Omron ZG - User manual

1ZG - Smart Profile Sensor
2D Profile Measuring Sensors
ZG - Smart Profile Sensor
The easy way to get your profile
The smart ZG sensor solves ambitious profile mea-
surement applications. An easy and intuitive user in-
terface enables efficient installation, setup and
operation. The advanced processing technology is
a break-through for the needs of high speed pro-
cesses. Precise shape measurement is guaranteed
on challenging materials and surfaces. A built-in
LCD monitor presents the measurement result in
real time.
• Easy to use - intuitive user interface
• Live - built-in LCD monitor for setup and
immediate profile display
• Versatile - 18 measurement tools
• Accurate - 5 µm resolution
• Wide profiles - up to 70 mm
• Fast - 5 ms sampling time
• Smart - powerful PC software for configuration
and post-processing (optional)
Easy to use
Complex operational procedures are time consuming and costly.
The new ZG differentiates from standard products by its usability.
The intuitive icon based menu, enables an easy setup and configu-
ration of advanced measurement tasks within 3 steps.
Live - built-in LCD monitor
The built-in LCD monitor of the ZG represents an intuitive user
interface for easy setup and immediate live feedback of measure-
ment result. This helps to save time for the initial configuration,
change of measurement task and reduces the training efforts for
personnel. A fine tuning of the settings can be achieved in sec-
onds. The LCD monitor enables to check the measurement result
at any time during operation, without the need to connect an exter-
nal PC. The reaction time for maintenance activities can be short-
ened.
Check on LCD display Simple ICON menu Automatic calculation
Step 1
Adjust Sensor Head
Step 2
Select function
Step 3
Select range
Check results on display Control with keys

2 Displacement & Width-Measuring Sensors
Versatile - diverse measurement functions
Intelligence inside - automatic adjustment of laser power
In many industrial processes sensors have to deal with difficult or
changing materials. In order to avoid time consuming reconfigura-
tions to reliably detect the objects, the sensor by itself has to man-
age the constraints of the process. The ZG provides an automatic
adjustment of the laser power, depending on the surface of the
object. The deviation of the reflection, e.g. of different colors can be
compensated by increasing or decreasing the laser power to
achieve the best result.
Further improvements of the measurement result can be achieved
e.g. on shiny surfaces. The reflection level on different parts of the
measurement object can be different, which can result in incomplete
profiles.
To complement the profile ZG has the capability to take several
images and to combine them. The "multi-sensitivity function" allows
to adjust the incident light on the different parts of the object and to
retrieve a complete shape.
Flexible - balance between speed and accuracy
The ZG Smart profile sensor offers different modes of operation, which allows adjusting the sensor behavior to the application requirements. The
optimization can be done either towards high speed or high accuracy. For high speed processes the sampling time can be decreased to 5 ms. In
the other direction 5 µm accuracy can be achieved.
Height
Point 3
Point 1 Point 2
Step from base
Others (Angle, Area, Calc ...)
Point 1
Point 2
Step
Edge and Width
The ZG can solve advanced measurement tasks. Up to 18 different
functions are available to meet the requirements of the applications.
They allow to calculate e.g. the width, height, angle or area of the pro-
file. The measurement functions can be selected from the easy to
understand icon based user interface on the LCD monitor.
Good Profile
Image with Hi-LD-power
Image with Lo-LD-power
Combine!
Bad reflection
Bad Profile
100 pixels
Standard mode — 8 ms
631 pixels
High-precision mode — 16 ms
631 pixels
400 pixels
High-speed mode — 5 ms
50 pixels
631 pixels

3ZG - Smart Profile Sensor
Applications
Width
measuremen
t
- car
b
o
d
y
• Task: Measure the gap between different
parts of the car body
• Industry: Automotive
• Challenge: Changing colours of the
objects
• Solution: Automatic Laser power
adjustment in ZG
• Key point: Higher accuracy than vision
systems
W
arpage measuremen
t
-
PCB
• Task: Measure the warpage of a PCB to
avoid soldering or connection defects
• Industry: Electronics
A
rea measuremen
t
- g
l
ue
b
ea
d
measurement
• Task: Measure the presence or shape of a
glue bead to control the continuous motion
of a robot
• Industry: Automotive

