5403S: P/N 800-5830-6R 89/336/EEC Electromagnetic Compatibility Directive EN 61000-6-3:2001 + A11:2004 Class B EN 61000-3-2:2000 + A2:2005 EN 61000-3-3:1995 + A1:2001 EN 61000-6-2:2001 COGNEX INTERNATIONAL Immeuble Le Patio 104 Avenue Albert 1er 92563 Rueil Malmaison Cedex - France

Declares this Product Number: Complies With:

Compliance Standards

European Representative:

Safety and Regulatory

UL and CUL Certification marks are present on products. LISTED FCC FCC Part 15, Class B This device complies with Part 15 of the FCC Rules. Operation is subject to the following two conditions: (1) This device may not cause harmful interference, and (2) this device must accept any interference received, including interference that may cause undesired operation. RoHS 6 Compliant.

RoHS

Regulations/Conformity

Declaration of Conformity
Manufacturer: Cognex Corporation One Vision Drive Natick, MA 01760 USA -marked Machine Vision System Product In-Sight 5600: P/N 800-5871-1R In-Sight 5603: P/N 800-5873-1R In-Sight 5604: P/N 800-5874-1R 89/336/EEC Electromagnetic Compatibility Directive EN 61000-6-4:2001 Class A EN 61000-3-2:2000 + A2:2005 EN 61000-3-3:1995 + A1:2001 +A2:2005 EN 61000-6-2:2005 EN 61000-6-3:2001 +A11:2004 Class B EN 55022:1988 +A1:2000 +A2:2003 Class B EN 61000-3-2:2000 + A2:2005 EN 61000-3-3:1995 + A1:2001 +A2:2005 EN 61000-6-2:2005 COGNEX INTERNATIONAL Immeuble Le Patio 104 Avenue Albert 1er 92563 Rueil Malmaison Cedex - France

Declares this

Product Number/Product Type: Complies With: Compliance Standards Class A1

Compliance Standards Class B2

European Representative:

Safety and Regulatory

UL and CUL Certification marks are present on products. LISTED FCC Class A1 FCC Part 15, Class A This device complies with Part 15 of the FCC Rules. Operation is subject to the following two conditions: (1) This device may not cause harmful interference, and (2) this device must accept any interference received, including interference that may cause undesired operation. This equipment generates, uses, and can radiate radio frequency energy and, if not installed and used in accordance with the instruction manual, may cause harmful interference to radio communications. Operation of this equipment in a residential area is likely to cause harmful interference in which case the user will be required to correct the interference at their own expense. FCC Class B2 FCC Part 15, Class B This device complies with Part 15 of the FCC Rules. Operation is subject to the following two conditions: (1) This device may not cause harmful interference, and (2) this device must accept any interference received, including interference that may cause undesired operation. RoHS 6 Compliant.

RoHS

1. Using Cognex Power Supply ACC-24I or equivalent Class A power supply. 2. Using Cognex Power Supply PS-Kit-1 or equivalent Class B power supply.

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In-Sight 5000 Series Vision System Installation Manual

Precautions
Observe these precautions when installing In-Sight 5000 series vision systems to reduce the risk of injury or equipment damage: In-Sight 5000 series vision systems are intended to be supplied by a Listed, Direct Plug-In Power Unit with a minimum output rated 24VDC, 600mA and marked Class 2, Limited Power Source (LPS). Any other voltage creates a risk of fire or shock and can damage the In-Sight components. Do not install In-Sight 5000 series vision systems where they are directly exposed to environmental hazards such as excessive heat, dust, moisture, humidity, impact, vibration, corrosive substances, flammable substances, or static electricity. To reduce the risk of damage or malfunction due to over-voltage, line noise, electrostatic discharge (ESD), power surges, or other irregularities in the power supply, route all cables and wires away from high-voltage power sources. The housing of the vision system is internally connected to the system ground wire (pin 8 of the Breakout cable). Therefore, if the mounting surface of the vision system is at a non-zero ground potential, it is strongly recommended that the vision system be mounted on an isolated or non-conductive mount. Do not expose the CCD to laser light; CCDs can be damaged by direct, or reflected, laser light. If your application requires the use of laser light that may strike the CCD, a lens filter at the corresponding laser's wavelength is recommended. Contact your local integrator or application engineer for suggestions. Do not open the In-Sight 5000 series vision system or remote head camera. These devices do not contain user-serviceable parts. Do not make electrical or mechanical modifications to In-Sight components. Unauthorized modifications may violate your warranty. Changes or modifications not expressly approved by the party responsible for regulatory compliance could void the users authority to operate the equipment. Cable shielding can be degraded or cables can be damaged or wear out more quickly if a bend radius or service loop is tighter than 10X the cable diameter. Service loops should be included with all cable connections.

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Precautions

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In-Sight 5000 Series Vision System Installation Manual

Table of Contents
1 Introduction
1.1 1.2 1.3 1.4 1.5 In-Sight 5000 Series Vision Systems Overview ............................................................... 1 In-Sight Support ............................................................................................................... 1 In-Sight 5000 Series Standard Components.................................................................... 2 I/O Module Compatibility .................................................................................................. 4 In-Sight 5000 Series Configurations ................................................................................ 4 1.5.1 Standalone Network.............................................................................................. 5 1.5.2 Configurations Using Switches/Routers................................................................ 6 1.5.3 Adding an In-Sight Network to the Factory Network ............................................. 7

2 Installing the Vision System

2.1 Connecting the In-Sight 5000 Series Vision System........................................................ 9 2.2 Connecting the In-Sight 5000 Series Components ........................................................ 10 2.2.1 Install the Lens .................................................................................................... 10 2.2.2 Attach the Remote Head Camera cable ............................................................. 13 2.2.3 Connecting the Network and Breakout Cables ................................................... 14

3 Specifications
3.1 General Specifications ................................................................................................... 17 3.1.1 In-Sight Standard Vision System Specifications ................................................ 18 3.1.2 In-Sight Stainless Steel Vision System Specifications ........................................ 20 3.1.3 In-Sight Remote Head Vision System Specifications.......................................... 22 3.1.4 In-Sight 5603 and 5600 Vision System Specifications........................................ 24 3.1.5 In-Sight 5604 Line Scan Vision System Specifications....................................... 26 3.2 I/O Specifications ........................................................................................................... 28 3.2.1 Acquisition Trigger Input ..................................................................................... 28 3.2.2 Encoder Inputs (In-Sight 5604 only).................................................................... 29 3.2.3 High-Speed Outputs............................................................................................ 30 3.2.4 24VDC Breakout Cable....................................................................................... 32 3.2.5 I/O Module Cable ................................................................................................ 33 3.2.6 Ethernet Cable .................................................................................................... 34 3.2.7 Camera Cable ..................................................................................................... 35 3.3 In-Sight Dimensional Drawings ...................................................................................... 36 3.3.1 5100, 5100C, 5400, 5401, 5400C and 5403 Vision System Dimensions ........... 36 3.3.2 5403S, 5400CS and 5400S Vision System Dimensions..................................... 38 3.3.3 5400R Vision System Dimensions ...................................................................... 40 3.3.4 Remote Head Camera Dimensions .................................................................... 41 3.3.5 Remote Head Camera Enclosure Dimensions ................................................... 42 3.3.6 Remote Head Camera Mount Dimensions ......................................................... 43 3.3.7 5600 and 5603 Vision System Dimensions......................................................... 44 3.3.8 5604 Vision System Dimensions......................................................................... 46 ix

Table of Contents

Appendix A
A.1 Installing the Remote Head Camera .............................................................................. 47

Appendix B
B.1 Cleaning/Maintenance .................................................................................................... 49 B.1.1 Cleaning the Vision System................................................................................. 49 B.1.2 Cleaning the CCD Window .................................................................................. 49

Introduction
In This Section
1.1 1.2 1.3 1.4 In-Sight 5000 Series Vision Systems Overview........................ 1 In-Sight Support ........................................................................ 1 In-Sight 5000 Series Standard Components............................. 2 I/O Module Compatibility........................................................... 4

1.1

In-Sight 5000 Series Vision Systems Overview

In-Sight 5000 series vision systems are compact, network-ready machine vision systems for automated inspection, measurement, identification, alignment and robot guidance applications on the factory floor. For a list of all available vision systems, refer to Table 1-1 on page 2. All models are configured remotely over a network using an intuitive interface. This interface also allows remote monitoring of the vision system's operation during runtime. These vision systems may also be controlled remotely from custom, user-defined applications using In-Sight Native Mode commands to change settings and retrieve results. This manual describes how to install In-Sight 5000 series vision systems. When referring to the In-Sight 5000 series vision systems, the term standard vision system refers to all vision systems except for the stainless steel, remote head and 5600 series vision systems.

