High-speed, High-Accuracy
Digital Displacement Sensor
EX-V Series
96M0558
Safety Precautions
Symbols
This instruction manual describes the operation and function of the EX-V. Read this
manual carefully to ensure safe use and maximum performance from your EX-V.
The following symbols alert you to important messages. Be sure to read these
messages carefully.
WARNING
Failure to follow instructions may lead to injury. (electric
shock, burn, etc.)
General precautions
CAUTION
Note:
• At startup and during operation, be sure to monitor the functions and performance of the EX-V.
• We recommend that you take substantial safety measures to avoid any damage
in the event a problem occurs.
• Do not open or modify the EX-V or use it in any way other than described in the
specifications.
• When the EX-V is used in combination with other instruments, functions and
performance may be degraded, depending on operating conditions and the
surrounding environment.
• Do not use the EX-V for the purpose of protecting the human body.
Failure to follow instructions may lead to product damage.
Provides additional information on proper operation.
i
Warning and cautions specific to the EX-V Series
Operating environment
For optimum performance of the EX-V, always maintain a proper operating environment.
CAUTION
Connecting the EX-V to analog input equipment
To prevent malfunction, do not install the EX-V in the following places:
• Places directly exposed to sunlight.
• Places where the ambient temperature drops below 0
• Places where the relative humidity drops below 35% or exceeds 85%.
• Places where temperature fluctuations may cause condensation.
• Places where the EX-V may be exposed to corrosive or flammable gas.
• Places exposed to airborne dust or corrosive substances such as salt or
metal particles.
• Places where the EX-V may be subjected to vibration or impact.
• Places where water, oil or chemicals may splash the EX-V .
• Places where the EX-V may be affected by noise interference.
Take the following countermeasures to prevent the EX-V from malfunctioning due
to noise interference.
Note 1: Use a 1-core shielded cable for the output line. When using an analog
voltage signal, do not use a cable longer than 10 m. If the cable needs to be
longer than 10 m, convert the voltage signal into a current signal.
1-core shielded cable
EX-V
Analog
voltage
output
0 V
Note 2: Keep the wiring and connection cables separate.
Note 3: Isolate the wiring and connection cables from high-voltage or power lines;
otherwise noise may cause the EX-V to malfunction.
°
C or exceeds 50°C.
Various types of
Input
0V
display equipment
96M0558
ii
MEMO
iii
How this manual is organized
Chapter 1Preparation
Describes the package contents, and explains the mounting and adjusting procedures of the controller and sensor head.
Chapter 2Quick Guide to Basic Mode Operation
Explains the kinds of the measurement modes and the selection procedure.
Selecting the mode best suited to your detection purpose allows you to quickly
operate the sensor by easy setting.
Chapter 3Use of Common Functions
Explains the functions common to the respective modes and the setting
procedure.
Chapter 4Use of Data Processing Functions
Explains the setting and operation procedures of the respective functions.
Chapter 5Troubleshooting
Explains the error messages displayed when an error has occurred, and
countermeasures to be taken.
Chapter 6Specifications and Dimensions
Read as necessary.
Index
Read as necessary.
Warranties
iv
Contents
Chapter 1Preparation
1.1Checking the Package Contents .......................................................... 2
1.2Part Names and Functions .................................................................... 3
1.3Terminal Names and Connections .......................................................4
Index .............................................................................................................. 101
Warranties
WARRANTIES AND DISCLAIMERS ............................................................ 109
vi
Quick Index by Function/Operation
This index helps you quickly find proper EX-V function/operation according to your
purpose.
Select action or operation you need to find the proper page and description.
1.6.2 Adjusting the output characteristics .........................................9
Chapter 1 Preparation
1.1Checking the Package Contents
The EX-V series package includes the following parts and equipment. Check that
all the parts and equipment are included in the package.
1
• Instruction manual: 1• Controller: 1
Instruction
Manual
High-speed, High-Accuracy
Digital Displacement Sensor
EX-V Series
• Sensor head:• Panel mounting frame: 1
Ordered one of the following
EX-305V
EX-110V
EX-416V
EX-422V
EX-614V
2
1.2Part Names and Functions
This section explains the part names and functions.
■ Controller
Display
Displays the measured value. The value is
displayed in green when the measured value is
within the tolerance range. The value is displayed
in red when the measured value is out of the
tolerance range.
Comparator output indicators
Illuminates when the comparator output
(HIGH, GO, LOW) is turned on.
