Koganei ZL2 User manual

❷❶
M020961
Ver.1.0
Ver. 1.0
Instruction Manual
ZL2
注：ｃタイプの使用サイズは左右 50mm未満
このデータからの縮率は50%より小さく
Linear Magnetic Sensor Controller Long Type
Thank you for purchasing this Koganei product.
Before using it, be sure to read this manual and make sure you use it correctly.
Keep this manual in a safe place for future reference.
󱦯Specications
Connector number
●Sensor head
Connector side number Signal name Lead wire color
1Sensor head voltage (+) Sensor head brown lead
2Sensor head voltage output A_IN Sensor head white lead
3Sensor head voltage output B_IN Sensor head black lead
4Indicator (LED) input Sensor head red lead
5GND Sensor head blue lead
6Sensor head voltage output C_IN Sensor head yellow lead
●Power supply
Pin No. Signal name Lead wire color
1Power supply voltage input (24 V) Brown
2Analog output (1 to 5V) Gray
3
Effective measuring range signal output (STABI) Black
4GND Blue
5Switch output OUT1 White
6Switch output OUT2 Red
7Switch output OUT3 Green
8Switch output OUT4 Yellow
●Sensor head
Item Model ZLL□-□L
Power supply voltage 5 VDC±5%
Consumption current 20 mA max.
Mounting methods Body embedded type (ZLL1, ZLL2), □4 type (ZLL3)
Operation indicator light Red LED lights at optimal sensitivity position (Operation position can be changed by setting.)
Lead wire Heat-resistant, oil-resistant vinyl sheath instrumentation cable φ2.8 6 core With 6P connectors
Insulation resistance 100 MΩ MIN. (500 VDC Megger, between case and lead wire terminal)
Withstand voltage 500 VAC (50/60 Hz) in 1 minute (between case and lead wire terminal)
Shock resistance 294.2 m/s2(non repetitive)
Protective structure IP67
Vibration resistance 88.3 m/s2(Double amplitude: 1.5 mm 10 ~ 55 Hz)
Ambient temperature 0 to 50℃ (non-condensation, non-freezing)
Storage temperature range -10 to 70℃ (non-condensation, non-freezing)
Mass 20 g (When 1L lead wire length is 1000 mm.)
Sensor head and connector connection overview
The ZLL-□-□Lsensor head is provided to you with the mini
plug wire mount plug connected to the sensor head unit. A
special tool is required if you need to reconnect in order to adjust
the length. Use the following procedure when reconnecting.
1. Be sure to use the mount plug and the special tool shown
below when reconnecting.
6P mini clamp wire mount plug Model: ZL-6M
Special tool Model: 1729940-1
Tyco Electronics Japan G.K.
2.
Check to make sure that the connector cover (lead wire inlet) is
sitting above the body of the connector. Note that a connector
whose cover is even with the body of the connector cannot be used.
3. Cut the sensor head cable to the required length.
Strip the outer covering of the cable, 50 mm from the end, to
expose the lead wires. Do not strip the insulation from the
individual lead wires at this time.
50mm
4. Insert the lead wires into the connector cover holes in
accordance with the information in the table below. Check to
make sure the lead wires are fully inserted (wire goes in about
9 mm) as far as they will go by viewing the semi-transparent
top cover of the connector.
Note that supplying power while connections are incorrect will
damage the sensor head and controller.
Connector side number Signal name Lead wire color
1Sensor head voltage (+)
Sensor head brown lead
2 Sensor head voltage output A_IN Sensor head white lead
3
Sensor head voltage output B_IN Sensor head black lead
4Indicator (LED) input Sensor head red lead
5GND Sensor head blue lead
6
Sensor head voltage output C_IN Sensor head yellow lead
5. Taking care not to allow the lead wires to come out of the
connector, use the special tool (don't try to use any other tool)
to squeeze the cover and body of the connector until the
cover is pressed into the body.
Connection is complete when the cover is even with the
connector body.
