Smart Sensor ZG2 Series 2D Measurement Sensor ZG2 debut! Achieving stable measurement through innovative technology Easier and much more accurate for profile measurement Stable measurement regardless of color, material, and shape complexity < Simple configuration > Plug & play! Just connecting Sensor head and Controller. Sensor head Controller Wide 2D laser beams capture the cross-sectional shape of the object All-in-one controller for checking profiles, setting parameters, and executing measurements Setup Support Software Smart Monitor ZG2 The ZG2 Smart Monitor software allows easy data logging, trend monitoring and full parameter configuration. ∗Equipped with sensor controller ZG2-WDC_1A as standard. Easier and much more accurate for profile measurement Stable measurement regardless of color, material, and shape complexity <Simple configuration> <Enhanced Performance> Through innovative technology the ZG2 offers superior performance to conventional 2D sensors. Plug & play! Just connecting Sensor head and Controller. 【Sensor head】 【Controller】 Wide 2D laser beams capture the cross-sectional shape of the object All-in-one controller for checking profiles, setting parameters, and executing measurements Evolution y’s Industrt bes 12x the conventional sensitivity y’s Industrt bes 2.5x 10x the conventional inclination tolerance the conventional speed Measurement can be performed at a stable level in a large amount of ambient light, even on objects that do not reflect light so much such as black ones. Measurement performance margin for transparent objects and glossy object has been significantly improved. Measurement is performed at a stable level even when an object is inclined or shaking slightly. The speed of the multi-sensitivity function, effective for measuring multi-material objects or complex shapes, has been increased. Measurement can be performed at a stable level even in high-speed takt-time lines. Luster side of painted object and black rubber CASE-001 Inclined transparent object and glossy object CASE-002 High-speed takt-time line CASE-003 A wide variety of measurement items Setup Support Software Smart Monitor ZG2 Height Peak The ZG2 Smart Monitor software allows easy data logging, trend monitoring and full parameter configuration. ※Equipped with sensor controller ZG2-WDC_1A as standard. 2 Point of inflection Edge width and edge position Step Average Point of inflection Step Edge width Point 1 Angle Point 2 Edge position Sectional area Inclination Point 1 Point 2 Bottom Intersection and angle Sectional area Reference plane Intersection 3 Measuring difficult problems by laser CASE-001 Evolution y’s Industrt bes 12x the conventional sensitivity 7x the conventional ambient illumination CASE-002 Evolution y’s Industrt bes 2.5x the conventional inclination tolerance Painted object and black rubber Inclined transparent object or glossy object Dark colored materials or materials with a matt finish, like black rubber often do not reflect sufficient light to maintain a stable measurement. They are also susceptible to the influences of ambient light so are difficult to measure using conventional laser measurement sensors. The ZG2 solves these problems because it is supersensitive and significantly reduces ambient noise. It also has an APS function to automatically tune parameters such as a receiver’s sensitivity and background suppression level at optimal levels according to the ambient light conditions. Shape profiles can also be easily reproduced at optimal conditions to achieve high precision measurement. Measurement of moving objects is possible because measurement can be performed within a short exposure time. On an object with strong regular reflection components such as luster sides and transparent objects, the amount of light reflection significantly reduces when the object is slightly inclined, lowering measurement stability. The sensor head ZG2-WDS3VT with a high-performance gauss lens is the solution for the problem. Its inclination acceptance range has been increased to 2.5 times as compared to conventional models so transparent objects can be measured up to a ±5°inclination at a stable level. Because the ZG2 has this function, it is useful for assembly inspections for lenses and glass plates. ※ For details, see descriptions of the high-performance gauss lens (page 8). ※ For details, see descriptions of the APS function (page 9) and new optical system ONPS (page 8). Flush and Gap on car doors Gaps on car doors can be measured at a stable level without being influenced by the color. Assembly inspection of electronic parts Assembly inspection of lenses The ZG2 can measure parts with glass or a glossy object such as CCDs, CMOSs, and crystal splinters of quartz resonators at a stable level. It can be used for assembly inspections of parts because it can measure steps on a substrate or package side. The ZG2 can measure the step between the peak of a lens and lens holder to check if they are assembled properly. Step CASE-003 Evolution 10x the conventional speed High-speed takt-time line Overlap or damage when manufacturing tires The ZG2 can check for overlap or damage of black rubber. Reproducing a clear, stable profile is difficult for objects with both black and metal sides, cylindrical objects, and complex-shaped objects because the amount of laser reflection and reflection angle differ according to the positions of different materials on such objects. To solve the problem, Omron’s unique “multi-sensitivity function”has been improved. The measurement speed for the function has been increased so that the function can be used in high-speed takt-time lines. ※ For details, see descriptions of high-speed multi sensitivity (page 9). 