SG1000B Operation Manual - Electro
Contents
1. G1000B Position Monitor SG1000B general description The SG1000B is a rugged medium cost encoder based position sensor with a 4 20 mA output The SG1000B is used to accurately measure or sense the linear position of a process or operation that has a repetitive linear movement To facilitate this measurement the SG1000B uses a Telescopic Arm to convert the process s linear movement into an angular movement The SG1000B then measures the arm s angle to determine the process s linear position Some applications where the SG1000B can be used to sense a linear position include the following a grain handling slidegate a security fence gate a pick and place operation a louver control and a cylinder arm s linear extension or reach Of these applications the most common is for sensing the position of a linear driven slidegate However since the SG1000B s use does not depend on how a slidegate is driven it can also be used to measure the linear position of a rack and pinion driven slidegate In whatever the application the SG1000B measures the Telescopic Arm s angle to determine the process s linear position In the slidegate example the SG1000B enables the end user to accurately monitor a slidegate s position allowing accurate blending operations The SG1000B has two modes calibration mode and normal operating mode A simple calibration procedure teaches programs the SG1000B the encoder values corresponding to t2. direction switch SW1 to the proper position CW or CCW before applying power to the SG1000B B As your gate moves from fully closed to fully open does the SG1000B s telescopic arm swing more than 130 or less than 5 6 If so then the SG1000B will not work in your application C Is your SG1000B terminal TB1 wiring correct e 24Vdc red wire to TB1 1 e 4 20mA signal clear wire to TB1 2 e Power supply ground black wire to TB1 3 D Assuming conditions A B and C are proper and your SG1000B still seems to behave improperly then try re calibrating again paying close attention to the ten calibration steps 2 Ifyou have gone through troubleshooting hints 1A 1B 1C and 1D and if your SG1000B seems to otherwise respond properly from fully closed to fully open with the only exception being that strange values other than 4 mA and 20 mA are output for the fully closed fully open positions e g 3 mA at one end and 23 mA at the other end then possibly the R7 and R8 factory potentiometer settings have been tampered with See Figure 7 for location of these pots Evidence of R7 and R8 tampering is most easily seen when in the calibration mode When R7 and R8 are at their factory settings the output signal is 12 mA during calibration mode Recall that the output signal remains at 12 mA until the calibration process is completed If during calibration mode the output signal is not 12 mA then most likely
3. the R7 and R8 factory settings have been tampered with If you feel confident that you have followed the calibration procedure properly perhaps have done it several times over and followed the troubleshooting hints in 1A 1B 1C and 1D AND you still see strange values other than 4 mA at one end and 20 mA at the other then you can attempt to restore R7 and R8 to the factory settings by doing the following This assumes you have already calibrated your SG1000B for the arm at perpendicular fully closed and fully open gate positions A During normal operating mode move the gate to your fully closed calibrated position Adjust R7 until 4 mA is output from the signal line B During normal operating mode move the gate to the fully open calibrated position Adjust R8 until 20 mA is output from the signal line C You can now test and verify that your R7 and R8 are indeed set back to factory settings Do this by re entering the calibration procedure press in SW2 then apply power If the 4 mA to 20 mA output signal is at 12 mA or fairly close when in the calibration mode then you have properly restored R7 and R8 settings Continue and complete the calibration procedure for the arm s perpendicular fully closed and fully open positions g How to clear out the existing calibration and reprogram the SG1000B First remove 24Vdc power then press and hold in the SW2 button while re applying the 24Vdc power to
4. 4 20 mA output has a 16 mA span a 0 2 resolution gives an incremental change of 0 032 mA and a 5 0 resolution gives an incremental change of 0 800 mA When power is shutdown or fails the EEPROM retains the telescopic arm calibration direction CW CCW and calibration positions arm at perpendicular arm at one end of span and arm at other end of span Mechanical packaging The SG1000B has a cylindrical aluminum housing cover Outside diameter of 3 11 16 inch Maximum length of 7 5 8 length includes cover and encoder shaft The Telescopic Arm is 1 8 wide at it widest Different arm lengths are available per application s needs For typical slidegate applications e The SG1000B mounts onto the slidegate frame using two supplied beam clamps or via two user supplied 5 16 diameter bolts length and thread type chosen by user as needed The narrow end of the Telescopic Arm attaches to the slidegate s plate using supplied hardware and one beam clamp supplied However depending on the slidegate the user may need to fabricate and install a small bracket onto the face of the slidegate s plate thus providing a grab point for the Telescopic Arm s beam clamp For all applications the wide end of the Telescopic Arm attaches to the SG1000B using supplied hardware For non slidegate applications e Different mounting hardware may be needed other than that supplied for both the SG1000B and
