Omron ZX-T OPERATION MANUAL

OPERATION MANUAL
Smart Sensors
ZX-T Series
Cat. No. E346-E1-04
READ AND UNDERSTAND THIS DOCUMENT

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 THE REQUIREMENTS OF THEIR INTENDED 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 CONNECTED 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 CONTAMINATION, 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 determination 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 exhaustive list of all possible uses of the products, nor is it intended to imply that the uses listed may be suitable for the products:
• Outdoor use, uses involving potential chemical contamination or electrical interference, or conditions or uses not described in this document.
• 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 determining 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 without 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.
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Preface
Section 1
Section 2
Section 3
Section 4
Section 5
Introduction, Contents, Precautions for Safe Use, Precautions for Correct Use, and How to Use This Manual
Features
Preparations for Measurement
Basic Operation
Main Applications and Setting Methods
Detailed Settings
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èÕPreface Section 1 Section 2 Section 3 Section 4 Section 5 Section 6
Section 6
Appendices
Index
Auxiliary Functions
Appendices Index
Troubleshooting, Specifications, Characteristic Data, etc.
Operation Manual
Smart Sensors ZX-T Series
Preface Introduction

PREFACE

Introduction

Thank you for purchasing an OMRON ZX-T-series Smart Sensor (High-precision Con-
tact Type). This manual describes the functions, performance, and application methods
for the ZX-T-series Smart Sensor. Observe the following items when using the Sensor
• To ensure safety, please read and understand this manual before using the Sensor.
Keep this manual in an easily accessible location for quick reference when
needed.
2
ZX-T
Operation Manual

Contents

PREFACE
ÇÕǹÇ?Ç ëÊ Preface Section 1 Section 2 Section 3 Section 4 Section 5 Section 6
Introduction 2 Contents 3 Precautions for Safe Use 7 Precautions for Correct Use 8 How to Use This Manual 10
Section 1 Features 13
ZX-T Features 14
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Section 2 Preparations for Measurement 19
Basic Configuration 20 Part Names and Functions 21 Installing the Amplifier Unit 24 Installing Sensor Heads 26 Connections 30 Wiring Output Cables 34 Confirming Warm-up Completion 36 Pressing Force Alarm 37
Appendices Index
Operation Manual
ZX-T
3
Preface Contents
PREFACE
Section 3 Basic Operation 39
Flow of Operation 40 Basic Knowledge for Operation 42 Function Transition Charts 47
Section 4 Main Applications and Setting Methods 51
Measuring Thickness 52 Measuring the Height of a Step and Flatness 57 Measuring Depth 62 Other Measurements 67
Section 5 Detailed Settings 69
Setting Number of Samples to Average 70 Using Hold Functions 71 Inverting Positive and Negative Values (Scale Inversion) 75 Entering Threshold Values 77 Linear Output 81 Calculating Measured Values 90 Using the Zero Reset Function 92 Error Output Function 98
4
ZX-T
Operation Manual
PREFACE
Section 6 Auxiliary Functions 101
Changing the Number of Display Digits 102 Reversing the Display 103
ÇÕǹÇ?Ç ëÊ Preface Section 1 Section 2 Section 3 Section 4 Section 5 Section 6
Adjusting Display Brightness (ECO Display) 105 Key Lock Function 106 Correcting the Distance Display (Span Adjustment) 107 Initializing Settings Data 109
Appendices 111
Actuators 112 Troubleshooting 115 Error Messages and Countermeasures 116 Q&A 118 Glossary 119 Specifications and Dimensions 120 Characteristic Data 131 Quick Reference for Displays 132
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Appendices Index
Index 134
Revision History 136
ZX-T
Operation Manual
5
Preface Contents
PREFACE
6
ZX-T
Operation Manual