4 5 Measuring difficult problems by laser CASE-001 Evolution y’s Industrt bes 12x the conventional sensitivity 7x the conventional ambient illumination CASE-002 Evolution y’s Industrt bes 2.5x the conventional inclination tolerance Painted object and black rubber Inclined transparent object or glossy object Dark colored materials or materials with a matt finish, like black rubber often do not reflect sufficient light to maintain a stable measurement. They are also susceptible to the influences of ambient light so are difficult to measure using conventional laser measurement sensors. The ZG2 solves these problems because it is supersensitive and significantly reduces ambient noise. It also has an APS function to automatically tune parameters such as a receiver’s sensitivity and background suppression level at optimal levels according to the ambient light conditions. Shape profiles can also be easily reproduced at optimal conditions to achieve high precision measurement. Measurement of moving objects is possible because measurement can be performed within a short exposure time. On an object with strong regular reflection components such as luster sides and transparent objects, the amount of light reflection significantly reduces when the object is slightly inclined, lowering measurement stability. The sensor head ZG2-WDS3VT with a high-performance gauss lens is the solution for the problem. Its inclination acceptance range has been increased to 2.5 times as compared to conventional models so transparent objects can be measured up to a ±5°inclination at a stable level. Because the ZG2 has this function, it is useful for assembly inspections for lenses and glass plates. ※ For details, see descriptions of the high-performance gauss lens (page 8). ※ For details, see descriptions of the APS function (page 9) and new optical system ONPS (page 8). Flush and Gap on car doors Gaps on car doors can be measured at a stable level without being influenced by the color. Assembly inspection of electronic parts Assembly inspection of lenses The ZG2 can measure parts with glass or a glossy object such as CCDs, CMOSs, and crystal splinters of quartz resonators at a stable level. It can be used for assembly inspections of parts because it can measure steps on a substrate or package side. The ZG2 can measure the step between the peak of a lens and lens holder to check if they are assembled properly. Step CASE-003 Evolution 10x the conventional speed High-speed takt-time line Overlap or damage when manufacturing tires The ZG2 can check for overlap or damage of black rubber. Reproducing a clear, stable profile is difficult for objects with both black and metal sides, cylindrical objects, and complex-shaped objects because the amount of laser reflection and reflection angle differ according to the positions of different materials on such objects. To solve the problem, Omron’s unique “multi-sensitivity function”has been improved. The measurement speed for the function has been increased so that the function can be used in high-speed takt-time lines. ※ For details, see descriptions of high-speed multi sensitivity (page 9). 4 5 Suitable for diversified needs CASE-004 0 Evolution Measurement off wide M id target A B A Installation/Setup Two sensor controllers are linked and two sensor heads perform synchronous measurement to increase the measurement range to 140 mm. With the link method, the ZG2 Series provides the optimum solution for any intended purpose. A B B Edge width CASE-007 Simplified Sensor Head Adjustment The “installation correction function” automatically makes adjustments to parallelly align the sensor head with the target. The function eliminates the gap between the reference plane and sensor head inclination caused during setup and in turn significantly reduces the time spent for adjustment during the setup of the sensor head. ∗ When inclination is great, a measurement error may occur. Check the measurement accuracy in actual measurement conditions prior to use. Measurement CASE-009 Simultaneous measurement of two or more points Measurements can be performed for up to eight measurement points selected from a profile simultaneously so different types of inspections can be carried out at the same time when necessary. Measurement items can be selected from among 20 items including edge width, height, inclination, step, and sectional area according to the intended purpose. CASE-011 Operation Peak Bottom Evolution Step Sectional area Warping inclination Edge width Edge position Host PC Memory card Data Storage and Trend Analysis A data storage unit is now available for storing measurement values and profile data. Data can be loaded on a PC from a memory card or via serial communication and can be used to manage manufacturing history, monitor tendency, or analyze defects. USB/RS-232C ∗ For logging capacity, see System Configuration (page 10). CASE-005 CASE-006 Evolution Evolution Measurement by finding the inflection point of the object Measurement of position and angle of intersection The sensor has a measurement function to capture points where an angle varies on a target as an “inflection point.” This function enables the measurement of a step or edge width of a feature point of a target. The sensor has a function to measure the “intersection coordinates” and “intersection angle” on two linear lines on a target. An example of a useful application of this function is tracer control for a welding torch for targets to be welded. Point of inflection CASE-008 Intuitive setting 1st STEP 2nd STEP 3rd STEP Display a profile. Select a measurement item. Specify the measurement range. A profile is displayed as soon as the power is turned ON.