SG1000RA SlideGate Monitor
SG1000RA general description (‘R’ is for ‘relays’)
The SG1000RA is a SlideGate Monitor with a 2-Relay output.
The SG1000RA is a rugged, medium cost encoder-based
monitoring device that enables the end-user to very accurately
monitor a slide-gate’s fully-open and fully-closed positions.
The SG1000RA has two modes: Calibration Mode, and Normal
Operating Mode. A simple calibration procedure teaches
(programs) the SG1000RA the fully-closed (0% open)
and fully-open (100% open) gate positions. Once programmed,
the SG1000RA de-energizes one relay when the gate is in the
fully-closed position, and de-energizes the other relay when the
gate is in the fully-open position. Any gate position between
fully-closed and fully-open, is represented by both relays being
energized.
Physical Appearance and Installation Overview
Figure 1 is the front-view of the SG1000RA, showing the
encoder-output-shaft (with the most common shaft end-thread
type shown).
Cable
The SG1000RA attaches to the slide-gate’s ‘rack and pinion’
shaft, or similar rotating mechanical component, using an “endof-shaft” mounting method. See Figure 2. In the most common
application, the SG1000RA’s encoder-shaft-end screws into a
single 3/8-inch diameter hole, to a depth of 0.625 inch, having
3/8” – 16 UNC-2B threads. (Other encoder-shaft end-thread
types are optional.)
Even though the SG1000RA is mounted to the process shaft
via the “end-of-shaft” mounting method, installation of exible
conduit and of the optional stabilizer bracket is recommended,
which allows the SG1000RA to “oat” along with any wobble
of the process’s shaft while still preventing the SG1000RA itself
from rotating along with that shaft (see Fig. 2).
Note: The stabilizer bracket’s U-bolt is slightly oversized
to provide about 1/8” of slack between it and the
SG1000RA. The U-bolt’s slack prevents it from
rigidly clamping to the SG1000RA’s conduit port.
Encoder-Shaft
3/8"-16 UNC-2A threads
Figure 1:
SG1000
Process Shaft
Stabilizer bracket
U-Bolt
with slack
Flexible
conduit
(use is optional)
Structural Framework
Figure 2:
Electrical connections
First, remove (twist CCW) the back-end-cover from the
SG1000RA’s red enclosure, to reveal the User Interface Board
(see Figure 3).
SW2 Calibration Button
Red LED
100% Open
Relay
RELAY 2
SW1 Relay
Setpoint
Selection
CAL
SW2
SET-POINT
0
1
F
2
E
3
D
4
C
5
B
6
A
7
9
8
SW1
CAL
1
2
3
Figure 3: User Interface Board
Second, remove the nylon-retained metal nuts that hold the User
Interface Board in place, to reveal the terminal block TB1 (see
Figure 4)
Terminal Block
TB1
1 2 3 4 5 6 7 8 9 10
Figure 4: Terminal Block View
Red LED
0% Open
Relay
RELAY 1
Green LEDs
Calibration
Status
Earth Ground
Screw
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The SG1000RA’s electrical connections are as follows:
Terminal Description
1 Relay 2 N.C.
2 Relay 2 N.O.
3 Relay 2 COM
4 AP2 (Alternate Power, Same as L1)
5 L1 (VAC Hot)
6 L2 (VAC Neutral/Hot)
7 Relay 1 N.C.
8 Relay 1 N.O.
9 Relay 1 COM
10 AP1 (Alternate Power, Same as L1)
• Connect the Vac’s earth ground wire to the ground screw
inside the SG1000RA housing (see Fig 4 for location of ground
screw).
• For 115 Vac, connect Vac’s HOT to terminal TB1-5.
• For 115 Vac, connect Vac’s NUETRAL to terminal TB1-6.
• For 230 Vac, connect Vac’s L1-HOT to terminal TB1-5.
