Page 1: Users Manual
Cat. No. Z288-E1-01 ZG2 Series Smart Sensor 2D Proﬁ le Measuring Sensors USERS MANUAL...
Page 3 • 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.
Page 4 READ AND UNDERSTAND THIS DOCUMENT(Please Read) User’s Manual BEFORE USE BASIC OPERATIONS FUNCTION SETTINGS CONNECTION WITH EXTERNAL DEVICES MEASUREMENT GANG- MOUNTED CONTROLLERS APPENDICES Smart Sensor 2D Profile Measuring Sensors ZG2 Series...
Page 5 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: •...
Page 6: Performance Data
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.
Page 7 Never look into the laser beam. Doing so continuously will result in visual impairment. Do not attempt to dismantle, pressurize, or incinerate the product. Doing so may cause the laser beam to leak, resulting in the danger of visual impairment. ZG2 User’s Manual...
Page 8 • 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.
Page 9: Before Use
• 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.
Page 10 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.
Page 11 ■ 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 important to achieve the full product performance, Important such as operational precautions.
Page 12: Table Of Contents
1. BEFORE USE ZG2 Series ........16 System Configuration .
Page 13 Adjusting the Output Conditions of the Measurement Result........111 Setting the Average Number of Measurements .
Page 14: Connection With External Devices
Layout of Output Terminals ..... 138 Output Circuit....... . 139 Output Format of Measurement Values .
Page 15: Measurement By Gang Mounted Controllers
I/O ........
Page 16: Appendices
Updating the Firmware..... . . 232 Index ........237 Revision History .
Page 17 MEMO ZG2 User’s Manual...
Page 18 BEFORE USE ZG2 Series Basic Knowledge for Operation Precautions when designing a production line Mounting and Connecting Devices Overview of Settings and Measurement...
Page 19: Zg2 Series
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.
Page 20 Graphic Data Controller ZP-C as a waveform, and judgment results can be displayed in color. Sensor Head-Controller extension cable (option) Exclusive extension cables are available for extending the installation distance between the Sensor Head and the Controller. Extension cable Cable for Sensor: ZG2-XC__CR: 0.5 m, 2 m (flexible cable)
Page 21: Part Names And Functions
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.
Page 22 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.
Page 23 Data Storage Units and Controllers. Slide the cover (supplied) downwards to open. (3) USB port Connect the USB cable (MINI-B) to the USB port to connect to a personal computer. (4) RS-232C connector Connect the RS-232C cable (exclusive product) when you are connecting the Controller to a PLC, programmable terminal or personal computer.
Page 24: Basic Knowledge For Operation
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...
Page 25: Precautions When Designing 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.
Page 26 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”...
Page 27: Trigger Measurement/Continuous Measurement
Trigger Measurement/Continuous Measurement The ZG2 series is provided with two measurement modes, “input of an external trigger to start measurement” and “continuous measurement without the need for input of a trigger.” Note, however, that available sensitivities are restricted by the type of trigger and direction in which the measurement object is moving.
Page 28 What is “Sensitivity Adjustment?” 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.
Page 29 Sensitivity Adjustment Functions of the ZG2 Series 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 The optimum sensitivity line is judged and the appropriate sensitivity...
Page 30: Mounting And Connecting Devices
Measuring stepped objects 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.
Page 31: Mounting Method
Mounting the ZG2-WDS70 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 Important For details on the positions of screw holes,...
Page 32 Measurement range 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. <Mounting for diffuse reflection measurement> Spread angle 10° Measurement center distance...
Page 33 Mounting for regular reflection measurement 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...
Page 34 Measurement range 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. <Mounting for diffuse reflection measurement> Spread angle 10° Measurement center distance...
Page 35 CENTER: 22mm 60 µm FAR end: 23mm 140 µm Important 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...
Page 36 Mounting for regular reflection measurement 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 ZG2 User’s Manual...
Page 37 Measurement range 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. <Mounting for diffuse reflection measurement> Spread angle 10° Measurement center distance...
Page 38 CENTER: 8.0mm 30 µm FAR end: 8.1mm 105 µm Important 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...
Page 39 Note 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...
Page 40 Measurement range 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. <Mounting for regular reflection measurement> Measurement range Measurement center distance (width) 22.3 mm...
Page 41 CENTER: 3.0mm 25 µm FAR end: 3.05mm 33 µm Important 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...
Page 42: Mounting The Controller
Do not install the Controller in the following orientations: Important • 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.
Page 43 Mounting on a DIN Track Mount Controllers on a DIN track correctly according to the number of Controllers to be used. When using only one Controller Hook the connector end of the Controller onto the DIN track. Push the Controller down onto the DIN track until the hook on the I/O cable side is locked.
Page 44 When gang-mounting devices 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. Hook the connector end of the Controller onto the DIN track. Push the Controller down onto the DIN track until the hook on the I/O cable side is locked.
Page 45 PFP-100N2 (1m) Attach the end plates on both sides of the Controller. Removing the Controller from the DIN track (when using only one Controller) Pull the hook on the I/O cable end of the Controller downwards. Lift up the Controller from the I/O cable end, and remove it from the DIN track.
Page 46 Removing Controllers from the DIN track (when gang-mounting devices) Controller Slide the Controller so that it is Link Unit removed from the connector on (sold separately) the Controller Link Unit. Remove the Controller Link Unit from the connector on the Data Storage Unit.
Page 47 Mounting on a Panel Mount Controllers on a panel correctly according to the number of Controllers to be used. When using only one Controller Panel Push out the Controller from the rear of the panel towards the front. When mounting on a panel p.206...
Page 48 Controllers onto the DIN track. When gang-mounting devices p.41 Important When mounting devices on a panel, too, be sure to install the DIN track on the rear side of the devices. Push out the Data Storage Unit and Controllers from the rear of Panel the panel towards the front.
Page 49 Panel Controllers with Mount Adapters attached onto the panel from the front. Important Take care not to nip the I/O cable. Hook the hooks of the mounting Mounting fixtures onto the two holes of the bracket short Mount Adapters and tighten the screws.
Page 50 Combinations of Gang-mounted Controllers With the ZG2 series, one Data Storage Unit (ZG2-DSU) and up to two Controllers (ZG2- WDC) can be gang-mounted. For details on the Data Storage Unit (ZG2-DSU), refer to the ZG2-DSU User’s Manual. Important • Supply power to all of the gang-mounted Controllers.
Page 51 • In the gang-mounted arrangement, the Data Storage Unit must be located at the leftmost end viewed from the front. • Even when the Data Storage Unit is not gang-mounted, the CH numbers of the Controllers are CH1 and CH2 in this order from the left.
Page 52: Connecting Devices
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. Ferrite core...
Page 53: Connecting Cables
• 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.
Page 54: Connecting The Power Supply
1:1 connection. Important 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.
