Omron Z4W-V User manual

LED Displacement Sensor Z4W-V
Low-cost LED Displacement Sensor
Offers 10-micron Resolution
Measurement point of 25 mm (0.98 in)
with measurement range of ±4mm
(0.16 in).
Easy-to-use, built-in amplifier.
Fast 5-millisecond response.
Visible beam spot means easy
installation.
Range and stability indicators simplify
set-up and monitoring.
IP66 enclosure rating.
LED light source does not require the
safety precautions of a laser-type light
source.
For signal processing or PLC
communication, use with K3TX or K3TS
intelligent Panel Meter.
Ordering Information
Sensing distance Resolution Part number
25±4mm 10 μmZ4W-V25R
Application Examples
Z4W-V25R LED Displacement Sensor
E3C Gate
Input Sensor
K3TS Intelligent
Digital Panel Meter
Forced Zero
Function Switch
Z4W-
V25R
Sensor
Z4W-V25R
Sensor
Two Z4W-V25R LED Displacement Sensors
E3C Gate
Input Sensor
K3TS Intelligent
Digital Panel Meter
Forced Zero
Function Switch
Z4W-V25R
Sensor
Measuring Height DifferenceChecking a Dimension After Assembly
Authorised Distributors:-
Intech Systems Chennai Pvt. Ltd, Chennai-600 032
Ph: 4353 8888 Mob: [phone] Fax: [phone]
E-mail: [email protected] Website: www.intechchennai.com

Specifications
RATINGS
Measurement range ±4 mm (0.16 in)
Measurement point 25 ±1 mm (0.98 in)
Light source Red LED
Spot diameter 2-mm (0.079 in) dia. at measurement point
External light 3,000 lux (incandescent light)
Resolution 10 microns
The resolution is the peak-to-peak
displacement conversion value of the
analog output. (Conditions: white alumina
ceramic at the measurement point.)
Output
fluctuation
Linearity ±3% FS
Response time 5 ms with a white alumina ceramic
object. Linearity changes according to
object.
Displace-
ment
Analog displacement
output
90
%
10
%
TT
The delays are the 10% to 90% rising
and falling times of the analog output in
response to a sudden change in the
displacement.
rl
Temperature characteristics ±0.3% FS/°C
Warm-up time required 3 minutes (within 1% of stable value)
Indicators Stability Stable range: Green
Operating range: Not lit
Dark: Red
Range In range: Green
Out of range: Red
Outputs Analog output 4to20mA/
±4mm
Load impedance: 300Ωmax.
DARK output NPN open collector
50 mA max., 30 VDC
Residual voltage: 1 V max.
CHARACTERISTICS
Power supply voltage 12 to 24 VDC±10%, max. permissible ripple: 10% peak-to-peak
Current consumption 80 mA max.
Vibration resistance Destruction: 10 to 55 Hz (1.5-mm double amplitude, 30G max.) for 15 minutes 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(14
°to 131°F) with no icing
Ambient humidity 35% to 85% (with no icing)
Enclosure rating IP66
Weight 150 g (5.29 oz.) with 5-m (16.4 ft.) cable; 50 g (1.76 oz.) without cable
Accessories supplied Mounting bracket, mounting screws, resistor (250 Ω,0.5W)
Z4W-V Z4W-V

Engineering Data
LINEARITY CHARACTERISTICS VS.OBJECTS
Linearity characteristic curves are obtained by detecting an object at different 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 (for example, a black object) or extremely large (for example, an object with a shiny surface).
Inclined Object (Typical Example)
Angle: 0

Angle: --15

Angle: +15

Error (% FS)
White ceramic
Black paper
Rolled steel
plate
Distance from measurement point (mm)
Error (% FS)
White ceramic
Black paper
Rolled steel
plate
Positive
inclination
Negative
inclination
Distance from measurement point (mm)
Error (% FS)
Positive
inclination
Negative
inclination
White ceramic
Black paper
Rolled steel
plate
Distance from measurement point (mm)
Angle: --30

Angle: +30°
Error (% FS)
Positive
inclination
Negative
inclination
White ceramic
Black paper
Rolled steel
plate
Distance from measurement point (mm)
Error (% FS)
Positive
inclination
Negative
inclination
White ceramic
Black paper
Rolled steel
plate
Distance from measurement point (mm)
Obliquely Positioned Object (Typical Example)
Angle: --15

