Omron ZG2 User Manual

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Cat. No. Z288-E1-01

ZG2 Series

Smart Sensor 2D Proﬁ le Measuring Sensors

USERS MANUAL

Introduction

Thank you for purchasing the ZG2 series. This manual provides information regarding functions, performance and operating methods that are required for using the ZG2. When using the ZG2, be sure to observe the following:

• The ZG2 must be operated by personnel knowledgeable in electrical engineering.

• To ensure correct use, please read this manual thoroughly to deepen your understanding of the product.

• Please keep this manual in a safe place so that it can be referred to whenever necessary.

■ How to Switch the Display Language to English

Turn the power ON with the MENU key held down. This displays the display language selection screen.

PLEASE SELECT LANGUAGE

ENG JPN

The Controller will start up with the messages displayed in English when it is next started up.

READ AND UNDERSTAND THIS DOCUMENT(Please Read)

User’s Manual

BEFORE USE

BASIC OPERATIONS

FUNCTION SETTINGS

CONNECTION WITH EXTERNAL DEVICES

MEASUREMENT BY GANGMOUNTED CONTROLLERS

APPENDICES

Smart Sensor 2D Profile Measuring Sensors

ZG2 Series

READ AND UNDERSTAND THIS DOCUMENT

Please read and understand this document before using the products. Please consult your OMRON representative if you have any questions or comments.

WARRANTY

OMRON’s exclusive warranty is that the products are free from defects in materials and workmanship for a period of one year (or other period if specified) from date of sale by OMRON.

OMRON MAKES NO WARRANTY OR REPRESENTATION, EXPRESS OR IMPLIED, REGARDING NON-INFRINGEMENT, MERCHANTABILITY, OR FITNESS FOR PARTICULAR PURPOSE OF THE PRODUCTS. ANY BUYER OR USER ACKNOWLEDGES THAT THE BUYER OR USER ALONE HAS DETERMINED THAT THE PRODUCTS WILL SUITABLY MEET T HE R EQU I RE MENT S OF T HE IR IN TE NDE D USE. OMRON DISCLAIMS ALL OTHER WARRANTIES, EXPRESS OR IMPLIED.

LIMITATIONS OF LIABILITY

OMRON SHALL NOT BE RESPONSIBLE FOR SPECIAL, INDIRECT, OR CONSEQUENTIAL DAMAGES, LOSS OF PROFITS OR COMMERCIAL LOSS IN ANY WAY CONNEC TED WITH THE PRODUCTS, WHETHER SUCH CLAIM IS BASED ON CONTRACT, WARRANTY, NEGLIGENCE, OR STRICT LIABILITY.

In no event shall responsibility of OMRON for any act exceed the individual price of the product on which liability is asserted.

IN NO EVENT SHALL OMRON BE RESPONSIBLE FOR WARRANTY, REPAIR, OR OTHER CLAIMS REGARDING THE PRODUCTS UNLESS OMRON’S ANALYSIS CONFIRMS THAT THE PRODUCTS WERE PROPERLY HANDLED, STORED, INSTALLED, AND MAINTAINED AND NOT SUBJECT TO CONTAMINAT ION, ABUSE, MISUSE, OR INAPPROPRIATE MODIFICATION OR REPAIR.

SUITABILITY FOR USE

THE PRODUCTS CONTAINED IN THIS DOCUMENT ARE NOT SAFETY RATED. THEY ARE NOT DESIGNED OR RATED FOR ENSURING SAFETY OF PERSONS, AND SHOULD NOT BE RELIED UPON AS A SAFETY COMPONENT OR PROTECTIVE DEVICE FOR SUCH PURPOSES. Please refer to separate catalogs for OMRON’s safety rated products.

OMRON shall not be responsible for conformity with any standards, codes, or regulations that apply to the combination of products in the customer’s application or use of the product. At the customer’s request, OMRON will provide applicable third party certification documents identifying ratings and limitations of use that apply to the products. This information by itself is not sufficient for a complete determinatio n of the suitability of the products in combination with the end product, machine, system, or other application or use.

The following are some examples of applications for which particular attention must be given. This is not intended to be an e xhausti ve li st of all possi ble use s of t he produc ts, nor is it intended to imply that the uses listed may be suit able for the products:

• Outdoor use, uses involving potential chemical contamination or electrical interference, or conditions or uses not described in this document.

ZG2 User’s Manual

• Nuclear energy control systems, combustion systems, railroad systems, aviation systems, medical equipment, amusement machines, vehicles, safety equipment, and installations subject to separate industry or government regulations.

• Systems, machines, and equipment that could present a risk to life or property.

Please know and observe all prohibitions of use applicable to the products. NEVER USE THE PRODUCTS FOR AN APPLICATION INVOLVING SERIOUS RISK TO LIFE OR PROPERTY WITHOUT ENSURING THAT THE SYSTEM AS A WHOLE HAS BEEN DESIGNED TO ADDRESS THE RISKS, AND THAT THE OMRON PRODUCT IS PROPERLY RATED AND INSTALLED FOR THE INTENDED USE WITHIN THE OVERALL EQUIPMENT OR SYSTEM.

PERFORMANCE DATA

Performance data given in this document is provided as a guide for the user in determin ing suitability and does not constitute a warranty. It may represent the result of OMRON’s test conditions, and the users must correlate it to actual application requirements. Actual performance is subject to the OMRON Warranty and Limitations of Liability.

CHANGE IN SPECIFICATIONS

Product specifications and accessories may be changed at any time based on improvements and other reasons.

It is our practice to change model numbers when published ratings or features are changed, or when significant construction changes are made. However, some specifications of the product may be changed without any notice. When in doubt, special model numbers may be assigned to fix or establish key specifications for your application on your request. Please consult with your OMRON representative at any time to confirm actual specifications of purchased products.

DIMENSIONS AND WEIGHTS

Dimensions and weights are nominal and are not to be used for manufacturing purposes, even when tolerances are shown.

ERRORS AND OMISSIONS

The information in this document has been carefully checked and is believed to be accurate; however, no responsibility is assumed for clerical, typographical, or proofreading errors, or omissions.

PROGRAMMABLE PRODUCTS

OMRON shall not be responsible for the user’s programming of a programmable product, or any consequence thereof.

This document shall not be copied for sales or promotions wit hout permission. This document is protected by copyright and is intended solely for use in conjunction with

the product. Please notify us before copying or reproducing this document in any manner, for any other purpose. If copying or transmitting this document to another, please copy or transmit it in its entirety.

ZG2 User’s Manual

Meanings of Signal Words

The following signal words are used in this manual.

Indicates a potentially hazardous situation which, if not avoided, will result in minor or moderate injury, or may result in serious injury or death. Additionally there may be significant property damage.

Meanings of Alert Symbols

The following alert symbols are used in this manual

Indicates general prohibitions for which there is no specific symbol.

Indicates the possibility of laser radiation.

Indicates prohibition when there is a risk of minor injury from electrical shock or other source if the product is disassembled.

This product is not designed or rated for ensuring safety of persons. Do not use it for such purposes.

Never look into the laser beam. Doing so continuously will result in visual impairment.

Do not attempt to dismantle, pressurize, or i ncinerate the product. Doing so may cause the laser beam to leak, resulting in the danger of visual impairment.

ZG2 User’s Manual

Precautions for Safe Use

The following points are important to ensure safety, so make sure that they are strictly observed.

1. Installation Environment

• Do not use the product in environments where it can be exposed to inflammable/ explosive gas.

• To secure the safety of operation and maintenance, do not install the product close to high-voltage devices and power devices.

• Install the product in such a way that its ventilation holes are not blocked.

2. Power Supply and Wiring

• The voltage and AC power supply must be within the rated range (DC 24 V ±10%).

• Reverse connection of the power supply is not allowed.

• Open-collector outputs should not be short-circuited.

• Use the power supply within the rated load.

• High-voltage lines and power lines must be wired separately from this product. Wiring them together or placing in the same duct may cause induction, resulting in malfunction or damage.

• Use the product within the power supply voltage specified by this manual.

• Use a DC power supply with safety measures against high-voltage spikes (safet y extra low-voltage circuits on the secondary side).

3. Other

• Do not disassemble, repair, or modify the product.

• Dispose of this product as industrial waste.

• Connect the exclusive device (Sensor). The product might break down or malfunction if you use a part not included in the exclusive products.

• Should you notice any abnormalities, immediately stop use, turn OFF the power supply, and contact your OMRON representative.

ZG2 User’s Manual

Precautions for Correct Use

Observe the following precautions to prevent failure to operate, malfunctions, or undesirable effects on product performance.

1. Installation Site

Do not install this product in locations subjected to the following conditions:

• Ambient temperature outside the rating

• Rapid temperature fluctuations (causing condensation)

• Relative humidity outside the range of 35 to 85%

• Presence of corrosive or flammable gases

• Presence of dust, salt, or iron particles

• Direct vibration or shock

• Reflection of intense light (such as other laser beams or electric arc-welding machines)

• Direct sunlight or near heaters

• Water, oil, or chemical fumes or spray

• Strong magnetic or electr ic field

2. Power Supply and Wiring

• When using a commercially available switching regulator, make sure that the FG terminal is grounded.

• If surge currents are present in the power lines, connect surge absorbers that suit the operating environment.

• Before turning ON the power after the product is connected, make sure that the power supply voltage is correct, there are no incorrect connections (e.g. load short-circuit), and the load current is appropriate. Incorrect wiring may result in breakdown of the product.

• Before connecting/disconnecting devices, make sure that the Sensor/Controller is turned OFF. The Sensor or Controller may break down if it is connected/disconnected while the power is ON.

• Use the extension cable sold separately for extending the cable between the Sensor and the Controller.

p.17

• Use only combinations of the Sensor and Controller specified in this manual.

• Before turning the Controller ON, connect the Sensor. If the Controller is turned ON without the Sensor connected, the Controller’s screen will remain dark and messages cannot be read.

3. Warming Up

After turning the power supply ON, allow the product to stand for at least 30 minutes before use. The circuits are still unstable just after the power supply is turned ON, so measurement values may fluctuate gradually.

ZG2 User’s Manual

4. Maintenance and Inspection

Do not use thinner, benzene, acetone or kerosene to clean the Sensor and Controller. If large dust particles adhere to the filter on the front of the Sensor, use a blower brush (used to clean camera lenses) to blow them off. Do not use breath from your mouth to blow the dust off. To remove dust particles from the Sensor, wipe gently with a soft cloth (for cleaning lenses) moistened with a small amount of alcohol. Do not use excessive force to wipe off dust particles. Scratches to the filter might cause error.

5. Measurement Target

The measurement target is a non-transparent object. The sensor cannot detect the following types of objects accurately: materials with extremely small reflectances, objects smaller than the beam diameter, objects with large curvatures, or objects tilted to a large degree.

6. Effect of Peripheral Lighting

Do not install the Sensor in a place where strong light hits the laser emitter/receiver section of the Sensor. Also, if a measurement target has a shiny surface, the light from the lighting will be reflected and a malfunction may occur. In such a case, prevent reflection by, for example, covering the light to stop reflection.

p.27

7. Compatibility of Mesurement Data

Bank data or System data saved with existing ZG series cannot be processed by ZG2.

ZG2 User’s Manual

Editor’s Note

Important

Note

■ Meaning of Symbols

Menu items that are displayed on the Controller’s LCD screen, and windows, dialog boxes and other GUI elements displayed on the PC are indicated enclosed by brackets “[ ]”.

■ Visual Aids

Indicates points that are import ant to achiev e the full product perf ormance, such as operational precautions.

Indicates application procedures.

Indicates pages where related information can be found.