* Adjust the Sensor Head position while viewing the profile on the screen. Basic setting requires only three steps. Omron’s unique interface maximizes the sensing performance with extremely simple operation. Select the icon for the item to be measured, such as height, step, or sectional area. * In the FUN mode Simply enclose the range to be measured with the box on the profile. The ZG2 automatically optimizes the sensing conditions. ∗ Screen images are simulated. CASE-0010 Active Position Compensation Control The position and inclination are automatically corrected even for targets for which positioning is difficult. This helps to perform stable in-line measurement. CASE-012 Example) 2-point step measurement Inclination correction Measurement result When a target is inclined, step measurement result is greater than the actual value. Inclination correction Measurement result Measurement can be performed accurately utilizing the “inclination correction function.” Evolution Large Programme Capacity Measurement conditions for up to 16 items (16 banks) can be registered in the sensor controller unit. Banks can be easily switched by inputting a signal, inputting a command, or operating a key. When the data storage unit is used, up to 4,096 banks can be registered for quick response to flexible production lines. Measurement conditions for up to 4,096 items can be stored in the data storage unit. Measurement conditions for up to 16 items can be stored in the sensor controller. Incorporating cutting-edge technology Sensor Head Sensor Controller 2 Dimensional Measurement Powerful functionality in a compact design A light-cutting method is used. The widely-spread laser beam is projected on the measurement object to measure its cross-sectional shape. The business card sized ZG2 controller incorporates a built in LCD monitor for profile visualization. The LCD display also gives access to the ZG2's intuitive and simple to use setup screens. The controller also includes a USB and RS-232 interface for easy connectivity. Measurement principle A band-like laser beam is projected on the measurement object, and the reflection from the object is received by the CCD. A shape profile of the measurement object is formed based on the principle of triangular distance measurement. Since 2D data of the X and Z axes are measured simultaneously, there is no need to move either the sensor or measurement object. Measurement conditions are indicated by easy-to-understand icons. Since three CCD modes are available; high-speed mode, standard mode, and high-precision mode, the ZG2 can be used for processes that require high speed or inspections that require higher precision. The measurement center distance remains fixed even when the mode is changed so the sensor head position does not need to be adjusted. The real-time parallel output unit for extending a parallel port is available (optional). CCD High-performance gauss lens「TAGG」 Evolution Full-scale photograph Stable measurement regardless of material and color APS function Suitable for transparent and mirror surface objetcs High-performance gauss lens「TAGG」 Patent pending Equipped with USB and RS-232C port as standard. Select an icon directly with a function key. [ Three CCD modes ] Evolution Input /output interface Operation interface Patent pending A feature of 2D measurement sensors is projecting a wide beam onto an object to be measured in order to simultaneously check dimensions such as the width and gap. However, since light reflects differently according to the material, color, and shape of an object’s surface, experience and skill are required to obtain the most adequate profile which is a prerequisite of high-precision measurement. As a result, measurement sometimes takes a long time. The ZG2 has an“APS function”developed by combining a variety of techniques for obtaining profiles. An optimal profile with no lost part can be obtained with the simple push of a button, even from black objects, and also in conditions with ambient light where adjustment was difficult using conventional sensors. Optimal tuning is simple and easy so startup work time can be significantly reduced. Mounted on the ZG2-WDS3VT The new gauss lens was born out of Omron’s passion for sensing technology. In the lens, a coupling lens structure including an aspherical lens is used, which allows for clear, bright images with low aberration, even though it is a wide-angle lens. Previous lens designs could not receive sufficient light reflection when objects were inclined. Using the new TAGG lens design, light reflection can be received at angles up to ±5° . The lens shows excellent performance for stable measurement of mirror and gloss surfaces with large amounts of regular reflection components and also transparent objects such as glass. 「TAGG」: Transparency And Gloss surface detector by Gauss composition Optimal tuning for the measurement object with the simple push of a button Before setting Lost part on a profile due to insufficient amount of light received 「APS」: Auto Profile Search Evolution New optical system ONPS 「ONPS」: Optical Noise Protection System Stable measurement for complex shapes High-speed multi sensitivity Patent pending Utilizing its unique optical filter technology, Omron has developed a new optical system where ambient light components are effectively removed so that only necessary reflection components from the object can be received. A control system is also used in which the laser exposure period and the CCD receiving period are synchronized. The combined effect of these has achieved ambient illumination resistence of 7,000 lx, seven times higher than conventional models. Measurement can be performed at a stable level without being influenced by fluorescent light or other surrounding conditions. 