Indicates the type of displayed tolerance limit
value when setting or calling the tolerance
limit value.
POWER indicator
Illuminates green:
When operation is normally performed
Illuminates red:
When the control output is reset to OFF
This section explains the mounting procedure for the controller and sensor head
and the wiring connections.
1.5.1 Mounting and dismounting the controller
1
Mounting
Insert the controller from the front of the panel and fix it using the panel mounting
frame.
Dismounting
1. Insert the controller.
Panel
While raising the catches at sections 1 and 2 with a flat blade screwdriver, push the
controller forward from the back.
1
2
2. Fix the controller using the
panel mounting frame.
Panel mounting frame
Push the controller forward.
6
1.5.2 Mounting the sensor head
Mounting
• Tighten the EX-305V set screw and EX-110V nut away from the tip of the
sensor head as shown in the figure.
M3 set screw
EX-305V
• Referring to the measuring distance in the table below, determine the distance
between the tip of the sensor head and target.
ledoM)mm(ecnatsidgnirusaeM
V503-XE1
V011-XE2
V614-XE5
V224-XE01
V416-XE4
Note: After making the adjustment, do not change the position of the nut or screw.
If the position is changed, the output characteristics may change even when the
nut or screw is positioned in the range shown in the figure.
Flush-mounting
To flush-mount the sensor head in a metal base, follow the guidelines given in the
table below.
ledoM
V503-XE019
V011-XE219
V614-XE5301
V224-XE5502
V416-XE23x615
5 mm min.
)mm(ecnatsiD
AB
Chapter 1 Preparation
8 mm min.
1
EX-110V
øA
B
* The table above shows the dimensions to use when the metal base is iron.
* The table above shows the dimensions to satisfy the specifications when the
sensor head is flush-mounted after the output characteristics have been
adjusted with no metal present around the head.
7
Chapter 1 Preparation
When mounting two or more sensor heads of the same model in parallel
• The sensor may not output the correct voltage due to mutual interference. Make
sure that the distance between sensor heads adjacent to each other is larger
than the values shown in the table below. (This allows the display resolution
specification to be satisfied when the number of measurements to average is
1
"64".)
• When two sensor heads are mounted in parallel, mutual interference can be
prevented by alternately oscillating the sensor heads using the synchronous
input terminal (
ledoM
➮
page 4
).
)mm(ecnatsiD
V503-XE08
V011-XE003
V614-XE056
V224-XE013
V416-XE542
Tightening torque
To tighten the EX-305V set screw, apply a torque of 0.2 N•m or less.
To tighten the nut of the other sensor heads, apply a torque shown in the table
below or less.
V011-XEV614-XEV224-XE
.xamm•N01.xamm•N02.xamm•N01
gnitnuomlellaraP
Parallel mounting
CAUTION
• If the applied tightening torque exceeds the specified one, the sensor
head may be deformed or malfunction.
• If the sensor cable is installed in the same conduit as high voltage lines or
power lines, the sensor may malfunction. Be sure to keep the wiring
separate.
Note: Do not change the sensor cable length (3 m). If the cable is extended or cut,
the characteristics will change.
8
1.6Adjustment
1.6.1 Connection
Chapter 1 Preparation
Though the EX-V series has been factory-adjusted, follow the procedure described
below to adjust the sensor using your actual target in order to satisfy the
specifications. When the sensor head has been replaced, be sure to make this
adjustment.
1. Connect the core and shielding wires of the sensor head to sensor head
connection terminals 11 and 12 of the controller.
1
2. After making the connection,
connect the power supply cable to
power supply terminals 1 and 2.
The POWER indicator on the
controller illuminates, and the
sensor enters the operation state.
24V DC
Note: Let the sensor warm up for 30 minutes or more after supplying power to it,
and then start the adjustment.
1.6.2 Adjusting the output characteristics
1. Press the key for at least 2 seconds.
The sensor displays "0" and enters the adjustment mode.
HIGHTIM
GO
LOW
SET
FUNC
UTILITY
–
+
MODE
10
9
8
7
6
5
4
3
2
1
Terminal block
CALL
CALIB
20
19
18
17
16
15
14
13
12
11
Sensor head
2. With no metal object present around the sensor head, press the
key.
The sensor displays "1" and moves to the next setting step.
Note 1: Do not touch the metal area of the sensor head with your hand.
Note 2: Make sure that no metal object is present within a radius of 15 centimeters
around the sensor head.