Angle: +15

Error (% FS)
Positive
inclination
Negative
inclination
White ceramic
Black paper
Rolled steel
plate
Distance from measurement point (mm)
Error (% FS)
Distance from measurement point (mm)
Positive
inclination
Negative
inclination
White ceramic
Black paper
Rolled steel
plate
Z4W-V Z4W-V

Obliquely Positioned Object (continued)
When installing the sensor, position the
s
e
n
s
o
r
c
o
r
r
e
c
t
l
y
f
o
r
t
h
e
t
y
p
e
o
f
o
b
j
e
c
t
t
o
Angle: --30

Angle: +30

sensor correctly for the type of object to
be detected. If a shiny object is
positioned at a large oblique angle to
the sensor, detection of the object will
be difficult and may cause an inaccurate
output.
Error (% FS)
Positive
inclination
Negative
inclination
White ceramic
Black paper
Rolled steel
plate
Distance from measurement point (mm)
Error (% FS)
Positive
inclination
Negative
inclination
White ceramic
Black paper
Rolled steel
plate
Distance from measurement point (mm)
SENSING VARIOUS OBJECTS
Offset Error vs. Object Material Offset Error Range (Typical Example)
When detecting a variety of objects
successively, refer to the offset error
graph shown here. The graph illustrates
changes in sensor output
characteristics when black paper is
compared to white paper.
To reduce the offset error value, install
the Sensor so that objects are detected
at (or as close as possible to) the
measurement point.
Offset Error (% FS)
Distance from measurement point (mm)
ANGLE CHARACTERISTICS
The angle characteristics were obtained
by detecting an object with different Inclined Object
(Typical Example) Obliquely Positioned Object (Typical Example)
b
y
d
e
t
e
c
t
i
n
g
a
n
o
b
j
e
c
t
w
i
t
h
d
i
f
f
e
r
e
n
t
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. Errors occur when
the object is positioned at a large
oblique angle to the sensor.
Inclination angle (  )
Error (% FS)
Positive
inclination
Negative
inclination
White ceramic
Black paper
Rolled steel
plate
Error (% FS)
Inclination angle (  )
Positive
inclination
Negative
inclination
White ceramic
Black paper
Rolled steel
plate
Z4W-V Z4W-V

Connections
SENSOR CONNECTIONS
Brown (red) 12 to 24 VDC
Power supply
Blue (black)
0VGND
Orange 50 mA max. at 30
VDC DARK output
Shield *
GND
Black (white) 4 to 20 mA
Analog output
* The two ground terminals,
blue (black) and shield are
internally connected. However,
the blue (black) ground must
be used with the brown (red)
terminal for the power supply;
the shield ground must be
used with the black (white)
terminal for the analog output.
Note: IEC wire colors shown first.
SENSOR OUTPUT CIRCUITS
Load power supply
(30 VDC max.)
12 to 24 VDC
4to20mA
0V
Brown
(red)
Signal processor
DARK output (Orange)
Black
(white)
Shield
Blue
(black)
Note: IEC wire colors shown first.
SENSOR TO Z4W-DD1C CONTROLLER SENSOR TO S3A-DAK-US CONTROLLER
Monitor
20
mA
Z4W-DD1C
Gate Sensor
Z4W-V25R
4to20mA Black(white)
0V
+12 V
0V
100 mA,
30 VDC max.
FG
100 to 240 VAC,
50/60Hz
+12 V Brown (red)
DARK output
0 V Blue (black) Shield
Output
12 V Brown (red)
Black (white)
(black)
Blue
Inhibit Trigger
Orange (orange)
4to
Note: IEC wire colors shown first.
0V
100/110
VAC,
50/60 Hz
Shield 0V
4to20mA
0V IN
Black (white)
80 mA, 30 VDC max.
3A, 250 VAC max
S3A-DAK
200/220 VAC,
50/60 Hz
HI MID LOW
HI MID LOW
+12

10% ERROR,
80 mA max.
Z4W-V25R
Blue (black)
Note: IEC wire colors
shown first.
Brown (red) +V
Z4W-V Z4W-V