5. See Figure 7 ELECTRO SENSORS SY e Ifthe encoder shaft turns in the CCW direction as the gate is moved from the fully closed to the fully open position then set SW1 to the ON position 1 e toward the edge of the PC board See Figure 7 Note The direction switch SW1 is monitored only briefly during a calibration power up i e calibration switch SW pressed in while applying 24 Vdc to the unit After the unit powers up and is in calibration mode SW1 is no longer relevant Hence changing SWI at this point has no effect Because of this SW1 must be set to the desired position before the 24 Vdc power is applied to the unit in order for the calibration power up to capture the desired setting of SW1 3 Press in the calibration switch SW2 then a power to the SG1000B Do not press SW2 multiple times or allow it to change state just keep it pressed in Continue to keep SW2 pressed in for a few seconds until the SG1000B outputs a constant 12 mA from its signal line then release the button The SG1000B is now in the calibration mode ly 24 Vde 4 Run the gate to the position that places the Telescopic Arm in a perpendicular 90 position to the gate s linear travel direction See Figure 8 Note If the slidegate drive system does not allow the user the ability to control the slidegate precisely enough so as to place the telescopic arm perpendicular to the direction of travel then the user can instead do the perpendicula
6. The SG1000B s electrical cable has three wires plus a shield wire Connect as follows See Figure 6 24Vdc Power Supply PLC Etc 250 to 500 ohm load Vv Figure 6 e Connect the shield wire to the earth ground e Connect the black wire to the power supply terminal e Connect the red wire to the power supply 24 Vdc terminal e Connect the clear wire to a resistive load of 250 Q to 500 Q usually this load is internal to a PLC etc Note The clear wire is the 4 20 mA DC output line The other side of the 250 Q to 500 Q load must be connected to the power supply terminal e See Figure 7 below for related information Free Catalog and Application Assistance 1 800 328 6170 Website www electro sensors com 990 002410 Revision F Calibration Procedure Calibration consists of teaching the SG1000B the encoder values for the following three telescopic arm positions arm perpendicular to the gate s linear travel direction arm with slidegate fully closed i e 0 open arm with slidegate fully open i e 100 open The 10 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 CC SG1000B This provides access to the edge of the SG1000B s printed circuit board namely the direction switch SW1 the slide switch and the calibration switc
7. alibration Error condition behavior Assuming the user followed the calibration process incorrectly the SG1000B behaves as follows The output signal remains at a constant 12 mA after the calibration mode is automatically exited An invalid calibration is most likely due to one of the following Ifthe user did not move the gate or moved it but less than a 5 6 swing of the arm between teaching the SG1000B the fully closed and fully open positions then the closed and open positions have the same or nearly the same encoder count The user accidentally double pressed SW2 either during power up or then while teaching the SG1000B the perpendicular or the fully closed positions Power ups calibration vs normal operating mode An SG1000B that is un calibrated or if the calibration attempt was invalid automatically powers up in the calibration mode the next time power is applied A properly calibrated SG1000B powers up in the normal operating mode when power is applied Free Catalog and Application Assistance 1 800 328 6170 Website www electro sensors com 990 002410 Revision F Troubleshooting Hints As an aid to troubleshooting see figure 6 on how to connect an ammeter to directly measure the 4 20mA output signal 1 If your SG1000B outputs a 4 mA to 20 mA signal but not at the gate positions expected then double check the following A Before you performed the calibration procedure did you set the
8. ed with the beam clamp thus allowing the beam clamp to directly grab the plate s edge See figure 3b Figure 3b There are some limitations as to where the SG1000B can be mounted along the perimeter of the slidegate s frame The SG1000B must be mounted within the end points of the sliding plate s linear travel See Figure 4 for examples of valid and invalid mounting positions Figure 4 shows the slidegate in the fully closed position i e 0 open lt invalid gt lt Valid gt lt invalid gt Invalid Good Best Good Invalid Invalid Front edge of Closed Open Front edge of plate at 0 open ____________ plate at 100 open Figure 4 The SG1000B mounting bracket has some vertical adjustment capability After the SG1000B has been mounted on the slidegate frame if need be loosen the two 5 16 diameter carriage bolts holding the two bracket halves together and set the height of the bracket so the narrow end of the telescopic arm ELECTRO SENSORS is centered evenly between the two springs on the telescopic arm mounting hardware this lessens stress on the telescopic arm Re tighten the carriage bolts when finished See Figure 5 S G1000B Telescopic Arm Mounting Hardware Make ij Telescopic Arm ps lt Adjustments Here Arm Centered Between Springs S G1000B Mounting Hardware Figure 5 Electrical connections