ZG2 User’s Manual

1. BEFORE USE

ZG2 Series. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16

System Configuration . . . . . . . . . . . . . . . . . . . . . . . . . . 16

Part Names and Functions . . . . . . . . . . . . . . . . . . . . . . 18

Basic Knowledge for Operation . . . . . . . . . . . . . . . . 21

Profile Screen . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 21

Precautions when designing a production line. . . . 22

Measurement Range in Height Direction and Resolution 22

Trigger Measurement/Continuous Measurement . . . . . 24

Mounting and Connecting Devices. . . . . . . . . . . . . . 27

Mounting the Sensor Head . . . . . . . . . . . . . . . . . . . . . . 27

Mounting the Controller. . . . . . . . . . . . . . . . . . . . . . . . . 39

Connecting Devices. . . . . . . . . . . . . . . . . . . . . . . . . . . . 49

Overview of Settings and Measurement. . . . . . . . . . 52

Operation Modes. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 52

Tasks and Bank Data . . . . . . . . . . . . . . . . . . . . . . . . . . 53

STD Menu and EXP Menu . . . . . . . . . . . . . . . . . . . . . . 55

Initializing Controller Settings . . . . . . . . . . . . . . . . . . . . 56

2. BASIC OPERATIONS

Flow of Basic Setup . . . . . . . . . . . . . . . . . . . . . . . . . . 58

Starting Measurement . . . . . . . . . . . . . . . . . . . . . . . . 66

Monitoring the Measurement Status . . . . . . . . . . . . . . . 66

Magnifying the Profile Display. . . . . . . . . . . . . . . . . . . . 67

Function Keys . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 68

ZG2 User’s Manual

3. FUNCTION SETTINGS

Setting Measurement Conditions . . . . . . . . . . . . . . . 70

How to Select Measurement Items . . . . . . . . . . . . . . . . 70

Measuring Height . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 72

Measuring Step . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 74

Measuring Position and Width. . . . . . . . . . . . . . . . . . . . 77

Measuring Angle . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 79

Measuring Angle and Point of Intersection . . . . . . . . . . 80

Measuring Cross-sectional Area . . . . . . . . . . . . . . . . . . 82

Measuring Point of Inflection. . . . . . . . . . . . . . . . . . . . . 83

Calculating Measurement Values . . . . . . . . . . . . . . . . . 86

Deleting measurement items. . . . . . . . . . . . . . . . . . . . . 86

Customizing Measurement Conditions . . . . . . . . . . 87

Magnifying the Profile Display. . . . . . . . . . . . . . . . . . . . 87

Changing Measurement Positions. . . . . . . . . . . . . . . . . 88

Changing Measurement Points. . . . . . . . . . . . . . . . . . . 89

Changing the Edge Level and Edge Direction. . . . . . . . 90

Scaling of Measurement Values . . . . . . . . . . . . . . . . 91

Image Adjustment. . . . . . . . . . . . . . . . . . . . . . . . . . . . 96

Adjusting Sensitivity. . . . . . . . . . . . . . . . . . . . . . . . . . . . 96

Changing Sensitivity Adjustment Region. . . . . . . . . . . . 99

Adjusting Profiles. . . . . . . . . . . . . . . . . . . . . . . . . . . . . 100

Adjusting the background filtering level. . . . . . . . . . . . 104

Setting noise filtering . . . . . . . . . . . . . . . . . . . . . . . . . . 104

Setting the high-power mode (increasing the amount of

emitted light) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 105

Adjusting received light gain . . . . . . . . . . . . . . . . . . . . 105

Position Correction . . . . . . . . . . . . . . . . . . . . . . . . . 106

Slope Correction . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 107

Height/Position Correction. . . . . . . . . . . . . . . . . . . . . . 109

Adjusting the Output Conditions of the Measurement

Result. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 111

Setting the Average Number of Measurements . . . . . 111

Setting Smoothing . . . . . . . . . . . . . . . . . . . . . . . . . . . . 111

Setting the Hold Function . . . . . . . . . . . . . . . . . . . . . . 112

Setting Zero Reset . . . . . . . . . . . . . . . . . . . . . . . . . . 114

Setting the Offset Value. . . . . . . . . . . . . . . . . . . . . . . . 114

ZG2 User’s Manual

Executing Reference Zero Reset . . . . . . . . . . . . . . . . 115

Bank Settings . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 116

Bank Switching (change of device setup) . . . . . . . . . . 116

Copying Bank Data . . . . . . . . . . . . . . . . . . . . . . . . . . . 116

Clearing Bank Data . . . . . . . . . . . . . . . . . . . . . . . . . . . 117

System Settings . . . . . . . . . . . . . . . . . . . . . . . . . . . . 118

Setting the Sensor Head Installation Status . . . . . . . . 118

Sensor Head Inclination Correction. . . . . . . . . . . . . . . 118

Setting the CCD Mode. . . . . . . . . . . . . . . . . . . . . . . . . 121

Setting the Sensor Head Data Loading Method . . . . . 121

Setting the Number of Digits Past the Decimal Point . 122

Setting/Changing the ECO Display . . . . . . . . . . . . . . . 122

Displaying the Controller Information . . . . . . . . . . . . . 122

Setting/Changing the Display Language. . . . . . . . . . . 123

Setting the Icon Color . . . . . . . . . . . . . . . . . . . . . . . . . 123

Saving the Setup Data. . . . . . . . . . . . . . . . . . . . . . . . . 123

4. CONNECTION WITH EXTERNAL DEVICES

ZG2 User’s Manual

Output Data List . . . . . . . . . . . . . . . . . . . . . . . . . . . . 126

Using the Controller I/O Cable. . . . . . . . . . . . . . . . . 127

Wiring the Controller I/O Cable . . . . . . . . . . . . . . . . . . 127

Assignments and Functions of I/O Signal Wires. . . . . 128

I/O Circuit Diagrams . . . . . . . . . . . . . . . . . . . . . . . . . . 130

Analog Output Settings . . . . . . . . . . . . . . . . . . . . . . . . 132

Setting for Measurement by the TRIG Signal . . . . . . . 136

Setting for Switching Banks by the BANK Signal . . . . 136

Checking Signal Statuses . . . . . . . . . . . . . . . . . . . . . . 137

Setting the GATE Signal . . . . . . . . . . . . . . . . . . . . . . . 137

Using the Parallel Output Unit (sold separately). . 138

Connecting the Parallel Output Unit . . . . . . . . . . . . . . 138

Layout of Output Terminals. . . . . . . . . . . . . . . . . . . . . 138

Output Circuit. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 139

Output Format of Measurement Values . . . . . . . . . . . 140

Output Format of Judgment Results . . . . . . . . . . . . . . 141

Assignment of Terminal Block Output. . . . . . . . . . . . . 143

Setting the Number of Digits Past

the Decimal Point . . . . . . . . . . . . . . . . . . . . . . . . . . . . 143

Setting GATE Signal at Parallel Output. . . . . . . . . . . . 143

I/O Timing Charts . . . . . . . . . . . . . . . . . . . . . . . . . . . 144

Serial Communication . . . . . . . . . . . . . . . . . . . . . . . 149

Using the Serial Interface . . . . . . . . . . . . . . . . . . . . . . 149

Connecting Peripheral and External Devices . . . . . . . 152

Serial Auto Output at Trigger Measurement . . . . . . . . 155

Setting Automatic Output. . . . . . . . . . . . . . . . . . . . . . . 155

Setting the RS-232C Communication Specifications . 156

Setting the Node No. . . . . . . . . . . . . . . . . . . . . . . . . . . 156

About Communication Commands . . . . . . . . . . . . . . . 157

Bank Control Commands . . . . . . . . . . . . . . . . . . . . . . 160

Measurement Control/Measurement Value Acquisition

Commands . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 162

Setting Acquisition/Change Commands . . . . . . . . . . . 165

Backup/Restore Commands . . . . . . . . . . . . . . . . . . . . 168

Utility commands. . . . . . . . . . . . . . . . . . . . . . . . . . . . . 172

Parameter List . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 176

Command Processing Time . . . . . . . . . . . . . . . . . . . . 181

5. MEASUREMENT BY GANG-MOUNTED CONTROLLERS

Mounting Order and Assignment of CH Numbers. 184

Setup Example . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 185

Measuring Wide Measurement Targets . . . . . . . . . . . 185

Required Settings. . . . . . . . . . . . . . . . . . . . . . . . . . . 187

Setting Mutual Interference Prevention . . . . . . . . . . . . 187

Settings Common to Gang-mounted Controllers. . . . . 189

Calculations Performed on Measurement Values Obtained

on Multiple Channels. . . . . . . . . . . . . . . . . . . . . . . . . . 190

I/O . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 191

ZG2 User’s Manual

6. APPENDICES

Specifications and External Dimensions . . . . . . . . 194

Sensor Head . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 194

Controller. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 203

Accessories. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 206

Error Messages and Corrective Actions . . . . . . . . 211

Troubleshooting . . . . . . . . . . . . . . . . . . . . . . . . . . . . 213

Menu List. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 216

List of Key Operations . . . . . . . . . . . . . . . . . . . . . . . 218

Laser Safety . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 219

Classification . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 219

Label Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . 219

Requirements from Regulations and Standards . . 222

Summary of Requirements to Manufactures. . . . . . . . 222

Summary of Requirements to User. . . . . . . . . . . . . . . 226

Definitions of Laser Classification . . . . . . . . . . . . . . . . 229

Compliance with EC Directives. . . . . . . . . . . . . . . . 231

Updating the Firmware. . . . . . . . . . . . . . . . . . . . . . . 232

Index . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 237

Revision History . . . . . . . . . . . . . . . . . . . . . . . . . . . . 240

ZG2 User’s Manual

MEMO

ZG2 User’s Manual

BEFORE USE

ZG2 Series 16 Basic Knowledge for Operation 21 Precautions when designing a production

line 22 Mounting and Connecting Devices 27 Overview of Settings and Measurement 52

BEFORE USE

ZG2 Series

Sensor Head

Controller Controller

ZG2 series

Up to two units

can be

gang-mounted.

ZG2-WDC11/WDC41

Smart Monitor ZG2 (exclusive PC software)

ZG2-WDS70 ZG2-WDS22 ZG2-WDS8T ZG2-WDS3VT

Detects the measurement target.

Performs measurement processing and outputs the result.

Photoelectric sensor, etc.

A trigger signal is input to control measurement timing.

Exclusive PC software allows complex setups and verification of measurement values to be performed with ease. SmartMonitor ZG2 and USB cable are ZG2-WDC_1A accessories.

Measurement by the ZG2 series can be started immediately merely by connecting the model of Sensor Head suited to the application to the Controller. Also, the ZG2 series can support various measurement applications by using it in combination with peripheral devices.

System Configuration

ZG2 Series

ZG2 User’s Manual

Sensor Head-Controller extension cable (option)

Extension cable ZG2-XC_ _CR: (3 m, 8 m, 15 m, 25 m) (flexible cable)

Cable for Sensor:

0.5 m, 2 m (flexible cable)

Exclusive extension cables are available for extending the installation distance between the Sensor Head and the Controller.

ZG-RP D

PARALLEL OUTPUT UNIT

RS-23 2 C

DATA

PLC

Graphic Data Controller ZP-C

Data Storage Unit ZG2-DSU11 /DSU41

RS-232C connector cable (option)

For PC: ZS-XRS2 For PLC/PT: ZS-XPT2

Parallel Output Unit ZG-RPD11 /RPD41

A USB connection allows measurement data to be captured easily on a PC. Also, the Controller can be controlled from a PC (e.g. switching/changing of setup data and input of measurement trigger).

Measurement values and judgment results can be output at high speed on the parallel interface.

Measurement values and judgment results can be acquired, and the controller can be controlled (e.g. setup data can be switched/changed and measurement triggers can be input).

The analog signals of measurement values can be displayed as a waveform, and judgment results can be displayed in color.

Measurement data can be collected and profiles saved. Also, up to 4096 banks' (16 banks x 256 files) of measurement conditions can be registered if the number of banks on the Controller is insufficient. A USB connection allows data to be captured on a PC. For details, refer to the ZG2-DSU User's Manual.