SENSOR TO K3TX PANEL METER SENSOR TO K3TS PANEL METER
Black
(white)
Z4W-
V25R
K3TS Panel Meter
Brown (red)
Blue (black)
Shield
12 VDC
10
1
17
9
+
--
Shield
Brown (red)
Blue (black)
Black
(white)
Z4W-
V25R
Blue
(black)
Black (white)
Brown (red)
12 to 24 VDC
Z4W-
V25R
K3TX Panel Meter
↓
Forced Zero
Function
Switch
4to20mA Shield 0 V 0V
Note: IEC wire colors shown first.
Note: IEC wire colors shown first.
Note: Use K3TX-VD DC voltage input models.
Nomenclature
Range indicator (green/red)
Stability indicator (green/red)
Optical axis marker
Receiver
Emitter or
light source
Operation
FUNCTIONS
Classification Functions
Range indicator
Outofthe
measurement range
21 mm
25 mm
29 mm
Red
Green
Red
Distance
Inside the
measurement range
Outofthe
measurement range
The green indicator is lit when the object is within the measurement
range. The red indicator is lit when the object is not within the
measurement range.
Note: When the intensity of the light input is insufficient (DARK
output is ON and the red stability indicator is lit), the
range indicator remains OFF even if the object is within
the measurement range.
12 mm
52 mm
Z4W-V Z4W-V

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
insufficient.
If the green indicator is lit when an object is 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. At this time, 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 insufficient. 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 Distance vs. Analog Output
Characteristics
Analog output (mA)
20
12
4
--4
An analog signal is output from the
output line according to the sensing
distance.
Measurement
point
Output:4to20mA/21to29mm
(±4 mm).
The output range lies between
20.5 and 26 mA when DARK
output is ON.
Load impedance: 300 Ωmax.
25±4mm
Distance from measurement point (mm)
04
Installation
INSTALLATION (AND OPERATING ADJUSTMENTS) FOR THE SENSING HEAD (OR SENSOR)
Sensor Installation Procedure
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 incorporates the light source is parallel with the
object). For accurate results, set the sensing distance at the
measurement point, 25 mm (0.98 in).
Do not fully tighten the mounting screws until after
completing the optical axis adjustment.
Wiring
Connect the Sensor to the controlling device using the
sensor cable.
Follow the Sensor operating adjustments and instructions in
this data sheet.
25 mm
(0.98 in)
8.5 mm
(0.33 in)
25
Surface from which
the beam is emitted
Surface of object
70 mm (2.76 in)
from the sensor
mounting holes
Surface
of object
Spot
Correct Incorrect
Axis Adjustment
When power is applied to the sensor, the red stability
indicator 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 inaccurate output will
result.
After the optical axis has been adjusted, tighten the mounting
screws firmly.
Conversion to Voltage Output (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.
Although a resistor is included, any resistor may be used that
provides a resistance of 300 Ωor less.
Check the
voltage here
Black (white) 4 to 20 mA
Resistor
Shield
0V IEC wire colors shown first.
Z4W-V Z4W-V

INSTALLATION (AND OPERATION) OF THE CONTROLLER
Using a Z4W-DD1C Linear Sensor Controller
Size Discrimination
To discriminate among objects according to size, use the
Z4W-V25R LED Displacement Sensor with a Z4W-DD1C
Linear Sensor Controller. The two outputs provided are used
in discrimination between acceptable and unacceptable parts.
The timing chart included here illustrates an inspection of
object height.
Object
size
Z4W-V25R
Analog output
Gate Sensor
Output
Z4W-DD1C
PASS output
Z4W-DD1C
NG output
20 mA
4mA
ON
OFF
ON
OFF
ON
OFF
Size too small OK Size too large
(Large) (OK) (Small)
Inspection Inspection Inspection
A Timing Chart for Object Height Inspection
Required Equipment
•Z4W-V25R LED Displacement Sensor
•Z4W-DD1C Linear Sensor Controller
•Gate Sensor (E3X Fiber Optic Photoelectric Sensor or
E3C-VM Miniature Head Photoelectric Sensor is recom-
mended)
•An object of standard specified dimensions
•An object of threshold dimensions
Installation Procedure Adjusting/Operating Linear Sensor Controller
Use the basic installation described previously for the Sensor.
When installing a gate Sensor, refer to the instruction manual
and read the precautions for the model. It is important to install
the gate Sensor so that the LED Displacement Sensor can
detect the object at a stable measurement position. Do not
tighten the mounting screws until after optical axis adjustment.
The Z4W-DD1C Linear Sensor Controller can be installed on a
wall and secured with screws, or DIN-rail mounted.
Wiring
Make sure that the Linear Sensor Controller, the LED
Displacement Sensor, and the gate Sensor are wired correctly
before power-up. Refer to pages 5 and 6 for appropriate wiring
connections.
Power is supplied to the LED Displacement Sensor and the
gate Sensor by the Linear Sensor Controller. It is important to
leave the output terminals (terminals 4, 5, 6) of the Linear
Sensor Controller open at this time. (Refer to: Determining
Controller Settings, found on the next page.)
Gate Sensor
Axis Adjustment
Follow this procedure:
1. Position the LED Displacement Sensor for synchronous
operation with the gate Sensor.
2. Adjust the optical axis of the LED Displacement Sensor.
3. Set the position of the gate Sensor so it will detect the
leading edge of the object.
4. Adjust the optical axis of the gate Sensor so that the LED
Displacement Sensor detects the object at the measure-
ment position in synchronous operation. This is important
because the Linear Sensor Controller operates synchro-
nously on receiving each output signal of the gate Sen-
sor.
Surface of object
LED Displacement Sensor
Leading edge
5. After adjusting the optical axis of the gate Sensor, tighten
the mounting screws to secure the gate Sensor firmly.
6. Adjust the sensitivity of the gate Sensor (for models in-
corporating a sensitivity adjuster).
Z4W-V Z4W-V

