Red Lion - Access, control and visualze machine data
Instruction Manual for RED LION models including: ZCG Series, Single Channel Output Rotary Pulse Generator, ZCG Series Single Channel Output Rotary Pulse Generator, Rotary Pulse Generator, Pulse Generator, Generator, ZFG Series, ZGG Series
Red Lion ZFG0001C Single Shaft Length Sensor, 1 PPR
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DocumentDocumentBulletin No. ZFG/ZCG-C Drawing No. LP0737 Revised 02/2022
MODEL ZCG - SINGLE CHANNEL OUTPUT ROTARY PULSE GENERATOR MODEL ZFG and ZGG - SINGLE CHANNEL OUTPUT LENGTH SENSORS
(Replaces MODELS RPGC, LSCS and LSCD respectively)
VARIOUS PULSE PER REVOLUTION (PPR) RATES Up to 200 PPR for fine, high-resolution counting or precision speed measurement from slow shaft speeds.
UP TO 10 KHz OUTPUT FREQUENCY
CURRENT SINK OUTPUT
LENGTH SENSORS AVAILABLE WITH: Single or Dual Ended Shaft
SEALED PRECISION BALL BEARINGS
VARIOUS CABLE LENGTHS AVAILABLE
RUGGED CAST ALUMINUM HOUSING
3/8" DIA. STAINLESS STEEL SHAFT
WIDE INPUT SUPPLY VOLTAGE RANGE & LOW CURRENT OPERATION
EASY INSTALLATION Eliminates air-gap, sensing distance, and beam alignment procedures of other types of sensing.
IDEAL FOR DUSTY, DIRTY ENVIRONMENTS Where "Non Contact" sensing means are impractical.
DESCRIPTION
The units are rugged, incremental encoders that convert shaft rotation into a current sinking pulse train.
Internally, a single L.E.D. light source and a photologic sensor in conjunction with a shaft-mounted, durable, metal-etched encoder disc, provides signal accuracy and reliability to 10 KHz. The DC input power supply requirement is a versatile +8 to +35 VDC, and is reverse polarity protected. The NPN Open Collector Transistor Output is current limited to 40 mA and is compatible with most RLC counters, rate indicators, controllers and accessories.
All units are packaged in a rugged cast aluminum housing with a gasketed, rear aluminum cover. The 3/8" (9.53 mm) diameter heavy duty stainless steel shaft and sealed, lifetime-lubricated precision ball bearings are preloaded for minimum end play and rated for continuous use up to 6000 RPM. They are designed to meet NEMA 13/IP54 environmental requirements. All units are supplied with 10 feet (3M) of PVC jacketed 3-wire, 22 AWG cable with stranded shield wire and 100% foil shield coverage. Operating Temperature range is -18°C to +60°C.
ZCG DIMENSIONS In inches (mm)
0.375 (9.53) DIA. SHAFT
2.75 (69.9)
3.38 (85.8)
2.00 (50.8)
+
+
+
+
+
0.99 (25.1) DIA FLANGE
1.50 (38.1) DIA. BOLT CIRCLE
#8-32 UNC x0.30" (7.6) DP. 4 PL., EQUALLY SPACED
0.75 (19)
0.022 (0.56)
1.65 (42)
0.08
(2)
0.05 (1.3)
0.13 (3.3)
1.20 (30.5)
1.25 (31.8)
2.00 (50.8) DIA. MOUNTING FACE
ROTARY PULSE GENERATOR
The ZCG can be direct-coupled to a machine shaft by means of a flexible bellows, spring or rubber sleeve type coupler, etc., that allows for axial and radial misalignment. They can also be coupled with instrument timing belts and pulleys or gears. The housing may be rigidly face-mounted with the 4, #8-32 threaded holes. The 3-wire shielded cable exits through a cord connector.
LENGTH SENSOR
The length sensors are available in both Single Ended Shaft (ZFG) and Double Ended Shaft (ZGG) versions, both of which include a Stainless Steel Handle Tube for mounting and 10 feet (3.05 M) of 3-wire shielded cable. When mounted to a Length Sensor Hinge Clamp Assembly (See Model LSAHC001) and coupled with one or two Measuring Wheels (See Measuring Wheels), a low cost, versatile and highly accurate length measurement system can be configured.
LENGTH SENSOR MEASUREMENT ACCURACY
Factors which affect measurement accuracy include Measuring Wheel accuracy and wear, and material conditions. Ideally, materials which are hard, thin and strong provide good readings. Conversely, soft, thick and elastic materials can present problems in obtaining true readings. Count or Rate Indicators with "input scaling" can compensate for Measuring Wheel wear and material elasticity and compliance errors. In addition, English/Metric conversions may also be accomplished.
