Omron ZS-L - User manual

USER’S MANUAL
Smart Sensor
ZS-L Series (Ver 2.0)
Cat. No. Z208-E1-02

Introduction
This manual provides information regarding functions, performance and operating
methods that are required for using the ZS-L Series.
When using the ZS-L Smart Sensor, be sure to observe the following:
• The ZS-L Smart Sensor must be operated by personnel knowledgeable in electrical engi-
neering.
• 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. This displays the display language
selection screen.
If you change and save the setting, the Controller will start up with messages displayed in
English when it is next started up.
Introduction
This manual provides information regarding functions, performance and operating
methods that are required for using the ZS-L Series.
When using the ZS-L Smart Sensor, be sure to observe the following:
• The ZS-L Smart Sensor must be operated by personnel knowledgeable in electrical engi-
neering.
• 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. This displays the display language
selection screen.
If you change and save the setting, the Controller will start up with messages displayed in
English when it is next started up.
1
Select Language
2Japanese English

Introduction
Section 1 Section 2 Section 3 Section 4 Section 5 Section 6
User’s Manual
Smart Sensor
2D CMOS Laser Type
ZS-L Series
APPLICATION CONSIDERATIONS (Please Read)
FEATURES
INSTALLATION & CONNECTION
SETUP
EXTERNAL I/O
APPLICATION SETTING EXAMPLES
APPENDIX
INTRODUCTION
SECTION 1
SECTION 2
SECTION 3
SECTION 4
SECTION 5
SECTION 6

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ZS-L
User’s Manual
Introduction
READ AND UNDERSTAND THIS DOCUMENT
Please read and understand this document before using the products. Please consult your OMRON
representative if you have any questions or comments.
WARRANTY
OMRON’s exclusive warranty is that the products are free from defects in materials and workmanship for
a period of one year (or other period if specified) from date of sale by OMRON.
OMRON MAKES NO WARRANTY OR REPRESENTATION, EXPRESS OR IMPLIED, REGARDING
NON-INFRINGEMENT, MERCHANTABILITY, OR FITNESS FOR PARTICULAR PURPOSE OF THE
PRODUCTS. ANY BUYER OR USER ACKNOWLEDGES THAT THE BUYER OR USER ALONE HAS
DETERMINED THAT THE PRODUCTS WILL SUITABLY MEET THE REQUIREMENTS OF THEIR
INTENDED USE. OMRON DISCLAIMS ALL OTHER WARRANTIES, EXPRESS OR IMPLIED.
LIMITATIONS OF LIABILITY
OMRON SHALL NOT BE RESPONSIBLE FOR SPECIAL, INDIRECT, OR CONSEQUENTIAL
DAMAGES, LOSS OF PROFITS OR COMMERCIAL LOSS IN ANY WAY CONNECTED WITH THE
PRODUCTS, WHETHER SUCH CLAIM IS BASED ON CONTRACT, WARRANTY, NEGLIGENCE, OR
STRICT LIABILITY.
In no event shall responsibility of OMRON for any act exceed the individual price of the product on which
liability is asserted.
IN NO EVENT SHALL OMRON BE RESPONSIBLE FOR WARRANTY, REPAIR, OR OTHER CLAIMS
REGARDING THE PRODUCTS UNLESS OMRON’S ANALYSIS CONFIRMS THAT THE PRODUCTS
WERE PROPERLY HANDLED, STORED, INSTALLED, AND MAINTAINED AND NOT SUBJECT TO
CONTAMINATION, ABUSE, MISUSE, OR INAPPROPRIATE MODIFICATION OR REPAIR.