1.2

In-Sight Support
Many information resources are available to assist you in using the In-Sight 5000 series vision systems and their spreadsheet interface: In-SightExplorer Help, an online HTML Help file installed with the In-Sight Explorer software. In-Sight computer-based tutorials provided on CD-ROM with selected In-Sight starter accessories kits. The In-Sight online support: http://www.cognexsensors.com/In-Sight

Introduction

1.3

In-Sight 5000 Series Standard Components

In-Sight 5000 series vision systems are shipped with the components listed in Table 1-1; component descriptions are given in Table 1-2.
Note: Cables are sold separately.

Table 1-1: In-Sight 5000 Series Vision System Standard Components

Vision System
In-Sight 5100 In-Sight 5110 P/N 800-5870-1R In-Sight 5400 In-Sight 5410 P/N 800-5855-1R In-Sight 5400S In-Sight 5410S P/N 800-5855-3R In-Sight 5400R In-Sight 5410R P/N 800-5829-1R In-Sight 5100C In-Sight 5400C P/N 800-5837-4R In-Sight 5400CS P/N 800-5837-6R In-Sight 5401 In-Sight 5411 P/N 800-5838-4R In-Sight 5403 In-Sight 5413 P/N 800-5830-4R In-Sight 5403S P/N 800-5830-6R In-Sight 5600 In-Sight 5610 P/N 800-5871-1R In-Sight 5603 In-Sight 5613 P/N 800-5873-1R In-Sight 5604 P/N 800-5874-1R X X X X X X X

50mm Lens Cover Kit (P/N 800-5842-x)

X

IP68 Lens Cover Kit (P/N 800-5892-x)

Thread Guard (P/N 370-0361)

X

Remote Head Camera (P/N 800-5808-x)

X X

X X X

In-Sight 5000 Series Vision System Installation Manual

Table 1-1: In-Sight 5000 Series Vision System Standard Components (Cont.)
Vision System
In-Sight 5100 In-Sight 5110 P/N 800-5870-1R In-Sight 5400 In-Sight 5410 P/N 800-5855-1R In-Sight 5400S In-Sight 5410S P/N 800-5855-3R In-Sight 5400R In-Sight 5410R P/N 800-5829-1R In-Sight 5100C In-Sight 5400C P/N 800-5837-4R In-Sight 5400CS P/N 800-5837-6R In-Sight 5401 In-Sight 5411 P/N 800-5838-4R In-Sight 5403 In-Sight 5413 P/N 800-5830-4R In-Sight 5403S P/N 800-5830-6R In-Sight 5600 In-Sight 5610 P/N 800-5871-1R In-Sight 5603 In-Sight 5613 P/N 800-5873-1R In-Sight 5604 P/N 800-5874-1R X X

Remote Head Accessory DIN Rail Mounting Lens Cleaning Kit Mounting Screw Kit Kit (P/N 800-5813-x) Bracket (P/N 800-9007-x) (P/N 195-0519R) (P/N 800-5843-x)
X X

X X X

X X X

X X X

X X X

X X

X X

Introduction

Table 1-2: In-Sight 5000 Series Standard Components Descriptions

Component Vision System Lens Cover Kit (includes lens cover and O-Ring) Thread Guard Remote Head Camera Remote Head Accessory Kit DIN Rail Mounting Bracket Lens Cleaning Kit Mounting Screw Kit Description Provides image acquisition, vision processing, job storage, serial and Ethernet connectivity and discrete I/O. Provides environmental protection for the lens. Protects the In-Sight vision system lens cover threads when lens cover is not used. Remove the Thread Guard prior to installing the Lens Cover. Acquires and sends images to the In-Sight 5400R vision system. Includes remote head camera mounting hardware and a 5mm extension ring (for use with C-mount lenses). Includes a bracket for mounting the In-Sight 5400R to a DIN rail. Includes a lens cleaning cloth and instructions on cleaning the lens. Includes M4 screws for mounting the vision system (quantity 4).

1.4

I/O Module Compatibility

Table 1-3 specifies which I/O modules are compatible with your In-Sight 5000 series vision system, along with the number of discrete inputs/outputs available for each I/O module.

Table 1-3: I/O Module Compatibility

I/O Module
CIO-1350 Breakout Module CIO-1400 CIO-1450 CIO-1460 CIO-MICRO CIO-MICRO-CC1

Vision System
All In-Sight 5000 series vision systems (except In-Sight 5604) All In-Sight 5000 series vision systems (except In-Sight 5604) All In-Sight 5000 series vision systems (except In-Sight 5604) All In-Sight 5000 series vision systems (except In-Sight 5604) In-Sight 5600 series vision systems In-Sight 5600 series vision systems

Discrete Inputs
none 7 general 8 general 8 general 8 general 8 general

Discrete Outputs
2 general 2 high-speed, 6 general 2 high-speed, 8 general 2 high-speed, 8 general 2 high-speed, 8 general 2 high-speed, 8 general

1. The CIO-MICRO-CC I/O module also adds CC-Link networking capability. For more information, refer to the In-Sight CIO-MICRO and CIO-MICRO-CC I/O Modules Installation Manual.

1.5

In-Sight 5000 Series Configurations

In-Sight 5000 series vision systems are designed to operate as a host vision system on an In-Sight Network. For the purposes of the instructions in this manual, an In-Sight Network is an In-Sight vision system connected over Ethernet to at least one other In-Sight vision system or personal computer running In-Sight Explorer software.

In-Sight 5000 Series Vision System Installation Manual These configurations may require additional components, such as an Ethernet switch. Many optional components may be purchased directly from Cognex. A complete catalog of In-Sight products and accessories is available on the Cognex web site at: http://www.cognex.com. These vision systems may be used in several possible network configurations. For each configuration, the vision system is managed using jobs in the In-Sight Explorer software, which also provides a remote display for that vision system. The jobs that can be stored are limited to the amount of local storage available on the vision system. Jobs that exceed this limit, and all image files, can be stored on the local PC.

1.5.1 Standalone Network

A standalone In-Sight network configuration includes a connection between an In-Sight vision system and a PC. In this configuration, the In-Sight network is isolated from the factory network. The most basic In-Sight network features a vision system connected directly to a PC running In-Sight Explorer software. In-Sight 5000 series vision systems have an Autosense capability, allowing the vision system to connect directly to a PC using either a straightpinned Ethernet cable or a crossover cable.
If the Microsoft Media Sense feature (which automatically detects whether or not your network interface is linked to a network) is enabled, communication with an In-Sight vision system may not be established. It is recommended to use a hub or switch with a standard Ethernet cable to configure the In-Sight vision system or configure your PC to disable the Media Sense feature. See Microsoft Knowledge Base article 239924 for details on this process.

