Omron Z4W-V User manual

1
LED Displacement Sensor Z4W-V
Low-cost Displacement Sensor with
10-micron Resolution with Red LED
Measurement point: 25 mm;
measurement range: "4 mm.
Easy adjustment, range/stable light indicators.
Easy-to-use built-in Amp.
High-speed response: 5 ms.
Visible beam spot.
Enclosure rating: IP66.
Ordering Information
Sensing distance Resolution Model
25" 4 mm 10 µm Z4W-V25R
Selecting a Controller
The following controllers can be used with the analog output of the Z4W -V25R. Select one that suits your application.
Unit Z4W-DD1C S3A-DjK-jK3TX K3TS CQM1
Name Linear Sensor
Controller
Linear Sensor
Controller
Intelligent Signal
Processor
Intelligent Signal
Processor
Linear Sensor
Interface Unit
Model Z4W-DD1C S3A-DAK K3TX-ADj-jj K3TS-SDjjj-jj CQM1-LSE01/02
Features Ideal for dimensional
checks with
Displacement Sensors
(tolerance: " 0.1 mm).
Accurate setting
possible via gauged
dials.
Provides both
open-collector and
relay outputs.
High accurate
(" 0.1%) panel meter .
Five discrimination
levels. A vailable with
BCD output.
High-speed sampling
of 1.04 ms. Dual inputs
with arithmetic
functions. Forced zero
function and other
versatile functions
incorporated.
A sensor power supply
with a capacity of
80 mA at 12 VDC
incorporated.
Five-level
discrimination.
High-speed sampling
of 1 ms
(03 ms for timing input)
without CQM1
programs.
A forced-zero function
lets you easily change
reference points for
dif ferent workpieces.
Monitor output
available with
CQM1-LSE02.

Z4W-V Z4W-V
2
Specifications
Ratings
Measurement range " 4 mm
Measurement point 25" 1 mm
Light source Red LED
Spot diameter 2-mm dia. (at measurement point)
Resolution 10 microns (see Note. 1)
Linearity " 3% FS (See Note. 2)
Response time 5 ms (In case of white alumina ceramic. Linearity change according to object.)
T emperature characteristics " 0.3% FS/ °C
W arming up time 3 min (within 1% of stable value)
Indicators Stability: Stable range: Lit green
Operating range: Not lit
Dark: Lit red
Range: In range: Green
Out of range: Red
Outputs Analog output: 4 to 20 mA/ " 4 mm
Load impedance: 300 Ω max.
DARK output: NPN open collector
50 mA max., 30 VDC
Residual voltage: 1 V max.
External light 3,000 ln (incandescent light)
Characteristics
Power supply voltage 12 to 24 VDC " 10%: ripple (p-p) 10% max.
Current consumption 80 mA max.
V ibration resistance Destruction: 10 to 55 Hz (1.5-mm double amplitude, 30G max.) for 15 min each in X, Y , and Z
directions
Shock resistance Destruction: 50G for 3 times each in X, Y , and Z directions
Ambient temperature Operating: –10 ° to 55 ° C (with no icing)
Ambient humidity 35% to 85% (with no icing)
Enclosure ratings IEC: IP66
Weight 150 g (with 5-m cable); 50 g (without cable)
Attachments Mounting bracket, mounting screws, resistor (250 Ω , 0.5 W)
Note: 1. Resolution
The
resolution is the peak-to-peak displacement
conversion value of the analog output. (Condi-
tions: white alumina ceramic at the measure-
ment
point)
Displacement
Analog displacement
output
90%
10%
Tr Ti
2. Response T ime
The
delays are the 10% to 90% rising and falling
times of the analog output in response to a sud -
den
change in the displacement.
Output
fluctuation
Engineering Data
Linearity Characteristics vs. Objects
Linearity characteristic curves are obtained by detecting an object
at dif ferent positions within the measurement range and plotting the
analog output error resulting from each operation.
The LED Displacement Sensor cannot detect an object accurately if
the reflection ratio of the object is extremely small (a black object) or
extremely large (an object with a glossy surface).