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ZS-L
User’s Manual
Introduction
Introduction
SUITABILITY FOR USE
THE PRODUCTS CONTAINED IN THIS DOCUMENT ARE NOT SAFETY RATED. THEY ARE NOT
DESIGNED OR RATED FOR ENSURING SAFETY OF PERSONS, AND SHOULD NOT BE RELIED
UPON AS A SAFETY COMPONENT OR PROTECTIVE DEVICE FOR SUCH PURPOSES.
Please refer to separate catalogs for OMRON’s safety rated products.
OMRON shall not be responsible for conformity with any standards, codes, or regulations that apply to
the combination of products in the customer’s application or use of the product.
At the customer’s request, OMRON will provide applicable third party certification documents identifying
ratings and limitations of use that apply to the products. This information by itself is not sufficient for a
complete determination of the suitability of the products in combination with the end product, machine,
system, or other application or use.
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:
• Outdoor use, uses involving potential chemical contamination or electrical interference, or conditions or
uses not described in this document.
• Nuclear energy control systems, combustion systems, railroad systems, aviation systems, medical
equipment, amusement machines, vehicles, safety equipment, and installations subject to separate
industry or government regulations.
• Systems, machines, and equipment that could present a risk to life or property.
Please know and observe all prohibitions of use applicable to the products.
NEVER USE THE PRODUCTS FOR AN APPLICATION INVOLVING SERIOUS RISK TO LIFE OR
PROPERTY WITHOUT ENSURING THAT THE SYSTEM AS A WHOLE HAS BEEN DESIGNED TO
ADDRESS THE RISKS, AND THAT THE OMRON PRODUCT IS PROPERLY RATED AND INSTALLED
FOR THE INTENDED USE 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.
CHANGE IN SPECIFICATIONS
Product specifications and accessories may be changed at any time based on improvements and other
reasons.
It is our practice to change model numbers when published ratings or features are changed, or when
significant construction changes are made. However, some specifications of the product may be
changed without any notice. When in doubt, special model numbers may be assigned to fix or establish
key specifications for your application on your request. Please consult with your OMRON representative
at any time to confirm actual specifications of purchased products.

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ZS-L
User’s Manual
Introduction
DIMENSIONS AND WEIGHTS
Dimensions and weights are nominal and are not to be used for manufacturing purposes, even when
tolerances are shown.
ERRORS AND OMISSIONS
The information in this document has been carefully checked and is believed to be accurate; however, no
responsibility is assumed for clerical, typographical, or proofreading errors, or omissions.
PROGRAMMABLE PRODUCTS
OMRON shall not be responsible for the user’s programming of a programmable product, or any
consequence thereof.
COPYRIGHT AND COPY PERMISSION
This document shall not be copied for sales or promotions without permission.
This document is protected by copyright and is intended solely for use in conjunction with the product.
Please notify us before copying or reproducing this document in any manner, for any other purpose. If
copying or transmitting this document to another, please copy or transmit it in its entirety.

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ZS-L
User’s Manual
Introduction
Introduction
Meanings of Signal Words
The following signal words are used in this manual.
The following alert symbols are used in this manual.
The following alert statements apply to the products in this manual. Each alert statement also
appears at the locations needed in this manual to attract your attention.
Meanings of Signal Words
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.
Meanings of Alert Symbols
Indicates the possibility of laser radiation.
Indicates prohibition when there is a risk of minor injury from electrical shock
or other source if the product is disassembled.
Indicates general prohibitions for which there is no specific symbol.
Alert statements in this Manual
This product is not designed or rated for ensuring safety of persons.
Do not use it for such purposes.
Never look into the laser beam. Doing so continuously will result in visual
impairment.
Do not disassemble the product. Doing so may cause the laser beam to
leak, resulting in the danger of visual impairment.

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User’s Manual
Introduction
Precautions for Safe Use
Please observe the following precautions for safe use of the products.
(1) Installation Environment
• Do not use the product in environments where it can be exposed to inflammable/
explosive gas.
• To secure the safety of operation and maintenance, do not install the product close to
high-voltage devices and power devices.
(2) Power Supply and Wiring
• The supply voltage must be within the rated range (DC24V±10%).
• Reverse connection of the power supply is not allowed.
• Open-collector outputs should not be short-circuited.
• Use the power supply within the rated load.
• High-voltage lines and power lines must be wired separately from this product. Wiring
them together or placing them in the same duct may cause induction, resulting in mal-
function or damage.
(3) Others
• Do not attempt to dismantle, repair, or modify the product.
• Dispose of this product as industrial waste.
Precautions for Safe Use