Precautions for Safe Use

Always observe the following precautions to ensure safety.
Environment
• Do not use the Smart Sensor in locations subject to explosive or flammable gases.
• To ensure safety in operation and maintenance, do not install the Smart Sensor near high-voltage equipment or power devices.
Power Supply and Wiring
• Do not impose voltages exceeding the rated voltage (12 to 24 VDC ±10%).
• When supplying power to the Sensor, make sure that the polarity of the power is cor­rect, and do not connect to an AC power supply.
• Do not short-circuit the load for the open collector output.
• Do not lay the power supply cable for the Smart Sensor together with high-voltage lines or power lines. Doing so, or placing them into the same duct, can cause induc­tion and lead to malfunction or damage.
• Always turn OFF the power supply before wiring and before connecting or disconnect­ing connectors.
• Use a DC power supply equipped with measures to counter generation of high volt­ages (safety overvoltage/undervoltage circuits) or use a UL Class 2 DC power supply. Do not ground the positive terminal on the secondary side (i.e., the DC side).
PREFACE
Preface Precautions for Safe Use
Settings
• When setting the threshold value with the Smart Sensor connected to an external device, turn ON the Amplifier Unit's judgement output hold input to prevent the judgement from being output to the external device.
Others
• The ZX-L-series Smart Sensors (Laser Type), ZX-E-series Smart Sensors (Linear Proximity Type), and ZX-W-series Smart Sensors (Microwave Type) are not compati­ble. Do not use ZX-L, ZX-E, or ZX-W-series Smart Sensors together with ZX-T-series Smart Sensors.
• Do not attempt to disassemble, repair, or modify the Smart Sensor.
• When disposing of the Smart Sensor, treat it as industrial waste.
Operation Manual
ZX-T
7
PREFACE
Preface Precautions for Correct Use

Precautions for Correct Use

Always observe the following precautions to prevent operation failures, malfunctions, and adverse effects on performance and equipment.
Smart Sensor Installation
Environment
Do not install the Smart Sensor in the following locations:
• Locations where the ambient temperature exceeds the rated temperature range.
• Locations subject to rapid changes in temperature (causing condensation).
• Locations where the relative humidity exceeds the range of 35% to 85%.
• Locations subject to corrosive or flammable gases.
• Locations where dust, salt, or metallic powder accumulate on the Sensor.
• Locations subject to direct vibration or impact.
• Locations subject to direct sunlight.
• Locations subject to exposure to water, oil, chemicals, etc.
• Locations subject to strong electromagnetic or electrical fields.
• Locations subject to water vapor.
Installation and Handling of Components
Power Supply and Wiring
• Do not extend the Sensor Head cable by more than 8 m. Use a ZX-XC@A Extension Cable (order separately) to extend the cable from the Sensor.
• Use a shielded cable to extend the Amplifier cable. The shielded cable must have the same specifications as that of the Amplifier cable.
• When using a commercially available switching regulator, ground the FG (frame ground) terminal. (ZX-TDS01T and ZX-TDS04T-@)
• If the power supply line is subject to surges, connect a surge absorber that meets the conditions of the application environment.
• When connecting multiple Amplifier Units, connect the linear grounds of all the Ampli­fier Units.
• The Sensor Head is not flame resistant (ZX-TDS10T-@@).
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ZX-T
Operation Manual
PREFACE
Sensor Head
• The Sensor Head is a high-precision device. Do not drop it or otherwise expose it to shock.
• Do not expose the plunger to forces exceeding the limits in the following diagram. Doing so may damage the plunger.
Preface Precautions for Correct Use
Plunger
Rubber boot
Actuator
30 N 30 N 1 N 0.15 N•m
• Take measurements within the range that does not set off the Pressing Force Alarm.
• Do not remove the rubber boot. Without the rubber boot, foreign matter may enter the Sensor Head, possibly causing the Sensor Head to malfunction.
• Mount the Sensor Head and Preamplifier in the specified location and under the spec­ified load. Excessive force during installation may damage the Sensor Head or Preamplifier.
• Replace worn actuators.
Replacing Actuators, p. 113
• Do not use the Sensor to measure objects that are revolving or moving (i.e., dynamic measurement).
• Do not use air pressure outside the rated range when using a vacuum retract (VR) or air push (AP). The measured pressure will fluctuate due to the air pressure, so the air pressure must be regulated. An air vacuum device and a solenoid are required (ZX­TDS10T-V@ only).
• Supply dry air with filtration of 5
µm max. (ZX-TDS10T-V@ only).
• The ZX-TDS10T-L can be mounted only facing downward.
Warming Up
After turning ON the power, allow the Smart Sensor to warm up for 15 minutes mini­mum prior to use. The circuitry is not stable immediately after turning the power ON, and the values gradually change until the Sensor is completely warmed up.
Maintenance and Inspection
• Always turn OFF the power supply before adjusting or removing the Sensor Head.
• Do not use thinners, benzine, acetone, or kerosene to clean the Sensor Head or Amplifier Unit.
Operation Manual
ZX-T
9
PREFACE
d
.
n
e
Preface How to Use This Manual