• For 230 Vac, connect Vac’s L2-HOT to terminal TB1-6.
• If using the SG1000RA’s relays to switch Vac power, if
desired you can power each of the two relay’s COMMON
pins via the Vac that is already powering the SG1000RA.
- Connect appropriate gauge jumper wire between terminal
TB1-10 (AP1: Alternate-Power1) and terminal TB1-9
(Relay1 Common).
- Connect appropriate gauge jumper wire between terminal
TB1-4 (AP2: Alternate-Power2) and terminal TB1-3
(Relay2 Common).
Note: In this case “appropriate” means a jumper wire
capable of carrying up to 0.5A at 125Vac, or 0.25A
at 250Vac, this assuming the relays will be running
at their maximum rated power in the application.
• If using the SG1000RA’s relays to switch Vdc power, then
do NOT connect jumpers from TB1-10 to TB1-9, NOR from
TB1-4 to TB1-3. Instead, connect your separately supplied
DC power to each of the two relay’s COMMON pins, at
terminal TB1-9 (Relay1 Common), and at terminal TB1-3
(Relay2 Common).
• Relay1 = Gate at 0%-open position.
- Relay1 COMMON pin is at terminal TB1-9.
- Relay1 NORMALLY OPEN pin is at terminal TB1-8.
- Relay1 NORMALLY CLOSED pin is at terminal TB1-7.
• Relay2 = Gate at 100%-open position.
- Relay2 COMMON pin is at terminal TB1-3.
- Relay2 NORMALLY OPEN pin is at terminal TB1-2.
- Relay2 NORMALLY CLOSED pin is at terminal TB1-1.
• See Figure 4 for related information.
Calibration Procedure
Calibration consists of teaching the SG1000RA the encoder
values for the fully-closed (0% open) and fully-open (100%
open) positions. The eight calibration steps are as follows (once
the user is familiar with the calibration procedure they need only
follow the underlined portions as a quick calibration guide):
1) Remove (twist CCW) the back-end-cover from the
SG1000RA.
This provides access to the SG1000RA’s User Interface
Board, namely the calibration switch SW2 (the pushbutton switch), and the relay set-point/hysteresis selection
16-position rotary switch (SW1). See Figure 3 for locations
of these switches.
Note: The SG1000RA has “Auto-Direction-Detection”
software to detect the direction the slide-gate’s shaft
is turning, CW or CCW, as it runs from 0%-open to
100%-open, so there is NO need for a ‘Direction-
Selection” switch in the SG1000Rx line of products
2) There are two ways to enter Calibration Mode.
• One, remove the Vac power, press-in and hold the
calibration switch SW2, then reapply the Vac power.
When the two green LEDs are ashing on the User
Interface Board then the SG1000RA is in Calibration
Mode, then release the SW2 button. (This is referred to as
“power-up” entry into Calibration Mode).
• Or two, while the SG1000RA remains powered, press-in
and hold the calibration switch SW2, for a constant 5 to
6 seconds. When the two green LEDs are ashing on the
User Interface Board then the SG1000RA is in Calibration
Mode, then release the SW2 button. (This is referred to as
“on-the-y” entry into Calibration Mode).
The SG1000RA is now in Calibration Mode.
Note: For either Calibration Mode entry method, do not
press SW2 multiple times or allow it to change state,
just keep it pressed-in until the SG1000RA’s two green
LEDs are ashing, then release the button. Also when
in Calibration Mode, both the relays are de-energized.
3) Move the gate to the fully-closed position (i.e., 0% open).
4) Momentarily press the calibration switch SW2.
• This captures the present encoder count. This value is then
used for the fully-closed position (0% open).
• One of the green LEDs goes solid ON (to indicate the
rst calibration point has been calibrated), while the other
green LED keeps ashing.
• Both relays remain de-energized.
5) Move the gate to the fully-open position (i.e., 100%
open).