8 Evolution Resists the effects of ambient light Fluorescent light Only ambient light components are blocked. Patent No. 3575693 [Example] A workpiece with a mountain-shaped reference plane. Reflectivity varies from part to part. Light reflected from these parts do not directly enter the CCD. Omron's unique "multi-sensitivity function" is used to measure complex shapes by varying the intensity of the laser light over different areas of reflectivity across the object. The function has been further improved in the ZG2 Series. The optimal profile is formed according to the reflection of the object approximately two to ten times faster than in former models. The ZG2 can now perform measurements on higher-speed takt-time lines. Principle While switching sensitivity levels for workpieces of which reflectivity varies from part to part, the sensor inputs multiple images and combines parts taken at the optimal sensitivity into a single image. This produces an image of the entire workpiece. After setting Irradiated light Effect Image obtained from ordinary processing Image obtained using the multi-sensitivity function Reference plane High Workpiece Low Medium Low High Reflectivity 9 Sensor Controller Powerful functionality in a compact design The business card sized ZG2 controller incorporates a built in LCD monitor for profile visualization. The LCD display also gives access to the ZG2's intuitive and simple to use setup screens. The controller also includes a USB and RS-232 interface for easy connectivity. Operation interface Input /output interface Measurement conditions are indicated by easy-to-understand icons. Equipped with USB and RS-232C port as standard. Select an icon directly with a function key. Evolution The real-time parallel output unit for extending a parallel port is available (optional). Full-scale photograph Stable measurement regardless of material and color APS function Patent pending A feature of 2D measurement sensors is projecting a wide beam onto an object to be measured in order to simultaneously check dimensions such as the width and gap. However, since light reflects differently according to the material, color, and shape of an object’s surface, experience and skill are required to obtain the most adequate profile which is a prerequisite of high-precision measurement. As a result, measurement sometimes takes a long time. The ZG2 has an “APS function” developed by combining a variety of techniques for obtaining profiles. An optimal profile with no lost part can be obtained with the simple push of a button, even from black objects, and also in conditions with ambient light where adjustment was difficult using conventional sensors. Optimal tuning is simple and easy so startup work time can be significantly reduced. Optimal tuning for the measurement object with the simple push of a button Before setting Lost part on a profile due to insufficient amount of light received [APS]: Auto Profile Search Evolution Stable measurement for complex shapes High-speed multi sensitivity Patent No. 3575693 [Example] A workpiece with a mountain-shaped reference plane. Reflectivity varies from part to part. Light reflected from these parts do not directly enter the CCD. Omron's unique "multi-sensitivity function" is used to measure complex shapes by varying the intensity of the laser light over different areas of reflectivity across the object. The function has been further improved in the ZG2 Series. The optimal profile is formed according to the reflection of the object approximately two to ten times faster than in former models. The ZG2 can now perform measurements on higher-speed takt-time lines. Principle While switching sensitivity levels for workpieces of which reflectivity varies from part to part, the sensor inputs multiple images and combines parts taken at the optimal sensitivity into a single image. This produces an image of the entire workpiece. After setting Irradiated light Effect Image obtained from ordinary processing Image obtained using the multi-sensitivity function Reference plane High Workpiece Low Medium Low High Reflectivity Leading to the Optimum Solution System Configuration Basic configuration Memory card Up to two units can be linked PLC Sensor head MEMORY CARD 256MB High-speed output to PLC For logging data PC PC RS-232C USB Smart Monitor ZG2 for setting from a PC (attached) PC Real-time parallel output unit Sensor controller Data storage unit RS-232C USB ∗ A controller link unit is necessary for the following cases. A data storage unit is connected. Evolution Two sensor controllers are linked. 27 m max. Evolution Sensor Head Extension Cables Highly-flexible extension cables of four different lengths are available. The distance between the sensor head and sensor controller can be extended up to 27 m without delaying image input periods. Flexible cables Sensor head cable length : 0.5 m / 2 m 25 m /15 m /8 m /3 m Multi function unit Data Storage Unit ZG2-DSU [ Collect measurement values ] [ Save profile data ] Up to 65,000 values can be stored in the memory of the main unit. Up to 7,150,000 values (65,000 values x 110 files) can be saved in a memory card (256 MB). Up to 5,120 object profiles can be saved. Up to 35,328 profiles (256 profiles x 138 files) can be saved in a memory card (256 MB). Saved data can be used for analyzing defects. [ Readiness for high-mix production ] Up to 4,096 banks of data for stage replacement can be saved for quick response for high-mix production lines. ∗ Saving capacity differs according to set conditions. See the Ratings and Specifications table. Setting, Analysis, and Data Storage via PC Setup Support Software Smart Monitor ZG2 Using the software equipped with the sensor controller ZG2-WDC_1A, sensing conditions can be easily specified using a PC. Intricate profiles, which cannot be sufficiently checked on the Controller's LCD monitor, can be enlarged for thorough checking on a PC screen. [ Measurement value logging ] [ Profile logging ] Measurement value logging results are displayed in a time series. They are useful for trend management. In addition to measurement values, profile