ZX Series
Operation Manual
Cat. No. Z157-E1-02
OMRON Corporation
Introduction
Thank you for purchasing an OMRON ZX-series Smart Sensor. We hope you will fully utilize this product and its performance for many years to come.
The ZX-series Smart Sensor is a laser product designed specifically as a sensing device. To ensure safety, read this manual carefully before using the Sensor. In addition, keep this manual in an easily accessible location for quick reference when needed.
READ AND UNDERSTAND THIS DOCUMENT
Please read and understand this document before using the products. Please consult your OMRON representative if you have any questions or comments.
WARRANTY
OMRON’s exclusive warranty is that the products are free from defects in materials and workmanship for a period of one year (or other period if specified) from date of sale by OMRON.
OMRON MAKES NO WARRANTY OR REPRESENTATION, EXPRESS OR IMPLIED, REGARDING NON-INFRINGEMENT, MERCHANTABILITY, OR FITNESS FOR PARTICULAR PURPOSE OF THE PRODUCTS. ANY BUYER OR USER ACKNOWLEDGES THAT THE BUYER OR USER ALONE HAS DETERMINED THAT THE PRODUCTS WILL SUITABLY MEET THE REQUIREMENTS OF THEIR INTENDED USE.
OMRON DISCLAIMS ALL OTHER WARRANTIES, EXPRESS OR IMPLIED.
LIMITATIONS OF LIABILITY
OMRON SHALL NOT BE RESPONSIBLE FOR SPECIAL, INDIRECT, OR CONSEQUENTIAL DAMAGES, LOSS OF PROFITS OR COMMERCIAL LOSS IN ANY WAY CONNECTED WITH THE PRODUCTS, WHETHER SUCH CLAIM IS BASED ON CONTRACT, WARRANTY, NEGLIGENCE, OR STRICT LIABILITY.
In no event shall responsibility of OMRON for any act exceed the individual price of the product on which liability is asserted.
IN NO EVENT SHALL OMRON BE RESPONSIBLE FOR WARRANTY, REPAIR, OR OTHER CLAIMS REGARDING THE PRODUCTS UNLESS OMRON’S ANALYSIS CONFIRMS THAT THE PRODUCTS WERE PROPERLY HANDLED, STORED, INSTALLED, AND MAINTAINED AND NOT SUBJECT TO CONTAMINATION, ABUSE, MISUSE, OR INAPPROPRIATE MODIFICATION OR REPAIR.
SUITABILITY FOR USE
THE PRODUCTS CONTAINED IN THIS DOCUMENT ARE NOT SAFETY RATED. THEY ARE NOT DESIGNED OR RATED FOR ENSURING SAFETY OF PERSONS, AND SHOULD NOT BE RELIED UPON AS A SAFETY COMPONENT OR PROTECTIVE DEVICE FOR SUCH PURPOSES. Please refer to separate catalogs for OMRON's safety rated products.
OMRON shall not be responsible for conformity with any standards, codes, or regulations that apply to the combination of products in the customer’s application or use of the product.
At the customer’s request, OMRON will provide applicable third party certification documents identifying ratings and limitations of use that apply to the products. This information by itself is not sufficient for a complete determination of the suitability of the products in combination with the end product, machine, system, or other application or use.
The following are some examples of applications for which particular attention must be given. This is not intended to be an exhaustive list of all possible uses of the products, nor is it intended to imply that the uses listed may be suitable for the products:
Outdoor use, uses involving potential chemical contamination or electrical interference, or conditions or uses not described in this document.
Nuclear energy control systems, combustion systems, railroad systems, aviation systems, medical equipment, amusement machines, vehicles, safety equipment, and installations subject to separate industry or government regulations.
Systems, machines, and equipment that could present a risk to life or property.
Please know and observe all prohibitions of use applicable to the products.
NEVER USE THE PRODUCTS FOR AN APPLICATION INVOLVING SERIOUS RISK TO LIFE OR PROPERTY WITHOUT ENSURING THAT THE SYSTEM AS A WHOLE HAS BEEN DESIGNED TO ADDRESS THE RISKS, AND THAT THE OMRON PRODUCT IS PROPERLY RATED AND INSTALLED FOR THE INTENDED USE WITHIN THE OVERALL EQUIPMENT OR SYSTEM.
PERFORMANCE DATA
Performance data given in this document is provided as a guide for the user in determining suitability and does not constitute a warranty. It may represent the result of OMRON’s test conditions, and the users must correlate it to actual application requirements. Actual performance is subject to the OMRON Warranty and Limitations of Liability.
CHANGE IN SPECIFICATIONS
Product specifications and accessories may be changed at any time based on improvements and other reasons.
It is our practice to change model numbers when published ratings or features are changed, or when significant construction changes are made. However, some specifications of the product may be changed without any notice. When in doubt, special model numbers may be assigned to fix or establish key specifications for your application on your request. Please consult with your OMRON representative at any time to confirm actual specifications of purchased products.
DIMENSIONS AND WEIGHTS
Dimensions and weights are nominal and are not to be used for manufacturing purposes, even when tolerances are shown.
ERRORS AND OMISSIONS
The information in this document has been carefully checked and is believed to be accurate;
however, no responsibility is assumed for clerical, typographical, or proofreading errors, or omissions.
PROGRAMMABLE PRODUCTS
OMRON shall not be responsible for the user’s programming of a programmable product, or any consequence thereof.
COPYRIGHT AND COPY PERMISSION
This document shall not be copied for sales or promotions without permission.
This document is protected by copyright and is intended solely for use in conjunction with the product. Please notify us before copying or reproducing this document in any manner, for any other purpose. If copying or transmitting this document to another, please copy or transmit it in its entirety.
For Your Safety
i
For Your Safety
Notation for Safety Information
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.
