IV4-500CA Keyence IV4 Series AI Camera | Advanced Vision Sensor

IV4-500CA | Keyence IV4 Series AI Vision Sensor

The IV4-500CA is a color vision sensor from the Keyence IV4 Series. It combines built-in AI vision functions, automatic focus adjustment, and industrial communication interfaces. Its 1/2.9-inch color CMOS sensor delivers 1280 × 960 pixels. The standard field-of-view design supports inspection distances from 50 mm to 3,000 mm. Engineers can configure up to 65 tools for different inspection tasks. The Keyence IV4-500CA supports Standard Mode, Sorting Mode, and AI Through Count Mode. These functions suit automated inspection, product classification, and counting applications. EtherNet/IP, PROFINET, OPC UA, and MQTT support integration with compatible factory systems.

01 | Hardware Architecture at a Glance

Manufacturer	Keyence
Series	IV4 Series
Model	IV4-500CA
Product Type	AI vision sensor / smart camera
Imaging Type	Color
Image Sensor	1/2.9-inch color CMOS
Image Resolution	1280 × 960 pixels
Focus Adjustment	Automatic
Installation Distance	50–3,000 mm
Lighting	White LED; pulse or continuous operation
Exposure Time	12 μs–10 ms
Available Tools	Up to 65
Operating Modes	Standard, Sorting, AI Through Count
Weight	Approximately 370 g without AI imaging illumination unit; 560 g with unit

02 | Field of View and Image Acquisition

The standard field-of-view configuration supports close-range and long-range inspection. Actual coverage depends on installation distance and the configured optical setup.

Installation Distance	Reference Field of View
50 mm	22 mm horizontal × 16 mm vertical
3,000 mm	1,184 mm horizontal × 888 mm vertical

The camera uses automatic focus adjustment to simplify setup across supported working distances. Exposure settings range from 12 microseconds to 10 milliseconds. Short exposure times can help reduce motion blur on fast-moving targets. Engineering selection note: Verify the smallest defect size against the actual field of view. A wider field covers more parts, but each part occupies fewer pixels. Validate the inspection with real samples before finalizing the mounting position.

03 | AI Inspection and Classification Functions

The IV4-500CA supports three specified operating modes.

• Standard Mode: Supports configured inspection tasks for product presence, appearance, and other suitable visual criteria.
• Sorting Mode: Supports classification tasks when products have defined visual differences.
• AI Through Count Mode: Supports counting applications using the available AI-based functionality.

The system provides up to 65 tools for configuring inspection tasks. The appropriate tool combination depends on the target, inspection objective, and available software functions. Typical inspection objectives include: - Detecting missing components during assembly. - Classifying products by visible appearance. - Counting suitable objects on a conveyor. - Checking component placement and orientation. - Identifying visible surface or packaging differences. - Confirming the presence of selected features before downstream processing. AI-based inspection still requires appropriate training or configuration where applicable. Confirm the supported tool behavior and setup procedure in the manufacturer's documentation.

04 | Industrial Communication and Network Integration

The sensor includes an M12 8-pin X-coded female Ethernet connector. It supports 1000BASE-T and 100BASE-TX Ethernet connections.

Protocol or Service	Supported Function
EtherNet/IP	Industrial controller integration
PROFINET CC-B	Industrial Ethernet communication
TCP/IP non-procedural communication	Two supported communication channels
FTP client	File transfer
SFTP client	Secure file transfer
SNTP client	Network time synchronization
OPC UA server	Structured industrial data access
MQTT client	Message-based data exchange

Communication expansion is available through compatible equipment.

• IV4-CU1 communication unit: Supports PROFINET CC-C and EtherCAT expansion.
• DL Series units: Support selected interfaces, including EtherCAT, CC-Link, DeviceNet, and RS-232C.

Confirm the exact communication-unit model, firmware compatibility, network topology, and required licenses or configuration tools before ordering. Protocol availability does not guarantee that every protocol operates simultaneously in every configuration.

