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OMRON ZG2-DSU User Manual

Smart sensor data storage unit.
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Cat. No. Z289-E1-01
ZG2-DSU
Smart Sensor

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Table Of Contents

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   Summary of Contents for OMRON ZG2-DSU

  • Page 1: Users Manual

    Cat. No. Z289-E1-01 ZG2-DSU Smart Sensor Data Storage Unit 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. About Trademarks • Microsoft and Windows are either registered trademarks or trademarks of Microsoft Corp. in the United States and/or other countries.

  • Page 4

    READ AND UNDERSTAND THIS DOCUMENT (Please Read) BEFORE USE User's Manual LOGGING FUNCTIONS EXTERNAL BANK FUNCTIONS SETTING ADDITIONAL FUNC- TIONS COMMUNICATION WITH EXTER- NAL DEVICES APPENDICES Smart Sensor Data Storage Unit ZG2-DSU...

  • Page 5: Limitations Of Liability

    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, Dimensions And Weights

    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.

  • Page 7

    The following signal words are used in this manual. Indicates a potentially hazardous situation which, if not avoided, will result in minor or moderate injury, or may result in serious injury or death. Additionally there may be significant property damage.

  • Page 8

    2. Power Supply and Wiring • The voltage and AC power supply must be within the rated range (DC 24 V ±10%). • Reverse connection of the power supply is not allowed. • Open-collector outputs should not be short-circuited.

  • Page 9

    • 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

    ■ Meaning of Symbols Menu items that are displayed on the Data Storage Unit’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 or tips.

  • Page 11

    MEMO ZG2-DSU User’s Manual...

  • Page 12: Table Of Contents, Before Use, Logging Functions

    1.BEFORE USE Data Storage Unit ......14 System Configuration ......14 Part Names and Functions .

  • Page 13: Table Of Contents, Setting Additional Functions

    ........35...

  • Page 14: Table Of Contents

    ........61...

  • Page 15

    MEMO ZG2-DSU User’s Manual...

  • Page 16: Table Of Contents

    BEFORE USE Data Storage Unit Mounting and Connecting Devices Functions of the Data Storage Unit Initializing Controller Settings Saving Setup Data...

  • Page 17: Data Storage Unit, System Configuration

    Sensor Controller installed on site, and can save this data to Memory Card. Data saved on Memory Card can be easily loaded to a PC for use in data analysis and operations. Measurement conditions for up to 4096 banks (16 banks x 256 files) can be registered to an inserted Memory Card as an external bank for the Sensor Controller.

  • Page 18: Part Names And Functions

    Function (1) CF power LED Displays the status of the power supplied to the Memory Card. This LED turns ON when power is ON, and turns OFF when power is OFF. (2) CF access LED This LED turns ON when the Memory Card is being accessed.

  • Page 19

    TEACH: This mode displays the menu for setting alarm output thresholds. RUN: Normally select this mode when performing logging. (9) Threshold selection Select which of the HIGH or LOW thresholds is to be set (or switch displayed). (10) OUT LED This LED turns ON during alarm output.

  • Page 20: Mounting And Connecting Devices

    Do not install the Data Storage Unit in the following orientations: Important •Do not block the ventilation holes at the top and bottom of the Data Storage Unit body. Doing so will cause heat to build up inside and result in a malfunction.

  • Page 21: Gang-mounting To A Controller

    Gang-mounting to a Controller For details on how to gang-mount and install devices, refer to the ZG2 series User's Manual. CH number when Controllers are gang-mounted In the gang-mounted arrangement, the Data Storage Unit must be located at the leftmost end viewed from the front.

  • Page 22: Attaching The Ferrite Core, Connecting The Power Supply

    VDC ( 10%) power supply. Note The following power supply is recommended: • S8VS-03024 (24 VDC, 1.3 A) Be sure to connect the Data Storage Unit to the power supply in a 1:1 connection. Mounting and Connecting Devices ZG2-DSU User’s Manual...

  • Page 23: Inserting Memory Cards, Inserting And Removing Memory Cards

    Before removing a Memory Card from the unit, make sure that the CF power LED and access LED are both OFF. If a Memory Card is removed with these LEDs still ON, there is the possibility that data stored on the Memory Card might be lost or the Memory Card or Data Storage Unit might malfunction.

