Omron Z500-SW2T User guide

Cat. No. Z158-E1-2 Note: Specifications subject to change without notice. Printed in Japan
0103-0.5C
Authorized Distributor:
Setup Manual
Profile Measuring System Z500 Manual 1: Setup Manual
Manual
Cat. No. Z158-E1-2
Cat. No. Z158-E1-2
Profile Measuring System
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-E1-2
Multi-Dimensional Controller
Z500
Operation Manual
Manual
Cat. No. Z000-E1-1
Cat. No. Z158-E1-2
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
Profile Measuring System
Z500
Z500-MC10E/MC15E
Setup Manual
INTRODUCTION 3
SECTION 1
Wiring and Connection 19
SECTION 2
Installation 29
SECTION 3
Connecting External Devices 47
SECTION 4
Appendix 59

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.
Regulations and Standards
The Z500 complies with the international regulations and standards below:
• EC Regulations
EMC Directive: No.89/336/EEC
• EN Standards (European Standards)
EN61326:1997 + A1:1998 + A2:2001 (EMI:Class A)
© OMRON, 2003
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
Read and Understand this Manual ..............................................................................4
Warranty, Limitation of Liability ..................................................................................4
Application Considerations .........................................................................................5
Disclaimers....................................................................................................................6
Precautions on Safety ..................................................................................................7
Laser Safety...................................................................................................................8
Precautions for Safe Use ...........................................................................................12
Notice ...........................................................................................................................13
Confirming Package Contents...................................................................................17
Editor's Note................................................................................................................18
SECTION 1
Wiring and Connection ...................................................................... 19
1-1 Basic System Configuration..............................................................................20
1-2 Component Names and Functions ...................................................................22
1-3 Connecting Peripheral Devices.........................................................................24
1-4 Power Supply and Ground.................................................................................26
SECTION 2
Installation .......................................................................................... 29
2-1 Mounting the Controller .....................................................................................30
2-2 Mounting the Sensor ..........................................................................................32
SECTION 3
Connecting External Devices............................................................ 47
3-1 Terminal Block Connections .............................................................................48
3-2 RS-232C Connections ........................................................................................52
3-3 Linear Sensor Controller Connections.............................................................54
SECTION 4
Appendix ............................................................................................. 59
4-1 Troubleshooting .................................................................................................60
4-2 Maintenance ........................................................................................................ 62
4-3 Specifications and Dimensions.........................................................................63
4-4 Laser Product Classifications ...........................................................................72

4
INTRODUCTION
Read and Understand this Manual
Z500
Setup Manual
INTRODUCTION
Read and Understand this Manual
Please read and understand this manual before storing, installing, programming, operating, maintaining,
or disposing of the products. Please consult your OMRON representative if you have any questions or
comments.
Warranty, Limitation of Liability
WARRANTY
OMRON's exclusive warranty is that the products are free from defects in mate-
rials 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 FIT-
NESS FOR PARTICULAR PURPOSE OF THE PRODUCTS. ANY BUYER OR
USER ACKNOWLEDGES THAT THE BUYER OR USER ALONE HAS DETER-
MINED THAT THE PRODUCTS WILL SUITABLY MEET THE REQUIRE-
MENTS 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 LIABIL-
ITY.
In no event shall the 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 PROP-
ERLY HANDLED, STORED, INSTALLED, AND MAINTAINED AND NOT SUB-
JECT TO CONTAMINATION, ABUSE, MISUSE, OR INAPPROPRIATE
MODIFICATION OR REPAIR.