How to Use This Manual

Page Format
Section Title Main Heading in
a Section
Linear Output
This function is used to set the output to external devices.
Output Settings (Monitor Focus)
A linear output refers to a measurement result that is converted an output as a current between 3 and 21 mA or a voltage between -5 and +5 V
Using the Zero Reset Functio Zero reset is canceled when the monitor focus setting is set. Set the
Section 5
Detailed Settings
Indicates page contents.
Outline
Provides an outline or gives a flowchart of the operation de­scribed under the main heading.
Sub-heading
Index Label
Gives the section number and subject matter.
Changing to T Mod
Set the mode switch to T.
Set the switch to the threshold value to be set.
Press any Cursor Key.
The first digit of the threshold value displayed on the sub-display will flash and direct input will be enabled.
Change the threshold value with the Cursor Keys.
To cancel the selected setting, use the LEFT Key to move the cursor to the leftmost digit and press the LEFT Key again. he display will return to the current setting.
Procedure and Additional Explanations
Information useful during the operation and reference pages are provided here with special marks to indicate the kind of information being provided.
Function Outline and Suggestions
Operation
Indicates the operation to be performed next.
ZX-T
Operation Manual
91
Display Area
Shows the display status after a step in an operation.
Keys and Switches
Provides an illustration of the keys or switches used during the operation.
10
ZX-T
Operation Manual
* This page does not actually exist in
this manual.
Notation
Menus
Items that appear on the digital displays are set in ALL-CAPS.
Procedures
The order for the procedures is indicated by numbered steps.
Visual Aids
PREFACE
Preface How to Use This Manual
Provides information on important operating procedures, gives advice on how to use functions, and highlights important performance information.
Indicates pages with relevant information.
Indicates useful information for when problems arise.
Operation Manual
ZX-T
11
PREFACE
Preface How to Use This Manual
12
ZX-T
Operation Manual

Section 1 FEATURES

ZX-T Features 14
Section 1 FEATURES
Operation Manual
ZX-T
13
Section 1 FEATURES

ZX-T Features

Section 1 ZX-T Features
The ZX-T-series Smart Sensor measures the height of sensing objects and minute steps (i.e., height differences).
Example: Measuring Electronic Components Dimensions
Measured value output
Judgement output
ZX-TDAZX-TDAZX-TDA
14
The small-diameter Sensor Heads enable multiple-point measurements on small components
ZX-T
Operation Manual
Section 1
FEATURES
Many, Simple Functions
Measurement Ready at Power ON
The Smart Sensor can be used simply by installing and wiring it. Simply turn ON the power and it’s ready to operate.
The measurement distance is displayed on the Amplifier Unit.
Simple Calculation Settings
Use Calculating Units to easily calculate step heights and thicknesses through multi­point measurements.
Section 1 ZX-T Features
p. 51
Calculating Units
Amplifier Units (8 Units max.)
Operation Manual
ZX-T
15
Section 1 FEATURES
Compatibility between Sensor Heads and Amplifier Units
Amplifier Units do not need to be changed when Sensor Heads are changed for main-
Section 1 ZX-T Features
tenance or to switch to new products.
Extendable Sensor Head Cables
An extension cable with a maximum length of 8 m can be connected. The ZX-XC-A Extension Cable is required to extend the Sensor Head cable.
p. 20
Extension Cable
Up to 8 m
16
ZX-T
Operation Manual
Convenient Notification Functions
Section 1
FEATURES
Preventing Malfunctions Caused by Excessive Pressing Force
Malfunctions caused by excessive plunger pressing force for unexpected measure­ments can be detected in advance and a signal can be output to stop the measurement or otherwise prevent malfunction.
p. 37.
Direction of sensing object movement
Warming Up Display
The display shows the warming-up status when the power is turned ON. This enables measurements to be started when the status has stabilized after warming up has been completed.
p. 36.
Section 1 ZX-T Features
POWER ENABLEZERO
SUB
The sub-display flashes W-UP during warm-up.
(mm)
Below specified
resolution
Fluctuation of measured value
Warming up in progress
Warming up completed
Time lapsed after power up (min.)
Operation Manual
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17
Section 1 FEATURES
Monitoring Measurement Status
Section 1 ZX-T Features
Use an Interface Unit and Smart Monitor V3 to view measurement waveforms and log measurement data on a personal computer. This function is useful for making on-site measurement adjustments and for day-to-day quality control.
p. 20
Interface Unit
Smart Monitor V3
Amplifier Unit (5 Units max.)
Confirm Measurement Status on a Personal Computer
18
ZX-T
Operation Manual