Note: As the gate moves from fully-closed to fully-open,
the SG1000RA’s encoder shaft must turn at least
1/4th-turn, but not more than 6-turns. Hence, if the
shaft turns more than 6-turns, or less than 1/4th-turn,
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then the SG1000RA will not work properly for the
application.
6) Momentarily press the calibration switch SW2.
• This captures the present encoder count. This value is then
used for the fully-open position (100% open).
• The SG1000RA then automatically exits Calibration
Mode
Note: Calibration Mode is exited at this point for both
valid and invalid calibrations.
- For a valid calibration the Normal Operating
Mode is now entered: Both green LEDs are now
solid ON (to indicate both calibration points have
been calibrated). If the user does not immediately
move the gate, then the 0%-open Relay1 energizes,
and the 100%-open Relay2 de-energizes assuming
the conditions of the SW1 set-point / hysteresis are
met (this because the gate was left in the fully-open
position from step 5).
- For an invalid calibration an “Error” condition is
indicated: Both green LEDs are now in a rapid ash,
and both relays remain de-energized. (The user must
re-enter Calibration Mode and try again).
See the “Valid Calibration” and “Invalid Calibration”
sections below for details regarding whether, or not, your
SG1000RA accepted the gate’s two calibration positions
7) Select the desired 0% and 100% set-point hysteresis.
How ‘tight’ or how ‘loose’ you want your relays to trigger
on or around the Slidegate’s fully-closed and fully-open
positions can be controlled by selecting the amount of Relay
set-point and hysteresis using the 16-position rotary switch
(SW1) found on the User Interface Board.
The SW1 Rotary Switch has 16 different selections
(0 thru F) and they are as follows:
SW1
Setting
Relay de-energize
set-point inboard of
calibration-pts
Relay re-energize setpoint further inboard of
the de-energize point
0 0 Encoder Positions 0 Encoder Positions
1 1 Encoder Position 1 Encoder Position
2 2 Encoder Positions 1 Encoder Position
3 4 Encoder Positions 1 Encoder Position
4 8 Encoder Positions 1 Encoder Position
5 12 Encoder Positions 1 Encoder Position
6 1 Encoder Position 2 Encoder Positions
7 2 Encoder Positions 2 Encoder Positions
8 4 Encoder Positions 2 Encoder Positions
9 8 Encoder Positions 2 Encoder Positions
A 12 Encoder Positions 2 Encoder Positions
B 1 Encoder Positions 4 Encoder Positions
C 2 Encoder Positions 4 Encoder Positions
D 4 Encoder Positions 4 Encoder Positions
E 8 Encoder Positions 4 Encoder Positions
F 12 Encoder Positions 4 Encoder Positions
SW1 sets the “number of encoder positions” inboard from
the fully-closed or fully-open calibration points at which
the relays de-energize, and then also sets the amount of
hysteresis encoder positions that must be surpassed further
inboard beyond the de-energized point before each relay gets
re-energized again.
Note: The SG1000RA’s internal encoder has 1024
positions, identied as 0 through 1023.
Note: The SW1 Rotary Switch selections can be done in
either Calibration Mode or in Normal Operating
Mode, but the effects are not seen until in Normal
Operating Mode.
Example: Assume that out of the encoder’s 1024 possible
positions, a certain calibration span is in the CW direction,
and places the gate’s 0%-open point at encoder position 200,
and places the gate’s 100%-open point at encoder position
800. So then, ‘inboard’ means any encoder position inside
the calibration span of 200 through 800, and ‘outboard’
would be any encoder reading ‘outside’ of the calibration
span If the user set the SW1 selection at a setting of ‘9’,
then that means:
- the 0%-open relay would de-energize at 8 counts inboard
of 200 which is 200+8 = 208, and re-energize at 2 counts
inboard of the de-energize point which is 200+8+2= 210.