Indicates a potentially hazardous situation which, if not avoided, will result in minor or moderate injury, or may result in serious injury or death. Additionally there may be significant property damage.
Indicates a potentially hazardous situation which, if not avoided, may result in minor or moderate injury, or in property damage.
Laser Safety
ii
Laser Safety
The ZX-LD@@, ZX-LD@@L, ZX-LD@@V, and ZX-LD@@VL Sensor Heads are Class 2 Laser Products according to EN60825-1 (IEC825-1) and Class II Laser Products according to FDA (21 CFR1040.10) (see note). The ZX- LT@@@ Sensor Heads are Class 1 and Class II Laser Products, respec- tively. The ZX Series is meant to be built into final system equipment. Pay special attention to the following precautions for the safe use of the prod- uct:
Note: Europe: Class 1 and Class 2 of EN60825-1: 1994 = IEC825-1: 1993 U.S.A.: Class I and Class II of FDA (21 CFR1040.10)
(1) Use this product as specified in this operation manual. Otherwise, you may be exposed to hazardous laser radiation.
(2) The ZX-series Smart Sensors radiate 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 termi- nated. If the Unit must be used without terminating the laser beam path, posi- tion 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.
Laser Safety
iii
Requirements from Regulations and Standards
EN60825-1 “Safety of Laser Products, Equipment Classification, Requirements and User’s Guide”
• Summary of Manufacturer’s Requirements
*With respect to the requirements of remote interlock connector, key con- trol, emission warning and attenuator, Class 3B laser products not exceed- ing five times the AEL of Class 2 in the wavelength range of 400 nm to 700 nm are to be treated as Class 3A laser products.
Requirements;
Sub-clause
Classification
Class 1 Class 2 Class 3A Class 3B* Class 4
Description of
hazard class Safe under reasonably foreseeable conditions
Low power;
eye protection normally af- forded by aver- sion responses
Same as Class 2. Direct intra- beam viewing with optical aids may be hazardous
Direct intra- beam viewing may be hazard- ous
High power; dif- fused reflection may be hazard- ous
Protective
housing Required for each laser product; limits access necessary for performance of functions of the products
Safety interlock in protective housing
Designed to prevent removal of the panel until accessible emission values are below the AEL (see note 2) for the class assigned
Remote control Not required Permits easy addition of external
interlock in laser installation
Key control Not required Laser inoperative when key is re-
moved Emission warn-
ing device Not required Gives audible or visible warning
when laser is switched on or if ca- pacitor bank of pulsed laser is be- ing charged
Attenuator Not required Gives means beside ON/OFF
switch to temporarily block beam Location con-
trols
Not required Controls so located that there is no danger of expo- sure to AEL above Classes 1 or 2 when adjust- ments are made.
Viewing optics Emission from all viewing systems must be below Class 1 AEL’s as applicable Scanning Scan failure shall not cause product to exceed its classification
Class label Required wording
Figures A and B and specified wording
Aperture label Not required Specified wording required
Service entry la-
bel Required as appropriate to the class of accessible radiation Override inter-
lock label Required under certain conditions as appropriate to the class of laser used User informa-
tion Operation manuals must contain instructions for safe use Purchasing and
service informa- tion
Promotion brochures must reproduce classification labels; service manuals must con- tain safety information
Medical prod- ucts
Special calibration instructions required Special calibration instructions, means for measurement and tar- get-indicator required
Fibre optic Cable service connections require tool to disconnect if disconnection breaks protective housing and permits access above Class 1
Laser Safety
iv
Note 1. The above table is intended to provide a convenient summary of requirements. See text of this standard for complete requirements.
2. AEL: Accessible Emission Limit
The maximum accessible emission level permitted within a particular class. For your reference, see ANSI Z136.1-1993, Section 2.
• FDA (Compliance Guide for Laser Products, 1985, according to 21 CFR1040.10)
Symbol and border: black Background: yellow
Figure A Warning label - Hazard symbol
Legend and border: black Background: yellow
Figure B Explanatory label
Requirements Class (see note 1)
I IIa II IIIa IIIb IV
Performance (all laser products) Protective hous-
ing R
(see note 2) R
(see note 2) R
(see note 2) R
(see note 2) R
(see note 2) R (see note 2) Safety interlock R (see
notes 3, 4) R (see
notes 3, 4) R (see
notes 3, 4) R (see
notes 3, 4) R (see
notes 3, 4) R (see notes 3, 4) Location of con-
trols N/A R R R R
Viewing optics R R R R R R
Scanning safe- guard
R R R R R R
Performance (laser systems)
Laser Safety
v
Abbreviations:
R: Required.
N/A: Not applicable.
S: Requirements: Same as for other products of that Class.
Also see footnotes.
NP: Not permitted.
D: Depends on level of interior radiation.
Footnotes:
1. Based on highest level accessible during operation.
2. Required wherever & whenever human access to laser radiation above Class I limits is not needed for product to perform its function.
3. Required for protective housings opened during operation or maintenance, if human access thus gained is not always necessary when housing is open.
4. Interlock requirements vary according to Class of internal radiation.
5. Wording depends on level & wavelength of laser radiation within protective housing.
Remote control connector
N/A N/A N/A N/A R R
Key control N/A N/A N/A N/A R R
Emission indica-
tor N/A N/A R R R
(See note 10.)
R (See note 10.)
Beam attenuator N/A N/A R R R R
Reset N/A N/A N/A N/A N/A R
(See note 13.) Performance (specific purpose products)
Medical S S S S
(See note 8.)
S (See note 8.)
S (See note 8.) Surveying, level-
ing, alignment
S S S S NP NP
Demonstration S S S S S
(See note 11.)
S (See note 11.) Labeling (all laser products)
Certification &
identification
R R R R R R
Protective hous- ing
D (See note 5.)
