Red Lion ZCG User Manual

+

+

+

+

+

1.25

(31.8)

0.75

0.022
(0.56)

0.05 (1.3)

1.65 (42)

0.08

2.00

1.20

0.13

3.38

2.75

2.00 (50.8)
DIA. MOUNTING
FACE

0.375
(9.53)
DIA. SHAFT

#8-32 UNC

x0.30" (7.6) DP.
4 PL., EQUALLY
SPACED

1.50 (38.1) DIA.
BOLT CIRCLE

0.99 (25.1) DIA
FLANGE

(2)

(19)

(50.8)

(85.8)

(69.9)

(30.5)

(3.3)

Bulletin No. ZFG/ZCG-B
Drawing No. LP0737
Released 12/10

Tel [phone]
Fax [phone]
www.redlion.net

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

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)



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.

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

1.65

0.08 (2.03)

0.75

0.04

1.20

MAX.

(30.5)

(41.9)

(1.0)

(19.0)

LED

REGU-

LATOR

RED

WHT

BLK

COMMON

OUTPUT:

8 to 35 VDC @ 50mA max.

V = 30 VDC max.
V = 1V max. @ 40mA

OL

OH

SHAFT

METAL
ETCHED
OPTICAL
DISC

PHOTOLOGIC DETECTOR
AND PULSE SHAPING CIRCUIT

BARE STRANDED SHIELD WIRE
CONNECTED TO INSTRUMENT
COMMON FOR INCREASED
NOISE IMMUNITY

.75 (19) DIA.

2.75

(69.8)

2.06

(52.3)

2.00

(50.8)

.13 (3.3)

3.38

(85.8)

2.75 (69.9)

4.00 (101.6)

1.65 (41.9)

0.375 (9.52)
DIA. SHAFT

2.00 (50.8) DIA.

.04

(1.0)

.08

(2.03)

MAX.

USABLE SHAFT

LENGTH

1.08 (27.4)

REF., TYP. 2

.75

(19.0)

TYP. 2

.022 (.56)

TYP. 2

ZFG DIMENSIONS

In inches (mm)

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)

ELECTRICAL SPECIFICATIONS

1. SUPPL Y V OLTAGE: +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.)

EQUIVALENT CIRCUIT & CONNECTIONS

ORDERING INFORMATION

MODEL NO. DESCRIPTION PPR

10 ZCG0010C

12 ZCG0012C

ZCG

Rotary Pulse Generator

(Replaces RPGC)

60 ZCG0060C

100 ZCG0100C

*120 ZCG0120C

*200 ZCG0200C

10 10/Foot ZFG0010C

12 1/inch ZFG0012C

20 60/Mt or Yd ZFG0020C

60 60/Foot ZFG0060C

100 100/Foot ZFG0100C

*120 10/Inch ZFG0120C

ZFG

Length Sensor

Single Shaft

(Replaces LSCS)

*200 600/Mt or Yd ZFG0200C

.333 1/Mt or Yd ZFG00/3C

3.333 10/Mt or Yd ZFG03/3C

33.333 100/Mt or Yd ZFG33/3C

10 10/Foot ZGG0010C

12 1/inch ZGG0012C

20 60/Mt or Yd ZGG0020C

60 60/Foot ZGG0060C

100 100/Foot ZGG0100C

*120 10/Inch ZGG0120C

ZGG

Length Sensor

Double Shaft

(Replaces LSCD)

*200 600/Mt or Yd ZGG0200C

.333 1/Mt or Yd ZGG00/3C

3.333 10/Mt or Yd ZGG03/3C

33.333 100/Mt or Yd ZGG33/3C

Flexible Coupling (1" Length) 0.250" - 0.375" RPGFC002

RPGFC

Flexible Coupling (1" Length) 0.375" - 0.375" RPGFC003

Flexible Coupling (1" Length) 0.375" - 0.500" RPGFC004

Flexible Coupling (1" Length) 0.375" - 6 mm 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.

OUTPUT

PULSE RATE

CODE

PART NUMBER

1 ZCG0001C

1 1/Foot ZFG0001C

1 1/Foot ZGG0001C

2

LENGTH SENSOR ACCESSORIES

Cast

Alum.

.376"
(9.6)
Bore
+.001"

-.000"

8-32 UNF
Set Screw

3/8"
(9.5)

Round Section Replaceable
Tire .210" Section Dia.
Black Neoprene

Diamond Knurled Aluminum
Tread

10-32 UNF
Set Screw

1"

(25.4)

Alum.

Cast

.376"

-.000"

+.001"

(9.6)
Bore

.376"
(9.6)
Bore
+.001"

-.000"

Tan, Smooth Polyurethane
Tread

10-32 UNF
Set Screw

Alum.