- the 100%-open relay would de-energize at 8 counts
inboard of 800 which is 800-8 = 792, and re-energize at
2 counts inboard of the de-energize point which is 800-8-
2= 790.
Since the SG1000RA has a 6:1 internal gear-ratio between
its output shaft and the internal encoder, this means that each
internal encoder count (i.e., 1 out of 1024 counts) is 0.35°
of rotation per count as seen at the encoder. But then, due
to the 6:1 internal gear-ratio this translates into a 6 * 0.35° =
2.11° per encoder count as seen by the output shaft.
Hence in the example above, a SW1 setting of ‘9’ provides
de-energize set-points at 8 counts inboard of the fully-closed
and fully-open positions, which translates out to be 2.11°
per count * 8 positions = 16.88°, or about a 17°-turn of the
output shaft inboard of each calibration point.
Likewise, the re-energize set-point in that example is
2.11° per count * (8 + 2) positions =
2.11° per count * (10) positions = 21.10°, or about 21°-turn
of the output shaft inboard of each calibration point.
8) Replace the back-end-cover onto the SG1000RA.
This ends the calibration procedure.
Valid Calibration (Normal Operating Behavior)
Assuming the user followed the calibration process correctly,
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the SG1000RA behaves as follows:
• Both green LEDs are solid ON.
• When the gate is at the fully-closed position (0% open), then
the 0%-open Relay1 de-energizes, and the 100%-open Relay2
remains energized. This behavior modies slightly when
accounting for any effect of the SW1 set-point and hysteresis
selection.
• When the gate is at the fully-open position (100% open), then
the 100%-open Relay2 de-energizes, and the 0%-open Relay1
remains energized. (Again, allow for any effect of the SW1
selection).
• Any gate position between 0% open and 100% open is
represented both relays being energized. (Again, allow for
any effect of the SW1 selection).
• If the gate is moved to a position that is slightly beyond
(outboard of) the fully-closed (0% open) calibrated position,
then Relay1 remains de-energized. This is known as 0% ‘runout’, and it holds to a certain point. If the encoder is turned
far enough beyond the fully-closed calibrated position, then
the encoder “wraps-around” and the relays ip-op to the
fully-open value of 100%-open Relay2 de-energized, and the
0%-open Relay1 energized.
• If the gate is moved to a position that is slightly beyond
(outboard of) the fully-open (100% open) calibrated position,
then Relay2 remains de-energized. This is known as 100%
‘run-out’, and it holds to a certain point. If the encoder is
turned far enough beyond the fully-open calibrated position,
then the encoder “wraps-around” and the relays ip-op to
the fully-closed value of 0%-open Relay1 de-energized, and
the 100%-open Relay2 energized.
• For a properly calibrated SG1000RA, the direction of
calibration (auto-detected CW or CCW), and the encoder
values for the fully-closed and fully-open gate positions are
all stored in the SG1000RA’s EEPROM memory
Note: Since a properly calibrated SG1000RA can never enter
Calibration Mode again by itself after Calibration
Mode is exited, this means that for a properly calibrated
SG1000RA running in Normal Operating Mode the
calibration results are protected until the user wants to
purposefully enter Calibration Mode again.
If re-calibration is needed, see the section below
titled “How to clear-out the existing calibration and
reprogram the SG1000RA.”
Invalid Calibration (Error condition behavior)
Assuming the user followed the calibration process incorrectly,
the SG1000RA behaves as follows:
• Both green LEDs are in a rapid ash.
• Both relays remain de-energized.
An “invalid calibration” is most likely due to one of the
following errors:
- If the user did not move the gate (or moved it but less
than 1/4th-turn, or more than 6-turns, of the encoder shaft)
between teaching the SG1000RA the fully-closed and fullyopen positions, then the closed and open positions have the
same (or nearly the same) encoder count.
- The user “double-pressed” SW2 during during entry into
Calibration Mode or while teaching the SG1000RA the fullyclosed position.