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ZS-L
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Introduction
Introduction
Precautions for Correct Use
Please observe the following precautions to prevent failure to operate, malfunctions, or
undesirable effects on product performance.
(1) Installation Site
Do not install the product in locations subjected to the following conditions:
• Ambient temperature outside the rating
• Rapid temperature fluctuations (causing condensation)
• Relative humidity outside the range of 35 to 85%
• Presence of corrosive or flammable gases
• Presence of dust, salt, or iron particles
• Direct vibration or shock
• Reflection of intense light (such as other laser beams or electric arc-welding
machines)
• Direct sunlight or near heaters
• Water, oil, or chemical fumes or spray
• Strong magnetic or electric field
(2) Power Supply and Wiring
• When using a commercially available switching regulator, make sure that the FG ter-
minal 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. load short-circuit)
and the load current is appropriate. Incorrect wiring may result in breakdown of the
product.
• Before connecting/disconnecting the Sensor Head, make sure that the Smart Sensor
is turned OFF. The Smart Sensor may break down if the Sensor Head is connected or
disconnected while the power is ON.
• Use the Extension Cable (provided) for extending the cable between the Sensor Head
and Sensor Controller. The total length varies according to the type of Extension
Cable.
Extension Cable: ZS-XC_A: within 10 m (including Sensor Head cable. Extension
Cable cannot be daisy-chained.)
Extension Cable: ZS-XC_B(R): within 22 m (including Sensor Head. Up to two Exten-
sion Cables can be daisy-chained.)
The cable may break at locations when it is made to bend. So, use the robot cable
type Extension Cable (ZS-XC5BR).
• Use only combinations of Sensor Heads and Sensor Controllers specified in this man-
ual.
Precautions for Correct Use

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Precautions for Correct Use
(3) Orientation when Installing the Sensor Controller
(4) Warming Up
After turning ON the power supply, allow the product to stand for at least 30 minutes
before use. The circuits are still unstable immediately after the power supply is turned
ON, so measured values may fluctuate gradually.
(5) Maintenance and Inspection
Do not use thinner, benzene, acetone or kerosene to clean the Sensor Head and Sen-
sor Controller. If large dust particles adhere to the front filter of the Sensor Head, use a
blower brush (used to clean camera lenses) to blow them off. Do not blow the dust par-
ticles with your mouth. To remove smaller dust particles, wipe gently with a soft cloth
(for cleaning lenses) moistened with a small amount of alcohol. Do not use excessive
force to wipe off dust particles. Scratches on the filter may cause errors.
(6) Sensing Objects
The product sometimes cannot accurately measure the following types of objects:
Transparent objects, objects with an extremely low reflection factor, objects smaller
than the spot diameter, objects with a large curvature, excessively inclined objects, etc.
Right
Wrong Wrong
To improve heat radiation, install the Sensor Controller only in
the orientation shown below.
Do not install the Sensor Controller in the following orientations.

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ZS-L
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Introduction
Introduction
Editor's Note
Editor's Note
Page Format
Section 3 SETUP
Section 3
Setting the Sensing Conditions
3-11
ZS-L
User’s Manual
Setting the Sensing Conditions
Set the conditions to be used for detecting workpieces by the sensor.
Setting the Measurement Mode
Set the measurement mode.
Select the measurement mode based on the items (e.g. speed, precision, or sensitivity)
that you want to give priority to in measurement.
FUN Mode - [SENSING] - [MODE]
In the HIGH SPEED mode, the measurement cycle changes according the actual settings. (When
only the average count is set, the measurement cycle becomes the maximum speed (approx. 110
s).) Check the actual measurement cycle at [INFO]-[CYCLE] under the top menu.
Setting the Head Installation
Set how the Sensor Head is installed.
FUN Mode - [SENSING] - [HEAD SENSOR]
Setting Description
STANDARD This is the standard measurement mode. (measurement cycle: approx. 500 s)
(default)
HIGH PRECISION Select this mode to measure workpieces at high precision. (measurement cycle:
approx. 2 ms)
HIGH SPEED Select this mode to measure workpieces at high speed. (measurement cycle: max.
speed approx. 110 s)
HIGH SENSITIVITY Select this mode to measure workpieces with sensitivity set high. In this measure-
ment mode, sensitivity to received light is much better than the HIGH PRECISION
mode as the sampling period is longer. (measurement cycle: approx. 4 ms)
Setting Description
Diffuse REFLECTION Select this item when the Sensor Head is installed for diffuse reflection sensing.
(default value)
Regular REFLECTION Select this item when the Sensor Head is installed for regular reflection sensing.
Header
Overview
Cross-header
Title of each section
Index label
Movement
through menus up
to setting items
Supplementary Explanation
Helpful information regarding operation and reference
pages are introduced here using symbols.
*This page has been made purely for explanatory purposes and does not exist.
Overview of the
cross-header
Explanation of
options
Indicates the section
number and title.