Exclusive cables are available to match the conn ected dev ice.

BEFORE USE

ZG2 User’s Manual

ZG2 Series

Part Names and Functions

[ZG2-WDS3VT] [ZG2-WDS8T/WDS22] [ZG2-WDS70]

(1)

(3)

(2)

(4)

(1)

(3)

(2)

(4)

(3)

(2)

(1)

(4)

Sensor Head

Name Function

(1) Laser indicator These are laser beam warning indicators. The “standby indicator

(STANDBY)” indicates that the laser beam is ready for emission, and the “laser energized indicator (LD ON)” indicates that the laser is energized. Both indicators are OFF until Controller startup is completed after the power is turned ON.

Indicator At startup RUN/ADJ/FUN mode

LD OFF in progress

Standby indicator (STANDBY)

Laser indicator (LD ON)

(2) Laser emitter This emits the laser for measurement. (3) Laser receiver This receives the laser light reflected from the measurement target. (4) Connector This is the connector for connecting to the Controller.

ZG2 Series

OFF ON ON

OFF OFF ON

LD ON in progress

ZG2 User’s Manual

Controller

(2) (3) (4)

(1)

(5)

(1)

(3)

(2)

Display Operation Panel Connectors

(2)

(1)

(3)

(4)

(5)

(6)

Display

Name Function

(1)Judgment indicator The indicator turns ON when the result of task judgment is OK, and

turns OFF when a setting is not made, measurement is OFF, the result of a judgment is NG, or an error occurs.

(2) Laser indicator The laser indicator turns ON while the Sensor Head is emitting a

laser beam.

(3) Zero Reset indicator The Zero Reset indicator turns ON when the zero reset function is

enabled. (4) Trigger indicator The Trigger indicator turns ON when a trigger signal is input. (5) LCD monitor The LCD monitor displays setup menus and images captured from

the Sensor Head.

BEFORE USE

ZG2 User’s Manual

ZG2 Series

Operation Panel

Important

Name Function

(1) Control keys These keys are used for setting measurement conditions or

switching the display.

List of Key Operations p.218

(2) Mode switch This switch selects the operation mode.

FUN : Select this mode when setting measurement conditions.

Select this mode when adjusting the judgment threshold value.

ADJ : RUN : Select this mode when performing measurement. Measurement results and judgment results are output only when the RUN mode is currently selected.

(3) Menu switch This switch selects the setup menu.

STD : Standard menu. Select this when setting the minimum

required items for measurement.

EXP : Expert menu. Select this when making a more detailed setup.

Connectors

Name Function

(1) Sensor Head

connector

(2) Function extension

connector

(3) USB port Connect the USB cable (MINI-B) to the USB port to connect to a

(4) RS-232C connector Connect the RS-232C cable (exclusive product) when you are

This connector connects the Sensor Head.

Insert this connector into the Controller Link Unit when gangmounting Data Storage Units and Controllers. Slide the cover (supplied) downwards to open.

personal computer.

connecting the Controller to a PLC, programmable terminal or personal computer.

RS-232C cable p.17

(5) Voltage/Current

switch

(6) I/O cable The I/O cable connects the Controller to the power supply and

ZG2 Series

This switch is for selecting voltage output or current output as the analog output. (default value: voltage output)

Before operating this switch, make sure that the Controller is turned OFF.

external devices, such as timing sensors or programmable controllers.

ZG2 User’s Manual

Basic Knowledge for Operation

X-axis +X-axis -

Z-axis -

Z-axis +

NEAR

-5.00 mm

FAR

+5.00 mm

The ZG2 series is a non-destructive type sensor that measures cross-section shapes by emitting a wide band of laser light onto the object and capturing light reflected from the object by a CCD. This CCD imaging information is used to generate a profile of the object’s shape, and dimensional shapes, such as height, steps, width, position, points of intersection, inclination, and cross-sectional area, can be measured instantaneously from the cross-section shape of the object.

Profile Screen

A cross-section shape of the measurement object displayed on screen is called a “profile.” Profiles are displayed on screen as a yellow line.

In the RUN/ADJ modes, the measurement state can be visually checked by these profiles. Also, in the FUN mode, profiles can be used to set the measurement conditions. Height measurement items are already set as the default, so it is possible to know immediately the detection status of the Sensor Head by setting the operation mode to the RUN mode.

On the ZG2 series, measurement points in the height and width directions are measured on the vertical (Z-axis) and horizontal (X-axis) axes, respectively. Measurement values are displayed as numerical values prefixed with a + (plus) or - (minus) sign depending on the coordinate position.

BEFORE USE

ZG2 User’s Manual

Basic Knowledge for Operation

Precautions when designing a production line

Measurement range in high-speed mode Measurement range in standard/high-resolution mode

Measurement center The measurement center distance does not change even if the CCD mode is changed.

The following describes details to be aware of before installing the ZG2 on a production line.

Measurement Range in Height Direction and Resolution

The ZG2 incorporates the CCD mode function that alters how the CCD is used to achieve high-speed and high-resolution measurement.

When the CCD mode is changed, the measurement range in the height direction and the resolution are altered.

For actual details of measurement ranges, refer to the respective pages that explain mounting of each of the sensor heads.

Mounting the Sensor Head p.27

Precautions when designing a production line

ZG2 User’s Manual

Three CCD Modes and Their Characteristics

High-resolution mode: min. 16 ms 400 pixels 100 pixels 50 pixels

Standard mode: min. 8 ms High-speed mode: min. 5 ms

631 pixels 631 pixels 631 pixels

By quadrupling the number of pixels in the height direction

By decreasing the number of pixels into 1/2 in the height direction

High-resolution measurement of the shape of measurement targets

Shape measurement in fast line speed processes

Standard images look flat.

Surfaces, in fact, are slightly uneven.

Resolution in the height direction changes as follows according to the CCD mode.

Setting the CCD Mode p.121

The resolution in the horizontal direction does not change. When measuring edge position or width, select the CCD mode based on the response time as the resolution will not change whichever mode is selected.

Note

Number of pixels and resolution

To express the clarity on a digital camera or image scanner, the term “resolution” is used. The same approach is used on the ZG2 series, too. A “high resolution” expresses a sharp image, while a “low resolution” expresses a grainy image. Resolution is determined by the number of pixels per unit area. Though a sh arper or highe r re solut ion image is obtained, the more pixels there are per unit area, processing takes that much longer proportionate to the amount of information for that image.

BEFORE USE

ZG2 User’s Manual

Precautions when designing a production line

Trigger Measurement/Continuous Measurement

Trigger

The ZG2 series is provided with two measurement modes, “input of an external trigger to start measurement” and “continuous measurement with out th e need for inp ut of a trigger.” Note, however, that available sensitivities are restricted by the type of trigger and direction in which the measurement object is moving. Select which combination to use to suit your specific application.

Measurement trigger and direction in which object is flowing Appropriate sensitivity

Measurement by external trigger When object can be made

stationary When object cannot be

made stationary

Continuous measurement AUTO sensitivity/FIXED

Note

High-speed MULTI sensitivity/MULTI sensitivity

AUTO sensitivity/FIXED sensitivity

sensitivity

The default setting is continuous measurement. To perform measurement by an external trigger, the setting must be changed.

Setting for Measurement by the TRIG Signal p.136

Precautions when designing a production line

ZG2 User’s Manual

What is “Sensitivity Adjustment?”

In the case of a mountain-shaped

measurement object

Light emitted from Sensor

Areas where reflected light will have difficulty entering the CCD

High Low Medium Low High

Reference plane

Reflectance

The reflectance of the reference plane differs from that of inclined surfaces.

Areas having low reflectance cannot be measured due to insufficient light amount.

Sensitivity adjustment

Reproduction of profile

It is relatively easy to measure the shape of a measurement target that receives a sufficient and uniform amount of light. However, in the case of measurement targets having a complex shape, inclined surfaces cause reflected light to decrease and areas of insufficient received light to occur. There are also cases where the amount of received light is insufficient or, alternatively, saturated caused by the color or material of the measurement target. In this way, the sensitivity of the Sensor must be adjusted so that shapes are accurately captured even if the shape, color, material, etc. of the measurement target is influenced.

BEFORE USE

ZG2 User’s Manual

Precautions when designing a production line

Sensitivity Adjustment Functions of the ZG2 Series

The optimum sensitivity is adjusted for individual lines and combined to form the image.

The optimum sensitivity common to all lines is adjusted.

Sensitivity is fixed for all lines.

The ZG2 series is provided with three sensitivity adjustment functions.

Adjusting Sensitivity p.96

High-speed MULTI sensitivity/MULTI sensitivity

The amount of received light per individual line is judged and the appropriate sensitivity for each individual line is adjusted to accommodate for all kinds of shape, color and material. The measurement target must be made stationary as time is required to capture multiple image frames while changing the sensitivity.

High-speed MULTI sensitivity is used when MULTI sensitivity is required on lines having a fast tact time. The upper/lower limit range at which sensitivity is switched and the capture count can be restricted. The optimum sensitivity and number of image frames are set automatically within this range. Note, however, that the measurement must first be made stationary even in the high-speed MULTI sensitivity mode.

AUTO sensitivity

FIXED sensitivity

Precautions when designing a production line

The amount of received light for all lines is judged to adjust to the appropriate s ensitivity for the entire area. As sensitivity is batchadjusted for all lines, the response is not as slow as that for MULTI sensitivity, so this mode is a generally applicable mode.

In this mode, a predetermined sensitivity is used. As sensitivity is not adjusted during measurement, response is fast, making it ideal for when a trigger is input at short intervals to perform measurement.

ZG2 User’s Manual

Mounting and Connecting Devices

Mounting the Sensor Head

Never look into the laser beam. Doing so continuously will result in visual impairment. Never look into the laser beam.

Do not attempt to dismantle, pressurize, or incinerate the p roduct. Doing so may cause the laser beam to leak, resulting in the danger of visual impairment. Do not attempt to dismantle, pressurize, or incinerate the product.

Installations to Suit Measur ement Target and Environment

Pay attention to the following points when mounting the Sensor Head to prevent measurement precision from dropping.

Color/shiny surface boundary

Emission axis

Boundary line

Narrow grooves or indentations

Reception axis

Mounting near walls

Measurement errors can be reduced by installing the Sensor Head with the line formed by the emission and reception axes parallel to the wall, and painting the wall with non-reflective black paint.

Rotating objects

You can minimize the influence caused by vibration of the rotating object and positional shifts by installing the Sensor Head with the line formed by the emission and reception axes parallel to the axis of rotation.

BEFORE USE

Measuring stepped objects

ZG2 User’s Manual

Effect of peripheral lighting

Do not install the Sensor Head in a place where strong light hits the laser emitter/receiver section of the Sensor. Also, if a measurement target has a shiny surface, the light from the lighting will be reflected and a malfunction may occur. In such as case, prevent reflection, for example, by covering the light to stop reflection.

Mounting and Connecting Devices

Mounting the ZG2-WDS70

Important

Mounting for diffuse reflection measurement

Emission axis

Reception axis

210 mm

19°

Measurement target

Fix by mounting screws making sure that the distance between the Sensor Head and measurement target is matched.

Mounting method

Fasten the Sensor Head onto the mounting base with M4 screws.

Tightening torque: 1.2 N·m

For details on the positions of screw holes, check the external dimensions in “APPENDICES.”

External dimensions p.196

Mounting position

Mount the Sensor Head according to the following distances and angle.

Mounting and Connecting Devices

ZG2 User’s Manual

Measurement range

Important

Numerical values in the figure are for when the standard CCD mode is set. When the CCD mode is changed, check the values in the table below.

