AMETEK 925 Linear Cable Reel Sensor User Manual

Principles of Operation

The Series 925 Linear Cable Reel can be used in any linear application up to 1200 inches.
The system consists of a heavy duty spring motor assembly attached to a precision
machined cable drum. As the cable is pulled off of the precision drum, the drum rotates
a shaft connected to it. This shaft is precisely geared such that the full number of
revolutions of the drum is equal to the appropriate number of revolutions required by
the chosen sensor.

Applications

The Series 925 can be used in any industrial application to monitor a linear or reciprocat­ing machine motion.

The sensor package, along with the associated electronics (i.e. programmable logic control
ler, programmable limit switch, counter card, etc.) can sense the position of any linear
motion and can, therefore, be used to control machines.

Advantages

-

This approach to machine positioning has several advantages over traditional limit
switches. In hostile environments, such as many steel mill applications, the cable reel
sensor can be mounted remotely. This protects the sensor from excessive heat, steam,
water, chemicals and physical damage. In addition, mounting alignment is not critical
in that the cable can be mis-aligned somewhat without harm, thus saving installation
time. The variety of sensors available allows the system to be easily integrated to existing
machine controls.

Part Numbering

925 A1

Cable Reel

Sensor

Hardware Type

A1 = 0 - 96 inch Stroke
A2 = 97 - 192 inch Stroke
B1 = 193 - 480 inch Stroke Single Spring
B2 = 193 - 480 inch Stroke Double Spring
C = 481 - 1200 inch Stroke

Active Stroke in Inches

Initial Cable Lead in Inches

First 72 inches of intial lead is no charge. Cable lead
above 72 inches an additional charge per inch.
Leave blank if no initial cable lead required.

Sensor Type

S = Single-turn Resolver
M = Multi-turn Resolver
P1 = Single-turn Potentiomenter
P2 = Multi-turn Potentiometer
E1 = Provision for an Incremental Encoder*
E2 = Provision for an Absolute Sensor*
DN = Single-turn Resolver with DeviceNet Interface
CO = 4 - 20mA Output (Resolution is 1,000 points of total stroke)

100

12

S

X

Options

X = None

* In instances where provisions for a customer supplied sensor are required, the following points must be covered:
A. A detailed dimension drawing of the sensor to be coupled must be supplied
B. A custom dimension/approval drawing will be made prior to manufacturing.
C. Special gearing of sensor may require an additional charge.

Sheave Assemblies

Description Part Number

Horizontal

Vertical

PSD0102600

PSD0102500

Description

Resolver & Mating

Connector

Replacement Spring Assembly

Description

Spring motor for A1&

A2 Style Units

Spring motor for B &

C Style Units

Points to note when ordering a linear cable reel sensor:

1. Hardware types determine the maximum capable stroke of each style. The actual stroke is customer specified. Three
initial wraps minimum remain on cable drum after the stroke length is reached. Pulling the cable out to its physical
maximum length may damage the unit.

Part Number

M0352900

SD039220

Resolver

Part Number

SD0308900

Cable Assembly

Part Number

SD0414600L__

2. Standard gearing of single-turn sensors is such that the active stroke of the cable reel will rotate the sensor 350 degrees.
Multi-turn sensors will rotate the maximum number of turns over the active stroke. Requests for gearing other than the
above must be called out clearly on order.

3. Mounting of customer supplied sensors is done in the most expedient way possible. Special mounting requirements
must be specified clearly on order.

1.86

.42

THROAT
CLEAR

VIEW "A"

.19

Dimensions

“A” Version (stroke 96” or less)

2.50

.20

2.11

SEE VIEW "A"

1.50

.26

5.94

6.46

.50

.38 SLOT

4 PLACES

ACTIVE

STROKE

AS SPECIFIED

6.13

5.08

1.86

.42

THROA
CLEAR

VIEW "A"

.19

T

SPECIFY INITIAL

CABLE LEAD

.20

2.11

CABLE

REPLACEMENT

ACCESS

1.48

5.06

8.04

“A” Version (stroke 97” to 192”)

2.50

1.50

SEE VIEW "A"

.26

6.48

5.94

.50

.38 SLOT

4 PLACES

GEAR REDUCER ACCESS

CONNECTOR

(MS-3102E-16S-1P)

ACTIVE

STROKE

AS SPECIFIED

6.13

5.08

GEAR REDUCER ACCESS

SPECIFY INITIAL
CABLE LEAD

E

CABL

REPLACEMENT

ACCESS

9.25

5.06

CONNECTOR
(MS-3102E-16S-1P)