Note:

Figure 1-1 shows a vision system connected directly to a PC using a Ethernet cable. The operator uses the PC, keyboard and mouse to configure applications and monitor runtime operation.

5000 Series Vision System

In-Sight Software

Figure 1-1: Standalone Vision System Configuration

Introduction

1.5.2 Configurations Using Switches/Routers

An In-Sight network may be extended to include multiple In-Sight vision systems by using a network router or Ethernet switch. The only limit on the size of this type of network is the number of routers or switches connected and the number of connections they provide. The standalone In-Sight network shown in Figure 1-2 includes two vision systems and a PC running In-Sight Explorer, connected by a switch/router. In this configuration, any In-Sight vision system on the network can be configured using In-Sight Explorer. In-Sight Explorer also provides additional job storage, and image and data archiving for all In-Sight vision systems on the network. The network switch/router may also connect to another network switch/router, which in turn could have a similar complement of network vision systems.

Switch/Router

In-Sight Software

5000 Series Vision System

5000 Series Vision System

Figure 1-2: Standalone Configuration with Ethernet Switch/Router

In-Sight 5000 Series Vision System Installation Manual

1.5.3 Adding an In-Sight Network to the Factory Network

Multiple In-Sight Networks may be connected to the larger, factory network, combining to create an In-Sight network of virtually unlimited size. Connecting an In-Sight network to the factory network allows real-time production data to be accessed remotely from any PC workstation with network access. For networks that cover large physical areas, a PC running In-Sight Explorer located on each In-Sight network provides local job configuration and image display for all In-Sight vision systems. As in the example in Figure 1-2, the In-Sight network shown in Figure 1-3 includes a vision system and a PC running In-Sight Explorer, connected to the same network switch/router. However, the switch/router for the In-Sight network is now connected to the factory network through another switch/router, which in turn may host connections to additional In-Sight networks.

Switch/Router

In-Sight Software

In-Sight Software

Switch/Router

5000 Series Vision System

Figure 1-3: Factory Floor Network Installation

Introduction

Installing the Vision System

In This Section...
2.1 2.2 Connecting the In-Sight 5000 Series Vision System ................ 9 Connecting the In-Sight 5000 Series Components................. 10

2.1

Connecting the In-Sight 5000 Series Vision System

This section describes the connection of the In-Sight 5000 series vision system to its standard and optional components. For a complete list of options and accessories, contact your local Cognex sales representative.
Note: When the vision system is powered up, User 0 LED and User 1 LED both momentarily turn on. Then, User 0 LED turns off and User 1 LED stays on. Next, User 0 LED turns on and User 1 LED turns off. Finally, both LEDs momentarily light up and then turn off.

Table 2-1: In-Sight 5000 Series Vision System Connectors and Indicators
User 0 LED Network Network Power Traffic LED Status LED LED ENET Connector
ENET

User 1 LED 24VDC Connector

24VDC

Connector/Indicator 24VDC Connector

Function Connects the In-Sight Breakout cable, which provides connections to an external power supply, the acquisition trigger input, high-speed outputs and RS-232 serial communications. Alternately, this connector is used to attach the I/O Module cable to an optional In-Sight I/O module, which adds general-purpose discrete I/O and light control functionality. Refer to Table 3-11 on page 32 and Table 3-12 on page 33. Green when active. User configurable using Discrete Output Line 4 (Line 10 for all I/O modules, except the CIO-1400, which uses Line 9). Red when active. User configurable using Discrete Output Line 5 (Line 11 for all I/O modules, except the CIO-1400, which uses Line 10). Green when power is applied. Flashes Green while transmitting and receiving data. Green when a network connection is detected. Connects the vision system to a network. The ENET connector provides the Ethernet connection to external network devices. Refer to Table 3-12 on page 33.

User 1 LED User 0 LED Power LED Network Traffic LED Network Status LED ENET Connector

Installing the Vision System

2.2

Connecting the In-Sight 5000 Series Components

2.2.1 Install the Lens

Installing a lens allows you to see the vision system acquire live video images. The exact lens focal length needed depends on the working distance and the field of view required for your machine vision application. In-Sight 5000 Series Vision System (except In-Sight 5604 and 5400R): 1. After removing the protective lens cap, attach a C-Mount lens to the vision system (Figure 2-1).

24VDC

Figure 2-1: Install the Lens

ENET

10

In-Sight 5000 Series Vision System Installation Manual In-Sight 5604 Line Scan Vision System: 1. After removing the protective lens cap and the protective film covering the CCD, attach a C-Mount lens to the vision system (Figure 2-2).

Figure 2-2: Install the Lens

11

Installing the Vision System In-Sight 5400R Remote Head Vision System: 1. Attach a CS-Mount or C-Mount (with 5mm extension ring) lens to the remote head camera (Figure 2-3).

Figure 2-3: Install the Lens

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In-Sight 5000 Series Vision System Installation Manual

2.2.2 Attach the Remote Head Camera cable

1. Attach the Camera cables female M12 connector to the remote head camera's male M12 connector. 2. Attach the Camera cables male M12 connector to the vision system's CAM0 connector (Figure 2-4).
Notes: Cables are sold separately. Refer to Appendix A for instructions on mounting the remote head camera.

Figure 2-4: CAM0 Connection Remove power from the vision system before connecting or disconnecting the remote head camera. Hot plugging the remote head camera can damage the In-Sight vision system and/or remote head camera. The cable connectors are keyed to fit the connectors on the vision system; do not force the connection or damage may occur.

Caution:

13

Installing the Vision System

2.2.3 Connecting the Network and Breakout Cables

Note: Cables are sold separately.

The vision system has an ENET connector and 24VDC connector. The ENET connector provides the Ethernet connection for network communications. The 24VDC connector supplies connections for the 24VDC power source, I/O, acquisition trigger, and serial communications. 1. Attach the Ethernet cables male M12 connector to the vision system's female M12 ENET connector (Figure 2-5).

Figure 2-5: Connect the Ethernet cable

2. Connect the Ethernet cables RJ-45 connector to the PC, switch, or router, as applicable. 3. Verify that the 24VDC power supply is not receiving power.

14

In-Sight 5000 Series Vision System Installation Manual 4. Connect the power supply to the Breakout cable (Figure 2-6). Attach the Breakout cable to the 24VDC connector on the vision system.
Unused bare wires can be clipped short or tied back using a tie made from nonconductive material. Keep all bare wires separated from the +24VDC wire. Notes: When using an In-Sight 5604 line scan vision system, the RS-232TX wire is used as Encoder A and the RS-232RX wire is used as Encoder B. For In-Sight 5604 line scan vision system encoder input specifications, see section 3.2.2. Never connect voltages other than 24VDC. Always observe the polarity shown. The cable connectors are keyed to fit the connectors on the vision system; do not force the connection or damage may occur.

Caution:

Breakout Cable

24VDC GND

RS-232TX (In-Sight 5604 Only: Encoder A) RS-232RX (In-Sight 5604 Only: Encoder B) HSOUT1 HSOUT0 TRGTRG+

Figure 2-6: Power Connections

15

Installing the Vision System

16

Specifications
In This Section
3.1 3.2 3.3 General Specifications ............................................................ 17 I/O Specifications .................................................................... 28 In-Sight Dimensional Drawings............................................... 36

3.1

General Specifications
The following sections list general specifications for the In-Sight 5000 series vision systems.
The In-Sight 5000 series includes vision systems that support ID tools only (ID Readers). ID Readers can be identified by the In-Sight 5000 series model number. An In-Sight 5000 series model number with a 1 in the third digit (e.g. 5110) is an ID Reader. An ID Reader has the same hardware as the corresponding general purpose vision system.

