Omron Z500 Series User guide

Cat. No. Z158-E1-1 Note: Specifications subject to change without notice. Printed in Japan
0202-
Authorized Distributor:
Multi-Dimensional Controller
Setup Manual
Manual
Cat. No. Z158-E1-1
Multi-Dimensional Controller
Z500

About this Manual
Manual 1: Setup Manual
Installation
Wiring
Please read the following manuals carefully and be sure you understand the information provided
before attempting to install or operate the Z500.
This manual describes the hardware for the Z500
(Multi-Dimensional Controller) and how to install the
components.
Be sure to read this manual first.
Manual 2: Operation Manual
Starting the Z500
and Positioning
the Workpiece
Adjusting Images
Setting
Measurement
Conditions
and Executing
Outputting to
External Devices
SECTION 2 Basic Operations
This section describes how to start the Z500
and how to display images on the monitor.
SECTION 7 I/O Format
This section provides details on the inputs and outputs
used for communications with external devices via
terminal blocks or RS-232C.
• Communications settings
• I/O format
• Timing for communications
SECTION 3
Menus for Conversational Menu
• Basic settings required for measurement
• Measurement of consistent workpieces
Menus for Conversational Menu
Settings can be made easily by entering
information as requested - just as
though you are having a conversation
with the Z500.
SECTION 4 Menus for Expert Menu
• Customized settings
• Detailed settings
• Measurement of workpieces placed at different
positions
Menus for Expert Menu
More detailed setting, such as position
compensation for workpieces placed at
different positions, can be made.
Cat. No. Z159-E1-1
Multi-Dimensional Controller
Z500
Operation Manual
Manual
Cat. No. Z000-E1-1
Cat. No. Z158-E1-1
Multi-Dimensional Controller
Setup Manual
Manual
Cat. No. Z000-E1-1
Multi-Dimensional Controller
Z500
OMRON Corporation
Industrial Automation Company
Application Sensors Division
Sensing Devices and Components Division H.Q.
Shiokoji Horikawa, Shimogyo-ku, Kyoto, 600-8530 Japan
Tel:[phone] / Fax:[phone]
Regional Headquarters
OMRON EUROPE B.V.
Sensor Business Unit
Carl-Benz Str. 4, D-71154 Nufringen,
Germany
Tel:[phone] / Fax:[phone]
OMRON ELECTRONICS LLC
1 East Commerce Drive, Schaumburg, IL 60173
U.S.A.
Tel:[phone] / Fax:[phone]
OMRON ASIA PACIFIC PTE.LTD.
83 Clemenceau Avenue, #11-01, UE Square,
239920 Singapore
Tel:[phone] / Fax:[phone]
OMRON CHINA CO.,LTD.
BEIJING OFFICE
Room 1028, Office Building,
Beijing Capital Times Square,
No.88 West Chang'an Road,
Beijing, 100031 China
Tel:[phone] / Fax:[phone]

Manual
1
INTRODUCTION
SECTION 1 SECTION 2 SECTION 3 SECTION 4
Multi-Dimensional Controller
Z500
Z500-MC10
Setup Manual
INTRODUCTION 3
SECTION 1
Wiring and Connection 17
SECTION 2
Installation 25
SECTION 3
Connecting External Devices 39
SECTION 4
Troubleshooting and Maintenance 51

2Z500
Setup Manual
Special or Critical Applications
When the Z500 will be used in one of the conditions or applications listed below, allow extra safety
margins in ratings and functions, add extra safety feature such as fail-safe systems, and consult your
OMRON representative.
• Operating conditions or environments which are not described in the manual
• Nuclear power control systems, railroad systems, aviation systems, vehicles, combustion systems,
medical equipment, amusement equipment, or safety equipment
• Other systems, machines, and equipment that may have a serious influence on lives and property and
require extra safety features
Product Availability
Some of the products listed may not be available in some countries. Please contact your nearest
OMRON sales office by referring to the addresses provided at the back of this manual.
© OMRON, 2002
All rights reserved. No part of this publication may be reproduced, stored in a retrieval system, or transmitted, in any
form, or by any means, mechanical, electronic, photocopying, recording, or otherwise, without the prior written
permission of OMRON.
No patent liability is assumed with respect to the use of the information contained herein. Moreover, because
OMRON is constantly striving to improve its high-quality products, the information contained in this manual is subject
to change without notice. Every precaution has been taken in the preparation of this manual. Nevertheless, OMRON
assumes no responsibility for errors or omissions. Neither is any liability assumed for damages resulting from the use
of the information contained in this publication.