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ZS-L
User’s Manual
Introduction
Editor's Note
■Meaning of Symbols
Menu items that are displayed on the Sensor Controller’s LCD screen, and windows,
dialog boxes and other GUI elements displayed on the PC are indicated enclosed by
brackets [aa].
■Visual Aids
Indicates points that are important to ensure full product performance, such as operational
precautions and application procedures.
Indicates pages where related information can be found.
Indicates information helpful in operation.

11
ZS-L
User’s Manual
READ AND UNDERSTAND THIS DOCUMENT
CONTENTS
CONTENTS
Section 1 Section 2 Section 3 Section 4 Section 5 Section 6 Section 7
CONTENTS
Meanings of Signal Words 5
Meanings of Alert Symbols 5
Alert statements in this Manual 5
Precautions for Safe Use 6
Precautions for Correct Use 7
Editor's Note 9
Page Format 9
CONTENTS 11
Section 1 FEATURES 1-1
ZS-L Features 1-2
ZS-L Applications 1-4
Basic Configuration 1-9
Part Names and Functions 1-10
Section 2 INSTALLATION & CONNECTION 2-1
About Installation and Connection 2-2
Sensor Controller 2-3
Attaching the ferrite core 2-3
Installing the Sensor Controller 2-4
About the I/O cable 2-7
Sensor Head 2-11
Attaching the ferrite core 2-11
Installing the Sensor Head 2-12
Connecting Sensor Heads 2-18
SmartMonitor ZS 2-19
Installing SmartMonitor ZS on a personal computer 2-19
Starting up SmartMonitor ZS 2-23
Section 3 SETUP 3-1
Setting Flow 3-2
About Setup 3-4
Basic Knowledge for Operation 3-4

12
CONTENTS
ZS-L
User’s Manual
READ AND UNDERSTAND THIS DOCUMENT
CONTENTS
List of Setting Items 3-9
Setting the Sensing Conditions 3-12
Setting the Measurement Mode 3-12
Setting the Head Installation 3-13
Setting the Emitted Light Intensity 3-13
Setting the Measurement Object 3-14
Setting Prevention of Mutual Interference 3-16
Setting Gain 3-17
Setting the Filter Function 3-18
Setting Smooth 3-18
Setting Average 3-19
Setting Differentiation 3-19
Setting Output Processing of Sensing Information 3-20
Setting Scaling 3-20
Setting Hold Functions 3-24
Setting Zero Reset 3-28
Setting Threshold Values 3-31
Setting the Display Method 3-32
Setting the Digital Displays 3-32
Setting the LCD Display 3-33
HELP 3-34
Setting Banks 3-34
Switching banks 3-34
Clearing banks 3-34
Setting the System Environment 3-35
Saving setup data 3-35
Initializing setup data 3-35
Checking Sensor Controller information 3-36
Setting key lock 3-36
Setting the sensor load method 3-36
Setting the display language 3-37

13
ZS-L
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READ AND UNDERSTAND THIS DOCUMENT
CONTENTS
CONTENTS
Section 1 Section 2 Section 3 Section 4 Section 5 Section 6 Section 7
Section 4 EXTERNAL I/O 4-1
Linear Input/Output 4-2
Setting Linear Output 4-2
Setting Judgment Output 4-5
Non-Measurement Settings 4-6
Input Signal Settings 4-7
I/O Assignment Settings 4-7
Timing Charts 4-9
RS-232C Input/Output 4-11
RS-232C Specifications 4-11
Setting the Communication Specifications 4-12
Section 5 APPLICATION SETTING EXAMPLES 5-1
Measuring the Front Side of Black Sheet Rubber 5-2
Measuring the Height of a PCB Surface 5-5
Measuring the Thickness of Glass 5-7
Section 6 APPENDIX 6-1
Troubleshooting 6-2
Error Messages and Countermeasures 6-3
Q&A 6-5
Glossary 6-6
Specifications and External Dimensions 6-7
Sensor Head 6-7
Sensor Controller 6-18
Panel Mount Adapters 6-20
RS-232C Cable for Connecting to a Personal Computer 6-21
Extension Cable 6-22
Laser Safety 6-23
Requirements from Regulations and Standards 6-24
Summary of Requirements to Manufactures 6-24
Summary of Requirements to User 6-28
Definitions of Laser Classification 6-31
Engineering Data 6-33