Note:

17

Specifications

3.1.1 In-Sight Standard Vision System Specifications

Table 3-1: 5100, 5100C, 5401, 5400C, 5403 and 5400 Vision System Specifications
Specification In-Sight 5100 In-Sight 5100C1 In-Sight version 3.4.0 In-Sight 5401 In-Sight 5400C In-Sight 5403 In-Sight 5400

Minimum Firmware Requirement In-Sight version 2.80.01 PR1 Memory Job/Program Image Processing Image Sensor Sensor Properties 64MB 1/3-inch CCD

In-Sight version 2.80.01 PR1

32MB non-volatile flash memory; unlimited storage via remote network device.

1/1.8-inch CCD 5.952mm diagonal, 4.65 x 4.65m sq. pixels 1024 x 768 32s to 1000ms 5.92mm diagonal, 7.4 x 7.4m sq. pixels 640 x 480 16s to 1000ms 8.8mm diagonal, 4.4 x 4.4m sq. pixels 1600 x 1200 27s to 1000ms

1/3-inch CCD 5.92mm diagonal, 7.4 x 7.4m sq. pixels 640 x 480 16s to 1000ms

5.92mm diagonal, 7.4 x 7.4m sq. pixels

Resolution (pixels)

640 x 480

Electronic 16s to 1000ms Shutter Speed Acquisition 256 grey levels 24 bit color (8 bits/pixel) 60 full frames per second.3 Lens Type CCD Alignment Variability4 I/O Trigger Discrete Inputs Discrete Outputs Status LEDs Communications Network Serial Power C-mount

Rapid reset, progressive scan, full-frame integration. 256 grey levels 24 bit color (8 bits/pixel) 17 full frames per second.2 60 full frames per second.3 256 grey levels (8 bits/pixel)

Gain/Offset controlled by software. 14 full frames per second.3 60 full frames per second.3

0.127mm (0.005in), (both x and y) from lens C-mount axis to center of imager.

1 opto-isolated, acquisition trigger input. Remote software commands via Ethernet and RS-232C. None built-in. Additional inputs available using a compatible I/O module (see Table 1-3). Unlimited inputs when using an Ethernet I/O system. 2 built-in, high-speed outputs. Additional outputs available using a compatible I/O module (see Table 1-3). Unlimited outputs when using an Ethernet I/O system. Power, Network Status, Network Traffic, 2 user configurable. 1 Ethernet port, 10/100 BaseT, TCP/IP protocol. Supports DHCP (factory default) or static IP address. RS-232C when connected to an optional I/O module. 24VDC 10%, 350mA maximum. 24VDC 10%, 24VDC 10%, 500mA 350mA maximum. maximum.

18

In-Sight 5000 Series Vision System Installation Manual Table 3-1: 5100, 5100C, 5401, 5400C, 5403 and 5400 Vision System Specifications (Cont.)
Specification Mechanical Material Finish Mounting Dimensions In-Sight 5100 Painted. Eight M4 threaded mounting holes (four front and four back). 83.3mm (3.28in) x 123.2mm (4.85in) x 61.4mm (2.42in) with Lens Cover installed. 43.5mm (1.71in) x 123.2mm (4.85in) x 61.4mm (2.42in) without Lens Cover installed (includes Thread Guard). Weight Environmental Temperature Humidity Protection Shock Vibration Regulatory Compliance 350 g (12.3 oz.) Lens cover installed, without lens. Operating: 0C to 45C (32F to 113F) Storage: 30C to 80C (22F to 176F) 95%, non-condensing (Operating and Storage) IP67 (with appropriate Lens Cover properly installed). 80 G Shock with 150 gram lens attached per IEC 68-2-27. 10 G from 10-500 Hz with 150 gram lens per IEC 68-2-6. CE, UL, CUL, FCC, RoHS In-Sight 5100C1 In-Sight 5401 In-Sight 5400C In-Sight 5403 In-Sight 5400

Die-cast aluminum housing.

1. In-Sight 5100C vision systems with P/N 800-5837-1 are compatible with firmware version 2.65.00 and higher. In-Sight 5100C vision systems with P/N 800-5837-4 are compatible with firmware version 3.4.0 and higher. To locate the Part Number, refer to the Part Number label on the back of your vision system. 2. Maximum frames per second are job dependent and based on an 8ms exposure and a full image frame capture. 3. Maximum frames per second are job dependent and based on the minimum exposure for a full image frame capture. 4. Expected variability in the physical position of the CCD, from vision system-to-vision system. This equates to ~ 17 pixels on a 640 x 480 resolution CCD and ~ 29 pixels on a 1600 x 1200 resolution CCD.

19

Specifications

3.1.2 In-Sight Stainless Steel Vision System Specifications

Table 3-2: 5400CS, 5403S, 5400S Vision System Specifications
Specification Minimum Firmware Requirement Memory Job/Program Image Processing Image Sensor Sensor Properties Resolution (pixels) Electronic Shutter Speed Acquisition In-Sight 5400CS In-Sight version 2.80.01 PR1 32MB non-volatile flash memory; unlimited storage via remote network device. 64MB 1/3-inch CCD 5.92mm diagonal, 7.4 x 7.4m sq. pixels 640 x 480 16s to 1000ms 1/1.8-inch CCD 8.80mm diagonal, 4.4 x 4.4m sq. pixels 1600 x 1200 27s to 1000ms 1/3-inch CCD 5.92mm diagonal, 7.4 x 7.4m sq. pixels 640 x 480 16s to 1000ms In-Sight 5403S In-Sight 5400S

Rapid reset, progressive scan, full-frame integration. 24 bit color 60 full frames per second.1 256 grey levels (8 bits/pixel) 14 full frames per second.1 60 full frames per second.1 Gain/Offset controlled by software.

Lens Type

C-mount

CCD Alignment 0.127mm (0.005in), (both x and y) from lens C-mount axis to center of imager. Variability2 I/O Trigger Discrete Inputs Discrete Outputs Status LEDs 1 opto-isolated, acquisition trigger input. Remote software commands via Ethernet and RS-232C. None built-in. Additional inputs available using a compatible I/O module (see Table 1-3). Unlimited inputs when using an Ethernet I/O system. 2 built-in, high-speed outputs. Additional outputs available using a compatible I/O module (see Table 1-3). Unlimited outputs when using an Ethernet I/O system. Power, Network Status, Network Traffic, 2 user configurable.

20

In-Sight 5000 Series Vision System Installation Manual Table 3-2: 5400CS, 5403S, 5400S Vision System Specifications (Cont.)
Specification Communications Network Serial Power Mechanical Material Finish Mounting Dimensions Weight Environmental Temperature Humidity Protection Shock Vibration Regulatory Compliance In-Sight 5400CS In-Sight 5403S In-Sight 5400S

1 Ethernet port, 10/100 BaseT, TCP/IP protocol. Supports DHCP (factory default) or static IP address. RS-232C when connected to an optional I/O module. 24VDC 10%, 350mA maximum. ASTM 316L Stainless Steel. Electropolish Passivated. Four M4 threaded mounting holes on back of vision system. 90.6mm (3.57in) x 124.0mm (4.88in) x 61.4mm (2.42in) with Lens Cover installed. 43.5mm (1.71in) x 124.0mm (4.88in) x 61.4mm (2.42in) without Lens Cover installed. 907 g (32.0 oz.) Lens cover installed, without lens. Operating: 0C to 45C (32F to 113F) Storage: 30C to 80C (22F to 176F) 95%, non-condensing (Operating and Storage) IP68 (with appropriate Lens Cover properly installed). 80 G Shock with 150 gram lens attached per IEC 68-2-27. 10 G from 10-500 Hz with 150 gram lens per IEC 68-2-6. CE, UL, CUL, FCC, RoHS 24VDC 10%, 500mA maximum. 24VDC 10%, 350mA maximum.