Z500
Setup Manual
INTRODUCTION
Table of Contents
3
INTRODUCTION
Table of Contents
INTRODUCTION.................................................................................... 3
Table of Contents..........................................................................................................3
Precautions on Safety..................................................................................................4
Laser Safety...................................................................................................................5
Export of the Products .................................................................................................9
Caution.........................................................................................................................10
Notice...........................................................................................................................11
Confirming Package Contents...................................................................................15
Editor's Note................................................................................................................16
SECTION 1
Wiring and Connection...................................................................... 17
1-1 Basic System Configuration..............................................................................18
1-2 Component Names and Functions ...................................................................20
1-3 Power Supply and Ground.................................................................................22
SECTION 2
Installation .......................................................................................... 25
2-1 Mounting the Controller.....................................................................................26
2-2 Mounting the Sensor..........................................................................................28
SECTION 3
Connecting External Devices............................................................ 39
3-1 Terminal Block Connections.............................................................................40
3-2 RS-232C Connections........................................................................................44
3-3 Linear Sensor Controller Connections.............................................................46
SECTION 4
Troubleshooting and Maintenance................................................... 51
4-1 Troubleshooting .................................................................................................52
4-2 Maintenance........................................................................................................54
4-3 Specifications and Dimensions.........................................................................55

4
INTRODUCTION
Precaution on Safety
Z500
Setup Manual
INTRODUCTION
Precaution on Safety
OMRON products are manufactured for use according to proper procedures by a qualified operator and
only for the purposes described in this manual.
The following conventions are used to indicate and classify precautions in this manual. Always heed the
information provided with them. Failure to heed precautions can result in injury to people or damage to
property.
DANGER Indicates an imminently hazardous situation which, if not avoided, will result in death or
serious injury.
WARNING Indicates a potentially hazardous situation which, if not avoided, could result in death or
serious injury.
CAUTION Indicates a potentially hazardous situation which, if not avoided, may result in minor or
moderate injury, or property damage.
WARNING Failure to read and understand the information provided in this manual may result in
personal injury or death, damage to the product, or product failure. Please read
each section in its entirety and be sure you understand the information provided in
the section and related sections before attempting any of the procedures or opera-
tions given.

Z500
Setup Manual
INTRODUCTION
Laser Safety
5
INTRODUCTION
Laser Safety
This manual uses the following signs and symbols to ensure safe operation of the Z500.
These signs and symbols are important for avoiding injury to people or damage to the product. Be sure
to pay attention to them.
Their meanings are given below.
Warning
Signs and Symbols
Safety precautions for using laser equipment
WARNING Do not to expose your eyes to the laser radiation either directly or
indirectly (i.e., after reflection from a mirror or shiny surface).
The laser radiation has a high power density and exposure may
result in loss of sight.
The Z500 series uses laser as the light source and is classified as shown below
according to the IEC standard (IEC60825-1).
Labeling on Laser Use
The Z500 has, on the side of its sensor, a warning label as shown below.
WARNING Indicates an imminently hazardous situation which, if not
avoided, will result in death or serious injury.
Laser Beam Hazard
Cautions to Indicate Potential Laser Beam Hazard
Z500-SW2 Z500-SW17
Wavelength 650 nm 658 nm
Maximum pulse duration 10 ms 17.5 ms
Cycle 0.5 to 10 ms 0.5 to 25 ms
Peak power 1 mW max. 15 mW max.
Class 23B
Z500-SW2 Z500-SW17