  • Page 24

    Memory Card slot. Remove the Memory Card. Memory Card EJECT button Important When Memory Cards are not to be used on the unit for a long time, insert the protective dummy card. Mounting and Connecting Devices ZG2-DSU User’s Manual...

  • Page 25: External Bank Function, Functions Of The Data Storage Unit, Logging Function

    Measurement values and profile data can be saved on the Data Storage Unit.Saved data can be loaded to a PC from a Memory Card or via USB/serial communication for use in managing production logs, monitoring trends and analyzing trouble that may occur.

  • Page 26: Initializing Controller Settings

    Important The settings of all banks and logging data are initialized regardless of the currently saved bank No. and logging data. To save settings and data, back them up to a personal computer before performing initialization. Acquiring setup data <DATAGET command> p.66 Switch to the FUN mode.

  • Page 27: Saving Setup Data

    •The settings of all banks are saved regardless of the currently selected bank No. •After you have made 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 the operation mode without saving data after you have changed settings.

  • Page 28: Table Of Contents

    LOGGING FUNCTIONS Logging Procedure How Logging Works Select the Logging Target Setting Logging Conditions Starting and Ending Logging Loading Logging Data to an External Device35...

  • Page 29: Logging Procedure

    Step 1 Measurement value p.31 Select the logging target. Profile p.31 Step 2 Only at an NG/only at an OK p.32 Set conditions to be used for Log by all conditions p.32 logging. Log at a fixed cycle p.33 Log at individual fixed counts p.33 Specify the logging cycle by an external signal p.33...

  • Page 30: How Logging Works

    (3) Logging end Logging is ended by the STOP signal or by the key. (4) Copy to Memory Card Logging data is copied automatically after logging ends to the Memory Card from the ZG2-DSU's internal memory. Note Approximate time required for copying logging data to Memory Card Timing charts p.56...

  • Page 31: Possible Number Of Logging Data

    120 files) regardless of preset number of tasks Important The numerical values in the table above are provided for reference only. Please note that the number of saves may fluctuate depending on the setup status even with the same number of channels or tasks.

  • Page 32: Folder Structure, Format Of Data Saved To Memory Card

    The same number as the folder name is used for the number appended to each file name. *2 The maximum number of folders that can be created is 999. The logging folder start No. can also be changed.

  • Page 33: File Format

    Measurement count (max. 256 times) Note Up to 5,120 profiles can be logged to internal memory. However, when these profiles are saved to Memory Card, the profiles are split up into 256 profiles for each individual file. How Logging Works ZG2-DSU User’s Manual...

  • Page 34: Select The Logging Target, Logging Measurement Values, Logging Profiles

    Setting value Description OFF/CH1/CH2 Sets the channel (CH) of the Sensor Controller targeted for logging. Important When two Sensor Controllers are gang-mounted, profiles are logged on only either one of the Sensor Controllers. Select the Logging Target ZG2-DSU User’s Manual...

  • Page 35: Setting Logging Conditions, Logging Only At An Ng/only At An Ok, Logging By All Conditions

    Setting Logging Conditions Set which data is to be logged. You can select from the following five logging conditions. • Only at an NG/only at an OK • All conditions • At a fixed cycle • At individual fixed counts •...

  • Page 36: Logging At A Fixed Cycle, Logging At Individual Fixed Counts

    Sets the count interval. (default value: 1) Specify the Logging Cycle by an External Signal All data is logged continuously for the duration that the TRIG signal is ON. Note •Logging is also performed while function key 1 is held down.

  • Page 37: Starting And Ending Logging, Starting Logging, Ending Logging

    Starting and Ending Logging The following describes the procedure for starting and ending logging. Starting Logging Switch to the RUN mode. TEACH Either input the START signal or Available MB ←→  press the key. Stopping ↑ START Logging is started.

  • Page 38: Loading Logging Data To An External Device

    Before removing a Memory Card from the unit, make sure that the CF power LED and access LED are both OFF. If a Memory Card is removed with these LEDs still ON, there is the possibility that data stored on the Memory Card might be lost or the Memory Card or Data Storage Unit might malfunction.

  • Page 39

    MEMO Loading Logging Data to an External Device ZG2-DSU User’s Manual...

  • Page 40

    EXTERNAL BANK FUNCTIONS Saving Bank Data to Memory Cards Transferring Bank Data to the Controller...