4 Displacement & Width-Measuring Sensors
P
os
iti
on measuremen
t
- paper
• Task: Control the position of the paper and
check whether there is a drift
(meandering)
• Industry: Paper
Task 1
Task 2
Task 2
Task 2
Task 3 =
A
ng
l
e measuremen
t
- car sea
t
• Task: Measure the angle of the car seat
• Industry: Automotive
• Key point: Controller can calculate any
angle by defining additional tasks
Groove
width
Groove
depth
M
easur
i
ng a
i
r-
b
ag no
t
c
h
• Task: Measure depth and width of an air-
bag notch
• Industry: Automotive
• Key point: High accuracy

5ZG - Smart Profile Sensor
Basic Configuration
Sensor Heads
200
Height
100
50
20
50
0
ZG-WDS70 ZG-WDS3T
ZG-WDS22
ZG-WDS8T
Height (resolution)
Width (resolution)
Linearity
210±30 mm (10 µm)
70 mm/631 pixels
±0.5% F.S.
100±12 mm (3 µm)
22 mm/631 pixels
±0.5% F.S.
50±3 mm (1 µm)
8 mm/631 pixels
±0.5% F.S.
20±0.5 mm (0.2 µm)
3 mm/631 pixels
±0.5% F.S.
ZG-WDC
Controller
Smart Monitor ZG
Setup Support Software
ZG-RPD
Parallel Output Unit
High-speed
Input Board (PC)
or
PLC
USBRS-232C
PLC
Note: Screen images are simulated.
Extension Cables (25 m max.)
Standard Sensor Head cable length
Cable length between Sensor Head and Controller
ZG-WDS@
Sensor Head
ZG-WDC@
Controller
ZG-WDC@
Controller ZG-XC02D
Connection Cable
ZG-WDS@
Sensor Head
ZG-XEQ
Digital Equalizer ZG-XEQ
Digital Equalizer
ZG-XC3CR/XC8CR/XC15CR/XC25CR
Flex-resistant Extension Cable
3, 8, 15, or 25 m
0.5 m, 2 m
0.5m, 2m
0.2 m
Flex-resistant cable

6 Displacement & Width-Measuring Sensors
Ordering Information
Sensor Heads
Sensor Controllers
Accessories (Order separately)
Real-time Parallel Unit (for the ZG-WDC-Series)
RS-232 Cable
Sensor Head Extension Cable
Parallel Mounting Adaptor
Optical method Sensing distance Resolution Model
Height direction Width direction Height direction Width direction
Diffuse reflective 210±30 mm 70 mm 10 µm 70 mm/631 pixels ZG-WDS70
Diffuse reflective 100±12 mm 22 mm 3 µm 22 mm/631 pixels ZG-WDS22
Diffuse reflective 50±3 mm 8 mm 1 µm 8 mm/631 pixels ZG-WDS8T
Regular reflective 20±0.5 mm 3 mm 0.25 µm 3 mm/631 pixels ZG-WDS3T
Appearance Power
supply
Output
type
Model
24 VDC NPN ZG-WDC11A*
* Included with Smart Monitor ZG Setup Support Software and USB
cable.
PNP ZG-WDC41A*
Appearance Output type Model
NPN ZG-RPD11
PNP ZG-RPD41
Connecting device Model Qty
For personal computer
connection (2 m)
ZS-XRS2 1
For PLC/PT connection (2 m) ZS-XPT2 1
Name Model Qty
3 m Extension Cable ZG-XC3CR 1
8 m Extension Cable ZG-XC8CR 1
15 m Extension Cable ZG-XC15CR 1
25 m Extension Cable ZG-XC25CR 1
Digital Equalizer
(Relay Device)
ZG-XEQ 1
0.2 m Digital Equalizer
Connection Cable
ZG-XC02D 1
Appearance Model
ZS-XPM1 For 1 Unit
ZS-XPM2 For 2 Units or more