data logging is now enabled. Evolution [ Setup support ] Profiles are displayed on a large screen. They can be enlarged by the [Zoom] button. Helps to check intricate profiles that cannot be sufficiently checked on the controller's LCD monitor and provides easy-to-view setting lists for easy setting. Connect the PC where Smart Monitor ZG2 is used and the sensor controller by the USB cable attached to the sensor controller (ZG2-WDC_1A) together with Smart Monitor ZG2. Order Information Sensor Heads Height 200 Height 210 mm 100 (±48 mm) Height 60 100 mm (±12 mm) Height 50 mm Height 22.3 mm (±3 mm) 20 0 (±0.5 mm) Width 3 mm Optical system Measurement range Resolution Height direction Width Width 8 mm 22 mm Width 70 mm Regular reflective Diffuse reflective Diffuse reflective Regular reflective Diffuse reflective Regular reflective 22.3±0.5 mm 10.6±0.4 mm 50±3 mm 44±2 mm 100±12 mm 94±10 mm 3 mm (typical) Width direction 8 mm (typical) Diffuse reflective 210±48 mm 22 mm (typical) 70 mm (typical) Height direction 0.25 μm 1 μm 2.5 μm 6 μm Width direction 5 μm (3mm/631pixels) 13 μm (8 mm/631 pixels) 35 μm (22 mm/631 pixels) 111 μm (70 mm/631 pixels) Model ZG2-WDS3VT 2M ZG2-WDS8T 2M ZG2-WDS22 2M ZG2-WDS70 2M ZG2-WDS3VT 0.5M ZG2-WDS8T 0.5M ZG2-WDS22 0.5M ZG2-WDS70 0.5M ∗ For details, see the Ratings and Specifications Table. Sensor Controllers Appearance Note : Setup support software for PC is attached. Power supply Output type NPN 24 VDC PNP Model Data Storage Unit Appearance Power supply ZG2-WDC11A(See note.) ZG2-WDC11 Output type Model NPN ZG2-DSU11 PNP ZG2-DSU41 24 VDC ZG2-WDC41A(See note.) ZG2-WDC41 Accessories (Order Separately) Real-time Parallel Output Unit Appearance Sensor Head Extension Cable (Robot Cable) Output type NPN Model Appearance ZG-RPD11 PNP ZG-RPD41 Connecting device Model Qty For PLC/PT connection (2 m) ZS-XPT2 1 For personal computer connection (2 m) ZS-XRS2 1 RS-232C Cable Cable length Model Qty 25 m ZG2-XC25CR 1 15 m ZG2-XC15CR 1 8m ZG2-XC8CR 1 3m ZG2-XC3CR 1 Parallel Mounting Adaptor Appearance Model ZS-XPM1 For 1 Unit ZS-XPM2 For 2 Units or more Memory Card Controller Link Unit Appearance Model ZS-XCN Capacity Model 256 MB HMC-EF283 512 MB HMC-EF583 Ratings and Specifications Sensor Heads Item Measurement range ZG2-WDS8T Diffuse reflective Optical system Height direction ZG2-WDS22 ZG2-WDS70 Regular reflective Diffuse reflective Regular reflective Diffuse reflective 44 ± 2 mm 100 ± 12 mm 94 ± 10 mm 210 ± 48 mm (In the high-precision mode) 50 ± 3 mm ZG2-WDS3VT Regular reflective Diffuse reflective 22.3 ± 0.5 mm 10.6 ± 0.4 mm Width direction (See note 5.) 8 mm (typical) 22 mm (typical) 70 mm (typical) 3 mm (typical) Height direction (See note 1.) 1 μm 2.5 μm 6 μm 0.25 μm 13 μm (8 mm / 631 pixels) 35 μm (22 mm / 631 pixels) 111 μm (70 mm / 631 pixels) 5 μm (3 mm / 631 pixels) Resolution Width direction Linearity (in the height direction) (See note 2.) ± 0.1 %F.S. Temperature characteristic (See note 3.) 0.03 %F.S./°C Light source Type Visible semiconductor laser Wavelength 658 nm Output 5 mW max. output, 1 mW max. exposure (without using optical instruments) Laser class Class 2M of EN60825-1 / IEC60825-1 Class IIIB of FDA (21CFR 1040.10 and 1040.11) Beam shape (at measurement center distance) (See note 4.) 0.02 %F.S./°C 0.08 %F.S./°C 650 nm 30 μm × 24 mm (typical) 1 mW max Class 2 of EN60825-1 / IEC60825-1 Class II of FDA (21CFR 1040.10 and 1040.11) 60 μm × 45 mm (typical) 120 μm × 75 mm (typical) LED STANDBY : Lights when laser irradiation preparation is complete (indication color : green) Measurement object Surface of non-transparent / transparent objects 25 μm × 4 mm (typical) LD_ON : Lights when the laser is irradiating (indication color : green) Environmental resistance Surface of non-transparent objects Ambient light intensity Illumination on the photo-receiving face 7,000 lx max. : Incandescent lamp Ambient temperature Operating : 0 to 50°C, Storage : -15 to 60°C(with no icing or condensation) Ambient humidity Operating and storage : 35 to 85 % (with no condensation) Degree of protection (See note 6.) IP66(IEC60529) Vibration resistance (destruction) 10 to 150 Hz with 0.35 mm single amplitude for 80 min each in X, Y, and Z directions Shock resistance (destruction) Surface of non-transparent / transparent objects IP67(IEC60529) 150 m/s2, 3 times each in 6 directions (up / down, right / left, forward / backward) Materials Case: Aluminum diecast, Front cover : Glass, Cable insulation : Heat-resistive polyvinyl chloride (PVC), Connector : Zinc alloy or brass Cable length 0.5 m, 2 m (flexible cable) Minimum bending radius 68 mm Weight Approx. 500 g Accessories Approx. 500 g Approx. 650 g Approx. 300 g Laser labels (English labels), Ferrite core (2), Instruction manual Note : 1. Obtained by setting an OMRON standard measurement object at the measurement center distance and determining the average height of the beam line. The conditions are given in the table below. However, satisfactory resolution cannot e attained in strong electromagnetic fields. The minimum resolution of the ZG2-WDS8T/WDS3VT is 0.25 μm, even when the average number of operations is increased. Resolution does not go any lower. Model CCD mode Average No. of operations Measurement object Regular reflective Diffuse reflective OMRON standard white alumina ceramic object ZG2-WDS8T/ZG2-WDS22/ZG2-WDS70 High-resolution mode 64 OMRON standard mirrored object ZG2-WDS3VT OMRON standard diffuse reflective object Note : 2. The tolerance for and ideal straight line obtained by determining the average height of and OMRON standard measurement object for the beam line. The CCD high-resolution mode is used. Linearity varies depending on the measurement object. Model CCD mode Average No. of operations Diffuse reflective OMRON standard white alumina ceramic object ZG2-WDS8T/ZG2-WDS22/ZG2-WDS70 