Open Collector Output Wiring The ZCG, ZFG, and ZGG series of sensors have open collector outputs. An
open collector output brings the uncommitted collector of the encoder switching device to the external world. Because the collector element is not associated with the sensor supply voltage, the sensor output collector may be "pulled up" to external voltages (40 VDC max.) different than the encoder supply voltage. NPN open collector outputs are current sinking devices. An output signal will not be generated unless a pull-up resistor is connected from the open-collector to the positive side of an external supply. The same supply can be used for powering the unit and for the pull-up resistor.
LENGTH SENSOR MOUNTING CONSIDERATION
1. Length Sensors should be mounted so measuring wheel(s) contact ribbon, strip or web as it passes over a roller. As an alternative, wheel(s) can be driven by roller surface next to material being measured.
2. Note: The weight at the Length Sensor unit provides sufficient traction for accurate operation when mounted, with arm angle from horizontal not exceeding ±30o.
3. Tension on signal cable can cause wheel(s) to lift. Make sure cable is clamped to machine frame near the unit and allow slack.
1
ZFG DIMENSIONS In inches (mm)
1.20 (30.5)
0.04 (1.0)
0.75 (19.0)
1.65 (41.9)
0.08 (2.03) MAX.
EQUIVALENT CIRCUIT & CONNECTIONS
LED REGULATOR
RED
8 to 35 VDC @ 50mA max.
This is the side view of the Model ZFG. All other dimensions (including the handle tube) are the same as the Model ZGG. See below.
ZGG DIMENSIONS In inches (mm)
2.75 (69.9)
3.38 (85.8)
2.00 (50.8)
.04 (1.0)
4.00 (101.6) 1.65 (41.9)
.08 (2.03) MAX.
.75 (19.0) TYP. 2
USABLE SHAFT LENGTH
1.08 (27.4)
REF., TYP. 2
.022 (.56) TYP. 2
0.375 (9.52) DIA. SHAFT
.13 (3.3)
2.06 (52.3)
2.00 (50.8) DIA.
2.75 (69.8)
.75 (19) DIA.
ELECTRICAL SPECIFICATIONS
1. SUPPLY VOLTAGE: +8 to +35 VDC (including power supply ripple) @ 50 mA max. (30 mA typ.); Reverse polarity protected.
2. OUTPUTS: NPN Open Collector Transistor; VOH = 30 VDC max., VOL = 1 V max. @ 40 mA Output current is limited to 40 mA.
3. OUTPUT FREQUENCY: Up to 10 KHz 4. CABLE CONNECTIONS:
RED = +VDC; BLACK = Common; WHITE = NPN O.C. Output.
MECHANICAL SPECIFICATIONS
1. MAXIMUM MECHANICAL SPEED: 6000 RPM 2. RADIAL SHAFT LOAD: 15 lbs. max. (66.7N) 3. AXIAL SHAFT LOAD: 15 lbs. max. (66.7N) 4. STARTING TORQUE: 3 oz.-in. (21.2N-mm) 5. MOMENT OF INERTIA:
Single Shaft = 2.82 x 10-4 oz. - in. - sec.2 (1.99 x 10-3N - mm - sec2) Dual Shaft = 3.09 x 10-4 oz. - in. - sec.2 (2.19 x 10-3N - mm - sec2) 6. OPERATING TEMPERATURE: -18°C to +60°C 7. WEIGHT (LESS CABLE): Rotary Pulse Generator = 15 oz (0.42 Kg) Length Sensors = 22 oz (0.62 Kg)
WAVE OUTPUT DIAGRAM
Square wave output for models with PPR 1, 10, 12, 20, 60 and 100. Square wave, 50/50 duty cycle ±10%.
Models that use 1/3 yd. or 1/3 mtr wheels with internal ÷ 3 circuits. 66/33 duty cycle.
Models with 120 and 200 PPR utilize internal doubling. (50 µsec ±20% neg. going pulse.)
METAL ETCHED OPTICAL DISC
SHAFT
WHT BLK
PHOTOLOGIC DETECTOR AND PULSE SHAPING CIRCUIT
BARE STRANDED SHIELD WIRE CONNECTED TO INSTRUMENT COMMON FOR INCREASED NOISE IMMUNITY
OUTPUT: VOH = 30 VDC max. VOL = 1V max. @ 40mA
COMMON
ORDERING INFORMATION
MODEL NO.
