Omron ZG2 User Manual
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)
1
User’s Manual
BEFORE USE
BASIC OPERATIONS
FUNCTION SETTINGS
CONNECTION WITH EXTERNAL
DEVICES
MEASUREMENT BY GANGMOUNTED CONTROLLERS
APPENDICES
1
2
3
4
5
6
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.
2
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.
COPYRIGHT AND COPY PERMISSION
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
3
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.
4
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
5
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.
6
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
7
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.
8
ZG2 User’s Manual
CONTENTS
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
1
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
9
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
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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
11
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
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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
13
MEMO
14
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
1
BEFORE USE
ZG2 Series
Sensor Head
Sensor Head
Controller Controller
ZG2 series
Up to two units
can be
gang-mounted.
ZG2-WDC11/WDC41
PC
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
16
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
PC
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.
1
BEFORE USE
ZG2 User’s Manual
ZG2 Series
17
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.
18
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.
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BEFORE USE
ZG2 User’s Manual
ZG2 Series
19
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.
20
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
0
+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.
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BEFORE USE
ZG2 User’s Manual
Basic Knowledge for Operation
21
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
22
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.
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BEFORE USE
ZG2 User’s Manual
Precautions when designing a production line
23
Trigger Measurement/Continuous Measurement
Trigger
Trigger
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
24
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.
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BEFORE USE
ZG2 User’s Manual
Precautions when designing a production line
25
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
26
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.
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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
27
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