BEFORE USE

Measurement center distance

NEAR end

CENTER

FAR end

210 mm

+30 mm

0 mm

-30 mm

CCD Mode Measurement

center distance

Standard mode

Highresolution mode

High-speed mode

210mm ±30 mm NEAR end: 63mm 300 µm

Spread angle 10°

Measurement range (width)

63 mm

70 mm

79 mm

Measurement range (height)

±48 mm NEAR end: 57mm 410 µm

±15 mm NEAR end: 66mm 210 µm

Measurement range (width)

CENTER: 70mm 120 µm FAR end: 79mm 300 µm

CENTER: 70mm 120 µm FAR end: 83mm 410 µm

CENTER: 70mm 120 µm FAR end: 74mm 210 µm

Angle of intersection 19°

: Irradiation range

: Measurement range

Beam diameter

The beam diameter and measurement range (width) between the NEAR/FAR ends are nominal values, and are not to be used as guaranteed values.

ZG2 User’s Manual

Mounting and Connecting Devices

Mounting the ZG2-WDS22

Important

Fix by mounting screws making sure that the distance between the Sensor Head and measurement target is matched.

Mounting method

Fasten the Sensor Head onto the mounting base with M4 screws.

Tightening torque: 1.2 N·m

For details on the positions of screw holes, check the external dimensions in “APPENDICES.”

External dimensions p.197

Mounting position

Mount the Sensor Head according to the following distances and angle.

12.5°

Emission axis Reception axis

100 mm

25°

Measurement target

Mounting for diffuse reflection measurement

Emission axis Reception axis

94 mm

Measurement target

Mounting for regular reflection measurement

Note

The default mounting state of the Sensor Head is for diffuse reflection measurement. To set the Sensor Head for regular reflection measurement, change the Sensor Head mounting setting.

Setting the Sensor Head Installation Status p.118

Mounting and Connecting Devices

ZG2 User’s Manual

Measurement range

NEAR end

+12 mm

CENTER

0 mm

FAR end

-12 mm

Measurement center distance

100 mm

Spread angle 10°

Angle of intersection 25°

: Measurement range

: Irradiation range

20 mm

22 mm

24 mm

Measurement range (width)

Beam diameter

Important

Numerical values in the figure are for when the standard CCD mode is set. When the CCD mode is changed, check the values in the table below.

BEFORE USE

CCD Mode Measurement

center distance

Standard mode/ high-resolution mode

High-speed mode

The beam diameter and measurement range (width) between the NEAR/FAR ends are nominal values, and are not to be used as guaranteed values.

100mm ±12 mm NEAR end: 20mm 220 µm

Measurement range (height)

±6 mm NEAR end: 21mm 140 µm

Measurement range (width)

CENTER: 22mm 60 µm FAR end: 24mm 220 µm

CENTER: 22mm 60 µm FAR end: 23mm 140 µm

Beam diameter

ZG2 User’s Manual

Mounting and Connecting Devices

Important

Measurement center distance

94 mm

NEAR end

CENTER

FAR end

+10 mm

0 mm

-10 mm

CCD Mode Measurement

center distance

Standard mode/

94mm ±10 mm NEAR end: 20mm 220 µm high-resolution mode

Measurement range (width)

20 mm

22 mm

24 mm

Measurement range (height)

Measurement range (width)

CENTER: 22mm 60 µm

Angle of intersection 25°

: Irradiation range : Measurement range

Beam diameter

FAR end: 24mm 220 µm

Spread angle 10°

High-speed mode

±6 mm NEAR end: 21mm 140 µm

CENTER: 22mm 60 µm FAR end: 23mm 140 µm

The beam diameter and measurement range (width) between the NEAR/FAR ends are nominal values, and are not to be used as guaranteed values.

Mounting and Connecting Devices

ZG2 User’s Manual

Mounting the ZG2-WDS8T

Important

Mounting for diffuse reflection measurement

Emission axis Reception axis

50 mm

30°

Measurement target

Mounting for regular reflection measurement

Emission axis Reception axis

44 mm

Measurement target

15°

Fix by mounting screws making sure that the distance between the Sensor Head and measurement target is matched.

Mounting method

Fasten the Sensor Head onto the mounting base with M4 screws.

Tightening torque: 1.2 N·m

For details on the positions of screw holes, check the external dimensions in “APPENDICES.”

External dimensions p.197

Mounting position

Mount the Sensor Head according to the following distances and angle.

BEFORE USE

Note

The default mounting state of the Sensor Head is for diffuse reflection measurement. To set the Sensor Head for regular reflection measurement, change the Sensor Head mounting setting.

Setting the Sensor Head Installation Status p.118

ZG2 User’s Manual

Mounting and Connecting Devices

Measurement range

Important

Numerical values in the figure are for when the standard CCD mode is set. When the CCD mode is changed, check the values in the table below.

Measurement center distance

50 mm

NEAR end

CENTER

FAR end

+3 mm

0 mm

-3 mm

CCD Mode Measurement

center distance

Standard mode/

50mm ±3 mm NEAR end: 7.9mm 120 µm high-resolution mode

Measurement range (width)

7.9 mm

8.0 mm

8.6 mm

Measurement range (height)

Angle of intersection 30°

: Irradiation range

: Measurement range

Beam diameter

Measurement range (width)

Beam diameter

CENTER: 8.0mm 30 µm FAR end: 8.6mm 120 µm

Spread angle 10°

High-speed mode

±1.5 mm NEAR end: 7.7mm 110 µm

CENTER: 8.0mm 30 µm FAR end: 8.3mm 110 µm

The beam diameter and measurement range (width) between the NEAR/FAR ends are nominal values, and are not to be used as guaranteed values.

Mounting and Connecting Devices

ZG2 User’s Manual

Important

Measurement center distance

NEAR end

CENTER

FAR end

44 mm

+2 mm

0 mm

-2 mm

Spread angle 10°

Measurement range (width)

7.9 mm

8.0 mm

8.6 mm

BEFORE USE

Angle of intersection 30°

: Irradiation range

: Measurement range

Beam diameter

CCD Mode Measurement

center distance

Standard mode/ high-resolution mode

High-speed mode

The beam diameter and measurement range (width) between the NEAR/FAR ends are nominal values, and are not to be used as guaranteed values.

44mm ±2 mm NEAR end: 7.9mm 120 µm

Measurement range (height)

±1 mm NEAR end: 7.9mm 105 µm

Measurement range (width)

CENTER: 8.0mm 30 µm FAR end: 8.6mm 120 µm

CENTER: 8.0mm 30 µm FAR end: 8.1mm 105 µm

Beam diameter

ZG2 User’s Manual

Mounting and Connecting Devices

Mounting the ZG2-WDS3VT

Important

Reception axis

22.3 mm

Emission axis

Measurement target Measurement target

Mounting for regular reflection measurement

Mounting for diffuse reflection measurement

20°

Emission axis Reception axis

10.6 mm

40°

Note

Fix by mounting screws making sure that the distance between the Sensor Head and measurement target is matched.

Mounting method

Fasten the Sensor Head onto the mounting base with M4 screws.

Tightening torque: 1.2 N·m

For details on the positions of screw holes, check the external dimensions in “APPENDICES.”

External dimensions p.199

Mounting position

Mount the Sensor Head according to the following distances and angle.

The default mounting state of the Sensor Head is for regular reflection measurement. To set the Sensor Head for diffuse reflection measurement, change the Sensor Head mounting setting.

Setting the Sensor Head Installation Status p.118

Mounting and Connecting Devices

ZG2 User’s Manual

Measurement range

2.9 mm

3.0 mm

3.1 mm

Measurement range (width)

Angle of intersection 40°

: Measurement rang

: Irradiation range

Beam diameter

+0.5 mm

CENTER

FAR end

Measurement center distance

22.3 mm

NEAR end

0 mm

-0.5 mm

Important

Numerical values in the figure are for when the standard CCD mode is set. When the CCD mode is changed, check the values in the table below.

BEFORE USE

CCD Mode Measurement

center distance

Standard mode/ high-resolution mode

High-speed mode

The beam diameter and measurement range (width) between the NEAR/FAR ends are nominal values, and are not to be used as guaranteed values.

22.3mm ±0.5 mm NEAR end: 2.9mm 40 µm

Measurement range (height)

±0.25 mm NEAR end: 2.95mm 33 µm

Measurement range (width)

CENTER: 3.0mm 25 µm FAR end: 3.1mm 40 µm

CENTER: 3.0mm 25 µm FAR end: 3.05mm 33 µm

Beam diameter

ZG2 User’s Manual

Mounting and Connecting Devices

NEAR end

+0.4 mm

CENTER

0 mm

FAR end

-0.4 mm

Measurement center distance

10.6 mm

2.9 mm

3.0 mm

3.1 mm

Measurement range (width)

Angle of intersectio

: Measuremen

: Irradiation ra

Beam diameter

Important

CCD Mode Measurement

center distance

Standard mode/

10.6mm ±0.4 mm NEAR end: 2.9mm 40 µm high-resolution mode

Measurement range (height)

Measurement range (width)

Beam diameter

CENTER: 3.0mm 25 µm FAR end: 3.1mm 40 µm

High-speed mode

±0.2 mm NEAR end: 2.95mm 33 µm

CENTER: 3.0mm 25 µm FAR end: 3.05mm 33 µm

The beam diameter and measurement range (width) between the NEAR/FAR ends are nominal values, and are not to be used as guaranteed values.

Mounting and Connecting Devices

ZG2 User’s Manual

Mounting the Controller

Important

Cautions Regarding the Mounting Orientation

To improve heat radiation, install the Controller only in the orientation shown below.

Do not install the Controller in the following orientations:

BEFORE USE

• Do not block the ventilation holes at the top and bottom of the Controller body. Doing so will cause heat to build up inside and result in a malfunction.

• When the temperature inside the control panel exceeds the ambient temperature of 50°C, provide forced-air cooling or more space at surrounding areas, or improve air circulation to lower the ambient temperature to 50°C or less.

ZG2 User’s Manual

Mounting and Connecting Devices

Mounting on a DIN Track

Important

DIN track (sold separately) PFP-100N (1 m) PFP-50N (0.5 m) PFP-100N2 (1 m)

End plate

Mount Controllers on a DIN track correctly according to the number of Controllers to be used.

When using only one Controller

1 Hook the connector end of the

Controller onto the DIN track.

2 Push the Controller down onto

the DIN track until the hook on the I/O cable side is locked.

After mounting the Controller on the DIN track, attach the end plates on both sides of the Controller.

Mounting and Connecting Devices

ZG2 User’s Manual

When gang-mounting devices

Controller Link Unit (sold separately)

Important

Indentation

The following explains how to mount Controllers when using a Data Storage Unit as well or when gang-mounting two Controllers on the DIN track.

1 Hook the connector end of the

Controller onto the DIN track.

2 Push the Controller down onto

the DIN track until the hook on the I/O cable side is locked.

3 Open the gang-mount cover.

Slide the cover downwards to remove.

4 Insert the Controller Link Unit into

the connector on the unit on the left side.

BEFORE USE

ZG2 User’s Manual

The connector must be inserted at the correct orientation. Insert so that the indentation on the Controller Link Unit in the figure above matches the connector protrusion on the unit on the left side.

Mounting and Connecting Devices

5 Slide the Controller on the right

Note

Important

DIN track (sold separately) PFP-100N (1m) PFP-50N (0.5m) PFP-100N2 (1m)

End plate

side towards the Controller Link Unit so that it fits into the Controller Link Unit.

The mounting method is the same even when two Controllers are gangmounted onto the Data Storage Unit. Mount in the following order: Data Storage Unit → 1st Controller → 2nd Controller.

Attach the end plates on both sides of the Controller.

Removing the Controller from the DIN track (when using only one Controller)

Mounting and Connecting Devices

1 Pull the hook on the I/O cable end

of the Controller downwards.

2 Lift up the Controller from the I/O

cable end, and remove it from the DIN track.