6
INTRODUCTION
Laser Safety
Z500
Setup Manual
INTRODUCTION
Safety Device
The Z500 is equipped with laser radiation warning lamp and laser off input
circuit. Interlocking unit can be configured in the external circuit.
Unless the product is in Run Mode, however, laser off input from the external
circuit is disabled. This ensures stable measurement. Be sure to use laser-
shielding safety goggles when installing or adjusting Z500-SW17.
Safety Instructions
• Use laser enclosure device to prevent specular object from reflecting laser
beam.
When used without an enclosure, be sure to avoid a laser path from eye level.
• Safe distance (Nominal Optical Hazard Distance: NOHD) is approximately 1
m; it is advisable, however, to terminate the laser on its path if possible. Non-
reflective, flatting material is recommendable for termination.
• Be sure to use laser-shielding safety goggles when installing or adjusting
Z500-SW17.
Outline of IEC60825 Standard
The following are the safety measures to be taken by the user for each type of
laser equipment.
Classification
Requirements Class 1 Class 2 Class 3A Class 3B* Class 4
Remote interlock Not required Connect to room or door
circuits
Key control Not required Remove key when not in
use
Beam attenuator Not required When in use prevents
inadvertent exposure
Emission
indicator device Not required Indicates laser is
energized
Warning signs Not required Follow precautions on
warning signs
Beam path Not
required Terminate beam at end of useful length
Specular
reflection Not required Prevent unintentional
reflections
Eye protection Not required
Required if engineering
and administrative proce-
dures not practicableand
MPE exceeded
Protective
clothing Not required Sometimes
required Specific
requirements
Training Not required Requiredfor all operator and
maintenance personnel
* With respect to the requirements of remote interlock connector, key control, beam
attenuator, and emission indicator, Class 3B laser products not exceeding five times
the AEL of Class 2 in the wavelength range of 400 nm to 700 nm are to be treated as
Class 3A laser products.

Z500
Setup Manual
INTRODUCTION
Laser Safety
7
INTRODUCTION
Re-labeling
Two different labels are provided, to be used selectively according to countries.
• for use in the U.S.: FDA label
• for use in countries other than the U.S.: Warning label
Be sure to turn off the sensor before replacing the label, or your hand or other
body parts may be exposed to the hazardous laser beam radiating from the
sensor.
Use in the U.S. When a laser product mounted on a certain device is to be used in the U.S., it has
to meet the requirements set forth by the FDA (regulations for laser products set
forth by the Food and Drug Administration). Three different FDA labels are
enclosed in the package. Attach them to the sensor body.
Applications have been approved by CDRH (Center for Devices and Radiological
Health) for Z500-SW17. Z500-SW2 should not be used in the U.S. at this
moment since the application for this model has not been approved yet.
FDA Labels for Laser Products
The Z500 is designed to be built into the finished system unit. Refer to the
following technical standard for installation.
FDA Labels
Be sure to attachFDA labels; do not attach EnglishWARNING labels by mistake.
21CFR1040.10 and 1040.11
CAUTION
CAUTION
PEAK POWER
PULSE DURATION
WAVE LENGTH
15000
25000
658
µw
µs
lass IIIB Caution logo type
Aperture Label Certification and Identification Label
AVOID
EXPOSURE
This laser product complies with
21 CFR 1040.10 and 1040.11.
Shiokoji Horikawa, Shimogyo-ku,
Kyoto 600-8530 JAPAN
OMRON Corporation
AYABE Factory, OMRON Corp.
Place of manufacture:
Manufactured in
Laser radiation
is emitted from
this aperture
Z500-SW17
15000
25000
658
µw
µs

8
INTRODUCTION
Laser Safety
Z500
Setup Manual
INTRODUCTION
Areas to Attach Labels
Use in Countries Other than the U.S.
Replace the warning label in Japanese on the sensor main body with the
attached English one upon use in countries other than the U.S. Attach the label
in the area where the original Japanese warning label was provided.
European EN60825-1 standard is applied to products exported to European
countries. The Z500 conforms to the standard.
Warning Labels
CAUTION
CAUTION
PEAK POWER
PULSE DURATION
WAVE LENGTH
15000
25000
658
µw
µs
Z500-SW17
AVOID
EXPOSURE
Laser radiation
is emitted from
this aperture
Class IIIB
Caution logo type
Aperture Label
Certification and
Identification Label
This laser product complies with
21 CFR 1040.10 and 1040.11.
Shiokoji Horikawa, Shimogyo-ku,
Kyoto 600-8530 JAPAN
OMRON Corporation
AYABE Factory, OMRON Corp.
Place of manufacture:
Manufactured in
15
25
658
Z500-SW17Z500-SW2
1.0
10
650

Z500
Setup Manual
INTRODUCTION
Export of the Products
9
INTRODUCTION
Export of the Products
Z500-SW2 is considered as special freight under the Foreign Exchange and Foreign Trade Laws and
therefore requires a license for export. As for other countries, observe the laws specified by each
country.