05 | Electrical Ratings and I/O Configuration

Supply Voltage	24 VDC, +25%/−20%, including ripple
Current Consumption at 19.2 V	3.4 A or less, under the stated configuration
Current Consumption at 24.0 V	2.7 A or less, under the stated configuration
Average Power Consumption	9.3 W without AI imaging illumination unit; 12.8 W with unit
PoE	Power Class 4/6, as specified
Inputs	Six total; three can be configured as input or output
Outputs	Six total; three can be configured as input or output
Output Type	Open collector; NPN/PNP selectable; N.O./N.C. selectable
Maximum Output Rating	30 V, 50 mA

The current figures depend on the stated configuration, including the communication unit and output load. Size the supply for the actual system arrangement rather than using the average power figure alone. The open-collector outputs support suitable control signals. Check the connected PLC input type, load current, polarity, and wiring diagram before commissioning.

06 | Environmental Protection and Mechanical Construction

Operating Temperature	0°C to +50°C, without freezing
Relative Humidity	85% RH or below, non-condensing
Protection Rating	IP67, subject to stated accessory exceptions
Vibration Resistance	10–500 Hz, 0.816 G²/Hz, X/Y/Z directions
Shock Resistance	500 m/s², three times in each of six directions
Main Housing	Die-cast aluminum
Front Cover	Hard-coated acrylic
ESD Compliance	IEC 61340-5-1, as specified

The supplied data does not specify the overall dimensions. Confirm the mounting envelope and connector clearance before designing a bracket or enclosure. The stated IP67 rating has exceptions when certain polarizing filters are installed. Review the exact filter model and installation conditions before using the sensor in washdown or wet-process areas.

07 | Suitable Machines and Industrial Applications

The IV4-500CA suits automated machines that need configurable color inspection, counting, or product classification.

• Assembly lines: Verify component presence, orientation, and assembly completeness.
• Packaging equipment: Inspect package features, label placement, and product presentation.
• Electronics manufacturing: Check selected connectors, visible component positions, and assembly features.
• Automotive production: Inspect clips, fasteners, and visible part characteristics.
• Food and beverage lines: Classify products by visible appearance and count suitable items.
• Material handling: Count products or identify categories before sorting and transfer.
• Pharmaceutical packaging: Inspect suitable visible packaging features within validated quality-control processes.

Application success depends on target contrast, color consistency, illumination, distance, motion, and inspection criteria. Reflective surfaces, transparent objects, and subtle defects may require additional testing or specialized lighting.

08 | Installation and Commissioning Procedure

1. Confirm the model. Check the label for IV4-500CA and verify the required accessories.
2. Determine the mounting distance. Position the camera within the supported 50–3,000 mm range.
3. Check target coverage. Confirm that the field of view includes the complete inspection area.
4. Secure the mounting. Minimize vibration and maintain a repeatable camera-to-target relationship.
5. Connect power and Ethernet. Verify the supply method and compatible M12 cabling.
6. Wire the I/O. Confirm input/output assignments, NPN/PNP settings, and PLC electrical compatibility.
7. Configure the inspection. Select the appropriate mode and configure the required tools.
8. Validate performance. Test good parts, known defects, trigger timing, and output behavior under actual production conditions.

Use the manufacturer's wiring and installation documentation for pin assignments, grounding, and safe handling. Disconnect power before changing electrical connections.

09 | Diagnostic Workflow and Common Faults

A repeatable diagnostic process helps identify whether a fault comes from imaging, triggering, electrical wiring, or network communication.

Symptom	Engineering Checks
Inconsistent classification	Compare lighting, target position, exposure, color variation, and configured inspection criteria.
Missed objects	Check trigger timing, object spacing, exposure, and the selected counting configuration.
Unstable image brightness	Inspect LED operation, ambient light, exposure settings, and reflective surfaces.
No PLC response	Check Ethernet link, protocol configuration, controller settings, and result-handling logic.
Input signal not detected	Verify wiring, voltage levels, input assignment, and trigger polarity.
Output does not switch	Check NPN/PNP configuration, N.O./N.C. settings, load current, and PLC input compatibility.
Unexpected restart or shutdown	Measure supply voltage under load and check cable integrity and power capacity.