6. Double check to make sure that wiring is correct.
654321
Sensor head
Red Black White Brown
654321
Sensor head
Yellow Blue
Attaching and detaching of the sensor head and power/switch cables
To attach the sensor head and the power/switch cables, position
the lock levers as shown in the illustration above, and then insert
until they lock into place with the controller side connectors. To
disconnect, press the lock lever down as far as it will go as you
pull the connector to unplug it. At this time, take care not to apply
undue force to the lead wires.
Attaching the protective front cover
Attach the protective front cover so the tabs inside the cover
enter the slots on the Linear Magnetic Sensor Controller.
* To remove the protective front cover, hook your finger on the
projection on one side of the cover and remove it.
Sensor head installation precautions
1. After inserting the sensor head into the Air Hand or cylinder
switch mounting groove (depending on which you are using) and
move the sensor head to the suitable position, secure it in place
with the fixing screw. Use a tightening torque of 0.2 N·m or less.
2. For information about the sensor head insertion direction, see the "Sensor
switch mounting method" for the Air Hand or cylinder you are using.
3. When the sensor head is installed in a position that causes it to
protrude from the Air Hand or cylinder body you are using, the sensor
head will move by the amount of the gap with the sensor groove,
which will cause deterioration of sensing precision. Affix insulating
tape or some other suitable material to the lower part of the sensor
head (as shown in the illustration below) in order to reduce the gap.
Protective front cover (available separately)
ZLBK100
Slot
Tab
Projection
󱦱Installation
Do not use this product for the purpose of accident prevention or
for other safety assurance purposes. Using the product in any of
the ways described above creates the risk. of loss of human life.
DANGER
●Controller
Item Model ZL2
Power supply voltage 24 VDC ±10%
Consumption current 50 mA max. (Not including supply power to sensor.)
Sensor input supply power and voltage 5 VDC
Sensor input maximum input voltage 3.0 V
Switch output method NPN open collector output, 5 points
Load voltage 30 VDC
Load current 50 mA max.
Switch output volume repeatability ±1%F.S. ±1 digit Note
Internal voltage drop 0.3 V MAX. (When Ic = 5 mA)
Response time 5 ms MAX.
Operation indicator light Lights red when each switch output is on.
Value display 1/1000 division display within effective measuring range(4 digits, 2-color display: red and green)
Analog output voltage range DC1 to 5V within effective measuring range, DC0.8V outside effective measuring range (1kΩ output impedance)
Analog output repeatability ±1% of F.S (25℃±5℃) Note
Insulation resistance 100 MΩ MIN. (500 VDC Megger, between case and lead wire terminal)
Withstand voltage 500 VAC (50/60 Hz) in 1 minute (between case and lead wire terminal)
Shock resistance 294.2 m/s2(non repetitive)
Ambient temperature 0 to 50℃ (non-condensation, non-freezing)
Storage temperature range -10 to 70℃ (non-condensation, non-freezing)
Mass 40 g
Note: This performance excludes the mechanical looseness of a cylinder with a fixed magnet (standalone performance). In the case of a movable type cylinder whose magnet
is not fixed, the movable part and repeatability are degraded.
1 2 3 4
ZL2
SW.OUT
654321
Brown
White
Black
Red
Blue
Yellow
Lock lever
Lock lever
8
7
6
5
4
3
2
1
Power/switch cable
ZLW-3L
Sensor head
ZLL□-□L
Insulation tape cutting dimensions
(reference values)
Large amount of free
movement
15
2
When sensor head is installed so it
protrudes from the Air Hand
Countermeasure: Affix
something like insulation
tape and then insert into
the sensor groove to
reduce movement.

❹❸
󱦳Inner Circuit Diagrams 󱦹Setting
󱦵Nomenclature and functions
󱦷Output mode
No.
Name
①Display Shows effective measuring range %, setting details, error indicators.
②Switch output indicators Light when switch output is ON (CH1 to CH4).
③UP key ( ) Use to increase a setting value.
④DOWN key ( ) Use to decrease a setting value.
⑤MODE key ( ) Use when configuring settings.