ZG2 User’s Manual

Removing Controllers from the DIN track (when gang-mounting devices)

Controller Link Unit (sold separately)

Note

1 Slide the Controller so that it is

removed from the connector on the Controller Link Unit.

BEFORE USE

2 Remove the Controller Link Unit

from the connector on the Data Storage Unit.

3 Attach the covers to the Data

Storage Unit and Controller g ang mount.

4 Pull the hook on the I/O cable end

of the Controller downwards.

5 Lift up the Controller from the I/O

cable end, and remove it from the DIN track.

The removal method is the same even when two Controllers are gangmounted onto the Data Storage Unit. Remove in the following order: 2nd Controller → 1st Contro ller → Data Storage Unit.

ZG2 User’s Manual

Mounting and Connecting Devices

Mounting on a Panel

Panel

Mounting

bracket

Mount Controllers on a panel correctl y according to the number of Control lers t o be used.

When using only one Controller

1 Push out the Controller from the

rear of the panel towards the front.

When mounting on a panel p.206

Panel mount adapter

2 Install the short Panel Mount

Adapters on the four holes on the Controller.

3 Install the long Panel Mount

Adapters on the two holes on the Controller.

4 Install the Controller with Mount

Adapters attached onto the panel from the front.

5 Hook the hooks of the mounting

fixture onto the two holes of the short Mount Adapters and tighten the screws.

6 Make sure that the Controller is

firmly fixed on the panel.

Mounting and Connecting Devices

ZG2 User’s Manual

When gang-mounting devices

Important

L D

O N

A B

L D

O N

A B

O N

E R

L E

O N

E R

L E

Panel

L D

O N

A B

L D

O N

A B

O N

E R

L E

O N

E R

L E

Panel mount adapters

Important

1 Mount the Data Storage Unit and

Controllers onto the DIN track.

When gang-mounting devices p.41

When mounting devices on a panel, too, be sure to install the DIN track on the rear side of the devices.

2 Push out the Data Storage Unit

and Controllers from the rear of the panel towards the front.

3 Install the short Panel Mount

Adapters on the four holes on the Data Storage Unit and Controllers.

BEFORE USE

ZG2 User’s Manual

Install the short Panel Mount Adapters on the gang-mounted Data Storage Unit and all Controllers.

Mounting and Connecting Devices

4 Install the long Panel Mount

LD ON ZERO

ENABLE

LD ON ZERO

ENABLE

LD ON

ZERO

ENABLE

LD ON

ZERO

ENABLE

Panel mount adapters

Important

Panel

Important

Mounting bracket

Important

Adapters on the two holes on the short Panel Mount Adapter.

Attach the long Panel Mount Adapters on only both sides of the gangmounted Data Storage Unit and Controllers.

5 Install the Data Storage Unit and

Controllers with Mount Adapters attached onto the panel from the

R O

B LE

L D

R O

front.

Take care not to nip the I/O cable.

Mounting and Connecting Devices

6 Hook the hooks of the mounting

fixtures onto the two holes of the short Mount Adapters and tighten

the screws.

Attach fixtures at two locations of each of the gang-mounted Data Storage Unit and all Controllers.

7 Make sure that the Data Storage

Unit and Controllers are firmly fixed on the panel.

ZG2 User’s Manual

Combinations of Gang-mounted Controllers

Important

OUTPUT

RUN

OUTPUT

RUN

OUTPUT

RUN

LD ON ZERO ENABLE

OUTPUT

RUN

ZG2-WDCZG2-WDC

ZG2-WDC ZG2-WDCZG2-DSU

ZG2-WDCZG2-DSU

With the ZG2 series, one Data Storage Unit (ZG2-DSU) and up to two Controllers (ZG2WDC) can be gang-mounted. For details on the Data Storage Unit (ZG2-DSU), refer to the ZG2-DSU User’s Manual.

• Supply power to all of the gang-mounted Controllers.

• The following three gang-mount combinations and arrangements are allowed. Note that other combinations and arrangements will not result in proper operation.

BEFORE USE

ZG2 User’s Manual

Mounting and Connecting Devices

CH number when Controllers are gang-mounted

Data Storage

Unit

CH0 CH1 CH2

Controller

(fixed)

Important

CH1 CH2

CH numbers are automatically assigned as follows when Controllers are gang-mounted. To collect data from a Controller using the Data Storage Unit (ZG2-DSU_1), select the CH number of the targeted Controller.

LD ON ZERO ENABLE

OUTPUT

RUN

• In the gang-mounted arrangement, the Data Storage Unit must be located at the leftmost end viewed from the front.

• Even wh en the Data Storage Unit is not gang-mounted, the CH numbers of the Controllers are CH1 and CH2 in this order from the left.

LD ON ZERO ENABLE

OUTPUT

RUN

Mounting and Connecting Devices

ZG2 User’s Manual

Connecting Devices

Important

Ferrite coreFerrite core

Ferrite core

Before connecting/disconnecting the Sensor Head, make sure that the Controller is turned OFF. The Controller may break down if the Sensor Head is connected or disconnected while the power is ON.

1 Attach the ferrite cores (supplied)

to both ends of the Sensor cable.

2 Insert the Sensor Head connector

into the Controller until it locks in place.

3 Connect the Controller’s I/O cable

and power supply.

If the Controller is turned ON without the Sensor Head connected, the Controller ’s screen will remain dark and messages cannot be read. Before turning the Controller ON, connect the Sensor Head.

Attaching the Ferrite Cores

Attach the ferrite cores (supplied) to both ends of the Sensor Head cable and to the Controller’s I/O cable.

BEFORE USE

ZG2 User’s Manual

Mounting and Connecting Devices

Connecting Cables

Important

1 Insert the Sensor Head’s

connector straight into the Sensor Head connector on the Controller.

Make sure that you hear the connector snap firmly into place when it is connected.

2 Fasten firmly with the fastening

screws (two screws, one each on the left and right).

• Do not touch the terminals inside the connector.

• All settings on the Controller will be cleared if the Sensor Head is replaced with a different type.

• Fasten the connector while making sure that it is not subjected to vibration or shock.

• Do not mount the Controller in such a way that a load is steadily applied on the connector, for example, with tension applied to the cables.

When wiring, do not bend the cable for at least 10 mm from the edge of the connector.

At least 10 mm

Mounting and Connecting Devices

If the cable is bent in the first 10 mm away from the edge of the connector, stress may adversely affect measurements.

10 mm or less

ZG2 User’s Manual

ZG2-XC3CR: 3 m ZG2-XC8CR: 8 m ZG2-XC15CR: 15 m ZG2-XC25CR: 25 m

Extension cable Cable for Sensor

(flexible cable): 0.5 m, 2 m

(Flexible cable)

Important

Loosen the fastening screws (two locations) to unlock the cable, and then draw out the connector straight from the Sensor side.

Note

The cable connection between the Sensor Head and the Controller can be extended by using the extension cable (sold separately). Attach the ferrite cores (supplied) to both ends of the extension cable.

To extend the connection between the Sensor Head and the Controller

Connecting the Power Supply

1 Connect the power wire (brown)

and GND wire (blue) of the Controller’s I/O cable to the 24 VDC (

±10%) power supply.

BEFORE USE

ZG2 User’s Manual

Note

The following power supply is recommended:

• S8VS-03024 (24V DC, 1.3 A)

Be sure to connect the Controller to the power supply in a 1:1 connection.

Mounting and Connecting Devices

Overview of Settings and Measurement

ADJ mode

RUN mode

FUN mode

MEAS

FUN

Top Screen

109.052 10 mm LV: 1-320

HEIGHT1 B01T1

Top Screen

Operation Modes

The ZG2-WDC has the following three operation modes. Switch to the desired mode before you start operation.

To switch the operation mode, use the mode switch.

Mode Description

FUN mode This mode is for setting the measurement

conditions. The easy-to-follow icon-based display allows operations to be performed intuitively.

ADJ mode This mode is for checking the

measurement state, and setting threshold values and output conditions.

RUN mode This mode is used for performing actual

measurement. The measurement information is displayed on the LCD screen.

Overview of Settings and Measurement

HEIGHT1 B01T1

109.052 10 mm LV: 1-320

ZG2 User’s Manual

Tasks and Bank Data

(Task 1)

Height

Width

Step

(Task 2)

(Task 3)

(Task 4)

Crosssectional area

Bank 1

Setting for product class A

Bank 2

For product class B

Bank 3

For product class C

Bank 4

For product class D

Multi-task Measurement

On the ZG2 series, up to eight measurements for a single profile can be processed simultaneously. This function is called “multi-task measurement.”

Example:

Measurement is performed with “height,” “width,” “step” and “cross-sectional area” set to tasks 1 to 4, respectively. In other words, this means that the total of tas ks 1 to 4 allow you to judge the shape.

Data for Change of Device Setup

If you register bank data for each individual model, you can reduce the time required for changing the device setup as all you need to do is to select different bank data to change the measurement conditions.

BEFORE USE

ZG2 User’s Manual

Overview of Settings and Measurement

Relationship between Tasks and Bank Data

You can register up to eight tasks to a single set of bank data. Up to 16 sets of bank data can be set and saved on the ZG2 series, so you can prepare up to 128 measurement patterns by combining bank data with task settings. Combinations of bank data and tasks become the measurement and judgment condition settings.

Measurement/judgment conditions

Bank 1

• Profile registration information

• Setup information of image adjustment function

•

Setup information of filter conditions

Bank 2

Bank 3

Bank 16

168x

Note

The maximum number of banks that can be saved on a Controller is 16. This can be expanded up to 4096 banks (16 banks × 256 files) by gang-mounting the Data Storage Unit (ZG2-DSU). For details, refer to the ZG2-DSU User’s Manual.

Number of banks

Task 1

• Item registration information

• Custom setup information

• Scaling setup information

• Judgment threshold value information

Task 2

Task 3

Task 8

=128 measurement patterns

Overview of Settings and Measurement

ZG2 User’s Manual

STD Menu and EXP Menu

Standard settings

Adjustment/ Custom setup

STD menu

EXP menu

Run in STD menu

Run in EXP menu

The Controller has two setup modes, the “STD menu” and the “EXP menu.” The features of each of these menus are as follows.

This menu is designed for ease of operation, so its setting and adjustment ranges are limited. Setting in this mode comprises only three steps, so you can start measurement immediately.

This menu allows you to set all adjustment functions. You can use this menu to execute advanced measurement processing, such as measurement of image angle, calculation of processing items and selection of characteristic points.

Switching the menu

The STD and EXP menus are switched by the menu switch on the front of the Controller. The two menus cannot be selected simultaneously during menu operation as the menu is fixed by the menu switch.

BEFORE USE

ZG2 User’s Manual

Overview of Settings and Measurement

Initializing Controller Settings

Important

The settings of all banks and system settings are initialized regardless of the currently selected bank No. To save the settings, back them up to a personal computer before performing initialization.

• Receive System Data <SYSSAVE command> p.171

• Receive Bank Data <BANKSAVE command> p.169

1 Switch to the FUN mode.

The top screen is displayed.

FUN

SYS

1. SAVE

INIT

3. SENSOR SET

4. CCD MODE

←→ P1/3

SYS/INIT

CLEAR ALL DATA

YES

2 Select [System].

3 Select [INIT].

4 Move to [YES] and press the SET

key.

Overview of Settings and Measurement

ZG2 User’s Manual

BASIC OPERATIONS

Flow of Basic Setup 58 Starting Measurement 66

BASIC OPERATIONS

Flow of Basic Setup

0.00000 mm LV:320

2PTS-2 B01T2

The following describes the flow of basic setup using, as an example, "2-pt step".

step 1

step 2

step 3

step 4

step 5

step 6

Displaying the reference target object Display the target profile on the Controller's LCD monitor.

p.59

Stabilizing the shape profile (APS function) Use the APS function to perform auto-tuning to obtain the optimum

settings to match the surface shape (e.g. color, shape and material) of the measurement object.

p.60 Registering the profile of th e re fe re nc e target Use this profile to set the measurement conditions.

p.61 Selecting measurement items Select from height, step, width, and other items to suit your particular

measurement requirements.

p.62 Setting the measurement area The optimum region can be automatically set by simply enclosing the

desired measurement area. This area can be fine-adjusted later on.

p.63 Adjusting the judgment threshold value Perform a test measurement and determine the threshold values.