DESCRIPTION
PPR
OUTPUT PULSE RATE
CODE
1
10
ZCG
12
Rotary Pulse Generator (Replaces RPGC)
60
100
*120
*200
1
1/Foot
10
10/Foot
12
1/inch
20 60/Mt or Yd
ZFG
Length Sensor Single Shaft
(Replaces LSCS)
60 100 *120
60/Foot 100/Foot 10/Inch
*200 600/Mt or Yd
.333 1/Mt or Yd
3.333 10/Mt or Yd
33.333 100/Mt or Yd
1
1/Foot
10
10/Foot
12
1/inch
20 60/Mt or Yd
ZGG
Length Sensor Double Shaft (Replaces LSCD)
60 100 *120
60/Foot 100/Foot 10/Inch
*200 600/Mt or Yd
.333 1/Mt or Yd
3.333 10/Mt or Yd
33.333 100/Mt or Yd
Flexible Coupling (1" Length) 0.250" - 0.375"
Flexible Coupling (1" Length) 0.375" - 0.375" RPGFC
Flexible Coupling (1" Length) 0.375" - 0.500"
Flexible Coupling (1" Length) 0.375" - 6 mm
PART NUMBER
ZCG0001C ZCG0010C ZCG0012C ZCG0060C ZCG0100C ZCG0120C ZCG0200C ZFG0001C ZFG0010C ZFG0012C ZFG0020C ZFG0060C ZFG0100C ZFG0120C ZFG0200C ZFG00/3C ZFG03/3C ZFG33/3C ZGG0001C ZGG0010C ZGG0012C ZGG0020C ZGG0060C ZGG0100C ZGG0120C ZGG0200C ZGG00/3C ZGG03/3C ZGG33/3C RPGFC002 RPGFC003 RPGFC004 RPGFC006
* Rotary pulse generators and length sensors with 120 & 200 PPR outputs employ an internal doubling circuit and deliver a fixed 50 µsec ±20% output pulse at the leading and trailing edge of a passing slot. Additional doubling in external indicators or circuits may not be applicable. These outputs are derated to 7300 Hz due to internal x2 circuitry. (See Wave Output Diagram)
Notes: 1. For 25 foot cable, replace the last character of the part number ("C") with "D".
For 50 foot cable, replace the last character of the part number ("C") with "E". 2. Wheels and mounting brackets are sold separately, see Length Sensor Accessories.
2
LENGTH SENSOR ACCESSORIES SEPARATE LENGTH MEASURING WHEELS - DIMENSIONS In Inches (mm)
WHEEL CODE
OR
8-32 UNF Set Screw .376" (9.6) Bore +.001" -.000"
Cast Alum.
3/8" (9.5)
Round Section Replaceable Tire .210" Section Dia. Black Neoprene
FOR USE ON: Metal, paper, foil, film and hard plastics. Line contact on material being measured, convenient when available measuring track is narrow or for measuring on end of roller beside passing material.
Max. Speed: 600 RPM
WHEEL CODE
.376" (9.6) Bore +.001" -.000"
OF
Cast Alum. 1" (25.4)
WHEEL
Tan, Smooth Polyurethane Tread
CODE
FOR USE ON: Soft, smooth
materials such as soft
paper, matting,
cardboard, fine weave
10-32 UNF textiles. Broad wheel
Set Screw tread minimizes contact
.376"
pressure and tan polyurethane tread
(9.6) Bore +.001"
minimizes marking.
-.000"
Max. Speed: 600 RPM
Balanced version of 1ft. circumference available. Balanced to ANSI S2.191989 Quality Grade 6.3 @ 3000 RPM.
OK
Diamond Knurled Aluminum Tread
10-32 UNF Set Screw
FOR USE ON: Rubber, coarse weave fabrics, rough wood surfaces, foam, insulation.
Max. Speed: 600 RPM
Cast Alum.
1" (25.4)
Balanced version of 1ft. circumference available. Balanced to ANSI S2.191989 Quality Grade 6.3 @ 3000 RPM.
SELECTING APPROPRIATE WHEEL SIZE & PPR (Pulses Per Rev.) OF ROTARY PULSE GENERATOR
When the desired output of a length sensor and wheel combination is either in inches, feet, yards, or meters selection of the proper combination is relatively straight forward. For example, with a 1-foot wheel circumference, a 1 PPR Rotary Pulse Generator will deliver 1 pulse/ft, 12 PPR would deliver 12 pulses/ ft (1 pulse/inch); 100 PPR would yield 100 pulses/ft; and 120 PPR would permit measuring to 1/10th of an inch (1/120th of a foot).
WHEELS & REPLACEMENT TIRES FOR CODE OR WHEELS
ORDERING INFORMATION
WHEEL CODE CIRCUMFERENCE
OR
1 foot (1/3 yd)
OF
1 foot (1/3 yd)
BF (Balanced) 1 foot (1/3 yd)
TOLERANCE ±0.40% ±0.35% ±0.40%
PART NUMBER WF1000OR WF1000OF WF1000BF
WHEEL CODE OK
BK (Balanced) Replacement Tires
for OR Wheels
CIRCUMFERENCE 1 foot (1/3 yd) 1 foot (1/3 yd)
1 foot (1/3 yd)
TOLERANCE ±0.35% ±0.35%
Note: After installation of measuring wheels, ensure guards, shields or other devices are in place to protect personnel from rotating equipment.