⑤
②
④
①
③
ZL2
1 2 3 4
SW.OUT
■Window comparator mode
Display
OUT1
LCD display
1000
600
400
0F
Response
differential (fixed)
t
Response
differential (fixed)
)
)
Effective
setting range
signal
(STABI)
The ON range of each output can be set within the effective
measuring range (sensor head ON range).
Response differential is fixed (2 digits)
When the controller setting and sensor heat setting positions are as shown below.
OUT1 Threshold value setting Upper limit: 600 Lower limit: 400
Display when hand is full open: 900
ZL2ZL2 ZL2ZL2
Hand full open Holding workpiece Hand fully closed Hand full open
■Hysteresis mode
Display
OUT1
LCD display
CAUTION: When the effective measuring range signal is OFF
(outside the measuring range), OUT also becomes OFF.
1000
200
400
0F
t
Hand full open Holding workpiece Hand fully closed Hand full open
Effective
setting range
signal
（STABI）
The ON position and OFF position each output can be set within the
effective measuring range (sensor head ON range).
When the controller setting and sensor heat setting positions are as shown below.
OUT1 Threshold value setting Upper limit: 400 Lower limit: 200
Display when hand is full open: 900
ZL2 ZL2 ZL2
ZL2
CAUTION
1. Incorrect wiring of the sensor head or power/switch cable will damage both the controller and the sensor head. Be sure to double-
check and make sure that wiring is correct before supplying power.
2. Parameters that are set are recorded into flash memory and retained there. Note that flash memory has a limited service life. The
guaranteed number of rewrites is 10,000.
■Getting ready to configure settings
・Connect the sensor head and power/switch cable to the controller. (Refer to "Attaching and detaching of the sensor head and power/
switch cables" on page ❷).
■Configuring settings
24 VDC
±10％
+
−
D
Linear magneticsensor controller
Sensor head
Power/switch cable
Note: Note that extending the cable can cause a drop in voltage due to cable resistance.
1
4
2
3
5
6
OV (blue lead)
C_IN (yellow lead)
B_IN (black lead)
A_IN (white lead)
LED (red lead)
+V (brown lead)
Tr1
Tr2
Tr3
Tr4
Tr5ZD5
ZD4
ZD3
ZD2
ZD1
3
5
1
6
7
8
4
2
STABI (black lead)
+Vcc (brown lead)
OUT1 (white lead)
OUT2 (red lead)
OUT3 (green lead)
OUT4 (yellow lead)
GND (blue lead)
Analog output (gray lead)
Signal D : Power supply reverse-polarity protection diode
ZD1~ ZD5 : Surge voltage absorption zener diode
Tr1~Tr5: NPN output transistors
Load
Load
Load
Load
Load
Main circuit
Sensor section
Main circuit
YES
Purchase the set of the
controller and the sensor head
Install direction setting
(SET0)
Equipped cylinder setting
(SET2)
Threshold and switch output mode
setting (SET1&SET3)
Additional settings as needed
(SET4~9)
Start
detection
Sensor head
parameter setting
(SETd)
NO
First specify the cylinder model that is equipped (SET2), and then configure the other settings (as shown below).
You also can use the procedure below to modify settings.
General flow
Note 1: Always be sure to
configure the
equipped cylinder
model setting. Failure
to do so creates the
risk of malfunction.
2: Note that initialization
(SETA, SETB)
initializes all settings,
so any settings you
have configured are
lost.
Note 2
Note 1
increases
the value,
decreases
it.
Detection mode
Detection
mode is
Indicated
when LCD
shows OF or
OFF.
Button operation
Long press
Install direction
setting
Congures the install
direction Sn-0
Sets the output range of
each channel.
HI:600
LO:400
Selects the model of the
equipped cylinder. 18
Selects the output mode
of each channel. CO
Can be used to invert the
switch output of each channel.
S-0
Changes the display position of
the sensor head LED indicator.
HI:600
LO:400
Congures the scaling
setting.
OFS:0
FS:1000
Congures the display
panel setting. bL-1
Congures the LCD
display cycle setting. dt-1
Adjusts the switch output
response time of each channel.