High-resolution mode ZG2-WDS3VT Measurement object Regular reflective 1 OMRON standard mirrored object OMRON standard diffuse reflective object Note : 3. A value attained by using an aluminum jig to secure the distance between the Sensor Head and the measurement object. The CCD standard mode is used. Note : 4. Defined as 1/e2 (13.5%) of the center light intensity. This may be influenced when light leakage also exists outside the defined area and the reflectivity of the light around the measurement object is higher than that of the measurement object. Note : 5. A typical value of the measurement range (width direction) near the measurement center distance. This is not a guaranteed value. Note : 6. Protection structure of connector area is IP40. Sensor Controllers Data Storage Unit Item ZG2-WDC11/WDC11A ZG2-WDC41/WDC41A NPN PNP Input/output type Item ZG2-DSU11 No. of connectable Sensor Heads 1 per Controller No. of connectable Controllers No. of connectable Controllers 2 Connectable Controllers Measurement cycle (See note 1.) 16 ms (high-precision mode), 8 ms (standard mode), 5 ms (high-speed mode) Min. display unit 10 nm LCD monitor LEDs External interface Input/output signal lines Analog outputs Judgment output (ALL-PASS/NG/ERROR) Trigger auxiliary output Judgment indicators for each task (indication color : orange): T1, T2, T3, T4 Laser indicator (indication color : green): LD_ON Zero reset indicator (indication color : green): ZERO Trigger indicators (indication color : green): TRIG Serial I/O Functions Laser stop input (LD-OFF) PNP open collector 50 mA max. Residual voltage : 1.2 V max. ON : O V short or 1.5 V max. ON : Power supply voltage short or power supply voltage -1.5 V max. Zero reset input (ZERO) Measurement trigger input (TRIG) Parallel output (when ZG-RPD is mounted) Main functions Bank switching input (BANK A~D) OFF : Open (leakage current : 0.1 mA max.) USB2.0 1 port, full speed (12 Mbps), MINI-B RS-232C 1 port, 115,200 bps max. Output 18 - terminal No. of setting banks Sensitivity adjustment Measurement items Ratings Environmental resistance OFF : Open (leakage current : 0.1 mA max.) Height, 2-point Step, 3-point Step, Edge position, Edge width, Angle, Intersection coordinates, Intersection angle, Sectional area, Calculations between tasks (up to eight items can be measured simultaneously) Profiles saved 16 profiles (1 profile per bank) Trigger modes External trigger / continuous Power supply voltage 21.6 to 26.4 VDC (including ripple current) Current consumption 0.8 A max. (per sensor head) Insulation resistance 20 MΩ at 250 V between lead wires and Controller case Dielectric strength 1,000 VAC, 50 / 60 Hz for 1 min between lead wires and Controller case Ambient temperature Operating : 0 to 50°C, Storage : -15 to 60°C (with no icing or condensation) Ambient humidity Operating and storage : 35 to 85 % (with no condensation) Degree of protection IP20(IEC60529) Vibration resistance Vibration frequency : 10 to 150 Hz, single amplitude : 0.35 mm, acceleration : 50 m/s2 (destruction) ON : Power supply voltage short or power supply voltage -1.5 V max. OFF : Open (leakage current : 0.1 mA max.) Judgment output (HIGH/PASS/LOW/ERROR) NPN open collector 30 VDC, 50 mA max. Residual voltage : 1.2 V max. PNP open collector 50 mA max. Residual voltage : 1.2 V max. USB2.0 1 port, full speed (12 Mbps), MINI-B RS-232C 1 port, 115,200 bps max. Memory of the main unit Profiles saved : 5,120 profiles Measurement values saved : 65,000 values max. (See note 3.) Memory card(256 MB) Profiles saved : 35,328 profiles max. (256 profiles x 138 files) Measurement values saved : 7,150,000 values max. (65,000 values x 110 files) (See note 4.) Ratings Environmental resistance Logging trigger functions External triggers, data triggers (self-triggers), and time triggers External banks functions 4096 Other functions Alarm output functions Power supply voltage 21.6 to 26.4 VDC (including ripple current) Current consumption 0.5 A max. Ambient temperature Operating : 0 to 50°C, Storage: 0 to 60°C (with no icing or condensation) Ambient humidity Operating and storage : 35 to 85% (with no condensation) Degree of protection IP20(IEC60529) Material Case : Polycarbonate (PC) Cable length 2m Minimum bending radius 52 mm Weight Approx. 280 g Accessories Ferrite Core (1 piece), Instruction Manual Multi, High-speed multi, Auto, Fixed Filter, Laser power adjustment, Position correction (height, position, lope), Linked operation, Point of inflection measurement Shock resistance Inputting starting/ terminating logging 16 Auxiliary functions (destruction) ZG2-WDC11/WDC41 (See note 2.) Select voltage or current (using the sliding switch on the bottom surface) Voltage output : -10 to 10 V, output impedance : 40 Ω Current output : 4 to 20 mA, maximum load resistance : 300 Ω NPN open collector 30 VDC, 50 mA max. Residual voltage : 1.2 V max. No. of logged data PNP 2 (See note 1.) ON : O V short or 1.5 V max. OFF : Open (leakage current : 0.1 mA max.) 1.8-inch TFT color LCD (557 x 234 pixels) (ENABLE/GATE) Serial I/O Input/output signal lines -999.99999 to 999.99999 Display range Display External interface ZG2-DSU41 NPN Input/output type 150 m/s2, 3 times each in 6 directions (up / down, right / left, forward / backward) Material Case : Polycarbonate (PC), Cable insulation : Heat-resistive polyvinyl chloride (PCV) Cable length 2m Minimum bending radius 57 mm Weight Approx. 300 g (including cable)(Packed state: Approx. 