Field example: A sorting machine occasionally sends correctly classified products to the wrong destination. The engineer compares the camera result with the PLC sequence and output timing. If the classification remains correct, the next checks include output mapping, conveyor tracking, and actuator delay. This procedure separates vision decisions from downstream machine-control errors. It does not assume that every fault is automatically diagnosed by the sensor.

10 | Global PLC Spare HUB's Insight

The main selection consideration for the IV4-500CA is the relationship between field of view, target size, and required inspection accuracy. A wide viewing area can cover more objects, but small defects occupy fewer pixels. For example, a production line may need to verify three small components on a moving assembly. The engineer should first confirm that all three components fit within the selected field of view. The engineer should then test the inspection with different component positions, lighting conditions, and representative defect samples. Communication planning is equally important. A camera may return the correct inspection result while the PLC still handles it incorrectly. Commissioning should therefore test image classification, output mapping, communication timing, and reject-actuator response as separate steps. Before final approval, validate the complete cycle under the fastest expected production conditions. This approach helps reveal timing issues that a static bench test may not detect.

11 | Product Selection Checklist

Choose this model when the project requires a color vision sensor with AI-based inspection modes and industrial Ethernet connectivity. Before purchasing, confirm:

• Field of view: The required inspection area fits the camera's optical coverage.
• Target detail: The image resolution supports the smallest feature or defect.
• Inspection mode: The required task fits Standard, Sorting, or AI Through Count Mode.
• Network compatibility: The PLC or industrial network supports the intended communication method.
• Power arrangement: The supply supports the camera, communication unit, outputs, and any lighting accessories.
• Environmental conditions: Temperature, humidity, vibration, and protection requirements fall within the specified limits.
• Accessories: Confirm cables, brackets, filters, communication units, and lighting requirements.

Do not select a vision sensor by resolution alone. Target geometry, contrast, cycle time, and the complete control-system response determine actual inspection performance.

12 | Packaging, Warranty, and Shipping

• Brand: Keyence
• Series: IV4 Series
• Model: IV4-500CA
• Packaging: Factory packing, subject to order confirmation.
• Warranty: 12 months, subject to the seller's confirmed warranty terms.
• Shipping carriers: FedEx, UPS, and DHL.
• Dispatch target: 24–48 hours after order confirmation, subject to stock and payment verification.

Contact Global PLC Spare HUB to confirm current availability, included accessories, delivery options, and final pricing before ordering.

13 | Frequently Asked Questions

1. How can I determine whether the standard field-of-view model covers my entire inspection area? Measure the target area at the planned mounting distance. Compare those dimensions with the specified horizontal and vertical field of view. Leave suitable alignment margin and test the actual fixture before finalizing the bracket. 2. Is this sensor suitable for inspecting products with different colors or finishes? It can support color-based inspection, but the result depends on illumination, surface reflectivity, and normal product variation. Test samples from different production batches and validate the inspection criteria before release. 3. What should I verify before connecting the sensor to a PROFINET or EtherNet/IP controller? Confirm the supported protocol, controller configuration, network settings, data mapping, and required communication accessories. Test result updates and fault handling during both normal operation and communication interruptions. 4. Can I use the sensor for high-speed counting on a conveyor? Potentially, if the target size, spacing, exposure, and configured inspection cycle meet the required throughput. Test the fastest production rate with closely spaced objects. Verify missed counts and duplicate detections before deployment. 5. Should I purchase the camera with its AI imaging illumination unit? The decision depends on the required lighting arrangement and exact product configuration. Confirm whether the project needs the additional illumination hardware, its compatible cables, and its power requirements. Ask the supplier to verify the complete order configuration before purchase.

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