Page 55: Overview Of Settings And Measurement
Overview of Settings and Measurement 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. FUN mode ADJ mode RUN mode Mode...
Page 56: Tasks And Bank Data
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.
Page 57 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.
Page 58: Std Menu And Exp Menu
STD Menu and 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. <STD menu> EXP menu This menu is designed for ease of operation,...
Page 59: Initializing Controller Settings
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 •...
Page 60 BASIC OPERATIONS Flow of Basic Setup Starting Measurement...
Page 61: Flow Of Basic Setup
Flow of Basic Setup The following describes the flow of basic setup using, as an example, "2-pt step". 2PTS-2 B01T2 0.00000 mm LV:320 step 1 Displaying the reference target object Display the target profile on the Controller's LCD monitor. p.59...
Page 62 Sensor Head mounting conditions 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...
Page 63 Stabilizing the shape profile (APS function) Display the screen on the left and MEAS press the MENU/VIEW key. confirmation message displayed. 1TEACH 2IMAGE MEAS Move to [YES] and press the SET key. EXECUTE FILTER SETTING AUTOMATICALLY. The optimum profile acquisition MEAS conditions are automatically set.
Page 64 Registering the profile of the reference target MEAS Select [TEACH]. 1TEACH 2IMAGE MEAS Move to [YES] and press the SET TEACH PROFILE key. 1TEACH 2IMAGE This registers the profile. Set the MEAS measurement position and edge level while viewing the registered profile.
Page 65 RIGHT key, and select the measurement item. 2PTS-2 ←→ P2/5 Note To measure multiple items 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...
Page 66 1ITEM 2CUSTOM 3SCALE Note • 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.
Page 67 Measurement result 109.052 10 mm LV: 1-320 Note ↑ ↓ To switch the task display, use the UP key/ DOWN key. Press the MENU/VIEW key. The condition setup monitor screen is displayed. Select [OUT]. HEIGHT1 B01T1 1FILTER 2OUT Select [JUDGE].
Page 68 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. ZG2 User’s Manual...
Page 69: Starting Measurement
Switch to the [RUN] mode. Measurement will start. Monitoring the Measurement Status The measurement information is displayed on the LCD screen. You can switch the screen to display different measurement information according to your specific application. Profile monitor Digital monitor...
Page 70: Magnifying The Profile Display
Task No.: measurement items T1: HEIGHT1 Measurement result 1,109.05210 mm T2: 2PTS-1 Note 1,109.05210 mm T3:---- To switch between the tasks 1 to 4 and tasks T4:---- ↑ ↓ 5 to 8 displays, use the UP key/ DOWN ↑↓ P1/2 key.
Page 71: Function Keys
If the F1 key is pressed when [I/O]-[I/O LINE]-[TRIGGER]- [ENABLE] is set, the trigger is input. The image is displayed. To return the display to the normal display, press the F2 key again. Measurement is stopped while the image is displayed.
Page 72: Function Settings
FUNCTION SETTINGS Setting Measurement Conditions Customizing Measurement Conditions Scaling of Measurement Values Image Adjustment Position Correction Adjusting the Output Conditions of the Measurement Result Setting Zero Reset Bank Settings System Settings...
Page 73: Setting Measurement Conditions
Setting Measurement Conditions How to Select Measurement Items Desired measurement Measurement item and setting Reference Height Peak, bottom, average Height measurement items p.72 Height at which angle varies Height measurement items p.83 considerably Point of inflection +[CUSTOM]-[POINT]-[BEND] Point of inflection...
Page 74 Desired measurement Measurement item and setting Reference Position Position of peak and bottom in Height measurement items p.72 X-direction p.88 +[CUSTOM]-[POS.]-[X POS] Width Edge width measurement items p.77 Width Angle Angle measurement items p.79 Angle (θ) Point of Point of intersection angle, point of p.80...
Page 75: Measuring Height
Measuring Height Three measurement items are provided according to the type of height measurement. Item Description Measures the average value inside a region. Height Average Measures the maximum value (peak) inside a region. Height Peak Measures the minimum value (bottom) inside a region.
Page 76 Note Hint for adjusting the measurement region Adjust the start and end points of the measurement region so that the desired measurement position is enclosed. Start position End position Note Custom settings available for height measurement Setting value Description Reference...
Page 77: Measuring Step
P1 and the Step maximum value of P2. Peak P1 (average) To measure an indentation (- direction) taking the top surface as the reference plane: Item Description Measures the step between the P1 (average) average values of P1 and P2.
Page 78 (P1, P2) as the reference plane. Peak P1 (average) P2 (average) To measure an indentation (- direction) taking the top surface as the reference plane: Item Description Measures the step between the P2 (average) average value of P3 taking the...
Page 79 1ITEM 2CUSTOM 3SCALE measurement point. Note Hint for adjusting the measurement region Adjust the start and end points of the region for each measurement point. 2-pt step 3-pt step (step=P3-(P1+P2)÷2) (step=P2-P1) (reference) (reference) (reference) Note Custom settings available for step measurement...
Page 80: Measuring Position And Width
Measuring Position and Width Performs measurement taking the point of intersection of the profile and the edge level as an edge. <Edge position> Item Description Measures the edge that is Edge position positioned on the left side inside a region.
Page 81 3SCALE Note Hint for adjusting the measurement region 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.
Page 82: Measuring Angle
Measuring Angle 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 Angle (θ) points. A straight line is drawn...
Page 83: Measuring Angle And Point Of Intersection
Measuring Angle and Point of Intersection The angle at the point of intersection of two lines and point of intersection coordinates are measured. Measurement of the angle and point of intersection is enabled only in the EXP menu. <Point of intersection angle>...
Page 84 (Z coordinate) or as the position in the horizontal direction coordinate measurement) (X coordinate). POINT (measurement Sets in more detail which height in the line beam that the p.89 point) target is to be measured at. Settings: AVE, PEAK, BTM ZG2 User’s Manual...
Page 85: Measuring Cross-Sectional Area
Measuring Cross-sectional Area 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...
Page 86: Measuring Point Of Inflection
Measuring Point of Inflection 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...
Page 87 Note Hint for adjusting the measurement region Adjust the start and end points of the measurement range so that the point of inflection to be detected is enclosed. Start position End positi MEAS/LV MEAS/BEND Select [CUSTOM]-[MEAS]- [BEND]-[TARGET]. [ 3 ]OK...
Page 88 The ZG2 treats angles as follows. 0° To measure the position where the angle of inclination is varying from “small → large,” select [UPSWING]. To measure the position where the angle of inclination is varying from “large → small,” select [DOWNSWING].
Page 89: Calculating Measurement Values
Measuring Wide Measurement Targets p.185 Calculations Performed on Measurement Values Obtained on Multiple Channels p.190 Important 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 <Deleting measurement items>...
