Zehntner ZOL 1150 User manual

ZOL 1150
Online-Glossmeter
Firmware as from v.2.1
for following measuring geometries:
20°, 60° an 85°
Instruction Manual

Page 3
In ex
Exclusion of liability ....................................................................................................... 5
1 Discription of evice ................................................................................................ 6
2 Safety information ................................................................................................... 7
2.1 Symbols use ..................................................................................................... 7
2.2 Safety notes an hints ....................................................................................... 7
3 Delivery of evice ..................................................................................................... 9
3.1 Damages uring carriage .................................................................................. 9
3.2 Shipment ............................................................................................................ 9
3.3 Stan ar elivery ............................................................................................. 10
4 Device overview ...................................................................................................... 11
4.1 Connection technology .................................................................................... 12
4.2 Measuring hea technology ............................................................................ 12
5 Setting up ............................................................................................................... 13
5.1 Connections an Signals ................................................................................. 13
5.2 Electrical characteristics of signals ............................................................... 14
5.3 Installation ....................................................................................................... 18
5.3.1 Mounting the evice ............................................................................... 19
5.3.2 Measuring area .................................................................................... 19
5.4 Starting up ....................................................................................................... 19
6 Z-axis ...................................................................................................................... 20
7 Web Interface ......................................................................................................... 22
7.1 Getting starte ................................................................................................. 22
7.2 Prerequisites ................................................................................................... 22
7.3 IP a ress ........................................................................................................ 22
7.4 Main page ......................................................................................................... 23
7.5 Calibrate page .................................................................................................. 25
7.6 Settings page ................................................................................................... 27
8 Measure ................................................................................................................. 29
8.1 General ............................................................................................................. 29

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8.2 Pass/Fail ........................................................................................................... 29
9 Calibrate .................................................................................................................. 30
9.1 Calibration proce ure ...................................................................................... 30
9.2 Calibration plate ............................................................................................... 30
9.3 Cleaning the calibration plate .......................................................................... 31
9.4 Replacing the calibration plate ........................................................................ 31
10 Maintenance an cleaning ..................................................................................... 32
10.1 Maintenance an cleaning work that can be carrie out by the user .......... 32
10.2 Cleaning .......................................................................................................... 32
10.3 Fault/Error iagnosis ..................................................................................... 32
11 Technical specifications ......................................................................................... 33
Glossary ........................................................................................................................ 34

Page 5
Exclusion of liability
The content of this ocument is intellectual property of Zehntner GmbH Testing
Instruments.
Illustrations, escriptions as well as the technical specifications conform to the
instruction manual on han at the time of publishing or printing. However, Zehntner
GmbH Testing Instruments policy is one of continuous pro uct evelopment. All
changes resulting from technical progress, mo ifie construction or similar are
reserve without obligation for Zehntner to up ate.
Some of the images shown in this instruction manual may be of a pre-pro uction
mo el an /or are computer generate ; therefore the esign / features of the
elivere pro uct may iffer in various aspects.
The instruction manual has been rafte with the utmost care. Nevertheless, errors
cannot be entirely exclu e . The manufacturer will not be liable for errors in this
instruction manual or for amages resulting from any errors.
The manufacturer will be grateful at any time for suggestions, proposals for
improvement an in ications of errors.
© Zehntner GmbH Testing Instruments

Page 6
1 Discription of evice
The ZOL 1150 is a tailore gloss-measuring system for in ustrial areas for
contactless online measurement of all gloss ranges from matt to high gloss up to
2‘000 GU.
Application areas:
• Measuring instrument for several in ustries such as paint, plastics, paper, foil
an metal in ustry
• For all gloss measurements
• Gloss measurement at manufacturing of sheet metal an floor coverings
• Finishing processes such as application of coating of all types, e.g. coil coating
• Combinable with other quality monitoring systems, e.g. humi ity, thickness
etc
In particular, this apparatus has the following features:
• Multi angle evice, up to three angles in the same evice
• Pathbreaking with various types of igital communication interfaces (RS232,
RS485 or Ethernet) an analog outputs
• Unique automatic in-situ calibration simplifies han ling an minimizes
hol ing times significantly
• Automatic measuring istance correction
• Online monitoring of gloss an glosshaze uring the pro uction with up to
1‘000 measurements per secon
• Integrate Z-axis
• Powerful stray light compensation allows exact measurements of transparent
objects
• Analog output of measuring value: 0-10 V, 0-20 mA or 4-20 mA
• Possibility to control the unit over igital inputs, this means the possibility of
(signal input for calibration an moving measuring hea )
• Signal outputs for alerts
• Reliable results