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CONTENTS
ZS-L
User’s Manual
READ AND UNDERSTAND THIS DOCUMENT
CONTENTS
Linearity Characteristic by Materials 6-33
Version Up Information 6-42
INDEX 6-43
Revision History 6-47

Section 1 FEATURES
1-1
ZS-L
User’s Manual
Section 1
FEATURES
ZS-L Features 1-2
ZS-L Applications 1-4
Basic Configuration 1-9
Part Names and Functions 1-10

1-2
Section 1 FEATURES
ZS-L
User’s Manual
Section 1
ZS-L Features
ZS-L Features
The ZS-L Series is a 2D CMOS laser type displacement sensor. It is provided with a high-
performance sensing function that uses a 2D CMOS image sensor, features a high-speed
transmission capability free from data degradation as a result of 100% digital handling of
data, and is extremely easy-to-use and handy.
(1) Compact Sensor Head
A 2D CMOS image sensor, proprietary algorithms, and other sensing technology are
incorporated in the compact Sensor Head. This achieves an improved dynamic range,
high-speed sampling up to 110 µs, and a high resolution.
(2) An Enhanced Lineup of Sensor Heads
Regular Reflection Type Diffuse Reflection Type
ZS-LD20T ZS-LD40T ZS-LD50 ZS-LD80 ZS-LD200
Measurement
distance:
20±1 mm
Measurement
distance:
40±2.5 mm
Measurement
distance:
50±5mm
Measurement
distance:
80±15 mm
Measurement
distance:
200±50 mm
Sensor Head
Sensor Controlle
r
(1)
(2)
(3)
(4)
(
6
)
(5)
Personal com
p
ute
r

Section 1 FEATURES
Section 1
ZS-L Features
1-3
ZS-L
User’s Manual
(3) High-speed Digital Transfer
The LVDS (Low Voltage Differential Signaling) high-speed communication interface is
used (an industry first) between the Sensor Head and the Sensor Controller. Data
detected by the Sensor Head is transferred at high speed without any degradation.
Moreover, the connection can be extended up to 22 m by 2 extension cables to suit
your setup environment.
Connection extended up to 22 m p.1-7
(4) Business Card-size Sensor Controller
• The Sensor Controller is designed to be compact so that it can be installed at a wide
range of sites.
External Dimensions p.6-18
• Large-size LCD screen and direct function keys ensure outstanding operability.
• The Sensor Controller supports various workpieces, which means that detailed and
flexible settings can be made.
• Incorporates extensive functions such as Filter and Hold to support a wide range of
applications.
• Mutual interference from 2 adjacent Sensor Heads can be prevented by shifting the
timing of laser beam emission.
List of Setting Items p.3-9
(5) USB Connection
The Sensor Controller is provided with a USB port (compliant with Full-Speed USB2.0
specifications) as standard. This enables detection data and setting data to be easily
uploaded to a personal computer.
(6) Dedicated Software “SmartMonitor ZS Professional”
The “SmartMonitor ZS Professional” software for setting up and monitoring multi-win-
dow displays and logging is provided (Sold separately). This software also supports the
display and setup of data such as monitoring of waveforms and designation of area that
is not possible on the Sensor Controller alone.

1-4
Section 1 FEATURES
ZS-L
User’s Manual
Section 1
ZS-L Applications
ZS-L Applications
●Detection of rubber and other black workpieces
The improved dynamic range enables the detection of black workpieces that reflect lit-
tle light.
●Detection of light-penetrating workpieces such as PCBs
Proprietary sensing algorithms enable the detection of workpieces through which light
penetrates.
●Detection of transparent workpieces such as glass
Proprietary sensing algorithms enable the detection of workpieces through which light
passes through.
Up to 3 sheets of glass can be detected, which means that the glass thickness and gap
between glass sheets can be measured.