  • Page 41: Saving Bank Data To Memory Cards

    Saving Bank Data to Memory Cards Bank data on Sensor Controllers can be saved on a Memory Card inserted on the Data Storage Unit. 16 sets of bank data on the Sensor Controller are saved to a single file on the Data Storage Unit. ...

  • Page 42: Transferring Bank Data To The Controller

    CH2 is not displayed when it is not connected. Important The current settings of the Sensor Controller will be changed. However, if you turn the power OFF without saving the settings, the settings will revert to the original settings before the bank data was transferred.

  • Page 43

    MEMO Transferring Bank Data to the Controller ZG2-DSU User’s Manual...

  • Page 44: Table Of Contents

    SETTING ADDITIONAL FUNCTIONS Judging Measurement Values (Alarm Outputs) Setting System Conditions Display Settings during Operation Bank Functions...

  • Page 45: Setting Judgment Conditions, Judging Measurement Values (alarm Outputs), Specifying Tasks

     FUN mode-[I/O SET]-[SOURCE] Setting value Description Selects the channel of the Sensor Controller targeted for alarm judgment. (1, 2, default value: 1) CH2 is not displayed when it is not connected. TASK Selects the task targeted for alarm judgment. (1-8) Setting Judgment Conditions Set the two values, HIGH and LOW thresholds, used for alarm output.

  • Page 46

    ←→ DIG↑↓VAL SET : OK To change numerical values, use the key/   key, and to change the number of digits use   key/ key. Press the SET key. The numerical value is applied. Switch the threshold selection switch to L , and set the LOW threshold.

  • Page 47: Setting The System Clock, Setting System Conditions, Locking Keys, Memory Card Operations

    Sets the time. Locking Keys The keylock disables all key input on the Data Storage Unit. Key input cannot be accepted until the keylock is canceled. This feature is handy for preventing settings from being changed inadvertently. Even during a keylock, however, you can move to the KEYLOCK menu and move between layers of the menu hierarchy with the MENU and ESC keys.

  • Page 48: Changing The Display Language, Displaying Data Storage Unit Information

    For details on removing Memory Cards, see "Inserting and Removing Memory Cards." p.20 Changing the Logging Folder Start No. When a logging file is saved to Memory Card, a folder with a running No. is automatically created. The start No. for this folder can be changed. Important Note that when an existing folder No.

  • Page 49: Display Settings During Operation, Setting The Digital Display

    Display Settings during Operation Setting the Digital Display Set details to be displayed on the Data Storage Unit during logging in the RUN mode. To set the display details, first switch to the RUN mode and then display the top menu.

  • Page 50: Lcd Screen Settings

    Description Displays the LCD screen at all times. (default value) AUTOOFF Hides the LCD screen if the unit has not been operated for one minute. Hides the LCD screen at all times. (This operation is enabled in the RUN mode only. Note, however, that the display customize menu is displayed when the MENU key is pressed.)

  • Page 51

     RUN mode-MENU key-[LCD]-[CUSTOM] Setting value Description ON/OFF Set this item to ON to display characters set by [CUSTOM] on the LCD screen. (default value: OFF) CUSTOM Edits the characters to display in the LCD screen. (max. 16 digits) •Call up the first characters of each character group with function keys 1 to 4.

  • Page 52: Switching Banks, Clearing Banks, Bank Functions

    Bank Functions Up to four setups can be stored on the Data Storage Unit, and these can be switched when setting up the unit. A set of these settings is called a "bank." Switching Banks Bank 1 is selected as the default. However, other banks 2 to 4 can be selected.

  • Page 53

    MEMO Bank Functions ZG2-DSU User’s Manual...

  • Page 54

    COMMUNICATION WITH EXTERNAL DEVICES List of Output Data Communication Using I/O Signals Timing Charts Serial Communication...

  • Page 55: List Of Output Data

    List of Output Data The Data Storage Unit can output judgment values to external devices. Use of serial communication enables measurement values to be output. Judgment value Output path Description Controller I/O cable Captures the measurement results of tasks specified at [I/O SET], and outputs the results of judging the judgment conditions on the Data Storage Unit.

  • Page 56: Communication Using I/o Signals, Using The Controller I/o Cable

    Communication Using I/O Signals Using the Controller I/O Cable By using the Data Storage Unit's I/O cable, you can output judgment results to external devices, or input a control signal from external devices. A predetermined I/O signal is assigned to each signal wire of the I/O cable.