Flow of Basic Setup

p.64

ZG2 User’s Manual

Displaying the reference target object

step 1

1 Switch to the STD menu.

Note

FUN

MEAS

1TEACH 2IMAGE

Sensor Head mounting conditions

2 Switch to the FUN mode.

The top screen of the FUN mode is displayed.

3 Select [MEAS].

4 Set the measurement object in

place.

The profile is displayed.

BASIC OPERATIONS

If necessary, change the Sensor Head installing settings (for diffuse reflection measurement or for regular reflection measurement), or change the receiving status of the Sensor Head CCD before setting the measurement conditions.

Setting the Sensor Head Installation Status p.118 Setting the CCD Mode p.121

ZG2 User’s Manual

Flow of Basic Setup

Stabilizing the shape profile (APS function)

step2

1TEACH 2IMAGE

MEAS

Note

1 Display the screen on the left and

press the MENU/VIEW key.

The confirmation message is displayed.

MEAS

EXECUTE FILTER SETTING AUTOMATICALLY. YES NO

MEAS

1TEACH 2IMAGE

2 Move to [YES] and press the SET

key.

The optimum profile acquisition conditions are automatically set.

When profiles are not displayed as intended

Troubleshooting p.213

Flow of Basic Setup

ZG2 User’s Manual

Registering the profile of the reference target

step3

1TEACH 2IMAGE

MEAS

1 Select [TEACH].

BASIC OPERATIONS

MEAS

TEACH

PROFILE

YES NO

1TEACH 2IMAGE

MEAS

1TEACH 2IMAGE 3SENS 4CORECT

2 Move to [YES] and press the SET

key.

This registers the profile. Set the measurement position and edge level while viewing the registered profile. The registered profile is held in memory until teaching is performed again.

ZG2 User’s Manual

Flow of Basic Setup

Selecting measurement items

step 4

1TEACH 2IMAGE 3SENS 4CORECT

MEAS

Important

1 Select [SENS].

Note

MEAS/SENS

TASK2:----

←→

P1/ 2

MEAS/ITEM T2

2PTS-2

←→

P2/5

To measure multiple items

2 Select [TASK2].

The default setting for [TASK1] is [HEIGHT1]. To change [TASK1] to another measurement item, select [TASK1] and change to the desired measurement item. When a measurement item is changed, the message "CHANGE ITEM" is displayed. Move to [YES], and press the SET key.

How to Select Measurement Items p.70

3 Select [2PTS-2] from the

measurement items.

Scroll pages by the

→ RIGHT key, and select the

measurement item.

← LEFT/

Simultaneous measurement of up to eight items can be performed. To do this, repeat steps 2 and 3.

Flow of Basic Setup

ZG2 User’s Manual

Setting the measurement area

step 5

↑↓ 50.000mm ←→

123LINE SET

TRIMMING

Important

Center line

Area for point 1 Area for point 2

1 Adjust the top left of the desired

measurement area, and press the SET key.

BASIC OPERATIONS

Note

TRIMMING

↑↓ 10.000mm ←→

450LINE SET

MEAS/2PTS-2

1ITEM 2CUSTOM 3SCALE

2 Adjust the bottom right of the

desired measurement area, and press the SET key.

Adjust the area so that the center line overlaps the vicinity of the area of the vertical line so as to enclose the two steps to be measured.

When the desired measurement area is enclosed, the region in which measurement points are extracted is automatically set.

• If the target area is not displayed by automatic setting, select [CUSTOM], and adjust the area for each individual measurement point.

• To narrow the area in the vertical direction, adjust by the sensitivity adjustment area.

p.99

ZG2 User’s Manual

Flow of Basic Setup

Adjusting the judgment threshold value

step 6

Profile

Measurement result

Note

HEIGHT1 B01T1

1FILTER 2OUT

1 Switch to the ADJ mode.

2PTS-2 B01T2

109.052 10 mm LV: 1-320

To switch the task display, use the ↑ UP key/↓ DOWN key.

The profile is continuously measured. Perform test measurement while altering the measurement target.

2 Press the MENU/VIEW key.

The condition setup monitor screen is displayed.

3 Select [OUT].

Flow of Basic Setup

HEIGHT1 B01T1

1JUDGE 2ZERO 3ERROR 4HOLD

4 Select [JUDGE].

ZG2 User’s Manual

HEIGHT1/JUDGE

Important

1.HIGH

2.LOW

to 6,000 mm

5 Set the HIGH and LOW

thresholds.

Note

To change numerical values, use the digits use the

The default judgment threshold value is the "rated measurement range of the currently connected Sensor Head ÷ 4".

Example: As the measurement range of the ZG2-WDS70 (diffuse reflection type) is "60 mm" (±30 mm), the default judgment threshold value becomes "60 ÷ 4=15". So, the default threshold judgment value is ±15 mm.

← LEFT key/→ RIGHT key.

↑ UP key/↓ DOWN key, and to change the number of

BASIC OPERATIONS

ZG2 User’s Manual

Flow of Basic Setup

Starting Measurement

Profile monitor Digital monitor Eco monitor

109.05210 mm LV: 1-320

HEIGHT1 B01T1

Measurement items Bank No.

Task No.

Profile

Measurement result Sensitivity level

1 Switch to the [RUN] mode.

Measurement will start.

Monitoring the Measurement Status

The measurement information is displayed on the LCD scree n. You can switch the screen to display different measurement information according to your specific application.

HEIGHT1 B01T1

109.052 10 mm

LV: 1-320

MENU /VIEW

B01 T1: HEIGHT1 1,109.05210 mm T 2: 2PTS-1 1,109.05210 mm T3:----

T4:----

Profile monitor

MENU /VIEW

XXXXms NORMAL

B01

MENU VIEW

The currently measured profile is displayed. When multiple tasks are registered, switch the profile and display it for each individual task.

Note

To switch the task display, use the ↑ UP key/

↓ DOWN key.

Starting Measurement

ZG2 User’s Manual

Digital monitor

B01 T1: HEIGHT1 1,109.05210 mm T2: 2PTS-1 1,109.05210 mm T3:----

T4:----

↑↓ P1/2

Bank No. Task No.: measurement items

Measurement result

Note

B01

XXXXms NORMAL

Bank No.

Measurement cycle CCD mode

When the desired region of the profile is enclosed, it is displayed magnified.

While the profile display is magnified, "SU" is displayed at the bottom right of the screen.

Measurement results for each individual t ask are displayed as a list as numerical values.

To switch between the tasks 1 to 4 and tasks 5 to 8 displays, use the

↑ UP key/↓ DOWN

key.

Eco monitor

The measurement cycle and CCD mode are displayed.

Magnifying the Profile Display

A specified area of the profile display can be magnified.

 RUN mode-F4 key-[MGNIFY]

MGNIFY

↑↓ 50.000mm ←→

123LINE SET

HEIGHT1

1MGNIFY 2RESET SU

BASIC OPERATIONS

ZG2 User’s Manual

Starting Measurement

Function Keys

Function keys

11.975 mm

LV: 1-320

HEIGHT1 B01T1

Lock status

In the RUN mode, the following functions are assigned to function keys F1 to F4.

Function keys Function

F1 If the F1 key is pressed when [I/O]-[I/O LINE]-[TRIGGER]-

[ENABLE] is set, the trigger is input.

F2 The image is displayed. T o return the display to the normal display ,

press the F2 key again. Measurement is stopped while the image is displayed.

F3 When the F3 key is pressed

and held down for 3 seconds or longer, the key lock confirmation message is displayed. When the key lock function is ON, the FUN/ADJ/ RUN modes cannot be switched. To cancel the key lock, press and hold down the

F3 key for 3 seconds or longer.

F4 Magnifies the profile display.

BASIC OPERATIONS

ZG2 User’s Manual

Magnifying the Profile Display p.67

Starting Measurement

FUNCTION SETTINGS

Setting Measurement Conditions 70 Customizing Measurement Conditions 87 Scaling of Measurement Values 91 Image Adjustment 96 Position Correction 106 Adjusting the Output Conditions of the

Measurement Result 111 Setting Zero Reset 114 Bank Settings 116 System Settings 118

FUNCTION SETTINGS

Setting Measurement Conditions

Point of inflection

Step

Edge position Edge position

How to Select Measurement Items

Desired measurement Measurement item and setting

Height Peak, bottom, average

Height at which angle varies considerably

Step One reference plane

Disparity (indentation and protrusion) between two reference planes

Height measurement items

+[CUSTOM]-[POINT]-[BEND]

2-pt step measurement items

3-pt step measurement items

Reference

p.72

p.83

p.74

Position Position in X-direction

Setting Measurement Conditions

Edge position measurement items

ZG2 User’s Manual

p.77

Desired measurement Measurement item and setting

Width

Angle (θ)

Angle2 (θ)

(X, Y)

Cross-sectional area (mm

)

Controller CH1

Width

Controller CH2

Position Position of peak and bottom in

X-direction

Height measurement items

+[CUSTOM]-[POS.]-[X POS]

Width

Angle

Edge width measurement items

Angle measurement items

Reference

p.72 p.88

p.77

p.79

FUNCTION SETTINGS

Point of intersecti on

Crosssectional area

Width Measurement by two Sensor Heads

Point of intersection angle, point of intersection coordinate measurement items

Cross-sectional area measurement items

Controller CH1 Edge position measurement items + calculation

Controller CH2 Edge position measurement items

p.80

p.82

p.77 p.86

ZG2 User’s Manual

Setting Measurement Conditions

Measuring Height

Height

Height Height

↑ ↓ 10.000 mm ←→ 450 LINE SET

MEAS/CUSTOM

Three measurement items are provided according to the type of height measurement.

Item Description

Measures the average value inside a region.

Average

Measures the maximum value (peak) inside a region.

Peak

Measures the minimum value (bottom) inside a region.

Bottom

Flow of Operations

Assign the desired item from among the height-related measurement items to an unused task.

Setting Measurement Conditions

MEAS/HEIGHT1

1ITEM 2CUSTOM 3SCALE

step4 Selecting measurement items p.62

2 Enclose the desired

measurement area.

The measurement region is automatically set.

In the EXP menu, select [AUTO] and set up this item.

3 Check that the region is set

correctly.

When the region is not ideally set to the desired measurement position, select [CUSTOM]-[REGION] to adjust the region.

ZG2 User’s Manual

Note

Start position

End position

Setting value Description

Reference

REGION Fine-adjusts the measurement region when it is not ideally

set by AUTO.

–

MGNIFY Magnifies the profile display. p.87 POS. (measurement

position)

Selects whether to output the position of the measurement value as the position in the height direction (Z coordinate) or as the position in the horizontal direction (X coordinate).

p.88

MEAS (enabled only in EXP menu)

Sets in more detail which height in the line beam that the target is to be measured at. Settings: AVE, PEAK, BTM, BEND

p.89

Adjust the start and end points of the measurement region so that the desired measurement position is enclosed.

Hint for adjusting the measurement region

Note

Custom settings available for height measurement

FUNCTION SETTINGS

ZG2 User’s Manual

Setting Measurement Conditions

Measuring Step

2-pt step

Step

3-pt step

Step

P2 (average)

P1 (average)

Step

P2 (peak)

P1 (average)

Step

P1 (average)

P2 (average)

Step

P1 (average)

P2 (bottom)

Measures the step from the reference plane.