7ZG - Smart Profile Sensor
Specifications
Sensor Heads
Note: 1 .Obtained by setting an OMRON standard measurement object at the
measurement center distance and determing the average height of
the beam line. The conditions are given in the table below. However,
satisfactory resolution cannot be attained in strong electromagnetic
fields.
2 .The tolerance for an ideal straight line obtained by determing the av-
erage height of an OMRON standard measurement object for the
beam line. The CCD standard models used. Linearity varies depend-
ing on the measurement object.
3 .A value attained by using an aluminium jig to secure the distance be-
tween the Head and the measurement object. The CCD standard
mode is used.
4 . Defined as 1/e2(13.5%) of the center light intensity. This may be influ-
enced when light leakage also exists outside the defined area and the
reflectivity of the light around the measurement object is higher than
that of measurement object.
Item Model ZG-WDS70 ZG-WDS22 ZG-WDS8T ZG-WDS3T
Optical system Diffuse reflective Diffuse
reflective
Regular
reflective
Diffuse
reflective
Regular
reflective
Regular
reflective
Diffuse
reflective
Measure-
ment
range
Height
direction
(in standard
mode)
210±30 mm 100±12 mm 94±10 mm 50±3 mm 44±2 mm 20±0.5 mm 5.2±0.4 mm
Width
direction 70 mm (typical) 22 mm (typical) 8 mm (typical) 3 mm (typical)
Resolution
Height
direction *1 10 µm 3 µm 1 µm 0.25 µm
Width
direction 70 mm/631 pixels 22 mm/631 pixels 8 mm/631 pixels 3 mm/631 pixels
Linearity
(in the height direction) *2 ±0.5% F.S.
Temperature
characteristic *3 0.1% F.S./°C
Light
source
Type Visible semiconductor laser
Wavelength 658 nm 650 nm
Output 5 mW max. output, 1 mW max. exposure (without using optical instruments) 1 mW max.
Laser class Class 2M (JIS C 6802 2005) Class 2 (JIS C 6802 2005)
Beam shape (at measure-
ment center distance) *4 120 µm×75 mm (typical) 60 µm×45 mm (typical) 30 µm×24 mm (typical) 25 µm×4 mm (typical)
LED STANDBY: Lights when laser irradiation preparation is complete (indication color: green)
LD_ON: Lights when the laser is irradiating (indication color: green)
Measurement object Opaque material
Environ-
ment
resistance
Ambient light
intensity Incandescent lamp: 1,000 lx max. (light intensity on the receiver surface)
Ambient
temperature Operating: 0 to 50°C, Storage: -15 to 60°C (with no icing or condensation)
Ambient
humidity Operating and storage: 35 to 85% (with no condensation)
Degree of
protection IP66 (IEC 60529) IP64 (IEC 60529)
Vibration
resistance
(destruction)
10 to 150 Hz with 0.35 mm single amplitude for 80 min each in X, Y and Z directions
Shock
resistance
(destruction)
150 m/s2, 3 times each in 6 directions (up/down, right/left, forward/backward)
Materials Case: Aluminium diecast, Front cover: Glass, Cable insulation: Heat-resistive polyvinyl chloride (PVC),
Connector: Zinc alloy or brass
Cable length 0.5 m, 2 m
Minimum bending radius 68 mm
Weight Approx. 650 g Approx. 500 g Approx. 500 g Approx. 300 g
Accessories Laser Labels (EN, 2 labels), Ferrite Core (1), Instruction Manual
Model CCD
Mode
Aver-
age No.
of Oper-
ations
Measurement object
Regular
reflective
Diffuse
reflective
ZG-WDS70/
WDS22/
WDS8T
Stan-
dard
mode
16 OMRON standard white alumina
ceramic object
ZG-WDS3T
Stan-
dard
mode
32
OMRON stan-
dard mirrored
object
OMRON stan-
dard diffuse re-
flective object
Model Measurement object
Regular reflective Diffuse reflective
ZG-WDS70/
WDS22/WDS8T OMRON standard white alumina ceramic object
ZG-WDS3T OMRON standard mir-
rored object
OMRON standard dif-
fuse reflective object