  • Page 57

    Starts logging. Logging end STOP Ends logging. Logging trigger TRIG When the logging condition is set to [TRIGGER], data during input of the TRIG signal is logged and saved. I/O Circuit Diagrams NPN type (ZG2-DSU11) Brown 24 V DC Load HIGH...

  • Page 58

    NPN type (ZG2-DSU41) Brown 24 V DC HIGH Green PASS Load Black Load Pink ERROR Load Gray BUSY 24 V Load Load Blue GND (0 V) Yellow TRIG Light blue Purple START White STOP Orange Communication Using I/O Signals ZG2-DSU User’s Manual...

  • Page 59: Timing Charts

    Timing Charts This section explains the timing charts of the I/O signals that are exchanged between the Data Storage Unit and external devices. Logging Logging start Logging end START signal or ↑ key Copy to (1) Logging Memory Card (2) Logging cycle STOP signal or ↓...

  • Page 60: Alarm Output, Transferring Bank Data

    Sensor Controller. • Profile display: approx. 150 to 300 ms (varies according to profile shape) • Digital display: approx. 50 ms per displayed task (i.e. approx. 200 ms when four tasks are displayed) To set the fastest measurement cycle, use the Sensor Controllers with the display OFF (ECO monitor).

  • Page 61

    FUN mode or TEACH mode. RS-232C Specifications Connecting a PC For details how to connect to a PC using the USB/RS-232C cable, refer to the ZG2 series User's Manual. Note Installation of the USB driver is necessary only when connecting an external device to the USB interface for the first time.

  • Page 62

    This control code indicates the end of the data. 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.

  • Page 63

    The sign (+, -) of the measurement value is stored. When the integer section of the measurement value is less Integer than 3 characters, it is prefixed with spaces for the number of insufficient data. When the number of digits past the decimal point is reduced, the length of the text string decreases proportionately.

  • Page 64

    This command acquires the measurement values saved on the Memory Card. All measurement values saved to the specified folder are output. Important This command can be used only when the Data Storage Unit is connected with the USB cable. <Command format> C F L O G G E T Folder No.

  • Page 65

    Measurement value of CH2 task 8 Configuration of measurement value data p.59 When processing fails • When there is no data corresponding to the specified folder No. N O F I L • When the Memory Card is not inserted D I R <Explanation of parameters>...

  • Page 66

    This command acquires the profiles saved on the Memory Card. The specified file is received by XMODEM protocol. Important This command can be used only when the Data Storage Unit is connected with the USB cable. <Command format> C F P R F G E T File No.

  • Page 67

    Acquire Measurement Value <MEASURE command> This command acquires measurement values set at [I/O SET]. <Command format> S U R E <Response format> When processing ends successfully Measurement value When processing fails <Explanation of parameters> Measurement value Measurement values set at [I/O SET] are acquired.

  • Page 68: Bank Data Transfer Commands

    When processing ends successfully When processing fails Save Bank Data to Memory Card <BKCTR2MC command> This command saves the data of banks 1 to 16 on a specified channel to the Memory Card as a single bank file. <Command format>...

  • Page 69

    Setting Acquisition/Change Commands Acquire Setup Data <DATAGET command> This command acquires the setup data on the Data Storage Unit. <Command format> D A T A G E T Data No. Unit No. <Response format> When processing ends successfully DATA When processing fails Note For details on parameters, see "Parameter List (p.71)."...

  • Page 70

    Save All Bank Data on the Data Storage Unit <DATASAVE command> This command saves all bank data to the Data Storage Unit's flash memory. <Command format> D A T A S A V E <Response format> When processing ends successfully When processing fails Acquire Version No.

  • Page 71

    Acquire Number of Connected Devices <CHGET command> This command acquires the number of gang-mounted Sensor 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 72: 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 - 4) Serial Communication ZG2-DSU User’s Manual...

  • Page 73: Utility Commands

    Utility Commands Initialize Memory Card <CFFORMAT command> This command initializes the Memory Card. <Command format> C F F O R M <Response format> When processing ends successfully When processing fails Serial Communication ZG2-DSU User’s Manual...