• When there is one reference plane, select “2-pt step”.

• When there are two reference planes, select “3-pt step”.

<2-pt step>

To measure a protrusion (+ direction) taking the base as the reference plane:

Item Description

Measures the step between the average values of P1 and P2.

Average

Measures the step between the average value of P1 and the maximum value of P2.

Peak

To measure an indentation (- direction) taking the top surface as the reference plane:

Item Description

Measures the step between the average values of P1 and P2.

Average

Bottom

Setting Measurement Conditions

Measures the step between the average value of P1 and the minimum value of P2.

ZG2 User’s Manual

<3-pt step>

Step

P3 (average)

P1 (average)

P2 (average)

Step

P3 (peak)

P1 (average)

P2 (average)

Step

P2 (average)

P1 (average)

P3 (average)

Step

P2 (average)

P1 (average)

P3 (bottom)

To measure a protrusion (+ direction) taking the base as the reference plane:

Item Description

Measures the step between the average value of P3 taking the average values of both sides (P1,

Average

Peak

P2) as the reference plane.

Measures the step between the maximum value of P3 taking the average values of both sides (P1, P2) as the reference plane.

To measure an indentation (- direction) taking the top surface as the reference plane:

Item Description

Measures the step between the average value of P3 taking the average values of both sides (P1,

Average

Bottom

P2) as the reference plane.

Measures the step between the minimum value of P3 taking the average values of both sides (P1, P2) as the reference plane.

FUNCTION SETTINGS

Flow of Operations

The following example describes how to set 2-pt step.

1 Assign the desired item from

ZG2 User’s Manual

among the 2-pt step-related measurement items to an unused task.

step4 Selecting measurement items p.62

Setting Measurement Conditions

TRIMMING

Important

Center line

(reference)

(step=P2-P1)

(reference) (reference)

P2P3

(step=P3 -(P1+P 2)÷2)

2-pt step 3-pt step

Setting value Description

Reference

REGION Fine-adjusts the measurement region when it is not ideally

set by AUTO.

–

MGNIFY Magnifies the profile display. p.87 POINT (enabled only in

EXP menu)

Sets in more detail which height in the line beam that the target is to be measured at. Settings: AVE, PEAK, BTM

p.89

2 Enclose the desired

measurement area.

In the EXP menu, select [AUTO] and set up this item.

↑↓ 10.000 mm ←→ 123 LINE SET

Adjust the region so that the center line is aligned with the “mid point between the top and bottom of the step.”

MEAS/2PTS-1

3 Check that the region is set

correctly.

When the region is not ideally set to the desired measurement position, select [CUSTOM]-[REGION] to

Note

1ITEM 2CUSTOM 3SCALE

Hint for adjusting the measurement region

adjust the region for each measurement point.

Adjust the start and end points of the region for each measurement point.

Note

Custom settings available for step measurement

Setting Measurement Conditions

ZG2 User’s Manual

Measuring Position and Width

Edge position

Width

Performs measurement taking the point of intersection of t he profile and the edge lev el as an edge.

Item Description

Measures the edge that is positioned on the left side inside a region.

Left

Measures the edge that is positioned on the right side inside a region.

Right

Item Description

Measures the width of the protrusions between edges that are extracted inside a region.

Width

Measures the width of the indentations between edges that are extracted inside a region.

Width

FUNCTION SETTINGS

The following example describes how to set edge width.

ZG2 User’s Manual

Flow of Operations

1 Assign the desired item from the

edge width-related measurement items to an unused task.

step4 Selecting measurement items p.62

Setting Measurement Conditions

TRIMMING

Important

Center line

Edge level

Start position End position

Setting value Description

Reference

REGION Fine-adjusts the measurement region when it is not ideally

set by AUTO.

–

MGNIFY Magnifies the profile display. p.87 EDGELV (enabled only

in EXP menu)

Selects the edge level and edge search direction. p.90

↑↓ 10.000 mm ←→ 123 LINE SET

2 Enclose the desired

measurement area.

In the EXP menu, select [AUTO] and set up this item.

Adjust the region so that the center line is aligned with the “edge to be detected.”

MEAS/WIDTH1

3 Check that the region is set

correctly.

When the region and edge level are not ideally set to the desired

1ITEM 2CUSTOM 3SCALE

Note

Adjust the start and end points of the measurement region, and edge level so that the desired measurement position is enclosed. The edge level can be changed only in the EXP menu.

Note

Hint for adjusting the measurement region

Custom settings available for position and width measurement

measurement position, adjust each of region and edge level.

Setting Measurement Conditions

ZG2 User’s Manual

Measuring Angle

Angle (θ)

Setting value Description

Reference

MGNIFY Magnifies the profile display. p.87 POINT (measurement

value)

Sets in more detail which height in the line beam that the target is to be measured at. Settings: AVE, PEAK, BTM

p.89

The angle of the profile inside the region is measured. Measurement of the angle is enabled only in the EXP menu.

Item Description

The average values inside the region are each extracted as points. A straight line is drawn

Angle

between the two extracted points, and the angle formed by the intersection between that straight line and the X-axis is measured as the angle.

Flow of Operations

1 Switch to the EXP menu.

Switching the menu p.55

2 Assign the angle measurement

item to an unused task.

step4 Selecting measurement items p.62

FUNCTION SETTINGS

MEAS/CUSTOM

1REGION 2MGNIFY 3POINT

Note

ZG2 User’s Manual

Custom settings available for angle measurement

3 Select [ CUSTOM ]-[ REGION ], and

set two regions on the line.

Setting Measurement Conditions

Measuring Angle and Point of Intersection

Angle2 (θ)

Measurement point (X, Z)

The angle at the point of intersection of two li nes a nd p oin t o f int ersecti on co ordi nates are measured. Measurement of the angle and point of intersection is en abled onl y in t he EXP menu.

Item Description

Extracts the average value of each region as points P1 to P4, respectively. Points P1/P2

Angle2

Item Description

Corner

and P3/P4 are each joined by a straight line, and the angle formed by the intersection between these two straight lines is measured. The angle is calculated in the clockwise direction taking the line formed by joining points P1 and P2 as the reference.

Extracts the average value of each region as points P1 to P4, respectively. Points P1/P2 and P3/P4 are each joined by a straight line, and, the height (Z coordinate or position (X coordinate) of that point of intersection is measured.

Flow of Operations

The following example describes how to set point of intersection angle.

1 Switch to the EXP menu. 2 Assign the point of intersection

Setting Measurement Conditions

angle measurement item to an unused task.

Switching the menu p.55

step4 Selecting measurement items p.62

ZG2 User’s Manual

MEAS/CUSTOM

Setting value Description

Reference

MGNIFY Magnifies the profile display. p.87 POS (measurement

position) (enabled only at point of intersection coordinate measurement)

Selects whether to output the position of the measurement value as the position in the height direction (Z coordinate) or as the position in the horizontal direction (X coordinate).

p.88

POINT (measurement point)

Sets in more detail which height in the line beam that the target is to be measured at. Settings: AVE, PEAK, BTM

p.89

1REGION 2MGNIFY 3POINT

3 Select [ CUSTOM ]-[ REGION ], and

set two regions each for the two straight lines.

Note

Custom settings available for angle and point of intersection measurement

FUNCTION SETTINGS

ZG2 User’s Manual

Setting Measurement Conditions

Measuring Cross-sectional Area

Setting value Description

Reference

MGNIFY Magnifies the profile display. p.87

The cross-sectional area of the profile inside the region is measured. Measurement of the cross-sectional area is enabled only in the EXP menu.

Item Description

The cross-sectional area of the object is measured. The cross-sectional area is calculated

Area

Start position

End position

by integrating the distance between each of the measurement point and the bottom face, with the line formed between the two points that intersect the start and end points of the measurement region taken to be the bottom face.

Flow of Operations

1 Switch to the EXP menu.

Switching the menu p.55

2 Assign the cross-sectional area

measurement item to an unused task.

step4 Selecting measurement items p.62

MEAS/CUSTOM

1REGION 2MGNIFY

Note

Setting Measurement Conditions

Custom settings available for cross-sectional area measurement

3 Select [ CUSTOM ]-[ REGION ], and

set the region for cross-sectional area measurement.

ZG2 User’s Manual

Measuring Point of Inflection

Height

Measures the height of the point (point of inflection) where the angle varies the most within a measurement region.

This item is useful for measuring positions that cannot be selected by the PEAK or BTM settings.

Item Description Height-related

measurement items

Measures the height of the point where the angle varies the most within a measurement region.

Peak

Average

Bottom

Flow of Operations

MEAS/HEIGHT1

FUNCTION SETTINGS

1 Switch to the EXP menu.

Switching the menu p.55

2 Assign the desired item from

among the height-related measurement items to an unused task.

step4 Selecting measurement items p.62

3 Select [ CUSTOM ]-[ REGION ], and

set the region.

ZG2 User’s Manual

1ITEM 2CUSTOM 3SCALE

Setting Measurement Conditions

Note

Start position End positi

Adjust the start and end points of the measurement range so that the point of inflection to be detected is enclosed.

Hint for adjusting the measurement region

MEAS/BEND

MEAS/LV

[ 3 ]OK

1TARGET 2LV

MEAS/TARGET

MEAS/BEND

1. UPSWING

2. DOWNSWING

4 Select [CUSTOM]-[MEAS]-

[BEND]-[TARGET].

5 Select [DOWNSWING] or

[ UPS W ING] to match the orientation of the point of inflection to be detected.

Setting Measurement Conditions

1TARGET 2LV

MEAS/BEND

MEAS/LV

[ 3 ]OK

1TARGET 2LV

MEAS/LV

[ 3 ]OK

UPSWING/DOWNSWING p.85

6 When noise, etc. prevents the

profile from stabilizing, increase the [LV] setting.

Setting range: 1 to 5 (default value: 1)

ZG2 User’s Manual

Note

0°

The ZG2 treats angles as follows.

To measure the position where the angle of inclination is var ying from “small → l arge,” s elect [UPSWING]. To measure the position where the angle of inclination is varying fr om “large → small,” select [DOWNSWING].

DOWNSWING

UPSWING/DOWNSWING

DOWNSWING

angle:15°

FUNCTION SETTINGS

angle:85°

angle:5°

angle:-85°

UPSWING

angle:-10°

UPSWING

ZG2 User’s Manual

Setting Measurement Conditions

Calculating Measurement Values

Important

The measurement results of other tasks can be used for calculation. The calculation setting is enabled only in the EXP menu.

Item Description

Set any equation to perform addition/subtraction on the measurement result. The equation can be substituted with measurement results obtained by other tasks. Also, when using two

Calc

Measuring Wide Measurement Targets p.185

Calculations Performed on Measurement Values Obtained on Multiple Channels p.190

Controllers in a gang-mount configuration, calculations can also be performed across channels.

Allowable equation: K+mX+nY

• EK range: -999.99999 to 999.99999 (default value: 0.00000)

• Em/n range:-10.0 to 10.0 (default value: 1.0)

• X/Y range: OFF (default value: OFF), TASK1 to TASK7 (Only task Nos. smaller than the task No. to which a calculation is set can be set.) In a gang-mount configuration, select the channel first in the additional channel selection menu before setting the task number.

When Controllers are gang-mounted, set calculation on the Controller set as channel 1 (CH1). Calculation cannot be set on the CH2 Controlled.

Deleting measurement items

Item Description

Delete the measurement items that are set to the currently selected task.

Delete

Setting Measurement Conditions

ZG2 User’s Manual

Customizing Measurement Conditions

Magnifying the Profile Display

A specified area of the profile display can be magnified.

 FUN mode-[MEAS]-[SENS]-[TASK1 to 8]-[CUSTOM]-[MGNIFY]

MEAS/MGNIFY

1MGNIFY 2RESET

MEAS/MGNIFY

↑↓ 50.000mm ←→

123LINE SET

MEAS/MGNIFY

↑↓ 10.000mm ←→

450LINE SET

1 Select [MGNIFY].

2 Adjust the top left of the desired

measurement area by the ↑, ↓, ← and → keys, and press the SET key.