Z4W-V Z4W-V
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Inclined Object (Typical Example)
Measurement point
(distance in mm)
Error (% FS)
Angle: –15 ° Angle: +15 °
Error (% FS)
Measurement point
(distance in mm)
Error (% FS) Error (% FS)
Measurement point
(distance in mm)
Angle: –30 ° Angle: +30 °
Measurement point
(distance in mm)
Negative
inclination
Positive
inclination
Negative
inclination
White ceramic
Black paper
Rolled steel
plate
White ceramic
Black paper
Rolled steel
plate
Positive
inclination
Negative
inclination
White ceramic
Black paper
Rolled steel
plate
Positive
inclination
Positive
inclination
Negative
inclination
White ceramic
Black paper
Rolled steel
plate
Angle: 0 °
Error (% FS)
Measurement point
(distance in mm)
White ceramic
Black paper
Rolled steel
plate
Obliquely Positioned Object (Typical Example)
Measurement point
(distance in mm)
Error (% FS)
Angle: –15 ° Angle: +15 °
Error (% FS)
Measurement point
(distance in mm)
Error (% FS) Error (% FS)
Measurement point
(distance in mm)
Angle: –30 ° Angle: +30 °
Measurement point
(distance in mm)
Note: The LED Displacement Sen -
sor cannot detect an object
accurately
if the object is po -
sitioned at an angle oblique
to the sensor position. If the
oblique
angle is large, detec -
tion is not possible because
of insufficient reflection of
light.
This must be taken into
consideration when install-
ing
the sensor .
Positive
inclination
Negative
inclination
White ceramic
Black paper
Rolled steel
plate
Positive
inclination
Negative
inclination
White ceramic
Black paper
Rolled steel
plate
Positive
inclination
Negative
inclination
White ceramic
Black paper
Rolled steel
plate
Positive
inclination
Negative
inclination
White ceramic
Black paper
Rolled steel
plate

Z4W-V Z4W-V
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Sensing Various Objects
Offset Error vs. Object Material
When detecting a variety of objects successively , refer to the of fset
error
graph below . The graph illustrates the change in sensor output
characteristics when black paper is compared to white paper . T o re -
duce the of fset error value, install the Sensor so that objects are de -
tected
at or as close as possible to the measurement point.
Offset Error Range
(Typical Example)
Measurement point
(distance in mm)
Offset Error (% FS)
Angle Characteristics
The angle characteristics were obtained by detecting an object with
different angles of inclination at the measurement point and plotting
the analog output error resulting from each operation.
The LED Displacement Sensor is designed to detect the front of an
object facing the sensor . Error occurs when the object is positioned
at an oblique angle to the sensor .
Inclined Object
(Typical Example)
Inclination angle ( °)
Error (% FS)
Obliquely Positioned Object
(Typical Example)
Error (% FS)
Inclination angle ( °)
Positive
inclination
Negative
inclination
White ceramic
Black paper
Rolled steel
plate
Positive
inclination
Negative
inclination
White ceramic
Black paper
Rolled steel
plate

Z4W-V Z4W-V
5
Nomenclature
Range indicator (green/red)
Stability indicator (green/red)
Optical axis marker
Transmitter Receiver
Operation
Connections/Output Circuits
Power supply (Brown) 12 to 24 VDC . . . .
GND (Blue) 0 V . . . . . . . . . . . .
DARK output (Orange) 50 mA max. at 30 VDC . . . .
Analog output (Black) 40 to 20 mA . . . .
GND (Shield)* . . . . . . . . . . . .
Load power supply
(30 VDC max.)
12 to 24 VDC
4 to 20 mA
0 V
(Red)
(White)
(Shield)
(Black) Linear
differentiator
, etc.
Signal processor
(Orange)
Note: 1. *The two ground terminals (black and shield) are inter -
nally connected. However, the black ground must be
used
with the red terminal for the power supply and the
shield ground must be used with the white terminal for
the
analog output.