9. h SW2 the push button switch See Figure 7 for locations of these switches the back end cover from the cw nuw smi CW OFF cron SW1 Detail TBI Clear Black Shield Figure 7 Note Also on the edge of the PC board are two adjustment potentiometers R7 and R8 and a 3 pin terminal TB1 Pot R7 is for tweaking the 4 mA output level Pot R8 is for tweaking the 20 mA output level These two pots are factory adjusted and the user normally should not have to adjust them It is best to leave these two pots alone The user normally should not have to disconnect the 3 wire cable from the SG1000B But if they do so they must reconnect the 3 wire cable to the SG1000B as follows e 24Vdc red wire to TB1 1 e 4 20mA signal clear wire to TB1 2 e Power supply ground black wire to TB1 3 2 Before applying 24 Vdc power to the SG1000B set the direction switch SW1 on the SG1000B s PC board to the proper position for the application SWI tells the SG1000B the direction the encoder turns CW or CCW as the gate is moved from the fully closed to the fully open position The CW or CCW direction is defined via the viewer looking at the back cover end of the enclosure and not the encoder shaft end of the enclosure e Ifthe encoder shaft turns in the CW direction as the gate is moved from the fully closed to the fully open position then set SW1 to the OFF position i e toward the center of the PC board
10. hree unique Telescopic Arm angles along the process s linear travel Once programmed the SG1000B outputs a 4 mA DC signal when the encoder is at one end of the calibration span when the slidegate is fully closed for example and outputs a 20 mA DC signal when the encoder is at the other end of the calibration span when the slidegate is fully open for example When the encoder is at any mid span position when the slidegate is somewhere between fully closed and fully open for example the SG1000B outputs a signal that is proportionally between 4 and 20 mA Note Since the SG1000B is mostly used with linear driven slidegates this user manual is written mainly for that application For other applications the SG1000B s proper mounting locations electrical connections calibration procedure troubleshooting hints and product specifications all still generally apply and should be followed as closely as possible for successful SG1000B operation However for non slidegate applications different mounting hardware may be needed other than that supplied for both the SG1000B and the Telescopic Arm Because of numerous variances if such other mounting hardware is needed the user must fabricate or acquire it on their own 6111 Blue Circle Drive Minnetonka MN 55343 Phone 952 930 0100 Fax 952 930 0130 ISO 9001 2000 Certified ELECTRO SENSORS SY Superior e Systems e Solutions Physical Appearance and Installation Overview Figu
11. is then used for the fully open position 100 open e The SG1000B then automatically exits the calibration mode and enters the normal operating mode Note The calibration mode is exited at this point for both valid and invalid calibrations For a valid calibration If the user does not immediately move the gate then the output signal is 20 mA Because the gate was left in the fully open position from step 8 the output signal is at 100 which is 20 mA For an invalid calibration The output signal remains at 12 mA See the Valid Calibration and Invalid Calibration sections below for details regarding whether or not your SG1000B accepted the gate s three calibration positions 10 Replace the back end cover onto the SG1000B This ends the calibration procedure Valid Calibration Normal Operating Behavior Assuming the user followed the calibration process correctly the SG1000B behaves as follows e When the gate is at the fully closed position 0 open the output signal is 4 mA e When the gate is at the fully open position 100 open the output signal is 20 mA e Any gate position between 0 open and 100 open is represented by the output signal being proportionally between 4 mA and 20 mA e Ifthe gate is moved to a position that is slightly beyond outside of the fully closed 0 open calibrated position then the output signal remains at 4 mA This is known as 0 run out and it holds up to a cer
12. l information about the SG1000B visit our website at www electro sensors com The SG1000B and Telescopic Arm have US Patent 7 191 527 and US Patent 7 444 751 Notice Copyright 2009 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 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 Free Catalog and Application Assistance 1 800 328 6170 Website www electro sensors com 990 002410 Revision F
13. r calibration point by first detaching the narrow end of the arm from the slidegate s plate by loosening the small beam clamp and manually setting the arm perpendicular to the travel direction SG1000B Figure 8 5 Press the calibration switch SW2 e This captures the present encoder count This value is then used for the telescopic arm at perpendicular position e The output signal remains at 12 mA e Reattach arm after step 5 if removed in step 4 Free Catalog and Application Assistance 1 800 328 6170 Website www electro sensors com 990 002410 Revision F Calibration Procedure Cont 6 Move the gate to the fully closed position 0 open 7 Press the calibration switch SW2 e This captures the present encoder count This value is then used for the fully closed position 0 open e The output signal remains at 12 mA 8 Move the gate to the fully open position 100 open Note As the gate moves from fully closed to fully open the SG1000B s encoder shaft must turn at least 1 64 of a turn but not more than 0 36 of a turn Or seen another way as the gate moves from fully closed to fully open the telescopic arm must swing at least 5 6 but not more than 130 Hence if the arm swings more than 130 or less than 5 6 then the SG1000B will not properly work for the application 9 Press the calibration switch SW2 e This captures the present encoder count This value