  • Page 74: Parameter List

    Parameter List Parameters Common to the DATAGET/DATASET Commands Targets for acquiring measurement values from Parameter Unit No. Parameter No. Measurement value/ acquisition value Measurement value of CH1 task 1 16 0: OFF, 1: ON Measurement value of CH1 task 2...

  • Page 75

    Alarm output threshold 2 -999999999 to lower limit 999999999(*1) Alarm output threshold upper limit *1: Digits past the decimal point cannot be handled by the DATAGET/DATASET commands. Input as follows:  Example: -999.999999 to 999.999999 -999999999 to 999999999 Serial Communication...

  • Page 76

    APPENDICES Specifications and External Dimensions 74 Error Messages and Corrective Actions Menu List Basic Knowledge for Operation Updating the Firmware INDEX...

  • Page 77: Specifications, Specifications And External Dimensions

    Residual voltage Residual voltage 1.2 V max. 1.2 V max. Serial I/O USB2.0 1 port, FULL SPEED [12 Mbps], MINI- RS-232C 1 port, max. 115,200 bps Function Number of Main memory Max. number of profile saves: 5,120 logging data (*2) Max.

  • Page 78

    Ferrite core (1 p'ce), Instruction Sheet *1: The Controller Link Unit is needed for gang-mounting. *2: During logging, data is saved to main memory and is automatically written to the Memory Card at the end of logging. The possible number of logs varies according to the setting conditions.

  • Page 79: External Dimensions

    External Dimensions (Unit: mm) 59.85 52.50 10.80 13 10 Specifications and External Dimensions ZG2-DSU User’s Manual...

  • Page 80: Error Message, 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 Display details Cause Remedy SYSTEM ERROR Internal bank data is in error. Hold down the key for 3 ...

  • Page 81

    CSV file CSV stands for "Comma Separated Values". CSV files are documents containing individual data elements separated by a comma as their delimiter. CSV files can be browsed in generally available spreadsheet software. Error Messages and Corrective Actions ZG2-DSU User’s Manual...

  • Page 82: Menu List

    Menu List FUN Mode This mode is for setting the logging conditions. p.31 SOURCE VALUE TASK p.31 PROFILE p.32 • CH LOGGING MEAS •JUDGE p.33 TRIGGER p.33 TIME p.33 POINT • CH p.42 I/O SET SOURCE •TASK p.49 BANK CHANGE p.49...

  • Page 83: Run Mode

    RUN Mode This mode is for executing logging. It is also for setting up the content of the digital display and other display-related settings, and for making settings when using Memory Cards as an external bank. p.39 BANK CF→Controller p.38 Controller←CF...

  • Page 84: Basic Knowledge For Operation, Digital Display, How To Select Menus

    Basic Knowledge for Operation How to Select Menus Select items displayed on the LCD screen directly with the functions keys. Digital display LCD screen VALUE PROFILE LOGGING Select directly with the function keys. MENU Control keys TEACH Digital display Menu setting items are displayed using the following alphabet characters.

  • Page 85

    Cancels the threshold you are setting up. *1: These keys can be used as a substitute for the TRIG signal when the logging condition is set to [TRIGGER]. Logging is also performed while function key 1 is held down. Basic Knowledge for Operation...

  • Page 86: Updating The Firmware

    •During a firmware update, do not turn the Data Storage Unit OFF. Doing so will prevent the Data Storage Unit from functioning normally. •When installing Smart Monitor and the USB driver on a PC, log in as an administrator or a user having the same privileges as a computer administrator for changing system settings.

  • Page 87

    MEMO Updating the Firmware ZG2-DSU User’s Manual...

  • Page 88

    CFFORMAT command CFLOGGET command CFPRFGET command CH number I/O circuit diagrams CHGET command Initialization Command format Communication commands Connecting the Power Supply 19 Control keys 15, 81 Controller Link Unit Judgment conditions Gang-mounting Keylock Data Storage Unit External dimensions Name...

  • Page 89

    Conditions Ending How it works VERGET command Measurement value Number of Data Procedure Profile Starting Wiring MEASURE command Memory Card 20, 35, 44 File No. Folder structure Initializing NODE Output data Response format RS-232C RUN mode Save Serial communication 35, 58...

  • Page 90

    MEMO INDEX ZG2-DSU User’s Manual...

  • Page 91: 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. Z289-E1-01 Revision code Revision code Revision date Revised content December 2008 First edition Revision History ZG2-DSU User’s Manual...

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