Z4W-V Z4W-V
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Functions
Classification Functions Remarks
Range indicator The green indicator is lit when the ob -
ject
is within the measurement range.
The red indicator is lit when the object
is not within the measurement range.
Out of the
measurement range
21 mm
25 mm
29 mm
Red
Green
Red
Distance
Inside the
measurement range
Out of the
measurement range
When the intensity of the
light input is insuf ficient
(DARK output is ON and
the red stability indicator is
lit), the range indicator all
remain OFF even if the
object is within the
measurement range.
Stability
indicator
These indicators indicate the intensity of the light input. The object in the
measurement range is detected when the green indicator is lit or OFF .
The red indicator is lit when there is no object in the measurement range or the
intensity of light input is insuf ficient.
If this green indicator is lit when there is an object in the measurement range, the
light source control circuit and light input sensitivity control circuit of the Sensor
operate.
Even if the green indicator is OFF , the Sensor works as long as the internal light
source control circuit and the light input sensitivity circuit are within the operating
range. In this case the red indicator is also OFF .
When the Sensor is active for a long duration, the green indicator may turn OFF .
This does not mean that the Sensor has malfunctioned.
---
DARK output The orange indicator (DARK output) is ON when there is no object in the
measurement range or when the input light intensity is insuf ficient. The red stability
indicator is also lit when DARK output is ON.
The Sensor has an open collector output of 50 mA at 30 VDC max.
---
Analog output An analog signal is output from the out -
put
line (white) according to the sensing
distance.
Output: 4 to 20 mA/21 to 29 mm
("
4 mm)
Load impedance: 300 Ω max.
The output range lies between 20.5 and
26 mA when DARK output is ON.
Distance vs Analog Output Characteristics
(Typical Example)
Analog output (mA)
Measurement point
(distance in mm)
20
12
4
–4 0 4
Measurement
point
25"1 mm
---
Operations
Basic Operation of the Z4W-V25R
Mounting
Install the Sensor so that of the optical axis of the Sensor and the
surface
of the object meet at right angles (i.e., the panel that incor -
porates
the light source is parallel with the object). For accurate re -
sults, it is recommended that the sensing distance is set to the
measurement
point (25 mm).
Note: Do not tighten the mounting screws
for the moment as the optical axis
must
be adjusted.
25 mm
70 mm from the
sensor mounting
holes
8.5 mm
25
Surface from which
the beam is emitted
Surface of object
Wiring
Connect
the Sensor to the controlling device using a sensor cable.
Do not switch power ON during wiring. Refer to the instructions on
the Sensor and the connection diagram (page 5) before connecting
the sensor to the controlling device.
Conversion to V oltage Output Model (1 to 5 V)
The Z4W -V25R has a current output of 4 to 20 mA. With the resistor
provided (250 Ω ), a voltage output of 1 to 5 V can be obtained. Refer
to the figure below for connection.
Check the
voltage here
(Black)
4 to 20 mA
Resistor
Shield
0 V
Although a resistor is included, any resistor may be used provided
the resistance is 300 Ωor less.

Z4W-V Z4W-V
7
Axis Adjustment
When the Sensor power is switched ON, the red transmitter indica -
tor
is lit. Move the Sensor so that the red beam (see the figure below)
focuses on the object. The entire light beam should be focused on
the object or an error will result.
Surface
of object
Spot
Correct Incorrect
After the optical axis has been adjusted, tighten the mounting
screws
firmly .
Connecting a Z4W-DD1C Linear Sensor Control-
ler
To discriminate among objects according to size, use the
Z4W-V25R LED Displacement Sensor with a Z4W-DD1C Linear
Sensor
Controller .
ÉÉÉ
ÉÉÉ
ÉÉÉ
ÉÉÉ
ÉÉ
ÉÉ
ÉÉ
Tolerance
Output
Output
NG
ON
OFF
ON
OFF
PASS
The following equipment is required:
•Z4W -V25R LED Displacement Sensor
•Z4W -DD1C Linear Sensor Controller
•Synchronization Sensor (E3X Fiber Photoelectric Sensor or
E3C-VM
Miniature Head Photoelectric Sensor is recommended)
•An object of standard dimensions
• An object of threshold dimensions
•Tools
Mounting
Mount as described on page 6.
When installing a Synchronization Sensor, refer to the instruction
manual
and read the precautions for the model. It is important to in -
stall the Synchronization Sensor so that the LED Displacement
Sensor
can detect the object at the measurement position. Do not
tighten the mounting screws for the moment since the optical axis
must be adjusted.
The Z4W -DD1C Linear Sensor Controller can be mounted on a wall
and secured with screws, or mounted to DIN rail.
Wiring
Make
sure that the Linear Sensor Controller , the LED Displacement
Sensor, and the Synchronization Sensor are wired correctly before
turning on the Linear Sensor Controller power (power is supplied to
the LED Displacement Sensor and the Linear Sensor Controller by
the Linear Sensor Controller). T o avoid trouble, leave the output ter -
minals
(No. 4, 5, 6) of the Linear Sensor Controller open for the mo -
ment.
Z4W-DD1C
Synchronization
sensor
Z4W-V25R
4 to 20 mA Black
0 V
+12 V 0 V 4 to 20 mA
100 mA
30 VDC
Max.
FG100 to 240 VAC
50/60HZ
+12 V Brown
DARK output
Orange
0 V Blue
Shield
0 V Blue
Output
Black
12 V Brown
Axis Adjustment
After adjusting the optical axis of the LED Displacement Sensor , ad -
just
the optical axis of the Synchronization Sensor so that the LED
Displacement Sensor detects the object at the measurement posi -
tion in synchronous operation. Since the Linear Sensor Controller
operates
synchronously on receiving each output signal of the Syn -
chronization Sensor , set the position of the Synchronization Sensor
so that the front edge of the object is detected by the Synchroniza -
tion
Sensor .
Synchronization
sensor Surface
of
object
Displacement
sensor
After the optical axis has been adjusted, tighten the mounting
screws and secure the Synchronization Sensor firmly. Some Syn-
chronization
Sensor models incorporate a sensitivity controller . For
the adjustment of such models, refer to the instruction manual for
the
Synchronization Sensor .

