Electro-Sensors SG1000RA User manual

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).

Encoder-Shaft

3/8"-16 UNC-2A threads

Cable

Figure 1:

The SG1000RA attaches to the slide-gate’s ‘rack and pinion’

shaft, or similar rotating mechanical component, using an “end-

of-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.

Process Shaft

SG1000

Stabilizer bracket

(use is optional)

U-Bolt

with slack

Structural Framework

Flexible

conduit

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).

RELAY 2

SW1

SW2

CAL

SET-POINT

RELAY 1

Red LED

100% Open

Relay

SW1 Relay

Setpoint

Selection

Red LED

0% Open

Relay

Green LEDs

Calibration

Status

SW2 Calibration Button

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

Earth Ground

Screw

12345678910

Figure 4: Terminal Block View

SG1000RA SlideGate Monitor

6111 Blue Circle Drive

Minnetonka, MN 55343

Phone: 952.930.0100

Fax: 952.930.0130

ISO 9001:2015 Certied

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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 push-

button 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 set-

point 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, identied 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 8counts inboard

of 200 which is 200+8 = 208, and re-energize at 2counts

inboard of the de-energize point which is 200+8+2= 210.

- the 100%-open relay would de-energize at 8counts

inboard of 800 which is 800-8 = 792, and re-energize at

2counts 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 8counts 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 modies 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% ‘run-

out’, 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 fully-

open 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 fully-

closed 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 1/4th-

turn, 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 fully-

open 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 Specications:

Input Power Input Current

115 - 230VAC

±10% 50/60Hz

60 mA for internal electronics

(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)

Input Signal Parameters

Type

Rotating shaft connected to internal 10 bit, 0

to 1023 count, absolute position magnetic-eld

encoder

Range of Operation

Continuous rotation with no physical end stops.

Calibratable span of 1/4 to 6 turns of output

shaft. Output shaft max RPM = 200.

Internal Gear Ratio 6:1

Output Parameters

Relay

Outputs

Two Form C Relays, w/programmable set-points:

(Relay1 @ user’s fully-closed position).

(Relay2 @ user’s fully-open position).

Relay

Ratings

(Resistive

Loads

Only)

125Vac @ 0.5A,

250Vac @ 0.25A,

30Vdc @ 0.5A,

110Vdc @ 0.3 A, and

220Vdc @ 0.27 A.

Accuracy

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.

Encoder

Resolution

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

specically) 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 3/8-16 UNC x 0.625 in.

(Other options available.)

Housing Material Cast Aluminum

Housing Dimensions Cylindrical, with diameter of 3-11/16”, length

of 7-5/8” (length includes housing & shaft)

Stabilizer Bracket

Mounted semi-rigidly to application’s

framework using two user supplied 5/16”

bolts.

Terminal Block

Torque

0.35Nm to 0.4Nm

3.10in-lb to 3.54in-lb

Physical/Enviroment Parameters

Class I, Groups C, D

Class II, Groups E, F, G

UL File: E249019

For use in Pollution Degree 2 Environments.

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 Enter Calibration Mode, and calibrate for

fully closed/fully open positions

One Rotary Switch Select relay set-point hysteresis

Memory EEPROM retains calibration during power

failure or power shut down

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.

Additional Information

To get additional information about the SG1000RA, visit our

website at: www.electro-sensors.com

Notice:

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.

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