Page 90: Customizing Measurement Conditions
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 Select [MGNIFY]. 1MGNIFY 2RESET MEAS/MGNIFY Adjust the top left of the desired measurement area by the ↑, ↓, ←...
Page 91: Changing Measurement Positions
1MGNIFY 2RESET 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 horizontal direction (X coordinate). Selection of measurement position is enabled when measuring height and point of intersection coordinates.
Page 92: Changing Measurement Points
Changing Measurement Points 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...
Page 93: Changing The Edge Level And Edge Direction
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.
Page 94: Scaling Of Measurement Values
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.
Page 95 Set the measurement target in place, and press the SET key. measurement value displayed. MEAS/AUTO FIRST POINT MEAS/AUTO Measurement Input the actual size value on the value lower section. 4.95000 [ 5.00000] Note Actual size To change numerical values, use the...
Page 96 2-pt scaling 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) 1st point 2nd point Actual size value (mm) ZG2 User’s Manual...
Page 97  FUN mode-[MEAS]-[SENS]-[TASK1 to 8]-[SCALE]-[AUTO] Set the measurement target in place, and press the SET key. measurement value displayed. MEAS/AUTO FIRST POINT SET Measurement Input the actual size value on the MEAS/AUTO value lower section. 9.05000 [ 10.00000] Note Actual size value To change numerical values, use the ↑...
Page 98 Manual Setting Method 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.
Page 99: Image Adjustment
Image Adjustment 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 ...
Page 100 The optimum lighting sensitivity is set automatically matched to the measurement target set in place. Important • 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...
Page 101 • To measure the shape of the measurement target in detail: Set a small interval (rough adjustment → standard → fine adjustment). • The processing time when the upper limit is set to LV440 becomes approximately 10 ms. Detailed setting of AUTO sensitivity ...
Page 102: Changing Sensitivity Adjustment Region
Important Adjustment in the Z direction of the measurement region is limited to the inside of the sensitivity adjustment region. Sensitivity adjustment region A: This region is targeted for both sensitivity adjustment and measurement.
Page 103: Adjusting Profiles
1CHANGE Adjusting Profiles Noise filtering, output at measurement failure, and other options can be set in more detail. Adjust the conditions when the measurement cannot be performed properly. Setting of profiles is enabled only in the EXP menu.
Page 104 Sets the number of data to average. (default value: 1) Important When measuring edge position and edge width, set the average number of times to “1”. Setting to a value other than “1” will result in a drop in the measurement accuracy. Note Averaging is not performed for the data on the right edge because the required number of samples cannot be obtained.
Page 105 Setting the interpolation method This is used for interpolating between data in areas where profile data is missing (areas where measurement is not possible). If there are lines where the measurement target cannot be measured due to different degrees of reflectance or other causes, the data of such lines can be obtained by interpolating between the data acquired for the lines that allow measurement as desired.
Page 106 Setting the number of interpolated pixels Set the number of pixels to be interpolated when interpolating profile data. Profile data is interpolated only if missing areas (areas where measurement data cannot be obtained) contain less than the specified number of pixels. Interpolation is not performed if a number of pixels greater than the specified number cannot be measured continuously.
Page 107: Adjusting The Background Filtering Level
Pixels in the received light image whose density is at the preset background filtering level or less are judged to be noise, and can be omitted from the extraction target of the profile. This enables profiles to be displayed stably even when measuring targets with poor reflectance or when measurement is influenced by external light.
Page 108: Setting The High-Power Mode (Increasing The Amount Of Emitted Light)
Increases the amount of light emitted from the Sensor Head. Important When the high-power mode is set to ON, the cycle per lighting becomes longer. The shortest measurement cycle becomes 95 ms regardless of the CCD mode setting. The actual measurement cycle can be checked by the ECO monitor in the RUN mode.
Page 109: Position Correction
Set the reference position and correction direction to correct position shift of the measurement target. The measurement value when these are set is registered as the reference position. So, place the measurement target at the correct position before you start settings.
Page 110: Slope Correction
Set the measurement target in place, and press the SET key. POINT1 START 0]LINE SET MEAS/REF.POINT Specify the start and end lines for point 1. ←/→ key: Moves the cursor. SET Key: Applies the setting. POINT1 START ESC Key: Cancels the setting.
Page 111 Increasing the speed of slope correction Correction is calculated to prevent measurement error from occurring due to the angle when performing slope correction. When correction calculation is turned OFF, slope correction can be performed at a faster speed.  FUN mode-[MEAS]-[CORECT]-[SLOPE]-[CORECT]...
Page 112: Height/Position Correction
SET Key: Applies the setting. HEIGHT START [ 128]LINE SET ESC Key: Cancels the setting. Important Leave the default setting as it is if correction in the height direction is not necessary. MEAS/REF.POINT Select the measurement point to HEIGHT POINT be used as the reference.
Page 113 SET key. EDGE SELECT Setting the correction method Sets correction ON/OFF in both the height and position directions.  FUN mode-[MEAS]-[CORECT]-[HGT POSN]-[METHOD] Setting value Description The position is not corrected. (default value) HEIGHT Correction is performed in the height direction.
Page 114: Adjusting The Output Conditions Of The Measurement Result
Moving average Simple average Simple average • Moving average: The average value is output from the past N number of results. • Simple average: Measurement is performed for N number of times, and the average value of these measurements is output.
Page 115: Setting The Hold Function
Setting the Hold Function Set the conditions for holding measurement values. The “hold” function holds (retains) values such as “max. value” or “min. value” specified in the measurement values that are output within a fixed period of time, or “sampling period.”...
Page 116 Setting value Description AVERAGE The “average of the measurement values” in the sampling period is held. The output measurement value is held at the same value for one sampling period, that is, until the next sampling period ends. Current Output...
Page 117: Setting Zero Reset
Setting Zero Reset Setting the Offset Value To set a reference value for zero reset to a value other than 0 (zero), set the offset amount using this function. After setting any target value, execute a zero reset in the RUN mode.
Page 118: Executing Reference Zero Reset
0 (zero). Note • To cancel a zero reset, press and hold the ESC key for 2 seconds or longer. • Zero reset can also be executed and canceled by an external input. • A value other than zero also can be set as the zero reset reference value.
Page 119: Bank Settings
Bank Settings The ZG2 can hold up to 16 sets of settings, which are called a “bank”. Bank 1 is displayed as the default bank when the Smart Sensor is turned ON. Banks 2 to 16 are also provided in addition to this.
Page 120: Clearing Bank Data
The content of banks can be cleared. Important Settings in [System] and [I/O] are not cleared.  FUN mode-[BANK]-[CLEAR] Setting value Description The content of the currently selected bank is cleared. The content of the currently selected bank is not cleared. ZG2 User’s Manual Bank Settings...