Z4W-V Z4W-V
8
Adjustment and Operation of the Linear Sensor Controller
Control panel of the Linear Sensor Controller
The control panel consists of two switches (MODE and MONIT OR),
two
adjusters (CENTER and WIDTH) and four indicators (POWER,
PASS, NG, INHIBIT) for monitoring.
By adjusting the settings of the Linear Sensor Controller and com -
pensating
for the position of the LED Displacement Sensor , the size
of the object of standard dimensions is registered with the Linear
Sensor
Controller . With the object of standard dimensions, operate
the LED Displacement Sensor as follows:
1. Set the MODE switch to NORMAL.
2. Turn the WIDTH adjuster counterclockwise to the MIN
position.
3. Turn the CENTER adjuster clockwise or counterclockwise
and
set the adjuster to the position where the P ASS indicator
is lit. If the P ASS indicator is lit for a wide range of positions,
set the adjuster in the middle of the range. If the PASS
indicator does not light with the CENTER adjuster in any
position,
turn the WIDTH adjuster clockwise slightly .
An object of threshold dimensions or a multimeter can be used to
determine
the tolerance (use the object where possible).
Determining Settings Using an Object
1. Prepare an object of threshold dimensions (an object with the
allowable upper threshold dimensions or with the allowable
lower threshold dimensions) to be detected by the LED
Displacement
Sensor .
2. Set the MODE switch to NORMAL.
3. Turn the WIDTH adjuster counterclockwise to the MIN
position.
The NG indicator will light.
4. Turn the WIDTH adjuster clockwise slowly to the position
where the NG indicator turns OFF. The PASS indicator will
light.
Determining
Settings Using a Multimeter
Determine the absolute tolerance, A (in mm), and obtain the voltage
Vx (V) as follows (example for tolerance of " 0.5 mm):
1. Set the MONIT OR switch to WIDTH.
2. Check the voltage of monitor terminals 10 (positive voltage
output)
and 8 (negative voltage output) of the Linear Sensor
Controller with the multimeter in the 10-VDC or 5-VDC range.
3. Turn the WIDTH adjuster clockwise or counterclockwise to
the
position where the voltage reaches V
x
(obtained from the
above formula).
Set the MODE switch to TRIG as follows:
1. Set the MODE switch to TRIG.
2. Set the MONIT OR switch to INPUT or OFFSET (RUN).
3. Turn
of f the power and wire the output terminals (No. 4, 5, and
6).

Z4W-V Z4W-V
9
Dimensions
Mounting Holes
20.3
11.4
10.5
Measurement point
28
550
50 45
(25)
Emitting
axis
Measurement point
Cord length: 5 m
Cord: 3.8 dia.
Two, M4
screws
30°
13.5
2.3
5.3
Measurement point
28 Two, 5 dia.
holes
(8.5)
(70)
Emitting
axis
Measurement point
Emitting
axis
Mounting Holes
W ith Mounting Bracket 1
*A mounting bracket can be attached to
this
face of the sensor .
**This
distance can be extended up to 44.5
mm. When this distance is 44.5 mm in
length,
the angle of the optical axis can be
adjusted after mounting by approximately
"5 max.
A*
11.4
10.5
12 12 Two mounting
holes
4.5
10.5
R27
4.5
10
32.3
22.2
42.5**
Measurement point
42 5.5
12.5
37
50
Two, M4
screws
28 22.5
55.5
57.8
22
20.3
Two, M4
25
Emitting
axis
Emitting
axis
Measurement point