Z500
Setup Manual
INTRODUCTION
Application Considerations
5
INTRODUCTION
Application Considerations
SUITABILITY FOR USE
OMRON shall not be responsible for conformity with any standards, codes, or
regulations that apply to the combination of the product in the customer's appli-
cation or use of the products.
At the customer's request, OMRON will provide applicable third party certifica-
tion documents identifying ratings and limitations of use that apply to the prod-
ucts. This information by itself is not sufficient for a complete determination of
the suitability of the products in combination with the end product, machine, sys-
tem, 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 manual.
• Nuclear energy control systems, combustion systems, railroad systems, avia-
tion systems, medical equipment, amusement machines, vehicles, safety
equipment, and installations subject to separate industry or government regu-
lations.
• Systems, machines, and equipment that could present a risk to life or prop-
erty.
Please know and observe all prohibitions of use applicable to the products.
NEVER USE THE PRODUCT 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 PRODUCTS ARE PROPERLY RATED AND INSTALLED FOR
THE INTENDED USE WITHIN THE OVERALL EQUIPMENT OR SYSTEM.
PROGRAMMABLE PRODUCTS
OMRON shall not be responsible for the user's programming of a programmable
product, or any consequence thereof.

6
INTRODUCTION
Disclaimers
Z500
Setup Manual
INTRODUCTION
Disclaimers
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 products may be changed without any notice. When
in doubt, special model numbers may be assigned to fix or establish key specifi-
cations for your application on your request. Please consult with your OMRON
representative at any time to confirm actual specifications of purchased prod-
ucts.
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 manual has been carefully checked and is believed to be
accurate; however, no responsibility is assumed for clerical, typographical, or
proofreading errors, or omissions.

Z500
Setup Manual
INTRODUCTION
Precaution on Safety
7
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.
Meanings of Signal Words
The following signal word is used in this manual.
WARNING 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 signifi-
cant property damage.
Meanings of Alert Symbols
The following alert symbol is used in this document.
Laser Beam Hazard
Cautions to Indicate Potential Laser Beam Hazard

8
INTRODUCTION
Laser Safety
Z500
Setup Manual
INTRODUCTION
Laser Safety
The Z500-SW2T Sensor Head is a Class 2 Laser Product according to
EN60825-1 (IEC60825-1) and Class II Laser Product according to FDA (21
CFR1040.10) (see note). The Z500-SW6 and Z500-SW17 Sensor Heads are
Class 3B and Class IIIB Laser Products, respectively. The Z500 Series is meant
to be built into final system equipment. Pay special attention to the following
precautions for the safe use of the product:
Note: Europe: Class 2 and Class 3B of EN60825-1: 1994 = IEC60825-1: 1993
U.S.A.: Class II and Class IIIB of FDA (21 CFR1040.10)
(1)Use this product as specified in the operation manual. Otherwise, you may
be exposed to hazardous laser radiation.
(2)The Z500 series radiates laser beams in the visible light range. Do not
expose your eyes directly to the laser radiation. Ensure that the laser beam
path is terminated during use. If a mirror or shiny surface is positioned in the
laser beam path, ensure that the reflected beam path is also terminated. If
the Unit must be used without terminating the laser beam path, position the
laser beam path so that it is not at eye level.
(3)To avoid exposure to hazardous laser radiation, do not displace nor remove
the protective housing during operation, maintenance, and any other servic-
ing.
(4)The user should return the product to OMRON for all repair and servicing.
(5)As for countries other than those of Europe and the U.S.A., observe the regu-
lations and standards specified by each country.
As for the Laser Product Classifications, refer to the Appendix.
REFERENCE
Refer to page 72.
WARNING
Do not to expose your eyes to the laser radiation either directly or indi-
rectly (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.
Z500-SW2T Z500-SW6/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
Setup Manual
INTRODUCTION
Laser Safety
9
INTRODUCTION
Labeling on Laser Use
The Z500 has, on the side of its sensor, a warning label as shown below.
Re-labeling
The following labels are provided, to be used selectively according to countries.
• for use in the U.S.: FDA label (Aperture label, Caution logo label, Certification
and Identification label)
• for use in countries other than the U.S.: Warning label according to EN/IEC
standards.
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.
Z500-SW2T Z500-SW6
Z500-SW17