Nomenclature Calibrate the Sensor Controller
Two adjusters:
•CENTER
•WIDTH
Two switches:
•MODE
•MONITOR
The linear sensor control panel control consists of the
indicators, switches and adjusters shown below.
Four indicators:
(as shown left)
•POWER
•PASS
•NG
•INHIBIT
Using an object of the standard specified dimensions,
calibrate the sensor controller as follows:
1. Set the MODE switch to NORMAL.
2. Turn the WIDTH adjuster counterclockwise to the MIN
position.
3. Turning the CENTER adjuster clockwise or counterclock-
wise, set the adjuster to the position where the PASS
indicator is lit.
4. Fine tune the controller to detect the target object. If the
PASS 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.
Determine Tolerance Determining Controller Settings Using a Multimeter
To determine tolerance, use either an object of threshold
dimensions or a multimeter. Use the object where possible.
Determining Controller Settings Using an Object
1. Prepare an object of threshold dimensions (an object with
the allowable upper threshold dimensions or with the al-
lowable 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.
Set the MODE switch to TRIG as follows:
5. Set the MODE switch to TRIG.
6. Set the MONITOR switch to INPUT or OFFSET (RUN).
7. Turn OFF the power and wire the output terminals (i.e., ter-
minals 4, 5, and 6).
Determine the absolute tolerance, A (in mm), and obtain the
voltage Vx(V) as follows:
Vx(V)= Monitor output voltage
±Wo(%FS) = Tolerance
Vx=3+W
ox1/25
1. Set the MONITOR switch to WIDTH.
2. Check the voltage of monitor terminals 10 (positive voltage
output) and 8 (negative voltage output) of the Linear Sen-
sor 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 Vx(obtained from
the above formula).
Set the MODE switch to TRIG as follows:
4. Set the MODE switch to TRIG.
5. Set the MONITOR switch to INPUT or OFFSET (RUN).
6. Turn OFF the power and wire the output terminals (i.e.,
terminals 4, 5, and 6).
Z4W-V Z4W-V

Dimensions
Z4W-V SENSOR
Mounting Holes
20.3
(0.80)
11.4
(0.46)
10.5
(0.41)
Measurement point
28
(1.10)
5
50
(1.97) 45
(1.77)
25
(0.98)
Emitting
axis
Measurement point
Cable length: 5 m (16.4 ft)
Cable dia.:
3.8 (0.15 in)
Two
M4 screws
30