Page 121: System Settings
Set how the Sensor Head is installed. This setting is automatically specified according to the type of the connected Sensor Head. However, if the Sensor Head is installed at an angle, and the default value and reflection angle are changed, change the settings according to the status of the Sensor Head installation.
Page 122  FUN mode-[SYSTEM]-[HEAD SET]-[CORECT]-[INCLINATION] SYS/INC. Set the measurement target in place, and select [TEACH]. 1TEACH SYS/INC. Move to [YES] and press the SET key. TEACH PROFILE Select [SET]. SYS/INC. 1TEACH 2SET Specify the start and end lines for SYS/INC. point 1.
Page 123 Press the SET key to apply the SYS/INC. setting. Setting correction ON/OFF Set Sensor Head inclination correction ON/OFF.  FUN mode-[SYSTEM]-[HEAD SET]-[CORECT]-[CORECT] Setting value Description Sensor Head inclination correction is not performed. (default value) Sensor Head inclination correction is performed. System Settings ZG2 User’s Manual...
Page 124: Setting The Ccd Mode
CCD mode. Three CCD Modes and Their Characteristics p.23 Important When the CCD mode is changed, the bank data is initialized. So, be sure to start with teaching again.  FUN mode-[SYSTEM]-[CCD MODE]...
Page 125: Setting The Number Of Digits Past The Decimal Point
Sets the number of display digits past the decimal point. (default value: 3) Note The number of digits past the decimal point in serial output follows the setting made here. Setting/Changing the ECO Display This function darkens the LCD screen to suppress current consumption when control keys or selection switches are not operated for three minutes or longer.
Page 126: Setting/Changing The Display Language
• The settings of all banks are saved regardless of the currently selected bank No. • After you have made or changed settings, be sure to save the setup data. All settings will be deleted if you turn the power OFF without saving the data. A message prompting you to save data will be displayed if you change to the RUN mode without saving data after you have changed settings.
Page 127 MEMO System Settings ZG2 User’s Manual...
Page 128: Connection With External Devices
CONNECTION WITH EXTERNAL DEVICES Output Data List Using the Controller I/O Cable Using the Parallel Output Unit (sold separately) I/O Timing Charts Serial Communication...
Page 129: Output Data List
Output Data List The ZG2 series can output 3 types of data (measurement values, judgment values and profile data) to external devices. All output data on the ZG2 series can be obtained by serial communication. Measurement value (result for each individual task)
Page 130: Using The Controller I/O Cable
By using the Controller's I/O cable, you can output the measurement value or judgment result to external devices, or input a control signal such as zero reset or LD-OFF from external devices. A predetermined I/O signal is assigned to each signal wire of the I/O cable.
Page 131: Assignments And Functions Of I/O Signal Wires
ANALOGGND voltmeter, and convert the measurement value for output as 4 to 20 mA analog current or -10 to +10 V analog voltage. With analog output, output values can be scaled or corrected to suit the conditions of the connected external device.
Page 132 Sets the measurement values of all tasks to zero. reset • At zero reset execution Input the zero reset signal for 50 to 800 ms. After the zero reset execution signal turns OFF, the zero reset is executed within 1 measurement cycle.
Page 133: I/O Circuit Diagrams
I/O Circuit Diagrams Important Make sure that the load connected to the "analog output wire (co-axial) - analog GND wire" satisfies the rating of the set state (voltage or current output) before turning the Controller ON. Otherwise, the Controller may be damaged.
Page 134 White ZERO-RESET Orange TRIG White/black RESET Current output 4 to 20 mA Voltage/Current Co-axial (black) Analog output switch Current output: 300 Ω max. 40 Ω Voltage output Load ±10 V Voltage output: 10 kΩ min. Shielded Analog GND ZG2 User’s Manual...
Page 135: Analog Output Settings
With analog output, the relationship between the displayed measured value and output value can be freely set as the measurement result is converted to a current of 4 to 20 mA or a voltage of -10 to +10 V, and is then output. Match the settings to suit the connected external device.
Page 136 ↑ /↓key, and press [ 4mA] the SET key. I/O/OUT MIN Select the output value of MIN by the ↑/↓ key, and press the SET key [ 4mA] twice. I/O/OUT MIN Input the measurement value corresponding to OUTPUT MIN, [-999.99999]...
Page 137: Correcting Analog Output Values
The analog output correction function can be used to correct this discrepancy. Output values are corrected by entering the correction value for the current (or voltage) values for any 2 points. (default value: OFF) Range: -999 to 999 Important Set scaling beforehand, and select current output or voltage output.
Page 138 Repeat steps 1 to 3 to set OUTPUT MAX. Analog Output Values at Measurement Failure Set the output methods for when a non-measurement state occurs temporarily, for example, due to insufficient received light amount or the reset input status.  ADJ mode-MENU/VIEW key-[OUT]-[ERROR]-[ERROR]...
Page 139: Setting For Measurement By The Trig Signal
Set the measurement timing method. The default setting is [DISABLE] (continuous measurement).  FUN mode-[I/O]-[I/O LINE]-[TRIGGER] Setting value Description ENABLE Measurement is performed synchronized to the trigger signal that is input from the external device. Trigger Trigger Trigger DISABLE The trigger is not used and measurement is performed continuously.
Page 140: Checking Signal Statuses
(default value: 3 ms) Setting the GATE delay Sets the time delay from when the result is output to the terminal block to when the GATE signal is turned ON. Output on the ZG-RPD1 conforms to the timing set here.
Page 141: Using The Parallel Output Unit (Sold Separately)
Using the Parallel Output Unit (sold separately) The Parallel Output Unit (ZG-RPD1) (sold separately) can be used to output measurement values or judgment results to external devices at high speed. Measurement values are converted to 16-bit binary data before they are output.
Page 142: Output Circuit
Output Circuit The following circuit configuration is employed for the total of 17 outputs (data outputs D0 to D15 and GATE signal). NPN output type (ZG-RPD11) PNP output type (ZG-RPD41) Load ZG-RPD41 ZG-RPD11 DC24V 20 mA (max.) ZG2-WDC ZG2-WDC 24 VDC...
Page 143: Output Format Of Measurement Values
Binary data of the measurement value <Output of Measurement Values (example)> The following shows an example where the number of digits past the decimal point is set to "3". Output of measurement standby status b15 b14 b13 b12 b11 b10 Output at "no measurement target present"...
Page 144: Output Format Of Judgment Results
The measurement result and measurement status of each task are output as binary data. <Output Format> When [4TASK] is set: Judgment result of Task 4 Judgment result of Task 3 Judgment result of Task 2 Judgment result of Task 1 b15 b14 b13 b12 b11 b10...
Page 145 HIGH ERROR Signal Description name The judgment result of TASK1 is output. The judgment result of TASK2 is output. The judgment result of TASK3 is output. The judgment result of TASK4 is output. The judgment result of TASK5 is output.