3 Adjust the bottom right of the

desired measurement area by the ↑, ↓, ← and → keys, and press the SET key.

FUNCTION SETTINGS

ZG2 User’s Manual

Customizing Measurement Condition s

MEAS/MGNIFY

X position (horizontal direction)

Z position (height direction)

MAGNIFY P ROFILE

YES

←→↑↑ SE

4 Move to [YES] and press the SET

key.

MEAS/MGNIFY

1MGNIFY 2RESET

The profile in the specified area is displayed magnified.

Changing Measurement Positions

Select whether to output the position of the measurement value as the position in the height direction (Z coordinate) or as the position in the horiz ontal direction (X coordinate). Selection of measurement position is enabled when measuring height and point of intersection coordinates.

 FUN mode-[MEAS]-[SENS]-[TASK1 to 8]-[CUSTOM]-[POS.]

Setting value Description

Z POS. (height direction)

X POS. (horizontal direction)

Customizing Measurement Conditions

Outputs the position of the measurement value as the position in the height direction (Z coordinate). (default value)

Outputs the position of the measurement value as the position in the horizontal direction (X coordinate).

ZG2 User’s Manual

Changing Measurement Points

Average

Peak Bottom

Point of

inflection

Setting UPSWING, DOWNSWING and LV

Measuring Point of Inflection p.83

Any measurement point inside the received light area can be measured. Set this menu item when measuring small unevenness.

The measurement point setting is enabled only in the EXP menu.

 FUN mode-[MEAS]-[SENS]-[TASK1 to 8]-[CUSTOM]-[POINT]

Setting value Description

AVE (average) Measures the average value inside the line beam.

PEAK Measures the peak position of the line beam.

BOTTOM Measures the bottom position of the line beam.

FUNCTION SETTINGS

BEND (point of inflection)

ZG2 User’s Manual

Measures the height of the point (point of inflection) where the angle of the profile varies the most within a measurement region. This item is displayed only when the measurement item [HEIGHT] is set. This item is useful for measuring positions that cannot be selected by the PEAK or BTM settings.

Note

Customizing Measurement Condition s

Changing the Edge Level and Edge Direction

Set the edge level and edge direction when selecting edge-related measurement items. These settings are enabled only in the EXP menu.

 FUN mode-[MEAS]-[SENS]-[TASK1 to 8]-[CUSTOM]-[EDGELV]

Changing the edge level

Setting value Description

Edge level Align the line of the edge level with the edge to be detected.

The range differs according to the CCD mode.

Standard and high-resolution mode: 0 to 399 High-speed mode: 0 to 199

Selecting the edge direction

Set the edge search direction.

Setting value Description

→ Forward direction The “1st edge from the left” in the region is searched for. ← Reverse direction The “1st edge from the right” in the region is searched for.

Customizing Measurement Conditions

ZG2 User’s Manual

Scaling of Measurement Values

Important

4.95

Measurement value (mm)

Actual size value (mm)

This error is corrected.

If scaling is set, differences between measurement values and actual sizes, that occur due to the color or material of the measurement target or other factors, can be corrected. There are two scaling setup modes, “automatic setting” and “manual setting.” In the automatic setting mode, actual measurement is performed, and in the manual setting mode, the correction values are set manually.

(default value: OFF)

The settings below return to the default settings when scaling is set. Set these items after scaling settings have been completed.

• Zero reset

Automatic Setting Method

Measurement is actually performed, and correction v alues a re set for tho se measurement values.

1-pt scaling

Measurement is performed once, and the actual size value for the measurement value is set. Set scaling by this method when 2-pt step, 3-pt step and edge width is set.

FUNCTION SETTINGS

ZG2 User’s Manual

Scaling of Measurement Values

 FUN mode-[MEAS]-[SENS]-[TASK1 to 8]-[SCALE]-[AUTO]

MEAS/AUTO

FIRST POINT

SET

INPUT CORRECT VALUE

MEAS/AUTO

4.95000 [ 5.00000]

Measurement value

Actual size value

Note

1 Set the measurement target in

place, and press the SET key.

The measurement value is displayed.

2 Input the actual size value on the

lower section.

To change numerical values, use the ↑ key/↓ key, and to change the number of digits use the → key/→ key.

Scaling of Measurement Values

ZG2 User’s Manual

2-pt scaling

1st point 2nd point

Measurement is performed at two positions, and actual size values are set for those measurement values. Set scaling by this method when height and edge position are set.

Measurement value (mm)

4 3

Actual size value (mm)

FUNCTION SETTINGS

ZG2 User’s Manual

Scaling of Measurement Values

 FUN mode-[MEAS]-[SENS]-[TASK1 to 8]-[SCALE]-[AUTO]

MEAS/AUTO

FIRST POINT SET

INPUT CORRECT VALUE

MEAS/AUTO

9.05000

[ 10.00000]

Measurement value

Actual size value

Note

INPUT CORRECT VALUE

MEAS/AUTO

4.02000

[ 3.00000]

1 Set the measurement target in

place, and press the SET key.

The measurement value is displayed.

2 Input the actual size value on the

lower section.

To change numerical values, use the ↑ key/↓ key, and to change the number of digits use the → key/→ key.

Scaling of Measurement Values

3 Move the position of the

measurement target, and press the SET key.

The measurement value is displayed.

4 Input the actual size value on the

lower section.

ZG2 User’s Manual

Manual Setting Method

‑4.0000

（mm）

4.0000

Measurement value

Displacement of measurement target

（mm）

Measurement value

Displacement of measurement target

Span and offset can be set by inputting numerical values manually to fine-tune the measurement values. These can be set for each individual task. Span and offset are automatically set after scaling is executed. So, modify these settings as necessary. Set scaling by this method when angle, point of intersection angle, point of intersection coordinates, and cross-sectional area are set. Manual setting is enabled only in the EXP menu.

 FUN mode-[MEAS]-[SENS]-[TASK1 to 8]-[SCALE]-[MANUAL]

Setting value Description

SPAN Sets the inclination of the sensor characteristics as a coefficient.

Range: -4.0000 to 4.0000

FUNCTION SETTINGS

OFFSET Adds/subtracts a fixed value to or from the measurement value.

Range: -999.99999 to 999.99999

ZG2 User’s Manual

Scaling of Measurement Values

Image Adjustment

Important

Adjusting Sensitivity

The sensitivity of the Sensor Head can be adjusted so that shapes are accurately captured even if the shape, color, material, etc. of the measurement target is influenced. The default setting is [MULTI].

Sensitivity Adjustment Functions of the ZG2 Series p.26

 FUN mode-[MEAS]-[IMAGE]-[LD-POWER]

Setting value Description

HS_MULTI (high-speed MULTI)

MULTI Measurement is performed with the sensitivity adjusted for each

AUTO Measurement is performed with the sensitivity adjusted

FIXED Measurement is performed with the sensitivity fixed.

This is a higher speed version of the MULTI mode. This method is suitable when the brightness of the measurement target surface fluctuates to a large degree but the measurement tact time must be increased.

individual line in the measurement region. This method is suitable when the brightness of the measurement target surface fluctuates to a large degree.

automatically based on the sensitivity information in the measurement region. This method is suitable when the brightness of the measurement target surface is uniform.

This method is suitable when accurate measurements cannot be made at the [AUTO] setting, for example, for lines on which measurement targets of various colors are fed alternately.

[MULTI] and [HS MULTI] are effective as a sensitivity adjustment function only when measuring stationary measurement targets. When the measurement target cannot be made stationary, use [AUTO] or [FIXED].

Note

The measurement cycle differs according to the preset sensitivity. The measurement cycle can be checked by the ECO monitor in the RUN mode.

Image Adjustment

Measurement cycle

Eco monitor p.67

ZG2 User’s Manual

Detailed setting of sensitiv ity adjustment

Important

The sensitivity adjustment upper/lower limits and interval can be adjusted in the EXP menu.

LD-POWER

High

LV4 40

Upper limit value

Lower limit value

LV1 Low

Measurement is performed with sensitivity adjusted for several lines in the upper/lower limit range.

Measurement is performed with sensitivity adjusted for each individual line in the upper/lower limit range.

Measurement is performed with sensitivity adjusted automatically in the upper/lower limit range.

Detailed setting of HS MULTI (high-spee d MULTI) sensitivity  FUN mode-[MEAS]-[IMAGE]-[LD-POWER]-[HS MULTI]

Setting value Description

CUSTOM HIGH Sets the sensitivity adjustment upper limit.

Range: LV1 to LV440 (default value: LV320)

(when high power mode is used, LV1 to LV320)

LOW Sets the sensitivity adjustment lower limit.

Range: LV1 to LV440 (default value: LV1)

(when high power mode is used, LV1 to LV320)

IMAGE NUM (lighting count)

Sets the lighting count when measurement is executed. Setting range: 2 to 10 (default value: 5) The measurement time becomes proportionately shorter as a smaller lighting count is set. However, measurement sometimes becomes unstable. If this happens, set a larger lighting count value.

SEARCH The optimum lighting sensitivity is set automatically matched to the

measurement target set in place.

FIXED sensitivityAUTO sensitivityHS MULTI sensitivity MULTI sensitivity

Measurement is performed at the preset sensitivity level.

FUNCTION SETTINGS

• When [HS MULTI] is selected, be sure to execute [SEARCH]. Otherwise, the lighting sensitivity will not be set to the optimum value.

ZG2 User’s Manual

Image Adjustment

Omron ZG2 User Manual

Specifications and Main Features

Frequently Asked Questions

User Manual

Meanings of Signal Words

Meanings of Alert Symbols

Precautions for Safe Use

Precautions for Correct Use

Editor’s Note

CONTENTS

BEFORE USE

ZG2 Series

System Configuration

Part Names and Functions

Sensor Head

Controller

Basic Knowledge for Operation

Profile Screen

Precautions when designing a production line

Measurement Range in Height Direction and Resolution

Three CCD Modes and Their Characteristics

Trigger Measurement/Continuous Measurement

What is “Sensitivity Adjustment?”

Sensitivity Adjustment Functions of the ZG2 Series

Mounting and Connecting Devices

Mounting the Sensor Head

Installations to Suit Measur ement Target and Environment

Mounting the ZG2-WDS70

Mounting the ZG2-WDS22

Mounting the ZG2-WDS8T

Mounting the ZG2-WDS3VT

Mounting the Controller

Cautions Regarding the Mounting Orientation

Mounting on a DIN Track

Mounting on a Panel

Combinations of Gang-mounted Controllers

Connecting Devices

Attaching the Ferrite Cores

Connecting Cables

Connecting the Power Supply

Overview of Settings and Measurement

Operation Modes

Tasks and Bank Data

Multi-task Measurement

Data for Change of Device Setup

Relationship between Tasks and Bank Data

STD Menu and EXP Menu

Switching the menu

Initializing Controller Settings

BASIC OPERATIONS

Flow of Basic Setup

Starting Measurement

Monitoring the Measurement Status

Magnifying the Profile Display

Function Keys

FUNCTION SETTINGS

Setting Measurement Conditions

How to Select Measurement Items

Measuring Height

Flow of Operations

Measuring Step

Flow of Operations

Measuring Position and Width

Flow of Operations

Measuring Angle

Flow of Operations

Measuring Angle and Point of Intersection

Flow of Operations

Measuring Cross-sectional Area

Flow of Operations

Measuring Point of Inflection

Flow of Operations

Calculating Measurement Values

Deleting measurement items

Customizing Measurement Conditions

Magnifying the Profile Display

Changing Measurement Positions

Changing Measurement Points

Changing the Edge Level and Edge Direction

Scaling of Measurement Values