Cast

1"

(25.4)

SEPARATE LENGTH MEASURING WHEELS - DIMENSIONS In Inches (mm)

WHEEL

CODE

OR

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

OF

FOR USE ON: Soft, smooth

materials such as soft
paper, matting,
cardboard, fine weave
textiles. Broad wheel
tread minimizes contact
pressure and tan
polyurethane tread
minimizes marking.

Max. Speed: 600 RPM
Balanced version of 1ft.

circumference available.
Balanced to ANSI S2.19­1989 Quality Grade 6.3 @
3000 RPM.

WHEEL

CODE

OK

FOR USE ON: Rubber,

coarse weave fabrics,
rough wood surfaces,
foam, insulation.

Max. Speed: 600 RPM

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

OR

OF

BF (Balanced)

CIRCUMFERENCE PART NUMBER

1 foot (1/3 yd) ±0.40% WF1000OR

1/3 meter ±0.40% WM0333OR

4/10ths yard ±0.40% WY0400OR

4/10ths meter ±0.40% WM0400OR

1 foot (1/3 yd) ±0.35% WF1000OF

1/3 meter ±0.30% WM0333OF

4/10ths yard ±0.30% WY0400OF

4/10ths meter ±0.30% WM0400OF

1 foot (1/3 yd) ±0.40% WF1000BF

TOLERANCE

WHEEL CODE CIRCUMFERENCE TOLERANCE PART NUMBER

OK

BK (Balanced) 1 foot (1/3 yd) ±0.35% WF1000BK

Replacement Tires

for OR Wheels

Note: After installation of measuring wheels, ensure guards,shields or other

devices are in place to protect personnel from rotating equipment.

1 foot (1/3 yd) ±0.35% WF1000OK

1/3 meter ±0.30% WM0333OK

4/10ths yard ±0.30% WY0400OK

4/10ths meter ±0.30% WM0400OK

1 foot (1/3 yd) TORF1000

1/3 meter TORM0333

4/10ths yard TORY0400

4/10ths meter TORM0400

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

TOP
VIEW

3.4

(86.4)

(73.7)

2.5 (63.5)

1.25

(31.8)

2.9

4X Ø 0.31 (7.9)

Lock washers (2) must be
installed between bolt heads
and top clamp piece.

.25 (6.3)

E-clip retaining ring (2)
must be installed in slots.

.88

(22.4)

SINGLE WHEEL

.85

2.93 (74.4)

(21.6)

DUAL WHEEL 4 (101.6)

Model ZGG Shown

WHEEL

RADIUS

OMITTED ON

SINGLE SHAFT UNITS

THIS WHEEL AND SHAFT

6.9 (175.3)

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.

1.9

(48.3)

0.75 (19.0)

4.50 (114.3)

5.70 (144.8)

2.00

(50.8)

1.50

(38.1)

0.75

(19.0)

ORDERING INFORMATION

MODEL NO. DESCRIPTION PART NUMBER

LSAHC LSAHC001Length Sensor Hinge Clamp Assembly

The Company warrants the products it manufactures against defects in materials and workmanship
for a period limited to two years from the date of shipment, provided the products have been stored,
handled, installed, and used under proper conditions. The Company’s liability under this limited
warranty shall extend only to the repair or replacement of a defective product, at The Company’s
option. The Company disclaims all liability for any affirmation, promise or representation with
respect to the products.

The customer agrees to hold Red Lion Controls harmless from, defend, and indemnify RLC against
damages, claims, and expenses arising out of subsequent sales of RLC products or products
containing components manufactured by RLC and based upon personal injuries, deaths, property
damage, lost profits, and other matters which Buyer, its employees, or sub-contractors are or may be
to any extent liable, including without limitation penalties imposed by the Consumer Product Safety
Act (P.L. 92-573) and liability imposed upon any person pursuant to the Magnuson-Moss Warranty
Act (P.L. 93-637), as now in effect or as amended hereafter.

No warranties expressed or implied are created with respect to The Company’s products except those
expressly contained herein. The Customer acknowledges the disclaimers and limitations contained
herein and relies on no other warranties or affirmations.

.88 (22.4)

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

Red Lion Controls
Headquarters
20 Willow Springs Circle
York PA 17406
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Fax [phone]

Red Lion Controls

Europe

Printerweg 10

NL - 3821 AD Amersfoort

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Red Lion Controls

India

54, Vishvas Tenement

GST Road, New Ranip,

Ahmedabad-382480 Gujarat, India

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Red Lion Controls

China

Unit 101, XinAn Plaza

Building 13, No.99 Tianzhou Road

ShangHai, P.R. China 200223

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