1. Maximum frames per second are job dependent and based on the minimum exposure for a full image frame capture. 2. Expected variability in the physical position of the CCD, from vision system-to-vision system. This equates to ~ 17 pixels on a 640 x 480 resolution CCD and ~ 29 pixels on a 1600 x 1200 resolution CCD.

21

Specifications

3.1.3 In-Sight Remote Head Vision System Specifications

Table 3-3: 5400R Vision System Specifications
Specification Minimum Firmware Requirement Memory Job/Program Image Processing I/O Trigger Discrete Inputs Discrete Outputs Status LEDs Communications Network Serial Power Mechanical Material Finish Mounting Dimensions Weight Environmental Temperature Humidity Protection Shock Vibration Regulatory Compliance In-Sight version 3.2.0 32MB non-volatile flash memory; unlimited storage via remote network device. 64MB 1 opto-isolated, acquisition trigger input. Remote software commands via Ethernet and RS-232C. None built-in. Additional inputs available using a compatible I/O module (see Table 1-3). Unlimited inputs when using an Ethernet I/O system. 2 built-in, high-speed outputs. Additional outputs available using a compatible I/O module (see Table 1-3). Unlimited outputs when using an Ethernet I/O system. Power, Network Status, Network Traffic, 2 user configurable. 1 Ethernet port, 10/100 BaseT, TCP/IP protocol. Supports DHCP (factory default) or static IP address. RS-232C when connected to an optional I/O module. 24VDC 10%, 250mA maximum. Die-cast aluminum housing. Painted. Four M4 threaded mounting holes on back of vision system. 34.0mm (1.34in) x 136.0mm (5.35in) x 61.4mm (2.42in) 295g (10.4 oz.) Operating: 0C to 55C (32F to 131F) Storage: 30C to 80C (22F to 176F) 95%, non-condensing (Operating and Storage) IP67 80 G shock per IEC 68-2-27. 10 G from 10-500 Hz per IEC 68-2-6. CE, UL, CUL, FCC, RoHS In-Sight 5400R

1. Maximum frames per second is job dependent and based on an 8ms exposure and a full image frame capture. 2. Expected variability in the physical position of the CCD, from vision system-to-vision system. This equates to ~ 17 pixels on a 640 x 480 resolution CCD.

22

In-Sight 5000 Series Vision System Installation Manual Table 3-4: Remote Head Camera Specifications
Specification Image Sensor Sensor Properties Resolution (pixels) Electronic Shutter Speed Acquisition 1/3-inch CCD 5.92mm diagonal, 7.4 x 7.4m sq. pixels. 640 x 480 25s to 1000ms (except value selected must be in increments of 50s i.e., 25s, 75s, 125s, etc.). Rapid reset, progressive scan (supports partial scan), full-frame integration. 256 grey levels (8 bits/pixel). Gain controlled by software. 31 full frames per second.1 Lens Type CCD Alignment Variability2 Mechanical Material/Finish Mounting Dimensions Weight Environmental Temperature Humidity Protection Shock Vibration CS-mount and C-mount (with 5mm extension, included). 0.254mm (0.01in), (both x and y) from lens C-mount axis to center of imager. Anodized, aluminum housing. Three M3 threaded holes. 32.0mm (1.26in) diameter, 50.6mm (1.99in) length 68 g (2.4 oz.) without lens Operating: 0C to 45C (32F to 113F) Storage: 30C to 80C (22F to 176F) 95% non-condensing (Operating and Storage). For environments where protection is required, use the optional protective Remote Head Camera Enclosure, Cognex P/N 800-5783-1. 80 G Shock with 150 g or lighter lens per IEC 68-2-27. Remote head properly mounted using Cognex mounting bracket with vibration dampener tube. 10 G from 10-500Hz Vibration per IEC 68-2-6 with 150 g or lighter lens attached. Remote head properly mounted using Cognex mounting bracket with vibration damper tube. CE, UL, CUL, FCC, RoHS Remote Head Camera

Regulatory Compliance

Table 3-5: Remote Head Camera Enclosure Specifications

Specification Mechanical Material/Finish Mounting Dimensions Weight Protection Remote Head Camera Enclosure Anodized aluminum housing with glass window. Stainless steel housing with polycarbonate window (optional). Three M3 threaded holes. Without remote head camera: 66.6mm (2.62in) high x 46.0mm (1.81in) diameter. Nominal height with remote head camera: 79.2mm (3.12 in) to 93.6mm (3.69 in). 136.1 g (4.8 oz.), without remote head camera. IP67

23

Specifications

3.1.4 In-Sight 5603 and 5600 Vision System Specifications

Table 3-6: 5603 and 5600 Vision System Specifications
Specification Minimum Firmware Requirement Memory Job/Program Image Processing Image Sensor Resolution (pixels) In-Sight 5603 In-Sight version 3.4.0 64MB non-volatile flash memory; unlimited storage via remote network device. 128MB 1/1.8-inch CCD 1600 x 1200 1/3-inch CCD 5.92mm diagonal, 7.4 x 7.4m sq. pixels 640 x 480 16s to 1000ms In-Sight 5600

Sensor Properties 8.8mm diagonal, 4.4 x 4.4m sq. pixels

Electronic Shutter 27s to 1000ms Speed Acquisition 256 grey levels (8 bits/pixel) Gain/Offset controlled by software. 14 full frames per second.1 Lens Type CCD Alignment Variability2 I/O Trigger Discrete Inputs Discrete Outputs Status LEDs Communications Network Serial Power Mechanical Material Finish Mounting Dimensions Weight C-mount

Rapid reset, progressive scan, full-frame integration.

60 full frames per second.1

0.127mm (0.005in), (both x and y) from lens C-mount axis to center of imager. 1 opto-isolated, acquisition trigger input. Remote software commands via Ethernet and RS-232C. None built-in. Additional inputs available using a compatible I/O module (see Table 1-3). Unlimited inputs when using an Ethernet I/O system. 2 built-in, high-speed outputs. Additional outputs available using a compatible I/O module (see Table 1-3). Unlimited outputs when using an Ethernet I/O system. Power, Network Status, Network Traffic, 2 user configurable. 1 Ethernet port, 10/100 BaseT, TCP/IP protocol. Supports DHCP (factory default) or static IP address. RS-232C when connected to an optional I/O module. 24VDC 10%, 600mA maximum. Die-cast aluminum housing. Painted/Powder coat (back plate). Eight M4 threaded mounting holes (four front and four back). 99.9mm (3.93in) x 124.1mm (4.88in) x 61.4mm (2.42in) with Lens Cover installed. 59.4mm (2.34in) x 124.1mm (4.88in) x 61.4mm (2.42in) without Lens Cover installed. 463 g (16.3 oz.) Lens cover installed, without lens. 409 g (14.4 oz.) Lens cover installed, without lens. 24VDC 10%, 500mA maximum.

24

In-Sight 5000 Series Vision System Installation Manual Table 3-6: 5603 and 5600 Vision System Specifications (Cont.)
Specification Environmental Temperature In-Sight 5603 Operating non-circulating air3: 0C to 45C (32F to 113F) Operating circulating air4: 0C to 50C (32F to 122F) Storage: 30C to 80C (22F to 176F) 95%, non-condensing (Operating and Storage) IP67 (with appropriate Lens Cover properly installed). 80 G Shock with 150 gram lens attached per IEC 68-2-27. 10 G from 10-500 Hz with 150 gram lens per IEC 68-2-6. CE, UL, CUL, FCC, RoHS In-Sight 5600

Humidity Protection Shock Vibration Regulatory Compliance

1. Maximum frames per second are job dependent and based on the minimum exposure for a full image frame capture. 2. Expected variability in the physical position of the CCD, from vision system-to-vision system. This equates to ~ 17 pixels on a 640 x 480 resolution CCD and ~ 29 pixels on a 1600 x 1200 resolution CCD. 3. The vision system should be mounted with sufficient clearance on all sides to allow air circulation around and through the cooling posts on the black heat sink. If the vision system is not mounted with sufficient clearance, a fan is recommended. 4. Additional cooling from a fan is required for operation above 40C. For operation up to 50C, there must be 4 CFM of air moving through the cooling posts on the black heat sink.