D (See Note 5.)
D (See note 5.)
D (See note 5.)
D (See note 5.)
D (See note 5.)
Aperture N/A N/A R R R R
Class warning N/A R
(See note 6.)
R (See note 7.)
R (See note 9.)
R (See note 12.)
R (See note 12.) Information (all laser products)
User information R R R R R R
Product literature N/A R R R R R
Service informa- tion
R R R R R R
Requirements Class (see note 1)
I IIa II IIIa IIIb IV
Laser Safety
vi
6. Warning statement label.
7. CAUTION logotype.
8. Requires means to measure level of laser radiation intended to irradiate the body.
9. CAUTION if 2.5 mW cm2 or less, DANGER if greater than 2.5 mW cm–2. 10.Delay required between indication & emission.
11.Variance required for Class IIb or IV demonstration laser products and light shows.
12.DANGER logotype.
13.Required after August 20, 1986.
Use Precautions
• EN60825-1
*With respect to the requirements of remote interlock connector, key con- trol, beam attenuator, and emission indicator, Class 3B laser products not exceeding five times the AEL of Class 2 in the wavelength range of 400 nm to 700 nm are to be treated as Class 3A laser products.
Note: This table is intended to provide a convenient summary of requirements.
See text of this standard for complete precautions.
• ANSI Z136.1:1993 “American National Standard for the Safe Use of Lasers” Control Measures for the Four Laser Classes
Requirements;
Sub-clause Classification
Class 1 Class 2 Class 3A Class 3B* Class 4
Remote interlock Not required Connect to room or door circuits
Key control Not required Remove key when not in use
Beam attenuator Not required When in use prevents inadvert-
ent exposure Emission indica-
tor device Not required Indicates laser is energized
Warning signs Not required Follow precautions on warning
signs Beam path Not required Terminate beam at end of useful length Specular reflec-
tion
No requirements Prevent unintentional reflec-
tions
Eye protection No requirements Required if engineering and administrative proce- dures not practicable and MPE exceeded Protective cloth-
ing
No requirements Sometimes re-
quired
Specific re- quirements Training No requirements Required for all operator and maintenance per-
sonnel
Control measures Classification
Engineering Controls 1 2a 2 3a 3b 4
Protective Housing (4.3.1) X X X X X X
Without Protective Housing
(4.3.1.1) LSO (see note 2) shall establish Alternate Controls
Laser Safety
vii
Interlocks on Protective Housing
(4.3.2) ✩ ✩ ✩ ✩ X X
Service Access Panel (4.3.3) ✩ ✩ ✩ ✩ X X
Key Control (4.3.4) --- --- --- --- • X
Viewing Portals (4.3.5.1) --- --- MPE MPE MPE MPE
Collecting Optics (4.3.5.2) MPE MPE MPE MPE MPE MPE
Totally Open Beam Path (4.3.6.1) --- --- --- --- X
NHZ X
NHZ
Limited Open Beam Path (4.3.6.2) --- --- --- --- X
NHZ X
NHZ Enclosed Beam Path (4.3.6.3) None is required if 4.3.1 and 4.3.2 fulfilled
Remote Interlock Connector (4.3.7)
--- --- --- --- • X
Beam Stop or Attenuator (4.3.8) --- --- --- --- • X
Activation Warning Systems
(4.3.9) --- --- --- --- • X
Emission Delay (4.3.9.1) --- --- --- --- --- X
Indoor Laser Controlled Area (4.3.10)
--- --- --- --- X
NHZ X NHZ Class 3b Laser Controlled Area
(4.3.10.1)
--- --- --- --- X ---
Class 4 Laser Controlled Area (4.3.10.2)
--- --- --- --- --- X
Laser Outdoor Controls (4.3.11) --- --- --- --- X
NHZ X NHZ Laser in Navigable Airspace
(4.3.11.2)
--- --- --- • • •
Temporary Laser Controlled Area
(4.3.12) ✩
MPE ✩
MPE ✩
MPE ✩
MPE
--- ---
Remote Firing & Monitoring (4.3.13)
--- --- --- --- --- •
Labels (4.3.14 and 4.7) X X X X X X
Area Posting (4.3.15) --- --- --- • X
NHZ X
NHZ Administrative & Procedural Con-
trols 1 2a 2 3a 3b 4
Standard Operating Procedures
(4.4.1) --- --- --- --- • X
Output Emission Limitations (4.4.2) --- --- --- LSO Determination
Education and Training (4.4.3) --- --- • • X X
Authorized Personnel (4.4.4) --- --- --- --- X X
Alignment Procedures (4.4.5) --- --- X X X X
Protective Equipment (4.4.6) --- --- --- --- • X
Spectator (4.4.7) --- --- --- --- • X
Service Personnel (4.4.8) ✩
MPE ✩
MPE ✩
MPE ✩
MPE X X
Demonstration with General Public
(4.5.1) MPE ✝ --- X X X X
Laser Optical Fiber Systems
(4.5.2) MPE MPE MPE MPE X X
Laser Robotic Installations (4.5.3) --- --- --- --- X NHZ
X NHZ
Control measures Classification
Laser Safety
viii
Note 1. LEGEND X: Shall
•: Should ---: No requirement
✩: Shall if enclosed Class 3b or Class 4 MPE: Shall if MPE is exceeded
NHZ: Nominal Hazard Zone analysis required
✝: Applicable only to UV and IR Lasers (4.5.1.2) 2. LSO: Laser Safety Officer
An individual shall be designated the Laser Safety Officer with the authority and responsibility to monitor and enforce the control of laser hazards, and to effect the knowledgeable evaluation and control of laser hazards.
For your reference, see ANSI Z136.1-1993, Section 1.3.