Page 7
2 Safety information
2.1 Symbols use
This note comprises instructions nee e to follow irections, specifications,
proper working proce ure an to avoi ata loss, amage or estruction of
the instrument.
This note signifies a warning about angers to life an limb if the apparatus
is han le improperly. Observe these notes an be particularly careful in
these cases. Also inform other users on all safety notes. Besi es the notes
in this instruction manual the generally applicable safety instructions an
regulations for prevention of acci ents must be observe .
2.2 Safety notes an hints
It is strictly forbi en to open the housing of the ZOL 1150. If not observe ,
all the guarantee an liability claims to Zehntner GmbH Testing Instruments
will be voi .
The ZOL 1150 is a high quality, state of the art instrument an is safe to
operate. However, there is always risk when the instrument is han le
improperly or otherwise as inten e by the manufacturer.
Always turn off the unit an unplug the power cable before any maintenance.
The ZOL 1150 is exclusively inten e for contactless online measurement of
all gloss ranges from matt to high gloss up to 2‘000 GU. Any other use is
consi ere as being not in accor ance with the intentions of the
manufacturer an is con ucte at the user's own risk. The manufacturer is
not liable for any resulting amages.
Every person operating or maintaining the ZOL 1150 must have rea an
un erstoo this instruction manual in its entirety, in particular the safety
precautions an warnings.
Avoi any mo e of operation that coul affect the safe working with the
ZOL 1150. The etermination of the gloss must take place as escribe in
this operating manual.
Unauthorize mo ifications an changes of the ZOL 1150 are not permitte .
All maintenance an repair not explicitly allowe an escribe in this
manual (see chapter 10.1 “Maintenance an cleaning work that can be
carrie out by the user” on page 32), shall only be carrie out by Zehntner
GmbH Testing Instruments or your authorise Zehntner agent, failure to
comply voi s warranty.

Page 8
Zehntner GmbH Testing Instruments refuses all warranty an liability
claims for amages cause by usage of the ZOL 1150 in combination with
non-original accessories, or accessories from thir party suppliers.
All local safety regulations apply for the operation of the ZOL 1150.

Page 9
3 Delivery of evice
3.1 Damages uring carriage
On receipt of the goo s, check for any visible amages on the packaging. If it is
un amage you may sign the receipt of the goo s. If you o suspect by visual
inspection that amage has occurre , make a note of the visible amage on the
elivery receipt an request the courier to countersign it. Moreover, the courier
service must be hel responsible for the amage in writing.
If a hi en amage is iscovere while unpacking, you have to inform an hol the
courier liable imme iately in the following way: “When opening the parcel we ha to
notice that … etc.“ This superficial checking of the goo s has to be one within the
time limit set by the carrier, which is normally 7 ays. However, the perio coul
vary epen ing on the courier. Hence, it is recommen e to check the exact time
limit when receiving the goo s.
If there are any amages also inform your authorise Zehntner agent or Zehntner
GmbH Testing Instruments imme iately.
3.2 Shipment
Shoul the evice be transporte again, it must be package properly. Preferably
use the original packaging for later shipments. A itionally use filling material in
the package to protect the evice from any shock uring carriage.

Page 10
3.3 Stan ar elivery
The following parts are inclu e in the elivery:
1 single, ual or triple angle measuring hea with
calibration plate
1 microfiber cleaning cloth
2 mounting brackets
4 screws with washers an nuts
1 certificate of manufacturer
1 certificate of calibration
1 instruction manual
Zehntner GmbH Testing Instruments refuses all warranty an liability
claims for amages cause by usage of the ZOL 1150 in combination with
non-original accessories, or accessories from thir party suppliers.