25

Specifications

3.1.5 In-Sight 5604 Line Scan Vision System Specifications

Table 3-7: 5604 Vision System Specifications
Specification Minimum Firmware Requirement Memory Job/Program Image Processing Image Sensor Resolution (pixels) Acquisition In-Sight version 4.3.0 64MB non-volatile flash memory; unlimited storage via remote network device. 128MB 1-inch CCD 1024 x 1 (CCD); 1024 x 2048 (up to 2048 lines for full resolution image). Line Scan integration. 256 grey levels (8 bits/pixel). Gain/Offset controlled by software. 44K lines per second.1 Lens Type CCD Alignment Variability2 I/O Trigger Discrete Inputs Discrete Outputs Encoder Inputs Status LEDs Communications Network Serial Power Mechanical Material Finish Mounting Dimensions Weight Environmental Temperature C-mount 0.127mm (0.005in), (both x and y) from lens C-mount axis to center of imager. 1 opto-isolated, acquisition trigger input. Remote software commands via Ethernet and RS-232C. None built-in. Additional inputs available using a compatible I/O module (see Table 1-3). Unlimited inputs when using an Ethernet I/O system. 2 built-in, high-speed outputs. Additional outputs available using a compatible I/O module (see Table 1-3). Unlimited outputs when using an Ethernet I/O system. 2 built-in, encoder inputs for use with a 24V signal. Power, Network Status, Network Traffic, 2 user configurable. 1 Ethernet port, 10/100 BaseT, TCP/IP protocol. Supports DHCP (factory default) or static IP address. RS-232C when connected to an optional CIO-MICRO OR CIO-MICRO-CC I/O module. 24VDC 10%, 350mA maximum. Die-cast aluminum housing. Painted/Powder coat (back plate). Eight M4 threaded mounting holes (four front and four back). 53.2mm (1.50in) x 124.1mm (4.88in) x 61.4mm (2.42in) 454 g (16 oz.) protective lens cap installed, without lens. Operating non-circulating air3: 0C to 45C (32F to 113F) Operating circulating air4: 0C to 50C (32F to 122F) Storage: 30C to 80C (22F to 176F) 95%, non-condensing (Operating and Storage) For environments where protection is required, use an optional protective enclosure. 80 G Shock with 150 gram lens attached per IEC 68-2-27. 10 G from 10-500 Hz with 150 gram lens per IEC 68-2-6. In-Sight 5604

Sensor Properties 14.3 mm x 14m active area, 14m x 14m sq. pixels.

Humidity Protection Shock Vibration

26

In-Sight 5000 Series Vision System Installation Manual Table 3-7: 5604 Vision System Specifications (Cont.)
Specification Regulatory Compliance CE, UL, CUL, FCC, RoHS In-Sight 5604

1. Maximum lines per second are based on the minimum exposure. 2. Expected variability in the physical position of the CCD, from vision system-to-vision system. This equates to ~ 8 pixels on a 2024 x 1 resolution CCD. 3. The vision system should be mounted with sufficient clearance on all sides to allow air circulation around and through the cooling posts on the black heat sink. If the vision system is not mounted with sufficient clearance, a fan is recommended. 4. Additional cooling from a fan is required for operation above 40C. For operation up to 50C, there must be 4 CFM of air moving through the cooling posts on the black heat sink.

27

Specifications

3.2

I/O Specifications
Cable and connector specifications and connection examples for the Acquisition Trigger input, encoder inputs (In-Sight 5604 only) and the high-speed outputs are provided in the following sections.

3.2.1 Acquisition Trigger Input

Table 3-8: Acquisition Trigger Input Specifications
Specification
Voltage Current

Description ON: 20 to 28V (24V nominal) OFF: 0 to 3V (12V nominal threshold) ON: 2.0 to 2.9mA OFF: <150A Resistance: ~10,000 Ohms

Delay

In-Sight 5100, In-Sight 5100C, 62s maximum latency between leading edge of trigger and start of acquisition. Input pulse should be a minimum of 1 ms In-Sight 5400C, In-Sight 5400CS, In-Sight 5400, wide. In-Sight 5400S, In-Sight 5400R, In-Sight 5600 In-Sight 5403, In-Sight 5403S, 66s maximum latency between leading edge of trigger and start of acquisition. Input pulse should be a minimum of 1 ms In-Sight 5603 wide. In-Sight 5401 76s maximum latency between leading edge of trigger and start of acquisition. Input pulse should be a minimum of 1 ms wide. 1 line (approximately equivalent to 23s, based on a 1.4s Exposure) is the maximum latency between leading edge of trigger and start of acquisition. Input pulse should be a minimum of 5s wide.

In-Sight 5604

The acquisition trigger input on the vision system is opto-isolated. To trigger from an NPN (pull-down) type photoelectric sensor or PLC output, connect pin 2 (TRG+) to +24V and connect pin 3 (TRG) to the output of the photoelectric sensor. When the output turns ON, it pulls TRG down to 0V, turning the opto-coupler ON. To trigger from a PNP (pull-up) photoelectric sensor or PLC output, connect pin 2 (TRG+) to the output of the photoelectric sensor and connect pin 3 (TRG) to 0V. When the output turns ON, it pulls TRG+ up to 24V, turning the opto-coupler ON.
Note: When using the vision system with the Breakout cable, the polarity of the input trigger (pins 2 and 3) is not critical. However, when using the optional Breakout or I/O modules, the polarity of the TRG+ and TRG terminals should be observed.

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In-Sight 5000 Series Vision System Installation Manual

TRG+ 2.2K 4.7K TRG4.7K 28V Max. Across input pins - Transition approx. 12V (Min).
Figure 3-1: Acquisition Trigger Input Schematic

3.2.2 Encoder Inputs (In-Sight 5604 only)

Pins 6 and 7 of the Breakout cable (see Table 3-11 on page 32 for cable pin-outs) can be used for communication between the In-Sight 5604 line scan vision system and a single or quadrature encoder. The signal from the encoder must be 24V (other input specifications are listed in Table 3-9) .

Breakout Cable Encoder A Encoder B HSOUT1 HSOUT0 TRGTRG+ Encoder Signal A Signal B GND 24VDC
Figure 3-2: Connect the Encoder

Power Supply GND 24VDC

Table 3-9: Encoder Input Specifications (In-Sight 5604 only)

Specification
Voltage Current

Description
ON: 20 to 28V (24V nominal) OFF: 0 to 3V (9.6V nominal threshold) ON: 84 to 118A OFF: <11A Resistance: ~233,000 Ohms

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Specifications

3.2.3 High-Speed Outputs

In-Sight 5000 series vision systems feature two built-in, high-speed outputs. Table 3-10: High-Speed Output Specifications
Specification
Voltage Current

Description
28V maximum through external load.

All In-Sight 5000 series 200mA maximum sink current. (except OFF state leakage current 200A maximum. In-Sight 5600 series) External load resistance 140 Ohms to 10K Ohms. Each line rated at a maximum 200mA, protected against over-current, short circuit and transients from switching inductive loads. High current inductive loads require external protection diode. In-Sight 5600 series 100mA maximum sink current. OFF state leakage current 200A maximum. External load resistance 280 Ohms to 10K Ohms. Each line rated at a maximum 100mA, protected against over-current, short circuit and transients from switching inductive loads. High current inductive loads require external protection diode.