Laser Product Classifications
• EN
Note: Conditions for safe viewing of diffuse reflections for Class 3B visible lasers are: minimum viewing distance of 13 cm between screen and cor- nea and a maximum viewing time of 10 s. Other viewing conditions require a comparison of the diffuse reflection exposure with the MPE.
Eye Protection (4.6.2) --- --- --- --- •
MPE X
MPE
Protective Windows (4.6.3) --- --- --- --- X
NHZ X
NHZ Protective Barriers and Curtains
(4.6.4) --- --- --- --- • •
Skin Protection (4.6.5) --- --- --- --- X
MPE X
MPE Other Protective Equipment (4.6.5) Use may be required
Warning Signs and Labels (4.7) (Design Requirements)
--- --- • • X
NHZ X NHZ Service and Repairs (4.8) LSO Determination
Modification of Laser Systems
(4.9) LSO Determination
Control measures Classification
Class Description
Class 1 Lasers which are safe under reasonably foreseeable conditions of operation.
Class 2 Lasers emitting visible radiation in the wavelength range from 400 nm to 700 nm.
Eye protection is normally afforded by aversion responses including the blink re- flex.
Class 3A Lasers which are safe for viewing with the unaided eye. For laser emitting in the wavelength range from 400 nm to 700 nm, protection is afforded by aversion re- sponses including the blink reflex. For other wavelengths the hazard to the unaid- ed eye is no greater than for Class 1. Direct intrabeam viewing of Class 3A lasers with optical aides (e.g., binoculars, telescopes, microscopes) may be hazardous.
Class 3B Direct intrabeam viewing of these lasers is always hazardous. Viewing diffuse re- flections is normally safe (see note).
Class 4 Lasers which are also capable of producing hazardous diffuse reflections. They may cause skin injuries and could also constitute a fire hazard. Their use requires extreme caution.
Laser Safety
ix
Comparison of Classifications between FDA and ANSILabel Indications
• EN
Note: Use of controls, adjustments, or procedures other than those specified herein may result in hazardous radiation exposure.
Class FDA definition ANSI description
Class I/1 Limits applicable to devices that have emissions in the ultraviolet, visible, and infrared spectra, and limits below which biological hazards have not been established.
A Class 1 laser is considered to be in- capable of producing damaging radia- tion levels during operation and maintenance and is, therefore, ex- empt from any control measures or other forms of surveillance.
Class IIa/
2a Limits applicable to products whose visible emis- sion does not exceed Class I limits for emission durations of 1,000 seconds or less and are not in- tended for viewing.
Class 2 lasers are divided into two subclasses, 2 and 2a. A Class 2 laser emits in the visible portion of the spec- trum (0.4 to 0.7 µm) and eye protec- tion is normally afforded by the aversion response including the blink reflex.
Class II/2 Limits applicable to products that have emissions in the visible spectrum (400 to 710 nm) for emis- sion durations in excess of 0.25 second, providing that emissions for other durations and/or wave- lengths do not exceed the Class I limits. Class II products are considered hazardous for direct long-term ocular exposure.
Class IIIa/
3a
Limits to products that have emissions in the visi- ble spectrum and that have beams where the total collectable radiant power does not exceed 5 milli- watts.
Class 3 lasers are divided into two subclasses, 3a and 3b. A Class 3 la- ser may be hazardous under direct and specular reflection viewing condi- tions, but the diffuse reflection is usu- ally not a hazard.
Class IIIb/
3b
Limits applicable to devices that emit in the ultra- violet, visible, and infrared spectra. Class IIIb products include laser systems ranging from 5 to 500 milliwatts in the visible spectrum. Class IIIb emission levels are ocular hazards for direct expo- sure throughout the range of the Class, and skin hazards at the higher levels of the Class.
Class IV/4 Exceeding the limits of Class IIIb and are a hazard for scattered reflection as well as for direct expo- sure.
A Class 4 laser is a hazard to the eye or skin from the direct beam and sometimes from a diffuse reflection and also can be a fire hazard. Class 4 lasers may also produce laser-gener- ated air contaminants and hazardous plasma radiation.
Laser warning label
EN/IEC warning label
Explanatory label with specified wording
Laser Safety
x
• FDA
Note: Use of controls, adjustments, or procedures other than those specified here- in may result in hazardous radiation exposure.
Certification and identification label
Aperture label Caution
logo type
Aperture Label Class II Caution logo type
Certification and Identification Label
Precautions
xi
Precautions
Ratings and Performance
(1) Conform to the specified ratings and performance.
Refer to "6-1 Ratings/Specifications"
• Do not impose voltage exceeding the rated voltage, otherwise the Sen- sor may be damaged.
• When supplying power to the Sensor, make sure that the polarity of the power is correct, otherwise, the Sensor may be damaged. Do not con- nect to an AC power supply.
• Do not short-circuit the load for the open collector output, otherwise the Sensor may be damaged.
(2) Do not disconnect the connector connecting the Sensor Head and the con- troller while power is being supplied, otherwise the Sensor may be damaged.
(3) Allow a warm-up period of approximately 10 minutes after turning ON the power supply.
(4) Objects of certain materials or shapes may not be detectable, or the detec- tion accuracy may not be sufficiently high. These include materials that are transparent or have extremely low reflectivity, and objects that are smaller than the Sensor’s spot diameter or have extreme curvature or inclination.
Power Supply and Wiring
(1) Prior to turning ON the power supply after wiring is completed, check to make sure that the power supply is correct, that there are no mistaken connections, e.g., connections that would short-circuit the load, and that the load current is appropriate. Incorrect wiring may result in damage to the Sensor or Unit.
(2) The total length of the Sensor cable or Amplifier cable must be 10 m or less.
Use an ZX-XC@A Extension Cable (order separately) if required to extend the cable from the Sensor. Use a shielded cable to extend the Amplifier cable. The shielded cable must be the same as that of the Amplifier cable.