9
Chapter 1 Preparation
3. Bring the sensor head in contact with the target.
SET
key.
CALL
1
4. Press the
The sensor displays "2" and moves to the next setting step.
5. Move the sensor head.
Move the sensor head so that the distance between the sensor head and target
is the full scale of the measuring distance (maximum distance) of the sensor
head.
Full scale
6. Press the
key.
The sensor displays "3" and moves to the next setting step.
SET
CALL
7. Move the sensor head.
Move the sensor head so that the distance between the sensor head and target
is half the measuring distance (half scale).
Half scale
8. Press the
key.
The sensor displays "End".
SET
CALL
10
9. Press the
key to complete the adjustment.
The sensor starts measurement.
Reference: To stop the adjustment, press the key. Then, the sensor starts
measurement without making the adjustment.
Note: If the distance between the sensor head and target is improperly adjusted
during the adjustment, "Err 6" is displayed. Press the key to cancel the error,
and then readjust the distance.
Chapter 2
Quick Guide to Basic Mode Operation
Explains the kinds of the measurement modes and the selection procedure.
Selecting the mode best suited to your detection purpose allows you to quickly
operate the sensor by easy setting.
2.2Quick Guide to Basic Mode Operation .............................. 14
2.2.1 Setting the bottom-dead-center mode ................................... 14
2.2.2 Setting the eccentricity/vibration mode ..................................18
2.2.3 Setting the thickness/gap mode............................................. 21
2.3Auto-Zero Function ............................................................. 24
2.4Tolerance Limit Value Setting ............................................ 25
2.5Checking the Tolerance Limit Values
(Calling the tolerance limit values) .................................... 27
Chapter 2 Quick Guide to Basic Mode Operation
2.1Measurement Modes
The EX-V series provides the following four measurement modes: "Bottom-deadcenter mode", "Eccentricity/vibration mode", "Thickness/gap mode" (which are
basic modes for quick operation), and "Manual mode" (which allows users to
perform setting as desired). This section explains the major functions of each
mode.
2.1.1 Bottom-dead-center mode
2
This mode is used to measure the displacement of the origin position of a machine
with stroke movements such as a press. When the displacement of the bottom
dead center or origin position is out of the preset tolerance range, the sensor
outputs an Alarm signal.
Major applications
• Detecting the bottom dead center position of a press
• Detecting the bottom dead center position of a press-fit machine
• Detecting the bottom dead center position of a welding machine
• Pressure control for a injection molding machine
• Measuring the depth of the recess on a piston head
Displacement
Bottom dead
center
Displayed value
Time
2.1.2 Eccentricity/vibration mode
This mode is used to measure the roller eccentricity or abnormal machine vibration.
When the amplitude of the runout or vibration is larger than the preset tolerance
limit value, the sensor outputs an Alarm signal.
Major applications
• Measuring roller eccentricity
• Measuring surface plate runout
• Detecting runout due to improper chucking
• Measuring drill bit eccentricity
12
OK
Displacement
NG
Time
2.1.3 Thickness/gap mode
This mode is used to measure target thickness or gap with a direct reading value.
When the thickness or gap is larger or smaller than the preset upper or lower value
for the tolerance limit, the sensor outputs an Alarm signal.
Chapter 2 Quick Guide to Basic Mode Operation
Displayed value
2.1.4 Manual mode
Displacement
Time
Major applications
• Measuring hoop material thickness
• Checking grindstone abrasion
• Thickness control during polishing ceramic components
In addition to the modes above, the manual mode is available. The manual mode
provides the following six data processing modes to allow adaptable measurement.
For details, see pages that describe each data processing mode.
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13
Chapter 2 Quick Guide to Basic Mode Operation
2.2Quick Guide to Basic Mode Operation
This section describes the major measurement modes and an easy setting
method.
2.2.1 Setting the bottom-dead-center mode
The following example explains how to mount the EX-V series to a press.
The basic operation is the same when mounting the EX-V series to other devices.
Be sure to adjust the output characteristics before performing the following procedure. (➮
2
Refer to page 9
1. Secure the sensor head to the lower die of the press.
• Referring to the figure below, prepare the sensor head mounting jig and a
target.
• Refer to pages 7 and 8 for the position of the sensor head nut and the tightening torque.
.)