Both of the high-speed outputs are NPN (pull-down) lines. The external load should be connected between the output and the positive supply voltage (<28V). The outputs pull down to <0.1V when ON (<1.25V for In-Sight 5604 only), which causes current to flow through the load. When the outputs are OFF, no current flows through the load.

Example 1
To connect the high-speed outputs to a relay, LED or similar load, connect the negative side of the load to the output and the positive side to +24V. When the output switches on, the negative side of the load is pulled down to 0V, and 24V appears across the load. Use a protection diode for a large inductive load, with the anode connected to the output and the cathode connected to +24V.

Breakout Cable

RS-232TX RS-232RX HSOUT1 HSOUT0 TRGTRG+

Power Supply GND 24VDC

Load (Coil, Relay, Pilot Light, etc.) NOT TO EXCEED 200mA

Figure 3-3: High-Speed Output Connection Example 1

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In-Sight 5000 Series Vision System Installation Manual

Example 2
To connect to an NPN-compatible PLC input, connect Output 0 or Output 1 directly to the PLC input. When enabled, the output pulls down the PLC input to 0V.

Breakout Cable RS-232TX RS-232RX HSOUT1 HSOUT0 TRGTRG+ NPN PLC NPN Compatible Input GND 24VDC

Power Supply GND 24VDC

Figure 3-4: High-Speed Output Connection Example 2

Example 3
High-Speed outputs can also be used with a PNP-compatible PLC input if a pull-up resistor (for example, 2.2k 0.5W) is connected from the output to +24V. In this case, the resistor supplies 24V to the PLC input. The output will pull the voltage down to 0V, turning off the PLC input. This creates an inversion, with the PLC input ON when the In-Sight output is OFF, and vice-versa. Use an external NPN to PNP converter when this inversion is not desired.

Breakout Cable

RS-232TX RS-232RX HSOUT1 HSOUT0 TRGTRG+

PNP PLC PNP Compatible Input GND 24VDC

Power Supply GND 24VDC

2.2K

Figure 3-5: High-Speed Output Connection Example 3

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Specifications

3.2.4 24VDC Breakout Cable

The 24VDC Breakout connector provides access to power, serial communications, trigger and high-speed outputs. The Breakout cable is not terminated. When using the In-Sight 5604, refer to Table 3-9 for encoder input specifications. Table 3-11: 24VDC Breakout Cable Pin-Out

7 6 5 4 3
Pin# 1 2 3 4 5 6 7 8

8 1

P1

Signal Name Power, +24 VDC Trigger + Trigger High-Speed Out 0 High-Speed Out 1 RS-232 Receive (RxD)1 (In-Sight 5604 Only: Encoder B) RS-232 Transmit (TxD)1 (In-Sight 5604 Only: Encoder A) Ground

Wire Color White/Green Green White/Orange Blue White/Blue Orange White/Brown Brown

1. If hardware handshaking is required, an I/O module must be used. Cables are sold separately. Unused bare wires can be clipped short or tied back using a tie made from non-conductive material. Keep all bare wires separated from the +24VDC (White/Green) wire. The housing of the vision system is internally connected to the system ground wire (pin 8 of the Breakout cable). Therefore, if the mounting surface of the vision system is at a non-zero ground potential, it is strongly recommended that the vision system be mounted on an isolated or non-conductive mount.

Notes:

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In-Sight 5000 Series Vision System Installation Manual

3.2.5 I/O Module Cable

The I/O Module cable is used with the optional I/O module and 1350 Breakout Module (Table 1-3 specifies which I/O modules are compatible with your In-Sight 5000 series vision system). The I/O Module cable connects the vision system directly to the applicable I/O module via the DB15 connector. When the I/O module or 1350 Breakout Module is used, all power and communication lines used by the vision system are connected using the I/O Module cable. Table 3-12: I/O Module Cable Pin-Out

7 6 5 4 3

8 1 9 1

15 P1 P2

P1 Pin# 1 2 3 4 5 6 7 8

Signal Name Power, +24 VDC Trigger + Trigger High-Speed Out 0 High-Speed Out 1 RS-232 Receive (RxD) (In-Sight 5604 Only: Encoder B) RS-232 Transmit (TxD) (In-Sight 5604 Only: Encoder A) Ground Cables are sold separately.

P2 Pin# 1 2 3 4 5 6 7 8

Notes:

Refer to your specific I/O module installation manual for more connection information.

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Specifications

3.2.6 Ethernet Cable

The Ethernet cable is used to connect the vision system to other network devices. The Ethernet cable can be connected to a single device or provide connections to multiple devices via a network switch or router. Table 3-13: Ethernet Cable Pin-Out

8 1

7 6 5

2 3
Signal Name TPO+ TPOTPI+ TRMA TRMB TPITRMC TRMD

P1

P2

P1 Pin# 6 4 5 7 1 8 2 3 Cables are sold separately.

P2 Pin# 1 2 3 4 5 6 7 8

Wire Color White/Orange Orange White/Green Blue White/Blue Green White/Brown Brown

Notes:

The wiring for this cable follows standard industrial Ethernet M12 specifications. This varies from the 568B standard.

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In-Sight 5000 Series Vision System Installation Manual

3.2.7 Camera Cable

The Camera cable connects the remote head camera to the 5400R vision system. The Camera cable provides power and communications to the camera. Table 3-14: Camera Cable Pin-out

7 6 5 4 3

8 1 1

7 6 5

P1

P2

2 3

P1 Pin# 1 2 3 4 5 6 7 8 Note:

Signal Name CTRL+ CTRLDAT+ +17V -10V DAT+6V GND Cables are sold separately.

P2 Pin# 1 2 3 4 5 6 7 8

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Specifications

3.3

In-Sight Dimensional Drawings

3.3.1 5100, 5100C, 5400, 5401, 5400C and 5403 Vision System Dimensions
Notes: All dimensions are in millimeters [inches] and are for reference purposes only. All specifications may be changed without notice.

123.2 4.85 31.0 1.22 OPTICAL AXIS OPTICAL AXIS 61.4 2.42

36.0 1.42

4X M4 33.0 1.30 30.0 1.18

4.0

OPTICAL AXIS

83.3 3.28 OPTICAL AXIS

35.5 1.40

20.4 .80 21.8 .86 109.1 4.29

25.4 1.00 5.7 .23 OPTICAL AXIS

4X M4

8.0 19.5 .77

25.0 .98 50.0 1.97 OPTICAL AXIS

22.4 .88

5.6 .22

98.0 3.86

Figure 3-6: Standard Vision System Dimensions (With Lens Cover)

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In-Sight 5000 Series Vision System Installation Manual

123.2 4.85 31.0 1.22

OPTICAL AXIS

61.4 2.42

OPTICAL AXIS

36.0 1.42

4X M4 33.0 1.30 30.0 1.18

4.0

OPTICAL AXIS OPTICAL AXIS

43.5 1.71

21.8 .86

35.5 1.40 20.4 .80

109.1 4.29

25.4 1.00 5.7 .23

OPTICAL AXIS

4X M4

8.0

19.5 .77

25.0 .98 50.0 1.97

OPTICAL AXIS

22.4 .88

5.6 .22

98.0 3.86

Figure 3-7: Standard Vision System Dimensions (Without Lens Cover)

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Specifications

3.3.2 5403S, 5400CS and 5400S Vision System Dimensions

Notes: All dimensions are in millimeters [inches] and are for reference purposes only. All specifications may be changed without notice.