Power-ups; Calibration vs. Normal Operating Mode
• An SG1000RA that is un-calibrated (or if the calibration
attempt was invalid) automatically powers-up in Calibration
Mode, the next time power is applied.
• A properly calibrated SG1000RA powers-up in Normal
Operating Mode, when power is applied.
• If the user accesses Calibration Mode via the “power-up”
method, then any previous calibration is immediately cleared.
• If the user accesses Calibration Mode via the “on-the-y”
method, then any previous calibration is retained until the
new calibration points have been acquired. (This allows
the user the option to bail out of Calibration Mode before
completing the new calibration by simply removing the
Vac power. In this case of intended power interruption, the
EEPROM never gets called to save any new calibration, thus
the old calibration is retained
Troubleshooting Hints
1) If your SG1000RA operates both relays, but not at the gate
positions expected, then double-check the following:
a) Do you have the Relay set-point/hysteresis selection
16-position rotary switch (SW1) set properly?
b) As your gate moves from fully-closed to fully-open, does
the SG1000RA’s encoder-output-shaft turn less than 1/4thturn, or more than 6-turns? If so, then the SG1000RA will
not work in your application.
c) Is your SG1000RA terminal TB1 wiring correct?
• Do you have your relay wiring ip-opped?
• See the section “Electrical Connections” for proper
terminal TB1 connections vs the internal Relay1 and
Relay2 pin-outs.
d) Assuming conditions (a) through (c) are proper, and your
SG1000RA still seems to behave improperly, then try
re-calibrating again, paying close attention to the eight
calibration steps and your gate’s fully-closed and fullyopen positions.
How to clear-out the existing calibration, and
reprogram the SG1000RA (Two methods)
One, remove the Vac power, press-in and hold the calibration
switch SW2, then reapply the Vac power. When the two
green LEDs are ashing on the User Interface Board then the
SG1000RA is in Calibration Mode, then release the SW2 button.
(This is referred to as “power-up” entry into Calibration Mode).
The old calibration has now been cleared-out, and the SG1000RA
is in Calibration Mode awaiting new calibration.
Or two, while the SG1000RA remains powered, press-in and hold
the calibration switch SW2, for a constant 5 to 6 seconds. When
the two green LEDs are ashing on the User Interface Board then
the SG1000RA is in Calibration Mode, then release the SW2
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button. (This is referred to as “on-the-y” entry into Calibration
Mode). (Technically, at this point for on-the-y” entry into
Calibration Mode, the old calibration does NOT get wiped-out
until the new calibration points have been acquired).
See the “Calibration Procedure” section for complete details.
SG1000RA General Specications:
Input Power Input Current
60 mA for internal electronics
115 - 230VAC
±10% 50/60Hz
Input Signal Parameters
Type
Range of Operation
Internal Gear Ratio 6:1
Output Parameters
Relay
Outputs
Relay
Ratings
(Resistive
Loads
Only)
Accuracy
Encoder
Resolution
(but if supplying Vac to the output relays then
allow for a maximum of 0.5 A @115Vac,
or 0.25 A @ 230 Vac, for each of the two relays)
Rotating shaft connected to internal 10 bit, 0
to 1023 count, absolute position magnetic-eld
encoder
Continuous rotation with no physical end stops.
Calibratable span of 1/4 to 6 turns of output
shaft. Output shaft max RPM = 200.
Two Form C Relays, w/programmable set-points:
(Relay1 @ user’s fully-closed position).
(Relay2 @ user’s fully-open position).
125Vac @ 0.5A,
250Vac @ 0.25A,
30Vdc @ 0.5A,
110Vdc @ 0.3 A, and
220Vdc @ 0.27 A.
The internal magnetic-eld encoder has a
Nominal accuracy of +/- 0.7°-turn, and a
Worst case accuracy of +/- 1.4°-turn,
of its internal shaft.