14. re 1 is the front view showing the SG1000B the telescopic arm and typical mounting hardware for both Q SS SG1000B Telescopic Arm Figure 1 The SG1000B mounts above or below the slidegate s frame depending on where there is sufficient clearance for the sweeping movement of the telescopic arm The SG1000B mounts to the slidegate s frame using two supplied beam clamps The SG1000B s mounting bracket has two 5 16 diameter holes spaced 2 apart along the base of the bracket allowing the user to bolt the SG1000B to the slidegate s frame if they desire Figure 2 shows the SG1000B mounted to the top of a slidegate s frame Material Flow Figure 2 The wide end of the telescopic arm attaches to the SG1000B encoder shaft using supplied hardware The arm s narrow end attaches to the slidegate s plate using supplied hardware and beam clamp Depending on the slidegate used the user may need to fabricate and install a small bracket onto the face of the slidegate s plate thus providing a grab point for the telescopic arm s beam clamp See figure 3a Free Catalog and Application Assistance 1 800 328 6170 Visit Us Online www electro sensors com 990 002410 Revision F Grab Point Bracket Slidegate Plate Figure 3a Or if there is clearance between the slidegate s frame and plate when the gate is fully open the telescopic arm s mounting hardware stud can be reconfigur
15. tain point If the encoder is turned far enough beyond the fully closed 0 open ELECTRO SENSORS calibrated position then the encoder wraps around and the output signal jumps to the fully open calibrated value of 20 mA If the gate is moved to a position that is slightly beyond outside of the fully open 100 open calibrated position then the output signal remains at 20 mA This is known as 100 run out and it holds up to a certain point If the encoder is turned far enough beyond the fully open 100 open calibrated position then the encoder wraps around and the output signal jumps to the fully closed calibrated value of 4 mA For a properly calibrated SG1000B the direction of calibration CW or CCW and the encoder values for the arm at perpendicular fully closed and fully open gate positions are all stored in the SG1000B s EEPROM memory Note Since a properly calibrated SG1000B can never enter the calibration mode again by itself after the calibration mode is exited the direction switch SW1 and the calibration switch SW2 are ignored during normal operating mode This means that for a properly calibrated SG1000B the calibration results are protected from the user inadvertently changing the SW1 position or by pressing SW during normal operating mode If re calibration is needed see the section below titled How to clear out the existing calibration and reprogram the SG1000B Invalid C
16. the SG1000B Continue to keep the SW2 button pressed in for a few seconds until the SG1000B outputs 12 mA then release the SW2 button The old calibration has now been cleared out and the SG1000B is in calibration mode awaiting new calibration See the Calibration Procedure section for complete details ELECTRO SENSORS 5 6 Free Catalog and Application Assistance 1 800 328 6170 Website www electro sensors com 990 002410 Revision F Specifications Performance The SG1000B s built in 9 bit absolute encoder measures the telescopic arm position internal readings are 0 up to 511 counts The SG1000B uses a 1 2 75 gear ratio on the output shaft of the encoder The maximum calibrate able span is 0 36 turns of the output shaft or a 130 swing of the telescopic arm The minimum calibrate able span is 1 64 turn of the output shaft or a 5 6 swing of the telescopic arm The SGI000B s 4 20 mA output signal resolution depends mostly on The number of encoder counts in the calibration span for the application s end to end swing of the telescopic arm e And the location of the telescopic arm s perpendicular point in the calibration span With these dependences the SG1000B s 4 20 mA resolution varies from a best of 0 2 of the calibrated span when calibrated at the maximum span of 511 encoder counts to a worst of 5 0 of the calibrated span when calibrated at the minimum span of 21 encoder counts Since the
17. the Telescopic Arm ELECTRO SENSORS MY 6 6 Because of numerous variances if such other mounting hardware is needed the user must fabricate or acquire it on their own Environmental considerations c UL LISTED CE NEMA4X Cast Aluminum Housing Temperature range of 40 C to 65 C 40 F to 149 F Humidity range of 0 to 90 non condensing Class I Div 1 Groups C D US Class II Div 1 Groups E F G UL File E249019 Operator interface One pushbutton enter calibration mode upon power up and calibrate for the three telescopic arm positions One slide switch select calibration direction CW CCW Operation modes Normal Operating Mode output 4 mA to 20 mA signal corresponding to the telescopic arm position Calibration Mode select calibration direction calibrate for the three telescopic arm positions T O requirements Input External power supply of 24 Vdc 10 The SG1000B s current draw is 40 mA DC or less Output 12 mA DC output signal for an un calibrated system when running in Calibration Mode or in Normal Operating Mode with improper calibration Output 4 mA DC to 20 mA DC output signal proportional to telescopic arm position for a properly calibrated system running in Normal Operating Mode Additional Information Some common Telescopic Arms used with the SG1000B are 16 Arm 800 010116 18 Arm 800 010118 20 Arm 800 010120 To get additiona
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