10
INTRODUCTION
Caution
Z500
Setup Manual
INTRODUCTION
Caution
Installation Environment Precautions
CAUTION Do not use the Z500 in environments with flammable or explosive gases.
CAUTION Install the Z500 away from high-voltage devices and moving machinery to allow
safe access during operation and maintenance.
Power Supply and Wiring Precautions
CAUTION Use the Z500 with the power supply voltages specified in this manual.
CAUTION Use crimp terminals for wiring. Do not connect the power supply wires by just
twisting stranded wire and connecting directly to the terminals.
CAUTION Use the wire and crimp terminals of the proper sizes as specified in this manual.
CAUTION Confirm that wiring has been performed correctly before turning ON the power
supply.
CAUTION Cover the terminal blocks with the Terminal Block Protection Covers.
Uncovered terminal blocks can result in electric shock.
CAUTION Use a DC power supply with countermeasures against high-voltage spikes (safe
extra low-voltage circuits on the secondary side).
CAUTION Be sure to securely tighten the screws when mounting the Z500.
Other Precautions
CAUTION Do not attempt to dismantle, repair, or modify the Z500.
CAUTION Dispose of the Z500 as industrial waste.

Z500
Setup Manual
INTRODUCTION
Notice
11
INTRODUCTION
Notice
The Z500 is highly reliable and resistant to most environment factors. The following guidelines, however,
must be followed to ensure reliability and optimum use of the Z500.
Installation of the Controller
Installation Site Do not install the Z500 in locations subjected to the following conditions:
•Ambient temperature outside of 0 to +50 ºC
•Condensation due to rapid temperature fluctuations
•Relative humidities outside 35 to 85%
•Corrosive or flammable gases
•Dust, salt, or iron particles
•Direct vibration or shock
•Reflection of intense light
(such as other laser beams or electric arc-welding machine)
•Strong magnetic fields
•Direct sunlight
•Water, oil, or chemical fumes or spray
Mounting of the Controller
To improve heat dissipation, install the Controller in the following direction only:
Do not install the Controller in the orientations shown in the following diagram.
CORRECT
INCORRECT

12
INTRODUCTION
Notice
Z500
Setup Manual
INTRODUCTION
Ambient temperature
•Maintain a minimum clearance of 50 mm above and below the Z500 to
improve air circulation.
•Do not install the Z500 immediately above significant heat sources, such as
heaters, transformers, or large-capacity resistors.
•Do not let the ambient temperature exceed 50 ºC.
•Provide a forced-air fan cooling or air conditioning if the ambient temperature
is near 50 ºC so that the ambient temperature never exceeds 50 ºC.
Ambient Illumination
•Do not let the ambient illumination exceed 3000lx.
•When using the Z500 near lighting equipment that turns ON and OFF
continuously, reduce the influence of the light by, for example, using a light
baffle.
Noise resistance
•Do not install the Z500 in a cabinet containing high-voltage equipment.
•Do not install the Z500 within 200 mm of power cables.
Sensor Maintenance
Install the Sensor in a clean environment and keep the filter on the front panel of
the Sensor free from oil and dust. If affected by oil or dust, clean the filter as
follows:
•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.
•Use a soft cloth (for lenses) with a small amount of alcohol to remove the
remaining dust. Do not use a scrubbing action when cleaning as scratches on
the filter could result in the Sensor malfunctioning.
Environment
The Sensor cannot accurately detect the following types of objects:
* Objects with an extremely low reflection ratio
* Objects with a small curvature
* Largely inclined objects
Control panel
Z500
ouver
Z500
Z500
2
00 mm min.
200 mm min.
Power cable
Z500