Page 146: Assignment Of Terminal Block Output
[4TASK]. When the number of setup tasks is five to eight, select [8TASK]. Setting the Number of Digits Past the Decimal Point Set the number of digits past the decimal point of the measurement value to output to the Real-time Parallel Output Unit.  FUN mode-[I/O]-[RPD]-[DIGIT] Setting value...
Page 147: I/O Timing Charts
(maximum value) At MULTI sensitivity: T3=T1 × average number of times This is the time from start of output up to when the GATE signal GATE output delay time turns ON. This time can be changed. This is the time to wait until stable output data can be obtained.
Page 148 Important • When the auto output for serial output is ON, input the next trigger after all measurement data is received. At this time, the ENABLE signal turns ON after all measurement data has finished being sent. • The GATE signal is output from both the Controller and Parallel Output Unit. For details of...
Page 149 (measurement values/judgment results) on external devices. Important • When the auto output for serial output is ON, input the next trigger after all measurement data is received. At this time, the ENABLE signal turns ON after all measurement data has finished being sent.
Page 150 • The ENABLE signal is ON at all times. • During output of the GATE signal, the next GATE signal is not output and is ignored. • The GATE signal is output from both the Controller and Parallel Output Unit. For details of...
Page 151 This is the time after the laser stop signal is canceled until laser Laser restore response emission is started. time 20 ms or less This is the time after input of the laser stop signal until the ENABLE ENABLE signal signal turns ON. OFF response time 10 ms or less...
Page 152: Serial Communication
Serial Communication Using the Serial Interface You can use the USB port or RS-232C connector of the Controller to perform serial communication with external devices such as a personal computer or programmable controller. By serial communication, you can obtain higher resolution and more stable measurement data than with analog output.
Page 153: Communication Interface Specifications
Communication Interface Specifications <USB> This interface allows full-speed (12 Mbps) communications compliant with USB 2.0 with a PC equipped with the same USB interface as standard. Communication method Full duplex Synchronization method Start-stop Transmission code ASCII (Binary format can be selected only for profile output.)
Page 154 By this method, command processing is executed when a command is sent to the Controller from an external device, and a response is returned to the external device from the Controller, when command processing ends. An error response is returned when the command sent from the external device is in error or when an error occurs during command processing on the Controller.
Page 155: Connecting Peripheral And External Devices
Connecting Peripheral and External Devices Connecting a PC Use the USB/RS-232C cable to connect the PC to the Controller. Important When connecting devices, refer to the Instruction Manual for the PC. Connecting by a USB cable Use the USB cable provided with the ZG2- WDC1A...
Page 156 Connecting by an RS-232C cable Use the exclusive cable to connect the Controller to the PC. RS-232C cable for connecting a personal computer Use a cable with the following pin layout. ZS-XRS2 (cable length: 2 m) Controller side Personal computer side (PC/AT compatible)
Page 157 Connecting to a PLC Use the RS-232C cable to connect the PC to a PLC. Important When connecting to a PLC, refer to the Instruction Manual for the PLC. RS-232C cable for connecting a PLC Use a cable with the following pin layout.
Page 158: Serial Auto Output At Trigger Measurement
With auto output, output on the USB interface only is enabled. Setting Automatic Output This function is enabled only when the auto output method is set for serial output. When [OFF] is set, specify the desired task to output as the parameter when the MEASURE command is input.
Page 159: Setting The Node No
This node No. sets the connection group No. as seen from the host device (PLC). Not only the ZG2 series but also multiple devices can be connected to the PLC. The No. assigned to devices connected to a PLC in this instance is referred to as a node No..  FUN mode-[SYSTEM]-[NODE]...
Page 160: About Communication Commands
When processing ends successfully Response data Delimiter Delimiter When processing fails Delimiter Command data Specifies the command and parameters. Response data Stores the acquired data. Delimiter This control code indicates the end of the data. ZG2 User’s Manual Serial Communication...
Page 161 Configuration of measurement value data Acquired measurement values are output as a data structure of variable length of up to 12 characters (when the number of digits past the decimal point is set to 5) including delimiters and sign. Delimiter Digits past the decimal point: 5 digits (Number can be changed.)
Page 162: Available Commands
DATASET Sets the bank data. p.165 DATASAVE Saves all bank data to the Controller's flash memory. p.166 DATAINIT Returns all Controller setup data (bank data and p.166 system data) to their defaults. CHGET Acquires the number of gang-mounted Controllers p.167...
Page 163: Bank Control Commands
B A N K S E T Bank No. <Response format> When processing ends successfully When processing fails <Explanation of parameters> Bank No. Specifies the bank No. after the bank is switched. (1 to 16) Serial Communication ZG2 User’s Manual...
Page 164 This command acquires the current bank No. <Command format> B A N K G E T <Response format> When processing ends successfully Bank No. When processing fails <Explanation of parameters> Bank No. The acquired bank No. is returned. (1 to 16) ZG2 User’s Manual Serial Communication...
Page 165 1 value of task 2 value of task 8 When a measurement error occurs - 9 9 9 . 9 9 9 9 9 When processing fails <Explanation of parameters> Task No. Specifies the task No. (1 to 8) "0"...
Page 166 After measurement is completed, acquire measurement values by the MEASURE command. Important This command functions only when trigger measurement is enabled. It cannot be used in the case of AUTO sensitivity. (If it is executed, ER is returned.) ZG2 User’s Manual...
Page 167 Execute a Zero Reset <ZERORST command> This command executes a zero reset on all tasks. <Command format> Z E R O R S T <Response format> When processing ends successfully When processing fails Cancel a Zero Reset <ZEROCLR command> This command cancels the zero reset on all tasks.
Page 168: Setting Acquisition/Change Commands
Unit No. <Response format> When processing ends successfully Setting value When processing fails For details on parameters, see "Parameter List (p.176)." Set Bank Data <DATASET command> This command sets the bank data. <Command format> D A T A S E T Setting value Parameter No.
Page 169 Save All Bank Data <DATASAVE command> This command saves all bank data to the Controller's flash memory. No parameters are provided for this command. <Command format> D A T A S A V E <Response format> When processing ends successfully When processing fails Initialize Controller <DATAINIT command>...
Page 170 Acquire Number of gang-mounted Controllers and Data Storage Units <CHGET command> This command acquires the number of gang-mounted Controllers and Data Storage Units. <Command format> C H G E T Parameter No. <Response format> When processing ends successfully Number When processing fails <Explanation of parameters>...
Page 171: Backup/Restore Commands
Backup/Restore Commands Send Bank Data <BANKLOAD command> This command sends the bank data to the Controller by XMODEM protocol. The data is loaded to the currently displayed bank. No parameters are provided for this command. <Command format> B A N K L O A D <File transfer>...