(3) Do not lay a power supply cable for the ZX together with high-voltage lines or power lines to prevent interference, damage, and malfunction.
(4) When using a commercially available switching regulator, ground the FG (frame ground) terminal.
(5) If the power supply line is subject to surges, connect a surge absorber that meets the conditions of the usage environment.
(6) When using a Calculating Unit, connect the corresponding linear ground of the Amplifier Unit.
Environment
(1) Do not use the Sensor in strong electromagnetic fields or in an environment where the operation of the Sensor is subject to the reflection of intense light (such as other laser beams or electric arc-welding machines.)
(2) Do not operate the Sensor in the following locations:
• Locations subject to strong vibration.
xii
• Locations subject to high humidity.
• Locations where the Sensor would accumulate dust, dirt, metallic pow- der, etc.
• Locations subject to corrosive or flammable gases.
• Locations subject to exposure to organic solvents, water, oil, etc.
• Locations subject to strong electromagnetic or electrical fields.
• Locations subject to rapid changes in temperature.
• Locations subject to freezing.
Maintenance
(1) Always turn OFF the power supply before adjusting or removing the Sensor Head.
(2) Cleaning
Do not use thinners, benzine, acetone, or kerosene for cleaning.
If dust or oil adheres to the filter on the front of the Sensor Head, use the fol- lowing procedure to clean.
• 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 because scratches on the filter could result in Sensor inaccuracy.
Compatibility
All Sensor Heads and Amplifier Units are compatible. Different Sensor Heads may be purchased at a later date and used with existing Amplifier Units.
Controlling Mutual Interference
Mutual interference can be prevented when using two Sensor Heads together, by connecting the ZX-CAL Calculating Unit between the two Amplifier Units. However, this effect cannot be attained if the laser beam of one Sensor Head is received when the other Sensor Head is approaching saturation. When considering the use of the ZX-CAL Calculating Unit to control mutual interference, confirm the operation with actual Units in advance.
Applicable standards
• EN61326-1
• Electromagnetic environment: Industrial electromagnetic environment (EN/IEC 61326-1 Table 2)
• There may be cases that current output or voltage output fluctuate within
±3 times of resolution when a sensor is experienced electromagnetic interference.
xiii
Table of Contents
For Your Safety ... i
Laser Safety... ii
Precautions... xi
SECTION 1 Before Use... 1
1-1 Names of Sensor Parts ...2
1-2 External Amplifier Unit I/O...5
1-3 I/O Circuit Diagrams ...6
1-4 Connections ...8
1-5 Installation ...11
1-6 Settings Required before Application...15
SECTION 2 Outline of Operation ... 19
2-1 Part Names and Functions ...20
2-2 Outline of Key Operations...21
2-3 Procedures for Reflective Sensor Heads...22
2-4 Procedures for Through-beam Sensor Heads ...24
2-5 Outline of Functions ...26
SECTION 3 Descriptions of Functions... 29
3-1 ZX-L Series ...31
3-2 Hardware Functions...34
3-3 Reflective Sensor Heads: RUN Mode Functions ...38
3-4 Reflective Sensor Heads: T Mode Functions ...41
3-5 Reflective Sensor Heads: FUN Mode Functions...44
3-6 Through-beam Sensor Heads: RUN Mode Functions ...71
3-7 Through-beam Sensor Heads: T Mode Functions ...75
3-8 Through-beam Sensor Heads: FUN Mode Functions ...79
SECTION 4 Operating Procedures ... 107
4-1 Display Operations ...108
4-2 Initial Display ...111
4-3 RUN Mode ...112
4-4 T (Threshold) Mode...118
4-5 FUN (Function) Mode ...124
SECTION 5 Troubleshooting... 141
5-1 Error Displays...142
5-2 Setting Problems...144
SECTION 6 Specifications and Dimensions ... 147
6-1 Ratings/Specifications ...148
6-2 Dimensions ...156
Revision History... 166
xiv
Visual Aids
The following icons are used to aid you in finding specific types of information.
Note: Indicates precautions to be observed during operation.
Indicates section numbers where related information can be found.
Indicates useful information.
POINT
xv
Displayed Form of Alphabet Letters
The letters of the alphabet are displayed digitally in the following forms.
xvi
SECTION 1 Before Use
This section describes preparations that are necessary prior to switching ON the power supply, such as installation, wiring, and connections.
1-1 Names of Sensor Parts ...2
1-1-1 Reflective Sensor Heads...2
1-1-2 Through-beam Sensor Heads ...3
1-1-3 Amplifier Units ...4
1-1-4 Calculating Unit ...4
1-2 External Amplifier Unit I/O...5
1-3 I/O Circuit Diagrams...6
1-3-1 NPN Amplifier Unit: ZX-LDA11...6
1-3-2 PNP Amplifier Unit: ZX-LDA41...7
1-4 Connections ...8
1-4-1 Sensor Head and Amplifier Unit ...8
1-4-2 Connecting Cable and Sensor Head...8
1-4-3 Extension Cables ...9
1-4-4 Amplifier Units and Calculating Unit ...9
1-5 Installation ...11
1-5-1 Reflective Sensor Heads...11
1-5-2 Through-beam Sensor Heads ...12
1-5-3 Amplifier Unit ...14
1-6 Settings Required before Application...15
1-6-1 Auto-scale ...15
1-6-2 Reference Incident Level...16
1-6-3 Linear Output...17
Names of Sensor Parts Section 1-1
2
1-1 Names of Sensor Parts 1-1-1 Reflective Sensor Heads
A Reflective Sensor Head is used for displacement measurements.