450 g) Accessories ZG2-WDC_1 : Large Ferrite Core (1 piece), Instruction Manual ZG2-WDC_1A : Large Ferrite Core (1 piece), Small Ferrite Core(2 pieces), Instruction Manual, Setup Support Software (CD-ROM), USB cable (1 m) Note : 1. The image input periods listed here are for fixed/auto sensitivity. The image input period will be longer for multi-sensitivity, high-speed multi-sensitivity, or other settings. When the high-power mode is ON, the shortest image input period is 95 ms regardless of the setting of the CCD mode. Use the eco monitor in the RUN mode to determine the actual image input period. Note : 1. The controller link unit is necessary for linking. Note : 2. Data is saved in the memory of the main unit during logging. The data is automatically saved in a memory card after logging is completed.The maximum number of logging differs according to set conditions. For details, refer to the Users Manual. Note : 3. Measurement values for 65,000 measurements can be saved even when two sensor controllers are connected and each performs eight tasks. Note : 4. The value is the maximum number achieved in the following conditions. One sensor controller performs one measurement task. Either profiles or measurement values are logged. Dimensions Sensor Heads ZG2-WDS3VT <Regular reflection> (Unit : mm) (Unit : mm) Reference plane <Diffuse reflective> Optical axis Sensor Heads (Unit : mm) ZG2-WDS70 <Diffuse reflective> 65 ± 0.1 3-M4 Optical axis 2-4.5 dia. mounting hole 35 22.17 15.3 Emitter optical axis 22.3 4.5 Measurement center Emitter 38 10.64 4.64 Operation indication lamp 65 56 4.5 52.5 65 56 40° Receiver optical axis 75.02 2-M4 28 46 21.66 Vinyl-insulated round cable 6.8 dia, standard length : 2 m Measurement center Vinyl-insulated round cable 6.8 dia, standard length : 2 m Connector 45 19° Connector Emitter optical axis Reference plane 16.4 13 dia Emitter Sensor Heads ZG2-WDS8T/WDS22 <Diffuse reflective> (Unit : mm) Reference plane 18 Emitter 2 Connector Data Storage Unit (Unit : mm) ZG2-DSU11/DSU41 59.85 52.50 60 20.8 5.2 11 Operation indication lamp ∗ 90 35.5 90 25 A° ( ) 100 Receiver optical axis Reference plane 3-4.5 dia. mounting hole Receiver 82 27.9 69 3.90 3.9 11.7 dia Heat-resistive polyvinyl chloride (PVC), 5.2 dia, standard length : 2 m 45.1 Vinyl-insulated round cable 6.8 dia, standard length : 2 m, 0.5 m USB connector Connector 4.30 4.3 18 16.9 3-M4 69 ± 0.1 57 52.5 60 ∗ 46 (Unit : mm) ZG2-WDC11/WDC41 3.34 L( ) 80 72 Measurement center 4 70 Emitter optical axis 9.5 25 16.4 22.7 Sensor Controller 36 Optical axis 25 Vinyl-insulated round cable 6.8 dia, standard length : 2 m, 0.5 m 56 ± 0.1 Mounting Hole Dimensions 70 ± 0.1 9.5 ± 0.1 120 115.06 56 ± 0.1 92.1 Operation indication lamp 47 Receiver optical axis 71.78 ± 0.1 Mounting Hole Dimensions 75 65 5 33.47 40° Reference plane 2-M4 210 Receiver 22.7 33.47 ± 0.1 Measurement center Receiver optical axis (1: 2 ) Mounting Hole Dimensions Reference plane 23.79 Reference plane 20.66 Receiver optical axis 2-4.5 dia. mounting hole 20.83 Emitter optical axis 31. 5 45 ± 0.1 19 81.06 71.78 Heat-resistive polyvinyl chloride (PVC), 5.2 dia, standard length : 2 m 13 10 13 10 RS-232C connector ∗ ZG2-WDS8T L=50, A=30° ZG2-WDS22 L=100, A=25° 32.9 24.2 Mounting Hole Dimensions 24.20 18 32.90 11.7 dia Sensor Heads (Unit : mm) ZG2-WDS8T <Regular reflection> 44.1 10.3 98.5 67.6 3-4.5 dia. mounting hole 18.1 23.1 28.8 Measurement center Receiver optical axis 3-M4 9.3 Panel Mounting Adaptor (Unit : mm) ZS-XPM1/XPM2 (Dimensions for mounting on a control panel) (60 × n )+12 60 × n 3-4.5 dia. mounting hole 13 3 Panel Real-time Parallel Output Unit ZG-RPD11/RPD41 29.60 15° 30° 37.7 12.5° 110.9 68.3 ± 0.1 24.2 ± 0.1 Reference plane 18.1± 0.1 Vinyl-insulated round cable 6.8 dia, standard length : 2 m, 0.5 m 64.2 ± 0.1 10.25 15.85 9 23.5 15.2 25° 90 122 109.6 (140 ) (14.15) 13 (2. 85) Receiver optical axis 3-M4 Reference 15.2 ± 0.1 plane 11.5 66.50 80 89 98 15.65 9 70 (150 ) Panel 55 Connector 65.3 ± 0.1 Vinyl-insulated round cable 6.8 dia, standard length : 2 m, 0.5 m Connector ∗When two or more units are aligned side-by-side. Panel Mounting Adaptor (2) (37. 5) 32.90 (Note: 1) 30 Panel cutout dimensions Mounting Hole Dimensions 21 30 65.3 64.2 Two,Mounting holes 8 24.2 Measurement center Emitter optical axis (Unit : mm) 7 DIN track 15.6 18.6 67.6 ± 0.1 27 ± 0.1 95.9 68.3 94.1 27 Emitter optical axis (Unit : mm) ZG2-WDS22 <Regular reflection> Note: 1. Dimensions are for a 2.0 mm thick panel. Mounting Hole Dimensions 116 ± 1 (60 × n ) + 8 6 35.20 Sensor Heads (Unit : mm) ZG2-WDS70 <Diffuse reflective> 65 ± 0.1 3-M4 Optical axis 38 45 ± 0.1 19 210 Receiver 22.7 75 65 5 28 (1 : 2 ) Mounting Hole Dimensions Reference plane Operation indication lamp 47 Receiver optical axis 46 Measurement center 120 115.06 45 19° Emitter optical axis Reference plane 16.4 13 dia Emitter 25 57 2 Vinyl-insulated round cable 6.8 dia, standard length : 2 m, 0.5 m Sensor Controller (Unit : mm) ZG2-WDC11/WDC41 Connector Data Storage Unit (Unit : mm) ZG2-DSU11/DSU41 59.85 52.5 60 52.50 60 20.8 3.34 5.2 11 90 35.5 90 27.9 3.90 3.9 11.7 dia Heat-resistive polyvinyl chloride (PVC), 5.2 dia, standard length : 2 m 18.4 Heat-resistive polyvinyl chloride (PVC), 5.7 mm dia., 16-core, standard length 2 m 13 10 13 10 32.9 24.2 4.30 4.3 24.20 18 32.90 11.7 dia Panel Mounting Adaptor (Unit : mm) ZS-XPM1/XPM2 (Dimensions for mounting on a control panel) (60 × n)+12 60 × n 13 3 Panel Real-time Parallel Output Unit ZG-RPD11/RPD41 29.60 Two,Mounting holes 7 DIN track 8 21 30 10.25 15.85 9 90 122 (Unit : mm) (140) (14.15) 13 (2. 85) 11.5 66.50 80 89 98 15.65 9 70 (150 ) Panel 55 ∗When two or more units are aligned side-by-side. Panel Mounting Adaptor (2) (37.5) 32.90 (Note: 1) 30 Panel cutout dimensions Note: 1. Dimensions are for a 2.0 mm thick panel. 