Page 172 <Command format> B A N K S A V E Bank No. <File transfer> The file is transferred by XMODEM (-CRC or -SUM) after READY is received. XMODEM (-K) is not supported. <Response format> R E A D Y When processing ends successfully When processing fails <Explanation of parameters>...
Page 173 <Command format> S Y S L O A D <File transfer> The file is transferred by XMODEM (-CRC or -SUM) after READY is received. XMODEM (-K) is not supported. <Response format> R E A D Y...
Page 174 <Command format> S Y S S A V E <File transfer> The file is transferred by XMODEM (-CRC or -SUM) after READY is received. XMODEM (-K) is not supported. <Response format> R E A D Y...
Page 175: Utility Commands
Utility commands Switch the Measurement Status Monitor <CHGDISP command> This command changes the measurement status monitor in the RUN mode. <Command format> C H G D I S Monitor type <Response format> When processing ends successfully When processing fails <Explanation of parameters>...
Page 176 - 9 9 9 . 9 9 9 9 9 Measurement error line - Acquisition type: when Binary is specified ... binary data of total 2524 bytes Binary data of 4 bytes per 1 data item x 631 points CRC16 ... 2-byte binary data When processing fails ZG2 User’s Manual...
Page 177 Specifies the acquisition type. 0: ASCII 1: Binary Number of lines sent This is the number of lines in the profile that is sent. (0 to 63) Start line This is the start line No. of the profile. End line This is the end line No.
Page 178 Automatically Set Sensitivity Adjustment Range <SEARCH command> This command automatically sets the sensitivity adjustment ranges of MULTI sensitivity/ HS MULTI sensitivity matched to the measurement target. No parameters are provided for this command. <Command format> S E A R C H <Response format>...
Page 179: Parameter List
1 to 440 AUTO LOW 1 to 440 FIXED 0 to 440 (0: laser out) HS MULTI max. 2 to 10 number of lightings The SEARCH command must be executed to enable the HS MULTI sensitivity setting. Serial Communication ZG2 User’s Manual...
Page 180 0: 1, 1: 2, 2: 4, 3: 8, 4: 16, 5: ALL interpolated pixels Noise filtering 0: 0, 1: 1, 2: 2, 3: 3, 4: 4, 5: 5, 6: 6, 7: 7 Gain 0: LV1, 1: LV2, 2: LV3, 3: LV4, 4:...
Page 181 Standard, high-resolution mode: 0 to 399 0: left → right (forward direction) P1 edge direction 40+10* (task-1) 1: right → right arrow left (reverse direction) 0: left → right (forward direction) P2 edge direction 40+10* (task-1) 1: right → right arrow left (reverse...
Page 182 (*1) Calculation 40+10* (task-1) -999.999999 to 999.999999 parameter K Number of digits past the decimal point cannot be handled by the DATASET command. Input as follows: → -100 to 100 Example: -10.0 to 10.0 -999.999999`999.999999 → -999999999`999999999 Note The region that can set (P1 to P3, etc.) differs according to the measurement item.
Page 183 Parameter No. Setting range (*1) Zero 40+10* (task-1) -999.999999 to 999.999999 Number of digits past the decimal point cannot be handled by the DATASET command. Input as follows: Example: -999.999999 to 999.999999 → -999999999 to 999999999 Serial Communication ZG2 User’s Manual...
Page 184: Command Processing Time
Command Processing Time The command processing time differs according to the command. The following shows typical command processing times for the TRIG, MEASURE and PROFILE commands. Command Setting Processing time RS-232C (115200 bps) TRIG Sensitivity: MULTI, CCD mode: 280 ms...
Page 185 MEMO Serial Communication ZG2 User’s Manual...
Page 186 MEASUREMENT BY GANG- MOUNTED CONTROLLERS Mounting Order and Assignment of CH Numbers Setup Example Required Settings...
Page 187: Mounting Order And Assignment Of Ch Numbers
Mounting Order and Assignment of CH Numbers With the ZG2 series, one Data Storage Unit (ZG2-DSU) and up to two Controllers (ZG2- WDC) can be gang-mounted. Gang-mount these devices in correct combinations and arrangements using the Controller Link Unit (sold separately).
Page 188: Setup Example
When two Controllers are gang-mounted, measurement values from two Sensor Heads can be acquired and calculations performed on these values. This enables measurement of wide measurement targets. Measuring Wide Measurement Targets Mount the two Sensor Heads aligned with the left and right of the measurement target. EDGE1 B01 T1 EDGE1...
Page 189 Calculations Performed on Measurement Values Obtained on Multiple Channels p.190 • Setting zero reset Executing Reference Zero Reset p.115 Setting the Offset Value p.114 Important Set calculation and zero reset on the Controller assigned channel number 1 (CH1). Setup Example ZG2 User’s Manual...
Page 190: Required Settings
Required Settings Setting Mutual Interference Prevention When two Sensor Heads are mounted next to each other, laser light reflected from each Sensor Head sometimes interferes with the light from the other, preventing light from being received correctly on each Sensor Head. If this happens, set the mutual interference prevention function ON.
Page 191 Measurement timing charts Mutual interference prevention function: OFF TRIG (input to CH2) Lighting Measurement Integration processing processing Lighting Measurement processing ENABLE signal (output from CH2) Measurement cycle PASS/NG signal (output from CH2) GATE signal (output from CH2) Mutual interference prevention function: ON...
Page 192: Settings Common To Gang-Mounted Controllers
Settings Common to Gang-mounted Controllers The table below summarizes the settings that should be set in common to both gang- mounted Controllers. Set these on the CH2 Controller. The settings made on the CH2 Controller are automatically reflected on the CH1 Controller.
Page 193 Set these calculations on the CH1 Controller. When Controllers are gang-mounted, the channel selection menu is added to the calculation menu on the CH1 Controller.  CH1-side-FUN mode-[MEAS]-[SENS]-[CALC]-[CUSTOM]-[TASK]-[X/Y] Additional menu in...
Page 194 The table below summarizes the I/O of each channel when Controllers are gang- mounted. Description Controller I/O Input TRIG signal This signal is input to CH2. CH1 is cable automatically interlocked to this signal. LD-OFF signal These signals are input to each channel.
Page 195 Measurement result measurement measurement results results (T1 to T8) (T1 to T8) <Gang-mounted calculation> Judgment result Serial auto output Serial auto output TRIG / TIMING ERROR ALL-PASS / NG / ERROR / ENABLE / GATE Required Settings ZG2 User’s Manual...
Page 196 APPENDICES Specifications and External Dimensions Error Messages and Corrective Actions Troubleshooting Menu List List of Key Operations Laser Safety Requirements from Regulations and Standards Compliance with EC Directives Updating the Firmware Index...
Page 197: Specifications And External Dimensions
Ambient humidity Operating and storage: 35% to 85%RH (with no condensation) Degree of protection IP66 (IEC60529) Vibration resistance 10 to 150 Hz (at a single-amplitude of 0.35 mm) for 80 minutes each in the (durability) X, Y, and Z directions Shock resistance...