8ZG - Smart Profile Sensor
Sensor Controllers
Note: 1 . The image input periode listed here are for fixed/auto sensitivity. The image input period will be longer for multi-sensitivity or other settings. Use the eco monitor
in RUN mode to determine the actual image input period.
Item Model ZG-WDC11A ZG-WDC41A
Input/output type NPN PNP
No. of connectable Sensor Heads 1 per Controller
Measurement cycle *1 16 ms (high-precision mode), 8 ms (standard mode), 5 ms (high-speed mode)
Min. display unit 10 nm
Display range -999.99999 to 999.99999
Display
LCD monitor 1.8 inch TFT color LCD (557×234 pixels)
LEDs
• Judgment indicators for each task (indication color: orange): T1, T2, T3, T4
• Laser indicator (indication color: green): LD_ON
• Zero reset indicator (indication color: green): ZERO
• Trigger indicators (indication color: green): TRIG
External
interface
Input/output
signal lines
Analog outputs
Select voltage or current (using the sliding switch on the bottom surface)
• Voltage output: -10 to 10 V, output impedance: 40 Ω
• Current output: 4 to 20 mA, maximum load resistance: 300 Ω
Judgment output
(ALL-PASSING/ERROR) NPN open collector
30 VDC, 50 mA max.
Residual voltage: 1.2 V max.
PNP open collector
50 mA max.
Residual voltage: 1.2 V max.
Trigger auxiliary output
(ENABLE/GATE)
Laser stop input
(LD-OFF)
ON: 0 V short or 1.5 V max.
OFF: Open (leakage current: 0.1 mA max.)
ON: Power supply voltage short or power sup-
ply voltage -1.5 V min.
OFF: Open (leakage current: 0.1 mA max.)
Zero reset input
(ZERO)
Measurement trigger
input (TRIG)
Bank switching input
(BANK A, B)
Serial I/O USB2.0 1 port, full speed (12 Mbps), MINI-B
RS-232C 1 port, 115,200 bps max.
Main functions
No. of setting banks 4
Sensitivity adjustment Multi/auto/fixed
Measurement items Height, 2-point Step, 3-point Step, Edge position, Edge width, Angle/Area Calculation (up to
four items can be measured simultaneously)
Trigger modes External trigger/continuous
Ratings
Power supply voltage 21.6 to 26.4 VDC (including ripple current)
Current consumption 0.8 A max.
Insulation resistance 20 MΩat 250 V between lead wires and Controller case
Dielectric strength 1,000 VAC, 50/60 Hz for 1 min between lead wires and Controller case
Environmental
resistance
Ambient temperature Operating: 0 to 50°C, Storage: -15 to 60°C (with no icing or condenstaion)
Ambient humidity Operating and storage: 35 to 85%
Degree of protection IP20 (IEC 60529)
Vibration resistance
(destruction)
Vibration frequency: 10 to 150 Hz, single amplitude: 0.35 mm, acceleration: 50 m/s2, 10 times
for 8 min each
Shock resistance
(destruction) 150 m/s2, 3 times each in 6 directions (up/down, right/left, forward/backward)
Materials Case: Polycarbonate (PC), Cable insulation: Heat-resistive polyvinyl chloride (PVC)
Cable length 2 m
Weight Approx. 300 g (including cable) (Packed state: Approx. 450 g)
Accessories Large Ferrite Core (1), Small Ferrite Core (2), Insulation lock (1), Instruction Manual, Smart
Monitor ZG Setup Support Software (CD-ROM), USB Cable (1 m)
In the interest of product improvement, specifications are subject to change without notice.
ALL DIMENSIONS SHOWN ARE IN MILLIMETERS.
To convert millimeters into inches, multiply by 0.03937. To convert grams into ounces, multiply by 0.03527.
Cat. No. Q150-E2-01-X