116 ± 1 (60 × n) + 8 6 35.20 Terms and Conditions Agreement Read and understand this catalog. Please read and understand this catalog before purchasing the products. Please consult your OMRON representative if you have any questions or comments. Warranties. (a) Exclusive Warranty. Omron’s exclusive warranty is that the Products will be free from defects in materials and workmanship for a period of twelve months from the date of sale by Omron (or such other period expressed in writing by Omron). Omron disclaims all other warranties, express or implied. (b) Limitations. OMRON MAKES NO WARRANTY OR REPRESENTATION, EXPRESS OR IMPLIED, ABOUT NON-INFRINGEMENT, MERCHANTABILITY OR FITNESS FOR A PARTICULAR PURPOSE OF THE PRODUCTS. BUYER ACKNOWLEDGES THAT IT ALONE HAS DETERMINED THAT THE PRODUCTS WILL SUITABLY MEET THE REQUIREMENTS OF THEIR INTENDED USE. Omron further disclaims all warranties and responsibility of any type for claims or expenses based on infringement by the Products or otherwise of any intellectual property right. (c) Buyer Remedy. Omron’s sole obligation hereunder shall be, at Omron’s election, to (i) replace (in the form originally shipped with Buyer responsible for labor charges for removal or replacement thereof) the non-complying Product, (ii) repair the non-complying Product, or (iii) repay or credit Buyer an amount equal to the purchase price of the non-complying Product; provided that in no event shall Omron be responsible for warranty, repair, indemnity or any other claims or expenses 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. Return of any Products by Buyer must be approved in writing by Omron before shipment. Omron Companies shall not be liable for the suitability or unsuitability or the results from the use of Products in combination with any electrical or electronic components, circuits, system assemblies or any other materials or substances or environments. Any advice, recommendations or information given orally or in writing, are not to be construed as an amendment or addition to the above warranty. See http://www.omron.com/global/ or contact your Omron representative for published information. Limitation on Liability; Etc. OMRON COMPANIES SHALL NOT BE LIABLE FOR SPECIAL, INDIRECT, INCIDENTAL, OR CONSEQUENTIAL DAMAGES, LOSS OF PROFITS OR PRODUCTION OR COMMERCIAL LOSS IN ANY WAY CONNECTED WITH THE PRODUCTS, WHETHER SUCH CLAIM IS BASED IN CONTRACT, WARRANTY, NEGLIGENCE OR STRICT LIABILITY. Further, in no event shall liability of Omron Companies exceed the individual price of the Product on which liability is asserted. Suitability of Use. Omron Companies shall not be responsible for conformity with any standards, codes or regulations which apply to the combination of the Product in the Buyer’s application or use of the Product. At Buyer’s request, Omron will provide applicable third party certification documents identifying ratings and limitations of use which apply to the Product. This information by itself is not sufficient for a complete determination of the suitability of the Product in combination with the end product, machine, system, or other application or use. Buyer shall be solely responsible for determining appropriateness of the particular Product with respect to Buyer’s application, product or system. Buyer shall take application responsibility in all cases. NEVER USE THE PRODUCT FOR AN APPLICATION INVOLVING SERIOUS RISK TO LIFE OR PROPERTY OR IN LARGE QUANTITIES WITHOUT ENSURING THAT THE SYSTEM AS A WHOLE HAS BEEN DESIGNED TO ADDRESS THE RISKS, AND THAT THE OMRON PRODUCT(S) IS PROPERLY RATED AND INSTALLED FOR THE INTENDED USE WITHIN THE OVERALL EQUIPMENT OR SYSTEM. Programmable Products. Omron Companies shall not be responsible for the user’s programming of a programmable Product, or any consequence thereof. Performance Data. Data presented in Omron Company websites, catalogs and other materials 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 user must correlate it to actual application requirements. Actual performance is subject to the Omron’s 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 part 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 part numbers may be assigned to fix or establish key specifications for your application. Please consult with your Omron’s representative at any time to confirm actual specifications of purchased Product. Errors and Omissions. Information presented by Omron Companies has been checked and is believed to be accurate; however, no responsibility is assumed for clerical, typographical or proofreading errors or omissions. Safety Precautions for Laser Equipment WARNING Class2 Do not expose your eyes to laser radiation either directly or reflected from a mirrored surface.The emitted laser beams have a high power density and direct exposure may result in loss of eyesight. Class2M The warning and explanatory label on the side of the Sensor Head in the ZG2 Series is in Japanese. Replace it with the English label that comes with the product. This document provides information mainly for selecting suitable models. Please read the User's Manual carefully for information that the user must understand and accept before purchase, including information on warranty, limitations of liability, and precautions. Note: Do not use this document to operate the Unit. OMRON Corporation Industrial Automation Company Authorized Distributor: Tokyo, JAPAN Contact: www.ia.omron.com Regional Headquarters OMRON EUROPE B.V. Sensor Business Unit Carl-Benz-Str. 4, D-71154 Nufringen, Germany Tel: (49) 7032-811-0/Fax: (49) 7032-811-199 OMRON ELECTRONICS LLC One Commerce Drive Schaumburg, IL 60173-5302 U.S.A. Tel: (1) 847-843-7900/Fax: (1) 847-843-7787 OMRON ASIA PACIFIC PTE. LTD. No. 438A Alexandra Road # 05-05/08 (Lobby 2), Alexandra Technopark, Singapore 119967 Tel: (65) 6835-3011/Fax: (65) 6835-2711 OMRON (CHINA) CO., LTD. Room 2211, Bank of China Tower, 200 Yin Cheng Zhong Road, PuDong New Area, Shanghai, 200120, China Tel: (86) 21-5037-2222/Fax: (86) 21-5037-2200 © OMRON Corporation 2008 All Rights Reserved. In the interest of product improvement, specifications are subject to change without notice. CSM_6_3_0416 Printed in Japan Cat. No. Q167-E1-01A 1208-1M(0109)(AS)