Z500
Setup Manual
INTRODUCTION
Notice
13
INTRODUCTION
Component Installation and Handling
Components The Sensor and Console must be products designed specifically for the Z500.
•Sensor (Z500-SW2 and Z500-SW17)
•Console (Z300-KP)
Connecting Cables
Always turn OFF the Z500's power before connecting or disconnecting cable.
Touching Signal Lines in Connectors or Terminals
To prevent damage from static electricity, use a wrist strap or another device for
preventing electrostatic discharges when touching terminals or signal lines in
connectors.
Wiring When using a transformer for the Z500's driving power supply, use an isolation
transformer in the way shown below. Do not use an auto-transformer. Doing so
may result in equipment failure.
Isolation transformer
Z500-MC10
Z500-MC10
Auto-transformer
Commercial
power supply
Commercial
power supply

14
INTRODUCTION
Notice
Z500
Setup Manual
INTRODUCTION
Turning OFF the Power
Do not turn OFF the power while a message is being displayed indicating that
processing is being performed. Data in memory will be destroyed, and the Z500
may not operate correctly the next time it is started.
Using the RESET Signal
Do not input the RESET input immediately after power is turned ON. When
using the RESET input to synchronize startup timing, wait at least 1 second after
the Z500's power supply is turned ON before turning ON the RESET terminal.
Securing the Video Monitor (When Using the Recommended F150-M09)
If the video monitor case is metallic, observe the following precautions to
prevent noise interference, because the video monitor case is connected to the
0V line in the internal circuits.
•Do not ground the video monitor.
•Do not ground the metallic part of the connector.
•Secure the video monitor with plastic screws if it is being mounted to a
metallic surface.
Warming Up After turning ON the power supply, allow the Z500 to stand for at least 30 minutes
before use. The circuits are unstable immediately after the power supply is
turned ON and attempting measurement mayresult in inconsistent measurement
values.
Saving
Scn 0 Save

Z500
Setup Manual
INTRODUCTION
Confirming Package Contents
15
INTRODUCTION
Confirming Package Contents
Check the contents of the package as soon as you receive the Z500.
It is extremely rare for components to be missing, but contact the nearest OMRON representative if any
of the following items are missing.
Z500 Controller. . . . . . . . . . . . . . . . . . . . . . . . . . Qty: 1
Manual 1: Setup Manual (This Manual) . . . . . . Qty: 1
Manual 2: Operation Manual . . . . . . . . . . . . . . . Qty: 1
Multi-Dimensional Controller
Setup Manual
Manual
Cat. No. Z000-E1-1
Multi-Dimensional Controller
Z500
Multi-Dimensional Controller
Z500
Operation Manual
Manual
Cat. No. Z000-E1-1

16
INTRODUCTION
Editor's Note
Z500
Setup Manual
INTRODUCTION
Editor's Note
Visual Aids
The following headings appear in the left column of the manual to help you
locate different types of information.
NOTICE Indicates information required to take full advantage of the functions and perfor-
mance of the product. Incorrect application methods may result in the loss or
damage to the product. Read and follow all precautionary information.
CHECK Indicates points that are important in using product functions or in application
procedures.
REFERENCE Indicates where to find related information.
HELP Indicates information helpful in operation.
OMRON Product References
All OMRON products are capitalized in this manual. The word "Unit" is also cap-
italized when it refers to an OMRON product, regardless of whether or not it
appears in the proper name of the product.

Z500
Setup Manual
SECTION 1 Wiring and Connection
17
SECTION 1
Wiring and Connection
1-1 Basic System Configuration 18
1-2 Component Names and Functions 20
1-3 Power Supply and Ground 22

18
SECTION 1 1-1 Basic System Configuration
Z500
Setup Manual
SECTION 1
Wiring and Connection
1-1 Basic System Configuration
NOTICE •The following diagram shows the basic Z500 system configuration. Some of the
components shown in the configuration diagram are special OMRON products that cannot
be substituted with comparable devices. These items are indicated with an asterisk.
•Always turn OFF the power supply before connecting or disconnecting cables. The
peripheral device may be damaged if connected or disconnected with the power supply
turned ON.
CHECK Up to 2 Sensors can be connected.
Z500-SW2 (2-m cable)
Z500-SW17 (2-m cable)
* Sensor Extension Cable
Z309-SC1 (3 m, 8 m, or 13 m)
Specify the required cable length when ordering.
Sensor