Range Indicator Lighting Status
Range indicators (green)
Display area Emitter/receiver
(optical filter )
Output cable (with connector)
Names of Sensor Parts Section 1-1
3 1-1-2 Through-beam Sensor Heads
A Through-beam Sensor Head is used for length measurements and con- sists of two main parts: An Emitter and a Receiver.
Emitter
Emitter
Laser ON indicator (green)
Lit when light is emitted.
Emitter-side Sensor Head connector
Receiver-side Sensor Head connector
Light emitter
Light receiver (optical filter)
Receiver Side-view Attachment
Mounting screw
Emitting/receiving section
Sensor Head to Amplifier Unit Connecting Cable (1.5 m) Emitter-side Sensor
Head connector Cable color: Gray
Receiver-side Sensor Head connector Cable color: Black
Amplifier Unit connector
Names of Sensor Parts Section 1-1
4
1-1-3 Amplifier Units
1-1-4 Calculating Unit
Input cable (with connector)
Display area
Controls
Connector (Cover opens and closes.)
Output cable
The current/voltage switch for the linear output is on the bottom.
Connection Indicators:
Light when the Calculating Unit is connected to Amplifier Units.
Display area
Connector
External Amplifier Unit I/O Section 1-2
5
1-2 External Amplifier Unit I/O
The following functions are allocated to the external I/O lines.
Refer to 3-2 Hardware Functions for I/O functions.
Note 1. Use a separate stabilized power supply for the Amplifier Unit, particu- larly when high resolution is required.
2. Wire the Unit correctly. Incorrect wiring may result in damage to the Unit. (Do not allow the I/O lines, particularly the linear output, to come into contact with other lines.)
3. Use the 0-V ground line (blue line) for the power supply and use the shield wire (linear output ground) together with the linear output (black line) for linear output. Each of these grounds must be used for the designed purpose. When not using the linear output, connect the lin- ear output ground to the 0-V ground line.
12 to 24 VDC GND (0 V) HIGH output PASS output LOW output Linear output Linear output GND Laser OFF input Zero reset input Timing input Reset input Brown
Blue White
Black Green
Shield Gray
Pink Orange Purple Red
I/O Circuit Diagrams Section 1-3
6
1-3 I/O Circuit Diagrams
1-3-1 NPN Amplifier Unit: ZX-LDA11
100 Load
Current output 4 to 20 mA
Voltage output 4 V
Load Load
Load
12 to 24 VDC Brown
Blue White
Green
Gray
12 to 24 VDC
HIGH output
PASS output
LOW output
GND (0 V)
Pink
Purple
Orange
Red
Black
Shield
Laser OFF input
Zero reset input
Reset input
Linear output
Linear output GND Current/voltage
switch
Current output: 300 max.
Voltage output: 10 min.k
Internal circuits
Timing input
I/O Circuit Diagrams Section 1-3
7 1-3-2 PNP Amplifier Unit: ZX-LDA41
Internal circuits
Load Load
Load Load
100
Current output 4 to 20 mA
Voltage output 4 V
12 to 24 VDC Brown
Blue White
Green
Gray
12 to 24 VDC
HIGH output
PASS output
LOW output
GND (0 V) Pink
Purple
Orange
Red
Black
Shield
Laser OFF input
Zero reset input Reset input
Linear output
Linear output GND Current/voltage
output selector
Timing input
Current output: 300 max.
Voltage output: 10 min.k
Connections Section 1-4
8
1-4 Connections
1-4-1 Sensor Head and Amplifier Unit
1. Insert the output cable connector of the Sensor Head into the in- put cable connector of the Amplifier Unit until the connector ring locks into place.
2. When disconnecting the Sensor Head, hold the connector ring and Amplifier Unit connector and pull them straight out.
1-4-2 Connecting Cable and Sensor Head
This procedure is necessary for Through-beam Sensor Heads only.
1. Insert the emitter-side and receiver-side connectors from the Sensor Head into both the emitter-side and receiver-side con- nectors on the Connecting Cable until they lock in place.
Connect the gray cables for the Emitter and the black cables for the Receiver.
2. When disconnecting the Sensor Head, detach the emitter-side and receiver-side connectors on the Connecting Cable from the emitter-side and receiver-side connectors on the Sensor Head cables and then pull them straight out.
• Do not pull only on the connector ring, because the input cable of the Amplifier Unit may be damaged.
• Do not touch the pins or contacts inside the connectors.
• Do not touch the pins or contacts inside the connector.
• Never allow the connectors to be subjected to electrostatic charges.
Connections Section 1-4
9 1-4-3 Extension Cables
When extending Sensor Head and Amplifier Unit cables, use the following special cables (order separately).
• 1-m Cable: ZX-XC1A
• 4-m Cable: ZX-XC4A
• 8-m Cable: ZX-XC8A
• 9-m Cable: ZX-XC9A (for use with Reflective Sensors only)
Connect the Extension Cable between the Connecting Cable and the Amplifier Unit.
Note: Never use two or more Extension Cables to extend the cable length.
1-4-4 Amplifier Units and Calculating Unit
1. Open the connector covers on the Amplifier Units by lifting and slide them open.
2. Mount the front section of the Calculating Unit to the DIN Track.
3. Slide the Calculating Unit on the DIN Track until the Calculating Unit connector connects securely to the connector on the first Amplifier Unit. The connectors should click into place.
Connections Section 1-4
10
4. Slide the other Amplifier Unit on the DIN Track until the Calculat- ing Unit connector connects securely to the Amplifier Unit con- nector. The connectors should click into place.
Note 1. Connect the connectors only after mounting the Units to the DIN Track.
2. Use an PFP-M End Plate when necessary to prevent the Amplifier Units from moving (e.g., as a result of vibration).
Installation Section 1-5
11
1-5 Installation
1-5-1 Reflective Sensor Heads
Install the Sensor Head using the screws provided with it.