Z4W-V Z4W-V
10
Mounting Holes
W ith Mounting Bracket 2
*A mounting bracket can be attached
to this face of the sensor .
Emitting
axis
Measurement point
A*
11.4
10.5
20.3 22
13.5 to
17.5
63.5 to 67.5
88.5 to 92.5
18.5 to
22.5
37
28 4.5
50
32.3 22.2
10 12
5.3
19
4.5
17.5
5
34.8
32.5
10.5
R27
25 Two, M4
holes
Emitting
axis
Emitting
axis
Measurement point

Z4W-V Z4W-V
11
Installation
Controller Connections
Z4W-DD1C Connection with a S3A-DAK
Connection with a K3TX
0 V Blue 0 V
DARK output
Orange
+12 V Brown
+12 V Brown
0 V
Blue
Output
Black
+12 V 0 V 4 to 20 mA
100 mA
30 VDC
Max.
FG100 to 240 VAC
50/60 Hz
Z4W-V25R Synchronization
sensor
4 to 20 mA Black
Z4W-DD1C
Shield
0 V
4 to 20 mA
0 V IN
Brown Black Blue
80 mA 30 VDC Max
3A 250 VAC Max
S3A-DAK
200/220 VAC 50/60 Hz
100/110 VAC
50/60 Hz
HI MID LOW
HI MID LOW
+12"10% ERROR
80 mA Max.
Shield
Z4W-V25R
Press switch to
calibrate to zero
Z4W-V25R
LED Displacement
Sensor
K3TS
Brown Black
Blue Shielded cable
12 VDC
10
1
17
9
+
–
Brown Black
Blue Shielded cable
Z4W-V25R
LED Displacement
Sensor

Z4W-V Z4W-V
12
Precautions
Install the Sensor in a clean environment keep the filter (on the front
of the Sensor) free from oil and dust. If af fected by oil or dust, clean
the Sensor as follows:
1. Use a blower brush (used to clean camera lenses) to blow
large dust particles from the surface. Do not blow the dust
away
with your mouth.
2. Use a soft cloth (for lenses) with a little alcohol to remove the
remaining dust.
Do not use a scrubbing action when cleaning as a scratch on
the filter could result in the Sensor malfunctioning.
Interference
Z4W-V25R LED Displacement Sensors can be installed within
close
proximity to each other and operate independently without in -
terference (refer to the figures below). However , if they are installed
at an oblique angle to each other , interference may result.
When using the LED Displacement Sensor in combination with an -
other type of Sensor (such as a Photoelectric Sensor), the sensor
beams should be as close to perpendicular as possible.
Environment
Refrain from using the LED Displacement Sensor in a strong elec -
tromagnetic field or in an environment where the operation of the
Sensor
is subject to the reflection of intensive light (such as a laser
beam or an electric arc welding machine).
The LED Displacement Sensor cannot accurately detect a mir-
ror-like
object, a transparent object, one with an extremely small re -
flection ratio, an object smaller than the diameter of the Sensor’s
sensing
spot, or an inclined object.
Wiring
The power supply cable for the Z4W -V25R should not be wired with
high-voltage lines or power lines in order to avoid interference, dam -
age,
or malfunction.
Others
The Sensor cannot detect an object accurately if the surface of the
object consists of dif ferent materials placed next to each other (refer
to the figures below). In such case install the Sensor so that the
boundaries
of the materials and the Sensor are parallel.
OMRON Corporation
Systems Components Division H.Q.
28th Fl., Crystal T ower Bldg.
1-2-27, Shiromi, Chuo-ku,
Osaka 540 Japan
Phone: [phone] Fax: [phone]
ALL DIMENSIONS SHOWN ARE IN MILLIMETERS.
To convert millimeters into inches, multiply by 0.03937. T o convert grams into ounces, multiply by 0.03527.
Cat. No. E217-E1-3 In the interest of product improvement, specifications are subject to change without notice.
Printed in Japan
0497-1.5M (0891) a