Target
Sensor head
14
Note: Be sure to use an IRON target with sufficient area for detection. (➮
Reference: When the comparator output is already connected to the emergency
stop or another input for the facility, short-circuit the OUTPUT DISABLE input
(terminal 3) and grounding terminal (terminal 7) to disable the comparator output
before making the adjustment.
* After making the adjustment, be sure to disconnect these terminals to enable the
comparator output.
2. Adjust the distance between the sensor head and target.
Move the press an inch at a time and lower the stripper (or upper die) to the
bottom dead center position. (Refer to the figure below.)
Half the measuring range
Stripper or upper die
Lower die
Die set
Adjust the distance between the sensor head and target so that the distance
between them is about half the measuring distance when the stripper is in the
bottom dead center position. The controller’s display shows a value close to the
half scale.
of the sensor to be used.
In the case of the EX-305V,
the value is close to “0.5”.
p.95
)
Chapter 2 Quick Guide to Basic Mode Operation
* The distance between the sensor head and target should be more than the full scale when the
stripper is in the top dead center position.
Sensor model
EX-305V10.5
EX-110V21
EX-416V52.5
EX-422V105
EX-614V42
Measuring distanceHalf scale
(mm) (Full scale)(mm)
3. Press the key for at least 2 seconds.
The sensor enters the mode setting state and displays the mode number.
Mode No
HIGHTIM
GO
4. Press the
• Pressing the
LOW
SET
FUNC
UTILITY
key to display “1” which indicates the “bottom-dead-center” mode.
key changes the mode number sequentially.
MODE
CALL
CALIB
Mode No.Measurement mode
0Manual
1Bottom-dead-cente
2Eccentricity/vibration
HIGHTIM
GO
LOW
3Thickness/gap
key
• The measurement mode is factory-set to manual.
➮
For the initial setting of each measurement mode, refer to “4.1 Table of Data Processing
Functions” on page 46.
5. Press the key to save the measurement mode setting.
The sensor returns to the measurement state.
Note: Changing the measurement mode initializes all preset values except for the
tolerance limit values.
2
6. Activate the machine and check the bottom dead center position during normal
operation. Press the [ZERO] key to set this position as the reference point.
When the [ZERO] key is pressed, “0000” appears on the measured value
display.
Stripper or upper die
Lower die
Die set
Reference: To compensate for the slight variation in the bottom dead center
position at press startup or the influence of temperature fluctuation, refer to “Previous value comparison function [d]” on page 56.
Normal bottom
dead center
HIGHTIM
GO
LOW
15
Chapter 2 Quick Guide to Basic Mode Operation
7. Set the upper value for the tolerance limit.
For a press, set the threshold value to the amount of the rise of the bottom dead
center due to swarf.
Stripper or upper die
Lower die
Die set
Upper limit value
2
1) Press the
• The sensor enters the tolerance limit setting mode.
• The setting number is displayed.
Note: Press the key for a short time. When the key is pressed for 2 seconds or
longer, the sensor enters the function setting mode and displays “Ab[d”. If you
accidentally put the sensor into the function setting mode, press the key again
to return to the measurement state.
2) Press the
• Pressing the
•“x” indicates the hysteresis setting. (➮
key.
Mode No
HIGHTIM
GO
LOW
SET
FUNC
UTILITY
MODE
CALL
CALIB
key to display the desired setting number.
key changes the setting number sequentially.
key
Refer to page 85.
)
16
Reference: Four kinds of tolerance limit values (“0” to “3”) can be saved in the
memory. The registered setting numbers can be switched using external signals.
(➮
Refer to page 4.
3) Press the
)
key.
• The sensor automatically enters the HIGH limit value setting mode.
• The setting value is displayed in red and the HIGH indicator illuminates.
HIGHTIM
GO
LOW
Chapter 2 Quick Guide to Basic Mode Operation
4) Press the or key to display the desired value.
• Pressing the
key changes the flashing digit to the right.
HIGHTIM
GO
LOW
• Pressing the
key changes the value.
• All digits flash when the fifth digit and sign can be changed.
No setting
(5th digit)
(1st to 4th digits)
Example
When setting the tolerance to +20 µm, specify “0020”.
5) Press the
key.
The HIGH limit setting value is saved. The sensor automatically enters the
LOW limit value setting mode.
HIGHTIM
GO
LOW
8. Set the lower value for the tolerance limit and press the
key.
• For a press, set the threshold value to the amount of the lowering of the
bottom dead center due to the absence of a target.
• Set the LOW limit value using the same procedure as in steps 7 3) and 4),
and press the
key to save the value.