3.12

Dimensions

“B” Version

16.00

15.00

INITIAL CABLE LEAD

2.00

STANDARD

7 PIN
CONNECTOR

3.12

1.89

5.18

12.82

.41

4 PLACES

SEE VIEW "A"

3.19

* *

“C” Version

ADD 1.75 (FOR
"B2" STYLE UNITS

11.47

1.86

8.50

VIEW "A"

2.11

.19

.42

THROAT

CLEARANCE

.20

18.60

19.60

N

7 PI
CONNECTOR

2.00

1.89

6.34

15.22

.41

4 PLACES

SEE VIEW "A"

4.94

1.86

.42

THROAT
CLEAR

10.69

VIEW "A"

2.11

.19

.20

Sensor Type

Single Turn Resolver

Cable reel sensor with single turn resolvers are
setup so that the full stroke of the cable reel is
equal to approximately 350 degrees rotation of
the resolver. The resolver signal is fed to a con­verting device, like the Gemco Series 2500 PLS.
The Series 2500 can be scaled to display the
linear motion of the cable reel sensor. Example:
A 20 ft.. stroke cable reel sensor is specified
to be used with our Series 2500 PLS. Desired
accuracy is .01 ft. By calculating a scale factor
based on 360 degrees rotation of the resolver
such that 2000 counts or (20.00 ft.) is obtained
at 350 degrees, full linear display is achieved.

Stroke Range

Mechanical Accuracy

Speed Range

Cable Tension

Cable Material

Housing Material

Seal

Temperature Range

Specifications

Up to 1200 inches (100 ft.) standard

0.05% of active stroke

Variable

Type A unit 2.5 lbs. to 4.2 lbs. (stroke to 96”)
Type A unit 1.25 lbs. to 4.2 lbs. (stroke to 192”)
Type B unit 1.6 lbs. to 14.27 lbs.
Type C unit .75 lbs. to 16.30 lbs.

.056” (actual) stainless steel aircraft grade

10 gauge cold rolled sheet steel with baked enamel
paint finish

Splash Proof

Sensor dependent (most encoders and potentiometers
are around 0° to 180° F standard, resolvers are
typically -50° to 250° F). Check manufacturers specs

Multi-Turn Resolvers

In instances where a high degree of accuracy
or a long stroke is required, it may be advanta­geous to use a multi-turn resolver. The multi­turn resolver can generate many counts per
revolution of the cable drum (up to 16,384 with
our Series 2500 electronics) and will accumu­late these counts per revolution to track the
total linear travel. By using the linear travel per
revolution of the drum we can formulate a scale
factor for the electronic package that will display
linear cable travel throughout the full stroke.

Encoder and Potentiometer Sensors

When encoders or potentiometers are used we
can formulate the outputs to most any customer
specification. As standard packages potentiom­eters would be geared so that the full stroke of
the cable reel sensor was equal to approximately
90% of the active rotation on a single turn pot
and approximately 90% of the last turn on a 10
turn pot.

Incremental encoders can be directly driven
off the cable drum to give a known number of
pulses per revolution.

Absolute encoders can be geared so that the
maximum number of counts would equal the
specified linear stroke. If maximum stroke is
exceeded, the encoder will roll through to zero.

MOVING
MEMBER

SHEAVE
ASSEMBLIES

CABLE REEL

SENSOR

CABLE REEL

SENSOR

Mounting & Sheave Assemblies

SHEAVE ASSEMBLY

CABLE REEL

SENSOR

G

MOVIN
MEMBER

SHEAVE

ASSEMBLIES

CABLE REEL

SENSOR

MOVIN
DEVICE

G

MOVING
DEVICE

2.00

3.00

1.03

SHEAVE ASSEMBLIES

HORIZONTAL MOUNT

P/N PSD-0102600

.38 DIA. MTG.
HOLES (4 PLACES)

5.47

6.22

VERTICAL MOUNT

P/N PSD-0102500

3.38 DIA.

2.00

0.25

0.70

3.15

2.37

.38 DIA. MTG.
HOLES (4 PLACES)

2.06

2.95

4.05

2.36

0.19

AUTOMATION & PROCESS TECHNOLOGIES

®

1080 N. Crooks Road, Clawson, MI 48017-1097

Phone: [phone] Toll Free: 800-635-0289

Fax: [phone] www.AMETEKAPT.com

925.B2R

10/05.Z12