After going through the 6:1 gear-ratio inside of the
SG1000RA, this results in a
Nominal accuracy of +/- 4.2°-turn, and a
Worst case accuracy of +/- 8.4°-turn,
of the SG1000RA’s output shaft.
The SG1000RA resolves down to 2 encoder counts of
the user’s calibrated span (span from fully-closed to
fully-open). This means the resolution varies linearly
from best of 0.2% of span, to worst of 5.0% of span,
depending on calibration (see details down below).
Note: The internal encoder resolves down to 1 count
of the user’s calibrated span. However the SG1000RA
software uses a +/- 1 count anti-jitter-lter, resulting in
more stable operation but at the expense of resolution,
for a nal resolution of 2 counts of the user’s calibrated
span.
Note: The SG1000RA software also monitors
a long-term trend, so if no jitter is present then a
resolution of 1 count of the user’s calibrated span may be
achieved (but is not guaranteed).
Resolution details as per the calibrated span:
A 0.2% resolution occurs when the application can make full use of
the 6-turn maximum capability of the SG1000RA, and in such a case
calibration is done at the maximum span of 1024 encoder counts.
That is, 1 count out of 1024 counts is about 0.001, or 0.1 %, but after
running through the SG1000RA’s anti-jitter-lter becomes 2 counts
out of 1024 counts, which is about 0.002 = 0.2%.
A 5.0% resolution occurs when calibrated at the minimum span of 43
encoder counts, which is 1/4th-turn of the output shaft. Allowing for
the +/- 1 count anti-jitter-lter, a 1 count out of 43 counts becomes 2
out of 43, which is about 0.05, or 5 %.
At temperatures -20F (-29C) and colder, the SG1000RA (relays
specically) may be unstable for a few seconds during a ‘cold-start’
power-up if the it has been sitting in the cold unpowered for awhile.
Mechanical Parameters
Mounting End of Shaft, single drilled and tapped hole.
Mounting Threads
Housing Material Cast Aluminum
Housing Dimensions
Stabilizer Bracket
Terminal Block
Torque
Physical/Enviroment Parameters
Additional Rating NEMA 4X, Gasket Provided
Temperature Range -40ºC to +65ºC (-40ºF to +149ºF)
Humidity 0% to 90% non-condensing
Operator Interface Parameters
One Pushbutton
One Rotary Switch Select relay set-point hysteresis
Memory
Operation Modes
Normal Operating Mode: (output relays per gate position).
- Output: Energize/de-energize two relays as per gate position, for a
properly calibrated SG1000R.
- Output: Both relays remain de-energized for an uncalibrated or
mis-calibrated SG1000R.
Calibration Mode: (calibrate for fully-closed / fully-open gate
positions, and select Relay set-point and hysteresis).
- Output: Both relays remain de-energized in this mode.
3/8-16 UNC x 0.625 in.
(Other options available.)
Cylindrical, with diameter of 3-11/16”, length
of 7-5/8” (length includes housing & shaft)
Mounted semi-rigidly to application’s
framework using two user supplied 5/16”
bolts.
0.35Nm to 0.4Nm
3.10in-lb to 3.54in-lb
Class I, Groups C, D
Class II, Groups E, F, G
UL File: E249019
For use in Pollution Degree 2 Environments.
Enter Calibration Mode, and calibrate for
fully closed/fully open positions
EEPROM retains calibration during power
failure or power shut down
Additional Information
To get additional information about the SG1000RA, visit our
website at: www.electro-sensors.com
Notice:
Copyright © 2018 Electro-Sensors, Inc. All rights reserved. No part
of this document can be duplicated or distributed without the express
written permission of Electro-Sensors, Inc.
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While the information in this manual has been carefully reviewed for
accuracy, Electro-Sensors, Inc. assumes no liability for any errors or
omissions in the information. Electro-Sensors, Inc. reserves the right
to make changes without further notice to any part of this manual or
product described in this manual.
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