124.0 4.88 31.0 1.22 OPTICAL AXIS

OPTICAL 61.4 2.42 AXIS

OPTICAL AXIS

90.6 3.57
OPTICAL AXIS

20.4 .80 21.8 .86 109.0 4.29 4X M4 8.0

25.4 1.00 5.7 .23 OPTICAL AXIS

19.5 .77

25.0 .98 50.0 1.97 OPTICAL AXIS 22.4 .88

5.6 .22

98.0 3.86

Figure 3-8: Stainless Steel Vision System Dimensions (With Lens Cover)

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In-Sight 5000 Series Vision System Installation Manual

124.0 4.88 31.0 1.22 OPTICAL AXIS

61.4 2.42

OPTICAL AXIS

OPTICAL AXIS
OPTICAL AXIS

43.5 1.71

20.4 .80 21.8 .86 109.0 4.29 4X M4 8.0

25.4 1.00 5.7 .23 OPTICAL AXIS

19.5 .77

25.0 .98 50.0 1.97 OPTICAL AXIS 22.4 .88

5.6 .22

98.0 3.86

Figure 3-9: Stainless Steel Vision System Dimensions (Without Lens Cover)

39

Specifications

3.3.3 5400R Vision System Dimensions

Notes: All dimensions are in millimeters [inches] and are for reference purposes only. All specifications may be changed without notice.

136.0 [5.35]

34.0 [1.34]

20.1 [.79] 22.4 [.88] 61.4 [2.42] 20.6 [.81] 4 x M4 7.9 [.31] 109.0 [4.29]

50.0 [1.97]

5.5 [.22] TYPICAL ALL SIDES

98.0 [3.86]

17.5 [.69]

Figure 3-10: 5400R Vision System Dimensions

40

In-Sight 5000 Series Vision System Installation Manual

3.3.4 Remote Head Camera Dimensions

Notes: All dimensions are in millimeters [inches] and are for reference purposes only. All specifications may be changed without notice.

50.6 [1.99] 39.7 [1.56] 26.4 [1.04] 120 32.0 30.0 [1.26] [1.18] 120 3X M3x0.5 - 6H 6.3 [0.25] 26.0 [1.02]

120

M12 CONNECTOR (MALE)

Figure 3-11: Remote Head Camera Dimensions

41

Specifications

3.3.5 Remote Head Camera Enclosure Dimensions

Notes: All dimensions are in millimeters [inches] and are for reference purposes only. All specifications may be changed without notice.

3 MOUNTING HOLES M3 SCREWS 6.3 [.25] DEEP

10.9 [0.43] 93.6 [3.69] NOMINAL

REMOTE HEAD (NOT SECTIONED)

LENS

29.6 [1.17]

44.1 [1.74] NOMINAL

66.6 [2.62]

79.2 [3.12]

ENCLOSURE GLASS

46.0 [1.81]

35.0 [1.38] 42.0 [1.65]

Figure 3-12: Remote Head Camera Enclosure Dimensions

42

In-Sight 5000 Series Vision System Installation Manual

3.3.6 Remote Head Camera Mount Dimensions

Notes: All dimensions are in millimeters [inches] and are for reference purposes only. All specifications may be changed without notice.

The remote head mounting bracket dimensions are illustrated below. Refer to Appendix A for installation instructions.
MOUNTING BRACKET
M6 THRU 2 HOLES .25 THRU 10.0 [.39] 17.3 [.68] 10.0 [.39] -20 THREADED THRU 8.1 [.32] 16.2 [.64] 21.3 [.84]

34.5 [1.36] M3 THRU 3 HOLES 27.4 [1.08] 23.3 [.92]

40.6 [1.60] 4.8 [.19]

27.4 [1.08]

31.5 [1.24]

MOUNTING BRACKET WITH REMOTE HEAD AND VIBRATION DAMPENER

19 [.75]

17.3 [.68]

41.2 [1.62]

35.0 [1.38]

50.8 [2.00]

Figure 3-13: Remote Head Camera Mount Dimensions

43

Specifications

3.3.7 5600 and 5603 Vision System Dimensions

Notes: All dimensions are in millimeters [inches] and are for reference purposes only. All specifications may be changed without notice.

124.1 4.88 31.0 1.22 OPTICAL AXIS

OPTICAL 61.4 2.42 AXIS

36.0 1.42

4X M4 4.0 33.0 1.30 OPTICAL AXIS 30.0 1.18

99.9 3.93 OPTICAL AXIS 52.0 2.05 38.1 1.50 36.9 1.45

109.1 4.30 4X M4 8.0 25.4 1.00 5.7 .23 OPTICAL AXIS 19.5 .77

25.0 .98 50.0 1.97 OPTICAL AXIS 22.4 .88

5.6 .22

98.0 3.86

Figure 3-14: 5600 and 5603 Vision System Dimensions (With Lens Cover)

44

In-Sight 5000 Series Vision System Installation Manual

124.1 4.88 31.0 1.22 OPTICAL AXIS

OPTICAL AXIS 61.4 2.42

36.0 1.42

4X M4 33.0 1.30 30.0 1.18

4.0

OPTICAL AXIS OPTICAL AXIS 59.4 2.34 38.1 1.50 52.0 2.05 36.9 1.45

109.1 4.30

4X M4 8.0 25.4 1.00 5.7 .23 OPTICAL AXIS 19.5 .77

25.0 .98 50.0 1.97 OPTICAL AXIS 22.4 .88

5.6 .22

98.0 3.86

Figure 3-15: 5600 and 5603 Vision System Dimensions (Without Lens Cover)

45

Specifications

3.3.8 5604 Vision System Dimensions

Notes: All dimensions are in millimeters [inches] and are for reference purposes only. All specifications may be changed without notice.

124.1[4.88] 31.0 1.22 OPTICAL AXIS

61.4 2.42

OPTICAL AXIS

36.0 1.42

4X M4 33.0 1.30 OPTICAL AXIS OPTICAL AXIS 53.2[2.09] 38.1 1.50 30.0 1.18

4.0

52.0[2.05] 36.9[1.45]

109.1 4.30 25.4 1.00 5.7 .23 OPTICAL AXIS 4X M4 8.0 19.5[.77]

25.0 .98 50.0 1.97 OPTICAL AXIS 22.4[.88]

5.6 .22

98.0 3.86

Figure 3-16: 5604 Vision System Dimensions

46

Appendix A
A.1 Installing the Remote Head Camera
The remote head accessory kit includes the hardware required to secure the remote head camera to a mounting surface. The Lens Tube (item 6) is included with the kit, but is not required for all applications. The Lens Tube is highly recommended for environments where vibration may be present.

5 1 2 3 4

Figure A-1: Remote Head Camera Installation Diagram

1. Attach the remote head camera bracket (item 4) to the mounting surface (refer to Figure 3-12 on page 42). 2. Attach the remote head camera (item 5) to the remote head camera bracket using three M3 x 8mm Phillips head screws (item 3). 3. If required, slide the Lens Tube (item 6) over the remote head camera (item 5) and secure to the remote head camera bracket (item 4), using four M4 x 18mm cap screws (item 1) and lock washers (item 2). 4. Connect the Camera cable to the remote head camera.

47

Appendix A - Installing the Remote Head Camera

48

Appendix B
B.1 Cleaning/Maintenance

B.1.1 Cleaning the Vision System

To clean the outside of the vision system, use a small amount of mild detergent cleaner or isopropyl alcohol on a cleaning cloth. Do not pour the cleaner directly onto the vision system.
Note: Do not attempt to clean In-Sight products with harsh or corrosive solvents, including Lye, methyl ethyl ketone (MEK) or gasoline.

B.1.2 Cleaning the CCD Window

To remove dust from the outside of the CCD window, use a pressurized air duster. The air must be free of oil, moisture or other contaminants that could remain on the glass and possibly degrade the image. Do not touch the glass window. If oil/smudges still remain, clean the window with a cotton bud using alcohol (ethyl, methyl or isopropyl). Do not pour the alcohol directly on the window.

49

Appendix B - Cleaning/Maintenance

50

P/N 597-0027-06
Printed in the USA