Mounting Hole Size
Refer to 6-2-1 Reflective Sensor Heads.
Note 1. Secure the connector so that it is not subjected to vibration or shock.
2. Do not touch the optical filter on the Sensor Head. Fingerprints or other contamination on the filter will interfere with correct Sensor oper- ation. If the filter is touched by mistake, clean it by wiping it gently with a soft clean cloth.
For the ZX-LD , use M3 screws.
For the ZX-LD30V , use M4 screws.
Installation Section 1-5
12
1-5-2 Through-beam Sensor Heads
Installation
• The Emitter and Receiver must be installed in the same direction to align the laser beam.
• Tighten the screws to a torque of 0.3 N⋅m or less.
Emitter
Mounting hole Receiver
Mounting hole
Correct
Incorrect
M3 screws
ZX-LT001/LT005
M3 screws
ZX-LT010
Installation Section 1-5
13
Optical Axis Adjustment
• Attach the optical axis adjustment seal provided with the Sensor Head to the front of the Emitter. Adjust the laser beam radiated from the Emitter so that it is aligned with the center of the cross on the seal. Always remove the seal after completing the adjustment.
If you need more accurate adjustment of the optical axis, adjust it to maxi- mize the value displayed on the Amplifier Unit.
Note: Do not touch the surface of the Emitter and Receiver on the Sensor Head. Fingerprints or other contamination on the surface will interfere with correct Sensor operation. If the surface is touched by mistake, clean it by wiping it gently with a soft clean cloth.
Mounting the Side-view Attachment
• The ZX-XF 2 Side-view Attachment (order separately) can be mounted to the Emitter, to the Receiver, or to both.
• To mount the Side-view Attachment, use the M2 screws provided and tighten them to a torque of 0.08 N⋅m or less.
Emitter
Optical axis adjustment seal
Installation Section 1-5
14
Note 1. Use the same tightening torque for the left and right screws. The laser beam may be distorted if the tightening torque is not the same.
2. If the screws are tightened at a stronger torque than specified, the screw holes may be damaged. Use the specified torque. Be sure to use the M2 screws provided with the Side-view Attachment when mounting.
3. When using the Side-view Attachment, adjust the optical axis after mounting the Attachment. Be sure to set the reference incident level after adjusting the optical axis.
1-5-3 Amplifier Unit
Note: Always mount the front of the Unit first.Mounting strength may decrease if mounting is performed in the reverse order.
DIN Track DIN Track
Mounting
1. Mount the front of the Unit to the DIN Track.
2. Press the rear of the Unit onto the DIN Track.
Removing
1. Press the Unit toward the front.
2. Lift the front of the Unit.
Settings Required before Application Section 1-6
15
1-6 Settings Required before Application
These settings are required only for a Through-beam Sensor Head.
The settings for the auto-scale, reference incident level, and linear output are required before application.
Perform the settings in the following order:
1-6-1 Auto-scale
↓
1-6-2 Reference Incident Level
↓
1-6-3 Linear Output
1-6-1 Auto-scale
Select either millimeters or a percentage for the unit on the main display, and select whether the incident level or the intercepted amount is dis- played.
For the default settings, the incident level is displayed as a percentage.
1. Display Unit
Select a percentage or mm to display the incident level on the main display.
2. Incident Level or Intercepted Amount
Select the incident level or the intercepted amount to use for the display and the linear output.
To measure the incident level, select -L.
To measure the intercepted amount, select -d.
The auto-scale function can be used only for a Through-beam Sen- sor Head.
POINT
Sensor Head Emitter Sensor Head Receiver
Sensing object
Intercepted beam width = Intercepted amount Incident beam width =
Incident level
Settings Required before Application Section 1-6
16
3. Confirmation
Select both the display unit and either the incident level or the in- tercepted amount, and then press the ENT Key to confirm the settings. An example is shown below for measuring the incident level in millimeters.
For details, refer to 3-8-1 Auto-scaling and 4-5-13 Auto- scale Settings.
1-6-2 Reference Incident Level
When the Sensor Head is mounted for the first time, set the reference inci- dent level after adjusting the optical axis.
Reset the reference incident level whenever the position of the Sensor Head is changed.
Adjust the optical axis in RUN Mode so that none of the laser beam is intercepted, and then press the DOWN Key ( ) for 3 seconds or longer.
For details, refer to 3-6-2 Reference Incident Level Setting Function and 4-3-3 Setting the Reference Incident Level.
ZX-LT005 Sensor Head Emitter
ZX-LT005 Sensor Head Receiver
Measurement width: 5 mm
Incident level display Select 5−L, and then press the ENT Key.
Sensor Head Emitter Sensor Head Receiver
Press the DOWN Key on the Amplifier Unit.
Settings Required before Application Section 1-6
17 1-6-3 Linear Output
The default linear output settings are listed in the following table. These settings are set at the factory and also after initializing the settings.
Use the monitor focus function when setting the output voltage to 0 to 5 V or 1 to 5 V instead of ±4 V.
Example: Setting Linear Output to 0 to 5 V 1. Set the mode switch to FUN.
2. Use the LEFT/RIGHT Keys to display .
3. Use the UP/DOWN Keys to change to , and then press the ENT Key to confirm the selection.
4. Use the LEFT/RIGHT Keys to display . Default linear
output setting Operation after setting reference incident level Voltage
output
±4 V Incident level display
None of beam intercepted 4 V Entire beam intercepted −4 V Intercepted
amount display
None of beam intercepted −4 V Entire beam intercepted 4 V Current
output
4 to 20 mA
Incident level display
None of beam intercepted 20 mA Entire beam intercepted 4 mA Intercepted
amount display
None of beam intercepted 4 mA Entire beam intercepted 20 mA
RUN T FUN
Settings Required before Application Section 1-6
18
5. Perform the following steps to set the linear output.
Monitor focus
Press the ENT Key to select the voltage output.