Page 11
4 Device overview
(1) Measuring hea
(2) Connector panel
(3) Optical lenses
(4) Calibration plate
(5) Z-axis
(6) Z-axis motor
(7) Re status LED
(8) Orange status LED
(9) Green status LED
(10) Green power LED
(1)
(3)
(4)
(5)
(2)
(6)
(7)
(8)
(9)
(10)

Page 12
4.1 Connection technology
The measuring hea can be connecte in the following ways:
• Ethernet / TCP/IP/UDP
By using Ethernet connection, the measuring hea can be accesse over a
web base interface. Over the web interface, it is possible to mo ify settings
on the measuring hea . Furthermore all functions of the measuring hea
software, such as calibration can be accesse .
• PLC Signals
The measuring hea can be controlle by har ware signals coming from a
comman unit, for example a PLC. Comman s such as calibration can be
engage .
• RS 232 / RS 485
The measuring hea can also be controlle over a RS 232 or RS 485 interface.
All comman s, such as "Calibrate" can be controlle over the interface.
• Analog output
The measure values are available as analog output signals. Three analog
output mo es are possible: 0-10V, 0-20mA an 4-20mA. The mo es can be
chosen over the web interface.
4.2 Measuring hea technology
The measuring hea is equippe with precision monoblock optics. This optical block
assures best precision of the optical apertures an light beams. The illumination
unit is a regulate white LED, which pro uces mo ulate light. Possible light
source instability ue to temperature changes or lifetime egra ation of the LED is
compensate with a special compensation circuit that has been evelope for this
evice.
The sensor is V (λ) a apte (a apte to the spectral sensitivity of the human eye).
The gloss measuring circuit compensates any offset pro uce by stray light or
other influences.
This lea s to extremely stable an precise measuring results.

Page 13
5 Setting up
5.1 Connections an Signals
Connector
Description
Typ
e
Recommen e
mating connector
J1
POWER 12
-
24 VDC 1.5A
Bin er 680 Serie
s
3 Way, M16
09 0307 00 03
Bin er 680 Serie
s
3 Way, M16
09 0306 00 03
J2
SIGNAL
Use for interfacing with
har ware comman s.
Bin er 680 Serie
s
8 Way, M16
09 0474 00 08
Bin er 680 Serie
s
8 Way, M16
09 0571 02 08 or
09 0571 00 08
J3
ANALOG OUT
Analog output of measure
gloss value.
Bin er 680 Serie
s
4 Way, M16
09 0312 00 04
Bin er 680 Serie
s
4 Way, M16
09 0309 00 04
J4
STATUS LAMPS
Switche outputs for status
lights
Bin er 680 Serie
s
4 Way, M16
09 0311 00 04
Bin er 680 Serie
s
4 Way, M16
09 0310 00 04
J5
SERIAL INTERFACE COM1
(RS 232 / RS 485)
D
-
Sub, 9 Way
J6
SERIAL INTERFACE COM2
(RS 232 / RS 485)
D
-
Sub, 9 Way
J7
RJ45
Jack Terminal for
Ethernet connection
Neutrik
NE8FDX-P6-B
NE8MC
o
r NE8MX
J7
J6
J5
J4
J3
J2
J1
F1
S1

Page 14
Switch &
Fuse
Description
Type
Recommen e
mating connector
S1
Main switch
-
-
F1
Main fuse
-
-
5.2 Electrical characteristics of signals
Connector
Pin
Name
Description
J1
1
Power negative
(groun )
Negative power potential, usually groun
J1
2
Power positive
Positive power potential, 12
–
24 VDC, ±10%,
Power consumption:
• Measuring max 10 W
• For movement of the Z-axis max 18 W
polarity protecte
J1
3
Housing
Connecte to the housing of the instrument.
Usually, this pin nee s to be connecte to
power negative (groun ). In some cases it
might be necessary to connect this pin to a
separate earth potential.
J1
Shiel
Connecte to the housing of the instrumen
t.

Page 15
Connector
Pin
Name
Description
J2
1
CALIBRATE
(Isolate Input)
Active Low Input
Active: “0” (≤0.8V) or tie to COMMON
(Signal Groun )
Not active “1” (≥1.4V) or leave unconnecte
Impe ance 20kΩ, max. 30V
J2
2
MOVE TO
MEASURING
POSITION
(Isolate Input)
Active Low
Input
Active: “0” (≤0.8V) or tie to COMMON
(Signal Groun )
Not active: “1” (≥1.4V) or leave unconnecte
Impe ance 20kΩ, max. 30V
When active, measuring hea will move to
the calibration position, but will not calibrate.
J2
3
MOVE TO
CALIBRATION
POSITION
(Isolate Input)
Active Low
Input
Active: “0” (<0.8V) or tie to COMMON
(Signal Groun )
Not active: “1” (≥1.4V) ) or leave unconnecte
Impe ance 20kΩ, max. 30V
When active, measuring hea will move to
the measuring position.
J2
4
RESET (Device
)
(Isolate Input)
Active Low
Input
Active: “0” (≤0.8V) or tie to COMMON
(Signal Groun )
Not active: “1” (≥1.4V) or leave unconnecte
Impe ance 160kΩ, max. 30V
J2
5
GROSS VALUE
ALARM
(Isolate
Output)
Ac
tiv
e Low
Output
(Typ
e
:
Open Collector
-
>
current-sourcing)
Protecte (Short Circuit, ESD)
max. 20mA (Loa ), max 30V
J2
6, 7
Not connecte
J2
8
COMMON
Groun Signal
Isolate
from Power Groun
J2
Shiel
Connecte to the housing of the instrument

