Nexen DPS30 User Manual

Dancer Position Sensor

WEB CONTROL PRODUCTS

User Manual

DPS30A and DPS60A

FORM NO. L-21260-A-1107

In accordance with Nexen’s established policy of constant product improvement, the specifications contained in this
manual are subject to change without notice. Technical data listed in this manual are based on the latest information
available at the time of printing and are also subject to change without notice.

Technical Support: 800-843-7445
[phone]

www.nexengroup.com

DANGER

Read this manual carefully before installation and operation.

Follow Nexen’s instructions and integrate this unit into your system with care.

This unit should be installed, operated and maintained by qualified personnel ONLY.

Improper installation can damage your system or cause injury or death.

Comply with all applicable codes.

Copyright 2007 Nexen Group, Inc.

FORM NO. L-21260-A-1107

Nexen Group, Inc.

560 Oak Grove Parkway

Vadnais Heights, Minnesota 55127

ISO 9001 Certified

2

TABLE OF CONTENTS

Introduction ---------------------------------------------------------------------------------------------------------------------------4

Installation -----------------------------------------------------------------------------------------------------------------------------4

Direct Connections ----------------------------------------------------------------------------------------------------------------5

Coupling Connection -------------------------------------------------------------------------------------------------------------5

Electrical Connections ------------------------------------------------------------------------------------------------------------6

Adjustment ----------------------------------------------------------------------------------------------------------------------------6

Troubleshooting ---------------------------------------------------------------------------------------------------------------------7

Mounting Dimensions -------------------------------------------------------------------------------------------------------------8

Parts List -------------------------------------------------------------------------------------------------------------------------------9

Replacement Parts -----------------------------------------------------------------------------------------------------------------9

Specifications ------------------------------------------------------------------------------------------------------------------------9

Warranty -----------------------------------------------------------------------------------------------------------------------------10

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FORM NO. L-21260-A-1107

INTRODUCTION

+.10

-.00

6.00

+.004

-.000

.236

min.

Nexen Dancer Position Sensors have been designed to accurately measure the rotational movement of a dancer
arm. This family of sensors use Hall Effect technology which provide for benefits such as infinite resolution, low
drag, and no mechanical wear. They are ideally suited to work with Nexen’s Dancer Position Controllers.

INSTALLATION

NOTE: Mounting of the Dancer Position Sensor can
be accomplished two ways. The first is the Direct
Connection method and the second is the Coupling
Connection method. Review the instructions for both
methods and select the method best suited for your
application.

DIRECT CONNECTION

1. Verify that the dancer arm pivot shaft’s end complies
with the dimensions given (See Figure 1).

2. Drill and tap two 4-40 threaded holes 90° apart for
two, .25” set screws.

Figure 1

3. The orientation of the Dancer Position Sensor (Item

1) must be as shown in order to match the mid out­put of the Dancer Position Sensor to the mid travel
position of the dancer arm (See Figure 2).

4. Attach Dancer Position Sensor (Item 1) to one of
the three hole configurations on the Bracket (Item

3) with two shorter Pan Head Screws (Item 4), Flat
Washers (Item 6), and Lock Washers (Item 5). (See
Figure 3).

5. Hand tighten the screws just enough to prevent it
from moving during installation (See Figure 3).

6. Slide the Dancer Position Sensor (Item 1) into the
shaft until the Bracket (Item 3) contacts the ma­chine’s side frame (See Figure 3).

7. Mark the location of the Bracket’s two mounting
holes.

8. Remove the Dancer Position Sensor (Item 1)
and Bracket (Item 3); then, drill and tap two 8-32
threaded holes centered within the marks drawn in
Step 7.

Figure 2

4

Figure 3

1

Machine

Frame

3

1

7

6

5

Dancer

Arm

Pivot

Shaft

5

9. With the dancer arm held firmly in its mid travel posi­tion, slide the Dancer Position Sensor (Item 1) into
the shaft while making sure the sensor shaft marking
is pointing toward the cable (See Figure 3).

10. Using the two set screws, secure the dancer pivot
shaft to the sensor shaft by tightening the screws
evenly.

FORM NO. L-21260-A-1107

11. Using the two longer Pan Head Screws (Item 7)
and Lock Washers (Item 5), secure the Bracket
(Item 3) to the machine’s side frame (See Figure 3).

4

Mid-Point of Output

when viewed from Front

Front

Back

COUPLING CONNECTION

1. Purchase a zero backlash flexible shaft coupler that
accommodates the diameter of the sensor shaft
(Item 1) on one end and the dancer arm pivot shaft
on the other end (See Figures 4 and 7).

2. Slide the shaft coupler onto the dancer arm pivot
shaft, inserting the shaft no further than half the
thickness of the coupler clamp; then, tighten the
clamp around the shaft (See Figure 4).

3. The orientation of the Dancer Position Sensor (Item

1) must be as shown in order to match the mid out­put of the Dancer Position Sensor to the mid travel
position of the dancer arm (See Figure 5).