Use UP/DOWN/LEFT/RIGHT Keys to set the focus value of the first point to 5 V at 100%.
Press the ENT Key to move to the monitor focus for the second point .
Use UP/DOWN/LEFT/RIGHT Keys to set the focus value of the second point to 0 V at 0%.
Press the ENT Key to complete the monitor focus setting.
Monitor focus calculations will be performed.
OK
End
SECTION 2 Outline of Operation
This section describes the overall flow of operation.
2-1 Part Names and Functions ...20 2-2 Outline of Key Operations ...21 2-3 Procedures for Reflective Sensor Heads ...22 2-3-1 Positioning and Setting Threshold Values...22 2-3-2 Setting Various Functions ...22 2-4 Procedures for Through-beam Sensor Heads ...24 2-4-1 Positioning and Setting Threshold Values...24 2-4-2 Setting Various Functions ...24 2-5 Outline of Functions ...26 2-5-1 RUN Mode Displays ...26 2-5-2 T Mode ...26 2-5-3 FUN Mode Displays ...26
Part Names and Functions Section 2-1
20
2-1 Part Names and Functions
Note 1. The current/voltage switch for the linear output is on the bottom of the Amplifier Unit.
2. The information displayed on the main display and sub-display is reversed if Reverse Mode is enabled.
Zero reset indicator (green)
Laser ON indicator (green) Enable indicator (green)
Sub-display
Threshold value, incident level, resolution, etc.
Main display See note 2.
Measured value, function, etc.
Judgement indicators
HIGH (orange) PASS (green) LO W (yellow)
See note 2.
Change Keys
Changing function, threshold values, set values, etc.
Selection Keys
RUN mode displays, function switching, numeric digit selection, etc.
ENT Key
Zero reset, teaching, function/
numeric value confirmation
Threshold Switch Selecting H or L
Mode Switch
Selecting RUN, T, or FUN
Outline of Key Operations Section 2-2
21
2-2 Outline of Key Operations
Note 1. Refer to 2-5-1 RUN Mode Displays for details.
2. Refer to 2-5-3 FUN Mode Displays for function details.
3. The DOWN Key is also used to input the reference incident level set- ting when a Through-beam Sensor Head is used.
Mode: RUN
Display selectionSee note 1.
Timing input Reset input
Zero reset
Threshold value Manual setting
Mode: T
Numeric value Digit position
Threshold value confirmation/Teaching See note 3.
Function/numeric value confirmation Function selection See note 2.
Function setting
Mode: FUN
See note 2.
Procedures for Reflective Sensor Heads Section 2-3
22
2-3 Procedures for Reflective Sensor Heads 2-3-1 Positioning and Setting Threshold Values
Manual Setting
3-4-2 Inputting Threshold Values Directly Automatic Setting
Workpiece surface positioning:
Position Teaching in 3-4-1 Teaching
Unknown size workpiece judgement:
Two-point Teaching in 3-4-1 Teaching
Judging workpiece with uneven surfaces, warped workpieces, or mov- ing workpieces:
Automatic Teaching in 3-4-1 Teaching
2-3-2 Setting Various Functions
Changing the display value:
3-5-1 Scaling
Changing response speed or increasing resolution:
3-5-2 Number of Samples to Average
Changing positioning accuracy when operating and releasing:
3-5-3 Hysteresis Setting
Holding value during measurement:
3-5-4 Hold Functions
Using OFF-delay timer:
3-5-5 Timer
Operation requiring two Sensor Heads:
3-5-6 Two-sensor Operation
Resetting default status:
3-5-7 Initializing Settings
Changing the output current or voltage range:
Special Functions (Set) 3-5-8 Monitor Focus Function
Detecting the optical level:
Special Functions (Set) 3-5-9 Intensity Mode
Procedures for Reflective Sensor Heads Section 2-3
23
Detecting minute changes:
Special Functions (Fun) 3-5-10 Differentiation Function
Reversing display order:
Special Functions (disp) 3-5-11 Display Reverse Function
Minimizing the current consumption of the Amplifier Unit:
Special Functions (disp) 3-5-12 ECO Display Function
Changing the number of digits on the display:
Special Functions (disp)
3-5-13 Limiting the Number of Display Digits
Setting status when not measuring:
Special Functions (Etc)
3-5-14 Setting for Non-measurement
Setting workpiece measurement to zero every time:
Special Functions (Etc)
3-5-15 Zero Reset Memory Function
Setting reception sensitivity (automatic switching or fixed):
Special Functions (Etc) 3-5-16 Gain Switch
Procedures for Through-beam Sensor Heads Section 2-4
24
2-4 Procedures for Through-beam Sensor Heads
2-4-1 Positioning and Setting Threshold Values
Manual Setting
3-7-2 Inputting Threshold Values Directly Automatic Setting
Workpiece surface positioning:
Position Teaching in 3-7-1 Teaching
Unknown size workpiece judgement:
Two-point Teaching in 3-7-1 Teaching
Judging workpiece with uneven surfaces, warped workpieces, or mov- ing workpieces:
Automatic Teaching in 3-7-1 Teaching
2-4-2 Setting Various Functions
Changing the incident level to any value:
3-8-1 Auto-scaling
Changing the display value:
3-8-2 Scaling
Changing the response speed or increasing resolution:
3-8-3 Number of Samples to Average
Changing positioning accuracy when operating and releasing:
3-8-4 Hysteresis Setting
Holding value during measurement:
3-8-5 Hold Functions
Using OFF-delay timer:
3-8-6 Timer
Operation requiring two Sensor Heads.
3-8-7 Two-sensor Operation
Resetting default status:
3-8-8 Initializing Settings