10
INTRODUCTION
Laser Safety
Z500
Setup Manual
INTRODUCTION
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 sensor package. Attach them to the sensor body.
Applications have been approved by CDRH (Center for Devices and Radiological
Health) for Z500-SW6 and Z500-SW17. Z500-SW2T 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 attach FDA labels; do not attach EN/IEC WARNING label by mistake.
21CFR1040.10 and 1040.11
DANGER
DANGER
PEAK POWER
PULSE DURATION
WAVE LENGTH
15000
25000
658
µw
µs
Class III B 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
15000
25000
658
µw
µs

Z500
Setup Manual
INTRODUCTION
Laser Safety
11
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 EN/IEC warning label upon use in countries other than the U.S. Attach
the label in the area where the original Japanese warning label was provided.
EN60825-1 (IEC60825-1) standard is applied to products exported to European
countries. The Z500 conforms to the standard.
EN/IEC Warning Labels
DANGER
DANGER
PEAK POWER
PULSE DURATION
WAVE LENGTH
15000
25000
658
µw
µs
Z500-SW6/Z500-SW17
AVOID
EXPOSURE
Laser radiation
is emitted from
this aperture
Class III B
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
AVOID EXPOSURE
Laser radiation is emitted from this aperture
CAUTION
CAUTION
PEAK POWER PULSE DURATION WAVE LENGTH
15000 25000 658
µw
µs
Caution Label
Aperture Label
This laser product complies with
21 CFR 1040.10 and 1040.11.
Shiokoji Horikawa, Shimogyo-ku,
Kyoto 600-8530JAPAN
OMRON Corporation
AYABE Factory,OMRONCorp.
Place of manufacture:
Manufactured in
Certification and
Identification Label
Z500-SW2T
15
25
658
Z500-SW6
Z500-SW17
Z500-SW2T
1.0
10
650

12
INTRODUCTION
Precautions for Safe Use
Z500
Setup Manual
INTRODUCTION
Precautions for Safe Use
Installation Environment Precautions
• Do not use the Z500 in environments with flammable or explosive gases.
• Install the Z500 away from high-voltage devices and moving machinery to
allow safe access during operation and maintenance.
Power Supply and Wiring Precautions
• Use the Z500 with the power supply voltages specified in this manual.
• Use crimp terminals for wiring. Do not connect the power supply wires by just
twisting stranded wire and connecting directly to the terminals.
• Use the wire and crimp terminals of the proper sizes as specified in this man-
ual.
• Confirm that wiring has been performed correctly before turning ON the power
supply.
• Cover the terminal blocks with the Terminal Block Protection Covers.
Uncovered terminal blocks can result in electric shock.
• Use a DC power supply with countermeasures against high-voltage spikes
(safe extra low-voltage circuits on the secondary side).
• Be sure to securely tighten the screws when mounting the Z500.
Other Precautions
• Do not attempt to dismantle, repair, or modify the Z500.
• Dispose of the Z500 as industrial waste.

Z500
Setup Manual
INTRODUCTION
Notice
13
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

14
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.
Sensor replacement
To replace the sensor being connected to the controller, turn OFF the download
function.
Control panel
Z500
Louver
Z500
Z500
200 mm min.
200 mm min.
Power cable
Z500

Z500
Setup Manual
INTRODUCTION
Notice
15
INTRODUCTION
If the sensor is replaced while the download function is ON, measurements can-
not be taken correctly with the new sensor, because the old sensor information
(such as the measurement range) is still stored.
REFERENCE
Refer to page 146 in the Operation Manual.
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
Component Installation and Handling
Components The Sensor and Console must be products designed specifically for the Z500.
• Sensor (Z500-SW2T, Z500-SW6, 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

16
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 may result in inconsistent measurement
values.
Saving
Scn 0 Save

Z500
Setup Manual
INTRODUCTION
Confirming Package Contents
17
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

18
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.