Section 2 PREPARATIONS FOR MEASUREMENT

Basic Configuration 20
Part Names and Functions 21
Installing the Amplifier Unit 24
Installing Sensor Heads 26
Connections 30
Wiring Output Cables 34
Confirming Warm-up Completion 36
Pressing Force Alarm 37
Section 2 PREPARATIONS FOR MEASUREMENT
Operation Manual
ZX-T
19
Section 2 Basic Configuration
Section 2 PREPARATIONS FOR MEASUREMENT

Basic Configuration

The basic configuration of the ZX-T-series Smart Sensors is shown below.
ZX-L-series Smart Sensors (Laser Type), ZX-E-series Smar t Sensors (Linear Proximity Type), and ZX-W­series Smart Sensors (Microwave Type) are not compatible. Do not use ZX-L-series, ZX-E-series, or ZX-W­series Smart Sensors together with ZX-T-series Smart Sensors.
Basic Configuration
Smart Monitor (software)
ZX-SW11 (Version 3.0 or later)
Controls Amplifier Units from a personal computer and monitors measured values.
Personal computer
Sensor Heads
ZX-TDS@@T
Sensor Heads measure sensing objects.
p. 26
Extension Cables
ZX-XC1A (1 m) ZX-XC4A (4 m) ZX-XC8A (8 m)
Used between Sensor Heads and Amplifier Units.
20
Interface Unit
ZX-SF11 (Version 2.0 or later)
Used when connecting a programmable controller.
p. 33
ZX-T
Operation Manual
Amplifier Units
ZX-TDA11/41
Process measure­ments and output measurement results.
p. 21
Power Supply
12 to 24 V DC (±10%)
Calculating Units
ZX-CAL2
Used when connecting multiple Amplifier Units.
Perform calculations.
p. 31
PREPARATIONS FOR MEASUREMENT
(12)
y(

