Red Lion ZR User Manual

Bulletin No. ZR-A
Drawing No. LP0747
Released 08/11

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MODEL ZR - C-FACE ENCODER WITH NPN OPEN COLLECTOR OUTPUT

THRU-SHAFT DESIGN FOR EASY MOUNTING
EXCELLENT CHOICE FOR VECTOR MOTOR DRIVE CONTROL
DESIGNED FOR INDUSTRIAL ENVIRONMENTS
QUADRATURE OUTPUT
POSITIVE INDEX PULSE
C-FACE GASKET KIT INCLUDED

DESCRIPTION

The Model ZR C-face encoder is a rugged, high resolution, high temperature
(100°C) encoder designed to mount directly on NEMA C-face motors. The ZR
contains a precision bearing and internal coupling that virtually eliminates
inaccuracies induced by motor shaft runout. This encoder is ideal for applications
using high performance AC vector motors.

The thru-shaft design allows fast and simple mounting of the encoder directly
to the accessory shaft or to the drive shaft of the motor, using the standard motor
face (NEMA sizes 56C, 143TC, 145TC, 182C, 184C). The tough anodized
aluminum housing with thru-shaft design resists the vibration and hazards of an
industrial environment. In addition, a C-face gasket kit is included free for motor
shaft protection and enclosure.

Open Collector Output Wiring

The ZR 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 different than the encoder supply voltage (40 VDC maximum). 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.

DIMENSIONS In inches (mm)

15°

3.000
(76.2)

1.75 (44.45)

+.002

4.501

-.000
+.050

(114.33 )

-.000

+.000

4.500

-.003
+.000

(114.3 )

-.076

.175

0.125 (3.18)

2.60

(66.04)

(4.45)

0.975

(24.77)

6.500

(165.10)

DRILLED THRU .386 ON 5.875 DIA
B.C. AT 90° (4) PLACES

TAP THRU 3/8-16 ON 5.875 DIA
B.C. AT 90° (4) PLACES

SPECIFICATIONS

ELECTRICAL SPECIFICATIONS

1. SUPPLY: 4.75 to 28 VDC, 40 mA current draw typical, 100 mA maximum.

2. OUTPUT: NPN Open Collector transistor , VOH = 40 VDC max.; 100 mA

max. current. Incremental - two square waves in quadrature with A leading B
for clockwise rotation. Positive pulse index.

3. CYCLES PER REVOLUTION: 256 or 1024

Note: Review the max. input rate of the RLC counter being used. The high

output rate of the 1024 version will quickly reach the max. input capability
of RLC quadrature counters. At 1024 PPR, high pulse rates are reached at
low RPM.

4. MAX. FREQUENCY: 200 KHz

5. NOISE IMMUNITY: Tested to BS EN61000-4-2; IEC801-3; BS

EN61000-4-4; DDENV 50141; DDENV 50204; BS EN55022; BS
EN61000-6-2; BS EN50081-2

6. SYMMETRY: 180° (±18°) electrical

7. QUAD PHASING: 90° (+22.5) electrical

8. MIN EDGE SEP: 67.5° electrical

9. RISE TIME: Less than 1 microsecond

MECHANICAL SPECIFICATIONS

1. MAX MECHANICAL SPEED: 6000 RPM

2. BORE DIAMETER: 0.625" or 1.0"

3. BORE TOLERANCE: +0.0015"/-0.000"

4. MOMENT OF INERTIA: 3.3  10

5. USER SHAFT TOLERANCES:

Radial Runout:0.005"
Axial Endplay: ±0.015"

6. ELECTRICAL CONNECTION: 36" (914.4 mm) cable. 24 AWG foil and

braid shield.

WIRE COLORFUNCTION

BLACKCOMMON
WHITEDATA A

DATA B

GREEN

ORANGEINDEX Z

7. HOUSING: All metal construction.

8. MOUNTING: NEMA 56C to 184C when proper bore size is selected

9. WEIGHT: 2.60 lb. (1.18 Kg) typical

ENVIRONMENTAL CONDITIONS

1. OPERATING TEMPERATURE: 0 to +100°C @ 4.75 to 24 VDC

2. STORAGE TEMPERATURE: -25 to +100°C

3. HUMIDITY: 98% RH non-condensing

4. VIBRATION: 10 g @ 58 to 500 Hz

5. SHOCK: 50 g @ 11 msec duration

6. SEALING: IP65 with included shaft cover and gaskets installed.

-3

oz-in-sec2 typical

RED+ VDC

0 to +70°C @ 4.75 to 28 VDC

1

MOUNTING INSTRUCTIONS

SHAFT LOCKING

COVER PLATE

4-40 ALLEN CAP SCREWS

3/8" - 16 X 1.0" SCREWS
(4) PLACES TYPICAL

(4) PLACES TYPICAL

COLLAR

Mounting Kit Items Included:

4 ea. - 3/8" 16 x 1.0" Length Socket Head Cap Screws,

Black Alloy.
4 ea. - 3/8" High Collar Spring Lock washer, Steel Zinc.
1 ea. 3/32" Hex Allen Wrench, Long arm.

Note: The ZR encoder can mount to many types of C face devices.

In these mounting instructions, we will refer to the device as a
motor.

Step 1

After carefully unpacking the unit, inspect to insure the motor

shaft is the correct size and free of all burrs or aberrations. Slide
the ZR Encoder over the motor shaft. DO NOT USE EXCESSIVE
FORCE: There is a rubber O-ring in the Encoder locking collar
that will provide a small amount of resistance as it engages the
shaft. If the encoder does not slide easily See Note 1 below.

Step 2

Install the four 3/8" 16 x 1.0" socket head cap screws with lock washers

through the holes in the Encoder C face and tighten securely to the motor.

Step 3

Insure the shaft locking collar is flush with the Encoder cover plate. Prevent

the motor shaft from turning (See Note 2 for additional information) and
tighten the four 4-40 Allen head cap screws in the locking collar evenly in a
crossing pattern. See Figure 1. Make sure the screws are securely tightened and
the front of the locking collar remains flush with the encoder cover plate. If the
collar does not turn true when the motor shaft is rotated, loosen the four screws
and repeat the procedure.

In Case of Difficulty:

Note 1: Make sure the four 4-40 Allen head cap screws in the front of the

Encoder locking collar are loose and the collar is not cocked or jammed.
Clean the shaft of any burrs using fine crocus cloth. The O- ring in the
Encoder locking collar may need a small amount of additional lubrication.

Note 2: When tightening the screws in the locking collar avoid holding the

motor shaft with anything that may scar or burr the shaft.

ORDERING INFORMATION

MODEL NO. DESCRIPTION PPR BORE SIZE PART NUMBER

256 0.625 ZRJ0256A

ZR

* Replaces ARC1. Available by special order, consult factory.

NEMA C Face Encoder

56C to 184C

(Must select proper bore size)

LIMITED WARRANTY

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.

1024 0.625 ZRJ1024A

256 1.0 ZRL0256A

1024 1.0 ZRL1024A

256 0.875 ZRI0256A *

1024 0.875 ZRI1024A *

Red Lion Controls
Headquarters
20 Willow Springs Circle
York PA 17406
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Red Lion Controls

Europe

Printerweg 10

NL - 3821 AD Amersfoort

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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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