Page 16
Connection iagram of the analog output:
Connector
Pin
Name
Description
J3
1
COMMON
-
Groun
(Analog output)
Isolate from Power Groun
J3
2
Current
-
Loop Output
(Isolate Output)
Current range
:
0
-
20mA o
r 4
-
20mA
Protecte (Short Circuit, ESD)
Supply Voltage for current loop
U = 5 to 30 V.
J3
3
Voltage Output
(Isolate Output)
Voltage range
: 0
-
10V
Protecte (Short Circuit, ESD)
Max. 65mA
J3
Shiel
Connecte to the housing of the
instrument.

Page 17
Connector
Pin
Name
Description
J4
1
COMMON
(Power)
Max. switching voltage 250 VAC, 30 VDC
Max. switching current: 2.5A
J4
2
System lamp
(green)
Active close contactor which in icates that
the system is running. It has always the same
status as the green status LED (9) on the
measuring hea .
J3
3
Action lamp
(yellow)
Active close contactor which in icates that
action is going on (such as motor moving) or
that a user interaction is require . It has
always the same status as the orange status
LED (8) on the measuring hea .
J4
4
Error lamp
(re )
Active close contactor which in icates an
error. It has always the same status as the
re status LED (7) on the measuring hea .
J4
Shiel
Connecte to the housing of the instrument
.

Page 18
5.3 Installation
The evice console allows mounting the evice in three ifferent ways.
Vertical to the material to be
measure .
Horizontal to the material to be
measure , version 1.
Horizontal to the material to be
measure , version 2.

Page 19
5.3.1 Mounting the evice
Only install the measuring hea if it is in the measuring position. Otherwise
you will risk a crash when the measuring hea moves out to the measuring
position.
The istance between the material an the measuring hea housing shoul be
a juste to 10 mm. You will nee to make sure that the measuring hea is
precisely parallel to the material.
5.3.2 Measuring area
The in ication arrow printe on the evice in icates the center of the measuring
range an the measuring irection.
5.4 Starting up
The evice is switche on by the main switch S1. After switching on, the power LED
(10) will light up an the evice will take up to 80 secon s until it has completely
boote up. Towar s the en of this proce ure, the orange status LED (8) starts to
blink once per secon an then extinguishes. Finally the green status LED (9) lights
up an the evice is rea y by turning automatically into the measuring mo e. It is
now provi ing measure ata on the Ethernet port an on the analog output.
Measuring area
10 mm

Page 20
If the Z-axis (5) is not in measuring position, the orange status LED (8) will keeps
glowing even after the booting process.
The evice can simply be shut off with the main switch S1.
6 Z-axis
The measuring hea has an integrate Z-axis (5). It is use for calibration an for
moving the measuring hea away from the material in case more istance between
the measuring hea an the material to be measure is nee e .
The position of the measuring hea is controlle with a motor (6) an has two
positions:
Calibration position:
In the calibration position, the
measuring hea (1) is away from the
material. The calibration tile (4) is
locate un er the measuring hea (1).
Measuring position:
In the measuring position, the
measuring hea (1) is close to the
material. The measuring hea is rea y
to measure.
A Z-axis movement is cause by two operations:
1) Calibration
When a calibration is initiate , the measuring hea will move from the measuring
position to the calibration position. After calibration it will move back to measuring
position.
2) Position control
The position of the Z-axis (5) can also be controlle manually with the position
control function. This function is nee e e.g. if you nee to move away from the
material because of maintenance work in the pro uction line.
Position control can be accesse either by the web interface or the Z-AXIS
POSITION input on connector J2 pin 3.