Part Names and Functions

Amplifier Units
Controls ()
Display area ()
Section 2
Section 2 Part Names and Functions
(4) Output cable
(1) Input cable
Details of Controls
and Display Area
(8) HIGH indicator
(9) PASS indicator
(10) LOW indicator
(11) Main display
Sub-displa
(3) Connectors (one on each side, two total)
(2) Current/voltage switch (back of Unit)
(5) Power ON indicator
(6) Zero reset indicator
(7) ENABLE indicator
13) Threshold switch
(15) Operating Keys
(14) Mode switch
(1) The input cable connects the Sensor Head.
(2) The current/voltage switch selects either a current or voltage linear output.
Current/voltage output selector
Monitor focus settings are also required when switching the output.
Voltage output
Current output
p. 81
(3) The connectors connect Calculation and Interface Units.
(4) The output cable connects to the power supply and external devices, such as sync sensors or
programmable controllers.
(5) The Power ON indicator lights when the power is turned ON.
(6) The Zero Reset indicator lights when the zero reset function is enabled.
(7) The ENABLE indicator lights when the measurement result is within the rated measurement
distance.
(8) The HIGH indicator lights when the judgement result is HIGH.
(9) The PASS indicator lights when the judgement result is PASS.
(10) The LOW indicator lights when the judgement result is LOW.
(11) The main display shows measured values and function names.
(12) The sub-display shows additional information and function settings for measurements.
Reading Displays, p. 43
(13) The threshold switch selects whether to set (and display) the HIGH or LOW threshold.
(14) The mode switch selects the operating mode.
Switching Modes, p. 42
(15) The Control Keys set measurement conditions and other settings.
Key Operations, p. 44
Operation Manual
ZX-T
21
Section 2 PREPARATIONS FOR MEASUREMENT
Sensor Heads
Section 2 Part Names and Functions
Actuator
Rubber boot
Plunger
Sensor Head
Calculating Units
Display (*)
Connector
Preamplifier
Connectors (one on each side, two total) Connects to Amplifier Unit.
Connects to Amplifier Unit.
Display Detail
Connector indicators Light when Calculating Unit is connected to Amplifier Units.
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ZX-T
Operation Manual
Interface Units
(2) Amplifier Unit Connector
(1) Communications Connector
Section 2
PREPARATIONS FOR MEASUREMENT
Display ()
Section 2 Part Names and Functions
Display Detail
(3) Power supply indicator
(4) Sensor communications indicators (BUSY and ERR)
(5) External terminal communications indicators (BUSY and ERR)
(1) The communications connector connects the communications cable to the Programmable
Controller.
(2) The Amplifier Unit connector connects to the Amplifier Unit.
(3) The power supply indicator lights when the power is turned ON.
(4) BUSY: Lights during communications with the Smart Sensor.
ERR: Lights if an error occurs during communications with the Smart Sensor.
(5) BUSY: Lights during communications with the Programmable Controller.
ERR: Lights if an error occurs during communications with the Programmable Controller.
Operation Manual
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23
Section 2 PREPARATIONS FOR MEASUREMENT

Installing the Amplifier Unit

Amplifier Units can be easily mounted to 35-mm DIN Track.
Section 2 Installing the Amplifier Unit
DIN Track (order separately) PFP-100N (1 m) PFP-50N (0. 5 m) PFP-100N2 (1 m)
End Plates (order separately) PFP-M
Installation
Hook the connector end of the Amplifier Unit on the DIN Track and press in at the bot­tom until the Unit locks into place.
Hook on the connector end
Always hook the connector end of the Amplifier Unit on the DIN Track first. Mounting strength may decrease if the output cable end is hooked on the DIN Track first.
24
ZX-T
Operation Manual
PREPARATIONS FOR MEASUREMENT
Removal Method
Push the Amplifier Unit up and pull out from the connector end.
Section 2
Section 2 Installing the Amplifier Unit
Operation Manual
ZX-T
25
Section 2 PREPARATIONS FOR MEASUREMENT

Installing Sensor Heads

This section describes how to install Sensor Heads and Preamplifiers.
Secure the connector so that it is not subjected to vibration or shock.
Section 2 Installing Sensor Heads
Sensor Heads
Installation
Do not clamp the Sensor Head directly on the end of the screw. Otherwise, the Sensor Head may be damaged.
Mounting Jig
ZX-TDS01T/TDS04T-@
Mount the Sensor Head using M3 screws and a mounting torque between 0.6 and
0.8 N·m.
Unit: mm
1.50
10
6 dia., H7
4
20
26
A
8
3.50 dia.
6.50 dia.
32
8
A
3.50
M3
Two, 3.50 dia.
Material: Aluminum
18
Recommendation: Misumi Corp.
Model: SHSTA6-20
ZX-TDS10T-@@
Mount the Sensor Head using M4 screws and a mounting torque between 2 and 3 N·m.
Unit: mm
18
2
63
02
6
42
A
8 dia., H7
A
M4
11
10
4.5
Cross-section
View A-A
30
4 dia.
8 dia.
Two, 4.5 dia.
Material: Aluminum
Recommendation: Misumi Corp.
Model: SHSTA8-20
26
ZX-T
Operation Manual
Mounting Jig for an 8-diameter Stand
Section 2
PREPARATIONS FOR MEASUREMENT
6
+0.01
0
dia.
1
dia.
0
0.03
8
1
12 dia.
5
15
Material: Brass
Section 2 Installing Sensor Heads
Operation Manual
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