4. Attach Dancer Position Sensor (Item 1) to one of
the three hole configurations on the Bracket (Item 3)
with the two shorter Pan Head Screws (Item 4), Flat
Washers (Item 6), and Lock Washers (Item 5) (See
Figure 4).

5. Hand tighten the screws just enough to prevent
sensor from moving during installation (See Figure

4).

Coupling

1

4

Figure 4

Machine

Frame

3

Customer supplied

6

5

Lock Washers.

Dancer

Arm

Pivot

Shaft

Spacer

Block

Screws and

6. Slide the Dancer Position Sensor (Item 1) into the
coupling (See figure 4).

7. Measure the distance from the bottom of the Brack­et (Item 3) to the machine’s side frame. Fabricate a
spacer block to make up the distance between the
Bracket and the machine’s side frame (See Figure

4).

8. Slide the Dancer Position Sensor (Item 1) into the
coupling again with the spacer block in place on the
machine’s side frame and mark the location for the
bracket’s two mounting holes.

9. Remove the Dancer Position Sensor (Item 1)
and Bracket (Item 3); then, drill and tap two 8-32
threaded holes centered within the marks drawn in
Step 8.

10. With the dancer arm held firmly in its mid travel
position, slide the Dancer Position Sensor (Item 1)
into the coupling again making sure the sensor shaft
marking is pointing toward the cable.

Insert the shaft no further than half the thickness of

the coupling clamp.

1

Figure 5

11. Tighten the clamp around the sensor shaft (See
Figure 4).

12. Using customer supplied 8-32 screws and lock
washers, secure the Bracket (Item 3) to the cus­tomer supplied spacer block and the machine’s side
frame (See Figure 4).

5

FORM NO. L-21260-A-1107

+24 VDC

SHIELD WIRE

BROWN

WHITE

GREEN

SIGNAL

DANCER
POSITION
CONTROLLER

COM

EARTH GROUND

ELECTRICAL CONNECTIONS

1. Route the Dancer Position Sensor signal cable
through the machine.

2. Connect the signal cable to a controller (See Figure

6).

NOTE: The shield wire from the signal cable should
be earth grounded at the controller.

If noise is still present on the position signal, ensure
the sensor shaft has a low impedance connection to
earth ground through the machine frame.

ADJUSTMENT

1. Apply power to the Dancer Position Sensor.

2. Refer to Installation for the proper alignment of the
sensor.

Figure 6

3. Using a voltmeter, measure the voltage across the
green (+) and brown (-) wires (See figure 6). The
voltage reading must match the supply voltage for
proper operation (See Specifications).

4. Measure the sensor output voltage across the white
(+) and brown (-) wires. With the dancer arm held
in its mid travel position, the sensor output should
be approximately +5 VDC. If it is not, then slightly
loosen the sensor’s fasteners and rotate the sensor
until the voltage reading is +5 VDC.

5. Tighten the fasteners securely to prevent the sensor
from moving.

6. Move the dancer arm through its full range of mo­tion and check that the voltage changes between
0 and 10 VDC. If the output voltage stops chang­ing as the dancer arm is moving, slightly loosen the
sensor’s fasteners and rotate the sensor. If this
persists, the angular movement of the dancer arm
might exceed the measurement range for the sensor
(See Specifications).

7. Trim back any unused wires to prevent electrical
shorting problems.

8. At this time the installation and adjustment of the
dancer position sensor is complete. Refer to the
controller manual for any further setup and calibra­tion procedures.

FORM NO. L-21260-A-1107

6

TROUBLESHOOTING

SYMPTOM PROBABLE CAUSE SOLUTION

No voltage from Dancer Position Sensor.

Dancer Position Sensor output does not
change.

Position Sensor Signal is erratic with no
dancer arm movement.

Dancer Position Sensor output voltage is
not changing through the full 30 degree
or 60 degree range.

No power to the Dancer Position sensor Turn on the power to the Dancer Position

Controller. Connect the Dancer Position
Sensor according to Figure 6.

Input power polarity is backwards Check polarity of the power supply. Con-

nect the Dancer Position Sensor accord­ing to Figure 6.

No power to the Dancer Position Sensor Turn on the power to the Dancer Position

Controller. Connect the Dancer Position
Sensor according to Figure 6.

Dancer Position Sensor misaligned Align the Dancer Position Sensor accord-

ing to Figure 2 for Mid Point of Output
and according to the instructions in the
INSTALLATION and ADJUSTMENT sec­tions.

Dancer arm exceeds the capacity of the
sensor.

Electrical noise interfering with sensor. Connect the shield directly to earth

Dancer Position Sensor misaligned Refer to Figure 2 for proper alignment

Switch to a DPS60A or restrict the swing
for the Dancer arm. Refer to SPECIFICA­TIONS

ground. If noise persists, ensure the
sensor shaft has a low impedance path to
earth ground. See WIRING INSTALLA­TION GUIDE

of the sensor. The shaft marking should
point toward the cable for mid-travel posi­tion of the dancer arm.