PART NUMBER WF1000OK WF1000BK
TORF1000
3
MODEL LSAHC - LENGTH SENSOR HINGE CLAMP ASSEMBLY
The Length Sensor Hinge Clamp Assembly provides an easy method for attachment and mounting of the Length Sensors and LSCB1 Conversion Bracket. The removable top on the solid zinc LSAHC mounting block allows quick installation of the Length Sensor handle tube and provides secure clamping retention. The mounting block pivots freely in zinc right angle brackets to allow mounting the assembly via clearance holes for 1/4" dia. bolts.
The lock washers must be used as indicated (between the bolt head and the top clamp piece). Assemble the top clamp piece as follows.
1. Tighten both bolts so that the top clamp half draws down evenly on the sensor tube.
2. Tighten the bolts until both lock washers are flat. 3. Then turn each bolt an additional ½ to ¾ turn.
DIMENSIONS In inches (mm)
FRONT VIEW
2.5 (63.5)
1.25 (31.8)
Lock washers (2) must be installed between bolt heads and top clamp piece.
.25 (6.3)
.85 (21.6)
SINGLE WHEEL 2.93 (74.4)
DUAL WHEEL 4 (101.6)
Model ZGG Shown
THIS WHEEL AND SHAFT OMITTED ON
SINGLE SHAFT UNITS
CAUTION: Downward tension on signal cable can cause wheel(s) to lift. Make sure cable is clamped to machine frame near encoder and allow slack.
NOTE: The weight at the Length Sensor unit provides sufficient traction for accurate operation when mounted as shown, with arm angle from horizontal not exceeding ±30°, and with hinge clamp toward the far extreme of the extension arm.
3.4 (86.4)
2.9 (73.7)
TOP VIEW
1.50 2.00 (38.1) (50.8)
0.75 (19.0)
4X Ø 0.31 (7.9) 0.75 (19.0)
E-clip retaining ring (2) must be installed in slots.
.88 (22.4)
WRHAEDEIULS
6.9 (175.3)
(14.98.3)
.88 (22.4)
4.50 (114.3) 5.70 (144.8)
ORDERING INFORMATION
MODEL NO.
DESCRIPTION
LSAHC Length Sensor Hinge Clamp Assembly
PART NUMBER LSAHC001
Model ZFG Shown
Length Sensors should be mounted so measuring wheel(s) contact ribbon, strip or web as it passes over a roller. As an alternative, wheel(s) can be driven by roller surface next to material being measured.
LIMITED WARRANTY
(a) Red Lion Controls Inc. (the "Company") warrants that all Products shall be free from defects in material and workmanship under normal use for the period of time provided in "Statement of Warranty Periods" (available at www.redlion.net) current at the time of shipment of the Products (the "Warranty Period"). EXCEPT FOR THE ABOVE-STATED WARRANTY, COMPANY MAKES NO WARRANTY WHATSOEVER WITH RESPECT TO THE PRODUCTS, INCLUDING ANY (A) WARRANTY OF MERCHANTABILITY; (B) WARRANTY OF FITNESS FOR A PARTICULAR PURPOSE; OR (C) WARRANTY AGAINST INFRINGEMENT OF INTELLECTUAL PROPERTY RIGHTS OF A THIRD PARTY; WHETHER EXPRESS OR IMPLIED BY LAW, COURSE OF DEALING, COURSE OF PERFORMANCE, USAGE OF TRADE OR OTHERWISE. Customer shall be responsible for determining that a Product is suitable for Customer's use and that such use complies with any applicable local, state or federal law. (b) The Company shall not be liable for a breach of the warranty set forth in paragraph (a) if (i) the defect is a result of Customer's failure to store, install, commission or maintain the Product according to specifications; (ii) Customer alters or repairs such Product without the prior written consent of Company. (c) Subject to paragraph (b), with respect to any such Product during the Warranty Period, Company shall, in its sole discretion, either (i) repair or replace the Product; or (ii) credit or refund the price of Product provided that, if Company so requests, Customer shall, at Company's expense, return such Product to Company. (d) THE REMEDIES SET FORTH IN PARAGRAPH (c) SHALL BE THE CUSTOMER'S SOLE AND EXCLUSIVE REMEDY AND COMPANY'S ENTIRE LIABILITY FOR ANY BREACH OF THE LIMITED WARRANTY SET FORTH IN PARAGRAPH (a). BY INSTALLING THIS PRODUCT, YOU AGREE TO THE TERMS OF THIS WARRANTY, AS WELL AS ALL OTHER DISCLAIMERS AND WARRANTIES IN THIS DOCUMENT.