Stripper or upper die
Lower die
Die set
HIGHTIM
GO
LOW
2
Note 1: The output is disabled during the tolerance limit value setting. When the
output is already on, however, the output is retained.
Note 2: Pressing the
key does not save the changes if [HIGH setting value –
Hysteresis] is smaller than [LOW setting value + Hysteresis]. In this case, “Err1” is
displayed. Press the
key again to cancel the error, and then specify the correct
values.
17
Chapter 2 Quick Guide to Basic Mode Operation
2.2.2 Setting the eccentricity/vibration mode
The following example explains the procedure for roller eccentricity measurement.
The basic operation is the same when mounting the EX-V series to other devices.
Be sure to adjust the output characteristics before performing the following
procedure (
➮
page 9
1. Mount the sensor head to the machine.
➮
For the sensor head mounting procedure, read "Mounting the sensor head" (pages 7 and 8).
2
).
Note: Be sure to use an IRON target with sufficient area for detection. (
➮
page 95
Reference: When the comparator output is already connected to the emergency
stop or another input for the facility, short-circuit the OUTPUT DISABLE input
(terminal 3) and grounding terminal (terminal 7) to disable the comparator output
before making the adjustment.
* After making the adjustment, be sure to disconnect these terminals to enable
the comparator output.
2. Press the
key for at least 2 seconds.
The sensor enters the mode setting state and displays the mode number.
Mode No.
HIGHTIM
GO
3. Press the
LOW
SET
FUNC
UTILITY
key to display "2" which indicates the "eccentricity/vibration"
MODE
CALL
CALIB
mode.
• Pressing the
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HIGHTIM
GO
LOW
)
18
key
Chapter 2 Quick Guide to Basic Mode Operation
• The measurement mode has been factory-set to manual.
➮
For the initial setting of the functions for each measurement mode, refer to "4.1 Table of Data
Processing Functions" (page 46).
4. Press the key to save the measurement mode setting.
The sensor returns to the measurement state.
Note: Changing the measurement mode initializes all preset values except for the
tolerance limit values.
5. Activate the machine and check the runout value during normal operation.
The value displayed in this step is the runout per cycle.
6. Set the upper value for the tolerance limit.
Calculate the upper limit value by adding the upper limit value of the required
tolerance to the value displayed during normal operation, and set the value as
the HIGH limit value.
Example
When the runout value during normal operation is "10 µm" and the tolerance is
"+30 µm", set the HIGH limit value to "0.040". When the runout value exceeds "40
µm", the comparator output is turned on.
1) Press the
key.
• The sensor enters the tolerance limit setting mode.
• The setting number is displayed.
Setting No.
HIGHTIM
GO
LOW
SET
FUNC
UTILITY
MODE
CALL
CALIB
Note: Press the key for a short time. When the key is pressed for 2 seconds or
longer, the sensor enters the function setting mode and displays "Ab(d". If you
accidentally put the sensor into the function setting mode, press the key again
to return to the measurement state.
2
2) Press the
• Pressing the
key to display the desired setting number.
key changes the setting number sequentially.
• "x" indicates the hysteresis setting (
➮
page 85
key
).
19
Chapter 2 Quick Guide to Basic Mode Operation
Reference: Four kinds of tolerance limit values ("0" to "3") can be saved in the
memory. The registered setting numbers can be switched using external signals
(
➮
page 4
).
3) Press the
key.
• The sensor automatically enters the HIGH limit value setting mode.
• The setting value is displayed in red and the HIGH indicator illuminates.
2
4) Press the
• Pressing the
• Pressing the
or key to display the desired value.
HIGHTIM
GO
LOW
key changes the flashing digit to the right.
HIGHTIM
GO
LOW
key changes the value.
• All digits flash when the fifth digit and sign can be changed.
No setting
(5th digit)
(1st to 4th digits)
5) Press the key.
The HIGH limit setting value is saved. The sensor automatically enters the
LOW limit value setting mode.
20
HIGHTIM
GO
LOW
6) Press the
key again.
7. Activate the machine to check whether the comparator output correctly works
according to the tolerance limit setting values.
• The GO comparator output indicator on the controller illuminates when the
measured value is within the tolerance range. The HIGH indicator illuminates
when the measured value is higher than the upper limit value. The LOW
indicator illuminates when the measured value is lower than the lower limit
value.
• To perform fine adjustment of the tolerance limit values, repeat steps 5) and
6) described above.
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