Page 198 When an OMRON-standard measurement target is placed at the measurement center distance, and its average height of all lines is measured. Conditions are as follows.Note that the resolution performance may not be satisfied in the presence of strong magnetic fields. The resolution of ZG2-WDS8T/WDS3VT is min. 0.25 ZG2 User’s Manual...
Page 199: External Dimensions
µm, and higher resolution than that value is not obtained even if the average number of measurements is increased. Model CCD mode Average Measurement target number of Regular reflection Diffuse reflection times ZG2-WDS70/WDS22/ High-resolution 64 times OMRON-standard white alumina ceramic...
Page 200 Three, 4.5-dia. Mounting holes Laser receiver 16.9 45.1 Connector 70±0.1 3-M4 9.5±0.1 Vinyl insulated round cable 6.8 mm dia. Standard length 2 m, 0.5 m * ZG2-WDS8T L=50, A=30° ZG2-WDS22 L=100, A=25° Mounting hole dimensions ZG2 User’s Manual Specifications and External Dimensions...
Page 201 • When used for regular reflection (ZG2-WDS8T) (Unit: mm) 44.1 98.5 10.3 67.6 Emission axis Three, 4.5-dia. Mounting holes Measurement center Reception axis 3-M4 Reference plane 67.6±0.1 27±0.1 Connector Vinyl insulated round cable 6.8 mm dia. Standard length 2 m, 0.5 m Mounting hole dimensions •...
Page 202 17.5 Measurement center 15.3 Laser emitter Laser receiver Reception axis 81.06 Reference plane 2-M4 Vinyl insulated round cable 6.8 mm dia. Standard length 2 m Connector 56±0.1 Mounting hole dimensions • When used for diffuse reflection (Unit: mm) 10.636 81.06 Two, 4.5-dia.
Page 203 Also, the mutual interface prevention function ensures that measurement is performed correctly even when beams overlap on the measurement object (stationary object). Setting Mutual Interference Prevention p.187 Important When the measurement object is a moving object, install the Sensor Heads so that beams do not overlap. ZG2-WDS70 (Unit: mm) Specifications and External Dimensions ZG2 User’s Manual...
Page 204 ZG2-WDS3VT (Unit: mm) ZG2-WDS22 (Unit: mm) ZG2 User’s Manual Specifications and External Dimensions...
Page 205 ZG2-WDS8T (Unit: mm) 55.5 44.5 55.5 44.5 Specifications and External Dimensions ZG2 User’s Manual...
Page 206 PNP type Number of connected Sensor Heads 1 Sensor/Controller Max. number of gang-mounted Controllers (*1) Measurement cycle 16 ms (high-resolution mode), 8 ms (standard mode), 5 ms (high-speed mode) Minimum display unit 10 nm Display range -999.99999 to 999.99999 Display LCD monitor 1.8"...
Page 207: Input Specifications
MULTI sensitivity/high-speed MULTI sensitivity mode is selected and according to other settings. Also, when the high power mode is set to ON, the shortest measurement cycle becomes 95 ms regardless of the CCD mode setting. Check the actual measurement cycle by the ECO monitor in the RUN mode.
Page 208 ON/OFF Analog Clamp value Clamp value Measurement value/clamp value (*1) Parallel Output Unit Measurement value/status output For details, see “Chapter 4 CONNECTION WITH EXTERNAL DEVICES.”p.125 External Dimensions ZG2-WDC11/WDC41 (Unit: mm) 52.5 20.8 11.7 mm dia. 10.8 Heat-resistant PVC 5.2 mm dia., standard length 2 m ZG2 User’s Manual...
Page 209 Note 1: Dimensions when the panel thickness is 2.0 mm Panel cutout dimensions (60 x n) + 8 Important When mounting multiple Controllers on a panel, be sure to install the DIN track on the rear side of the Controllers for support. Item ZS-XPM1 (for 1st unit)
Page 210: Extension Cable
Operating and storage: 35% to 85% (with no condensation) Vibration (resistance) 10 to 150 Hz (0.7 mm double amplitude), 80 min each in X, Y, and Z directions Shock resistance (destructive) 300 m/s 3 times each in six directions (up/down, left/right, forward/backward)
Page 211 100 MΩ (by 500 V DC megger) Vibration (resistance) 10 to 150 Hz (0.7 mm double amplitude), 80 min each in X, Y, and Z directions Shock resistance (destructive) 300 m/s 3 times each in six directions (up/down, left/right, forward/backward)
Page 212 Connected to ZG2-WDC_1, across all lead wires and controller case of the ZG2-WDC_1: 1000 VAC, 50/60 Hz 1 min Vibration (resistance) 10 to 150 Hz (0.7 mm double amplitude), 80 min each in X, Y, and Z directions ZG2 User’s Manual Specifications and External Dimensions...
Page 213 Operating and storage: 35% to 85% (with no condensation) Vibration (resistance) 10 to 150 Hz (0.7 mm double amplitude), 80 min each in X, Y, and Z directions Shock resistance (destructive) 300 m/s 3 times each in six directions (up/down, left/right, forward/backward)
Page 214: Error Messages And Corrective Actions
Error Messages and Corrective Actions The following shows error messages that are displayed on the LCD screen and their corrective actions. Error message Probable cause Reference AUTO SETTING FAILED Automatic setting cannot be executed on the current p.70 region. Set the region again referring to the manual.
Page 215 2. To use the Controller and a standalone device, press [OK] to start up the Controller and save the settings. When the Sensor Head is not connected, the Controller screen darkens, making the error message no longer visible. Error Messages and Corrective Actions...
Page 216: Troubleshooting
(1) When the measurement target is dark: p.96 → Set larger sensitivity-related setting values. If this does not remedy the problem, proceed to (6) → (7) → (8). Menu Key FUN mode-[MEAS]-[IMAGE]-[LD-POWER] p.97 (2) When differences in the color and angle of the measurement target cause the amount of received light to vary: →...
Page 217 Menu Key FUN mode-[MEAS]-[IMAGE]-[LD-POWER]-[HSMULTI] I want to improve When using fixed sensitivity, view the image in the RUN mode and if p.96 measurement accuracy. it appears saturated (received light surface of measurement target looks bloated), either adjust the sensitivity to a lower setting, or use AUTO sensitivity, MULTI sensitivity, or HS MULTI sensitivity.
Page 218 If the setup support software Smart Monitor ZG2 packaged with the p.152 Sensor Controller ZG2-WDC11A/41A is used, more detailed profiles that cannot be fully verified on the Controller’s LCD monitor can be verified on a PC’s larger size screen. ZG2 User’s Manual...