7

FORM NO. L-21260-A-1107

MOUNTING DIMENSIONS

DANCER POSITION SENSOR

Figure 7

FORM NO. L-21260-A-1107

8

PARTS LIST

3

1

5

6

4

7

5

Figure 8

ITEM DESCRIPTION QTY

1

3

4

Dancer Position Sensor

Bracket

Pan Head Phillips Screw

1

1

2

REPLACEMENT PARTS

The item or balloon number for all Nexen products is
used for part identification on all product parts lists,
product price lists, unit assembly drawings, bills of mate­rials, and instruction manuals.

SPECIFICATIONS

DPS30A

Product Number 964517

Supply Voltage 24 ± 6 VDC

Output Voltage 0~10VDC

Reverse Polarity Protection -30VDC maximum

Temperature -40oF [-40oC] to 185oF [85oC]

Enclosure IP65

Accuracy ± 1º

Angular Rotation +/- 15o maximum

@ max. angular rotation

ITEM DESCRIPTION QTY

5

6

7

Lock Washer

Flat Washer

Pan Head Phillips Screw

4

2

2

When ordering replacement parts, specify model des­ignation, item number, part description, and quantity.
Purchase replacement parts through your local Nexen
Distributor.

DPS60A

Product Number 964518

Supply Voltage 24 ± 6 VDC

Output Voltage 0~10VDC

Reverse Polarity Protection -30VDC maximum

Temperature -40oF [-40oC] to 185oF [85oC]

Enclosure IP65

Accuracy ± 1º

Angular Rotation +/- 30o maximum

@ max. angular rotation

9

FORM NO. L-21260-A-1107

WARRANTY

Warranties

Nexen warrants that the Products will be free from any defects in material or workmanship for a period of 12 months
from the date of shipment. NEXEN MAKES NO OTHER WARRANTY, EXPRESS OR IMPLIED, AND ALL IMPLIED
WARRANTIES, INCLUDING WITHOUT LIMITATION, IMPLIED WARRANTIES OF MERCHANTABILITY AND FIT­NESS FOR A PARTICULAR PURPOSE ARE HEREBY DISCLAIMED. This warranty applies only if (a) the
Product has been installed, used and maintained in accordance with any applicable Nexen installation or maintenance
manual for the Product; (b) the alleged defect is not attributable to normal wear and tear; (c) the Product has not been
altered, misused or used for purposes other than those for which it was intended; and (d) Buyer has given written no­tice of the alleged defect to Nexen, and delivered the allegedly defective Product to Nexen, within one year of the date
of shipment.

Exclusive Remedy

The exclusive remedy of the Buyer for any breach of the warranties set out above will be, at the sole discretion of Nex­en, a repair or replacement with new, serviceably used or reconditioned Product, or issuance of credit in the amount of
the purchase price paid to Nexen by the Buyer for the Products.

Limitation of Nexen’s Liability

TO THE EXTENT PERMITTED BY LAW NEXEN SHALL HAVE NO LIABILITY TO BUYER OR ANY OTHER PER­SON FOR INCIDENTAL DAMAGES, SPECIAL DAMAGES, CONSEQUENTIAL DAMAGES OR OTHER DAM­AGES OF ANY KIND OR NATURE WHATSOEVER, WHETHER ARISING OUT OF BREACH OF WARRANTY OR
OTHER
BREACH OF CONTRACT, NEGLIGENCE OR OTHER TORT, OR OTHERWISE, EVEN IF NEXEN SHALL HAVE
BEEN ADVISED OF THE POSSIBILITY OR LIKELIHOOD OF SUCH POTENTIAL LOSS OR DAMAGE. For all of
the purposes hereof, the term “consequential damages” shall include lost profits, penalties, delay images, liquidated
damages or other damages and liabilities which Buyer shall be obligated to pay or which Buyer may incur based
upon, related to or arising out of its contracts with its customers or other third parties. In no event shall Nexen be li­able for any amount of damages in excess of amounts paid by Buyer for Products or services as to which a breach of
contract has been determined to exist. The parties expressly agree that the price for the Products and the services was
determined in consideration of the limitation on damages set forth herein and such limitation has been specifically bar­gained for and constitutes an agreed allocation of risk which shall survive the determination of any court of competent
jurisdiction that any remedy herein fails of its essential purpose.

Limitation of Damages

In no event shall Nexen be liable for any consequential, indirect, incidental, or special damages of any nature whatso­ever, including without limitation, lost profits arising from the sale or use of the Products.

Warranty Claim Procedures

To make a claim under this warranty, the claimant must give written notice of the alleged defect to whom the Product
was purchased from and deliver the Product to same within one year of the date on which the alleged defect first
became apparent.

FORM NO. L-21260-A-1107

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