13.5
(0.53)
2.3
(0.09)
5.3
(0.20)
Measurement point
Two 5 (0.20
)
Dia. holes
8.5
(0.35)
70
(2.76)
Emitting
axis
Measurement point
Emitting
axis
28
(1.10)
50
(1.97)
Unit: mm (inch)
MOUNTING OPTION 1
10.5
(0.41)
11.4
(0.45)
10
(0.39)
Mounting Holes
12
(0.47) Two mounting holes
4.5
(0.18)
10.5
(0.41)
R27
4.5
(0.18)
22.2
(0.87)
Measurement point
42
(1.65)
5.5 (0.22)
12.5
(0.50)
Two M4
screws
28
(1.10) 22.5
(0.89)
55.5 (2.19)
57.8 (2.28)
22
(0.98)
20.3
(0.80)
Two
M4 holes
Emitting axis Emitting axis
Measurement point
For mounting
option 1, attach the
mounting bracket
to this side of the
sensor.
50
(1.97)
12
(0.47)
42.5
(1.67)
37
(1.46)
25
(0.98)
32.3 (1.27)
*This distance can be extended up to 44.5 mm (1.75 in). After mounting, when this distance is 44.5 mm in length, the angle of the
optical axis can be adjusted by approximately ±5°max.
Unit: mm (inch)
Secure the mounting bracket to the
sensor side as indicated below.
*
Z4W-V Z4W-V

MOUNTING OPTION 2
Mounting Holes
Emitting
axis
Measurement point
11.4
(0.45)
10.5
(0.41)
22
(0.87)
13.5 to
17.5
63.5 to 67.5
(2.50 to 2.66)
88.5 to 92.5
(3.49 to 3.64)
18.5
to
22.5
37 (1.46)
28 91.10) 4.5
(0.18)
50
(1.97)
32.3
(1.27) 22.2
(0.87)
10
(0.39) 12
5.3
19
(0.75)
4.5
(0.18)
17.5
(0.69)
5
34.8 (1.37)
32.5 (1.28)
10.5
(0.41)
R27
25
(0.98) Two
M4 holes
Emitting
axis
Emitting axis
Measurement point
20.3
(0.80)
(0.20)
For mounting
option 2, attach the
mounting bracket to
this side of the
sensor.
Unit: mm (inch)
Secure the mounting bracket to the sensor
side as indicated here.
Precautions
CLEANING
Install the Sensor in a clean environment to keep the filter (on the
front of the Sensor) free from oil and dust.
If the sensor is affected by oil or dust, clean it 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
because a scratch on the filter could result in Sensor mal-
function.
ENVIRONMENT
Do not use the LED Displacement Sensor in a strong
electromagnetic field or in an environment where the operation of
the Sensor is subjected to the reflection of intense light (such as
light from a laser beam or an electric arc welding machine).
Do not use the LED Displacement Sensor to detect objects that
are mirror-like, or transparent, or have an extremely small
reflection ratio (i.e., either an object smaller than the diameter of
the Sensor’s sensing spot, or an inclined object).
WIRING
Do not wire the power supply cable for the Z4W-V25R within a
conduit carrying high-voltage lines or power lines; the result
would be interference, damage, or Sensor malfunction.
Z4W-V Z4W-V

MUTUAL INTERFERENCE
Two Z4W-V25R LED Displacement Sensors can be installed in
close proximity to each other and operate independently without
interference (refer to the figures below). Do not install two
sensors at an oblique angle to each other; interference may
result.
When using the LED Displacement Sensor in combination with
another type of Sensor (such as a Photoelectric Sensor), the
sensor beams should be as close to perpendicular as possible.
FOR A SURFACE OF VARYING MATERIALS
When the surface of the target object consists of different
materials placed next to each other, the Sensor can accurately
detect the object only if the Sensor is parallel to the boundary of
the varied materials.
Positioning the Sensor
Incorrect
Positioning
Correct
Positioning
Cat. No. GC MSEN3 2/98 Specifications subject to change without notice. Printed in U.S.A.
OMRON ELECTRONICS, INC.
One East Commerce Drive
Schaumburg, IL 60173
NOTE: DIMENSIONS SHOWN ARE IN MILLIMETERS. To convert millimeters to inches divide by 25.4.
1-800-55-OMRON
OMRON CANADA, INC.
885 Milner Avenue
Scarborough, Ontario M1B 5V
8
416-286-6465
Z4W-V Z4W-V
Authorised Distributors:-
Intech Systems Chennai Pvt. Ltd
S-2, Thiru. Vi. Ka. Industrial Estate, Guindy, Chennai-600 032
Ph: 4353 8888 Mob: [phone] (Board Line) Fax: [phone]
E-mail: [email protected] Website: www.intechchennai.com