Page 219: Menu List
Menu List Enabled only in the expert menu Teaching p.59 p.60 Image Automatic settings • MULTI - Custom, Search p.96 LD-POWER •HSMULTI - Custom, Search •AUTO - Custom p.99 Region •FIXED - Sensitivity level p.100 Profile Inspection target p.100 Average p.101...
Page 220 Enabled only in the expert menu p.116 Bank switching p.116 Copying banks p.117 Clearing banks p.132 p.136 Analog Task I/O line Bank p.136 p.132 Scaling Trigger p.137 p.135 Clamp GATE period p.137 p.134 Correction GATE delay p.155 Serial p.143 AUTO...
Page 221: List Of Key Operations
List of Key Operations The functions of keys differ according to the currently selected mode. Description FUN mode ADJ mode RUN mode Function These keys directly set the icon and No. These keys can be keys preceding the items displayed on the LCD used as function screen.
Page 222: Laser Safety
FDA labels (supplied) referring to the figure below. Make sure that the labels are affixed at the correct locations as indicated. The ZG Series is intended to be fitted into a system as a terminal device. Follow the following technical standards when fitting in the device.
Page 223 PULSE DURATION 25000 PULSE DURATION 10000 WAVE LENGTH WAVE LENGTH (2)Aperture Label (3)Certification and Identification Label This laser product complies with AVOID 21 CFR 1040.10 and 1040.11. EXPOSURE OMRON Corporation Laser radiation Shiokoji Horikawa, Shimogyo-ku, is emitted from Kyoto 600-8530 JAPAN...
Page 224 Use in Countries Other than the U. S. A. The warning label written in Japanese is affixed to the Sensor unit. For countries other than the U.S.A., warning labels must be replaced by English ones (supplied with the Sensor unit).
Page 225: Requirements From Regulations And Standards
AEL above Classes 1 or 2 when adjustments are made Viewing optics Emission from all viewing systems must be below Class 1M AEL required Scanning Scan failure shall not cause product to exceed its classification Class label...
Page 226 Note: 1. This table is intended to provide a convenient summary of requirements. See text of this standard for complete requirements. 2. For the safety medical laser products, IEC 60601-2-22 applies 3. AEL: Accessible Emission Limit The maximum accessible emission level permitted within a particular class.
Page 227 IIIa IIIb Performance (all laser products) Protective R (see note 2) R (see note 2) R (see note 2) R (see note 2) R (see note 2) R (see note 2) housing Safety interlock (see notes 3,4) (see notes 3,4)
Page 228 Footnotes: Note 1: Based on highest level accessible during operation. Note 2: Required wherever & whenever human access to laser radiation above Class I limits is not needed for product to perform its function. Note 3: Required for protective housings opened during operation or maintenance, if human access thus gained is not always necessary when housing is open.
Page 229: Summary Of Requirements To User
1. This table is intended to provide a convenient summary of requirements. See text of this standard for complete precautions. 2. Class 1M laser products that failed condition 1 of table10 of the standard. Not required for Class 1M laser products that failed condition 2 of table10 of the standard. See the text for details.
Page 230 For U. S. A ANSI Z136.1:1993 “American National Standard for the Safe Use of Lasers” Control Measures for the Four Laser Classes Control measures Classification Engineering Controls Protective Housing (4.3.1) Without Protective Housing (4.3.1.1) LSO (see note 2) shall establish Alternate Controls ✰...
Page 231 2. LSO: Laser Safety Officer An individual shall be designated the Laser Safety Officer with the authority and responsibility to monitor and enforce the control of laser hazards, and to effect the knowledgeable evaluation and control of laser hazards. For your reference, see ANSI Z136.1993, Section 1.3.
Page 232: Definitions Of Laser Classification
Note: Conditions for safe viewing of diffuse reflections for Class 3B visible lasers are: minimum viewing distance of 13 cm between screen and cornea and a maximum viewing time of 10 s. Other viewing conditions require a comparison of the diffuse reflection exposure with the MPE.
Page 233 Class. Class IV/4 Exceeding the limits of Class IIIb and are a A Class 4 laser is a hazard to the eye or skin hazard for scattered reflection as well as for from the direct beam and sometimes from a direct exposure.
Page 234: Compliance With Ec Directives
Applicable directive Safety category Low-Voltage EMC directive directive (*1) (*1) Compliance Exception Complied For details of detailed compliance levels, we have issued the “EC Declaration of Conformity: EN45014.” Please contact your OMRON sales representative. ZG2 User’s Manual Compliance with EC Directives...
Page 235: Updating The Firmware
• During a firmware update, do not turn the Controller OFF. Doing so will prevent the Controller from functioning normally. • When installing Smart Monitor and the USB driver, log in as an administrator or a user having the same privileges as a computer administrator for changing system settings.
Page 236 Installing Warp Engine Zero Install Warp Engine Zero on the Starting Up Warp Engine Zero Important Start Warp Engine Zero only when the PC recognizes the Controller normally. Select [Programs]-[OMRON]- [SmartMonitorZG2]- [WarpEngineZero] from the Windows [Start] menu. The [WarpEngineZero] window is displayed.
Page 237 Click the [Loading file] button to select the file to be written. The model and version of the Controller that is held in the file are displayed. Updating the firmware Click the [Start upgrade] button. A message indicating the start of the update is displayed.
Page 238 Important • During a firmware update, an error may occur on the Controller. Please wait. • If the update progress bar stops or the update is not completed within ten minutes, there is a possibility that the update has failed.
Page 239 If startup of Warp Engine Zero fails, a message is displayed, followed by the dialog box shown below. Select [Settings]-[Control Panel] from the [Start] menu in the PC and double- click [System]. The [System Properties] dialog box is displayed. Open the [Hardware] tab and click [Device Manager].
Page 240 Index Numerics Communication specifications 156 Connecting Devices 49 Connecting the Power Supply 51 2-pt step 74 Control keys 20 3-pt step 75 Controller Common Settings 189 External dimensions 205 Gang-mounted 47 Link Unit 210 ADJ mode 52 Mounting 39 APS function 60...
Page 241 Multi-task measurement 53 High-resolution mode 121 Mutual interference 200 High-speed mode 121 Node No. 156 I/O cable 20 Number of digits past the decimal I/O circuit diagrams 130 point I/O timing charts 144 Display digits 122 Initialization 56 Parallel Output Unit 143...
Page 242 Scaling 91 Voltage/Current switch 20 Analog output 132 SEARCH command 175 Sensitivity adjustment 96 Sensor Head External dimensions 196 Wiring the I/O cable 127 Mounting 27 Mutual interference Adjusting 200 Part Names and Functions 18 Setting Mutual Interference ZERO 114...
Page 243: Revision History
Revision History A manual revision code appears as a suffix to the catalog number at the bottom of the front and back covers of this manual. Cat. No. Z288-E1-01 Revision code Revision code Revision date Revised content December 2008 First edition Revision History ZG2 User’s Manual...

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