FL-0
Performs Initialization 1.
Performs Initialization 2
(display, output check).
Adjusts the maximum output
voltage of analog output.
Congures the sensor
head parameters.
Exits the settings and returns
to the detection mode
Setting items LCD display
Description
Initial default
Switch output
threshold setting
Equipped cylinder
model setting
Switch output
mode setting
Switch output
reverse setting
Sensor head LED indicator
display range setting
Scaling setting
Display backlight
color setting
Display refresh
cycle setting
Adjustment setting
Initialization (except SETC&SETd)
[Press △▽□ at the same time]
Initializes all settings
[Press △▽□ at the same time]
Analog output maximum
voltage setting
Sensor head
parameter setting
Exit setting
Press
Detailed
conguration
of each
setting is
supported.

Sensor head parameter setting (SETd)
Congures the sensor head parameters.
This setting is not required if the controller and the sensor head are purchased as a set (Model: ZL2-ZLL □-□LK) as it is already congured.
Install direction setting (SET0)
Congures the install direction of the sensor head. This setting must be congured after installing the cylinder head to the cylinder.
If the system is used without conguring this setting, correct detection or output cannot be achieved.
Factory setting:
Setting : or
The behavior differs depending whether the sensor head is connected or not.
Return to
*
*
Press □  When the sensor head
connected (automatic setting)
1 second later
After judging the
install direction
When the sensor head is not
connected (manual setting)
Reciprocate the
cylinder a few times
while checking the
toggle of the sensor
head LED ON/OFF.
The setting
value matches
the sensor head
install direction is
displayed.
Press □1 second later
Press □1 second later Return to
Use △or ▽key to
change the setting
values.
Note 1) If the □key is pressed before the setting judgment by automatic judgment, the display returns to “ ” without any change.
Threshold value setting (SET1)
Use this setting to set threshold values for each channel.
Factory setting Input value Window comparator mode Hysteresis mode
Threshold (L2) 600 0 to 1000 Upper threshold ON point
Threshold (L1) 400 0 to 1000 Lower threshold OFF point
Note1) Input condition L2 ＞L1+1
<About TEACH setting>
While actually moving the cylinder (hand), set the threshold based on the value displayed.
Because the threshold is set based on the displayed value, perform this task while the sensor head is connected.
(If TEACH setting is entered without setting the sensor head, E-1 is displayed)
It would be the same area as the threshold storage location. To see the stored value, use SET1.
Output behavior when congured with the tolerance = 10 and the displayed value 525 (in Window comparator mode)
1010
2
Fixed hysteresisFixed hysteresis
ToleranceTolerance
515
513 537
525 535
Display valueL1 L2
2
Return to
INPT: Use the △▽ buttons
to set the threshold
TEAC: Congure the
threshold based on
the actual position
Press □Press □
Press □Press □
Press □
Press □
Press □
Press □
Press □
Setting CH is displayed
CH1 to 4: Individual settings
for the selected CH
ALL: Sets CH1 to 4 in a row
Set the threshold L2.
The indicator corresponding
to the setting CH turns on.
The current position is
displayed.
Move to the L2 setting
position. The indicator
corresponding to the
setting CH blinks.
Backlight color: red
Backlight color: red
Use △or ▽key to
change the setting
values.
Input value: 0 to 1000
Factory setting: 600
Set the threshold L1.
The indicator corresponding
to the setting CH turns on.
Backlight color: green
Backlight color: green
Use △or ▽key to
change the setting
values.
Input value: 0 to 1000
Factory setting: 400
1 second
later
Press □Press □Press □
ALL: when selected, moves to the
next CH setting
(If not completed to CH4)
1P: 1-Point teaching
threshold setting
2P: 2-Point teaching
threshold setting Set the threshold.
Use △or ▽key to
change the tolerance
values.
Input value: 1 to 1000
Setting CH is displayed
CH1 to 4: Individual settings
for the selected CH
ALL: Sets CH1 to 4 in a row
Setting CH is displayed
CH1 to 4: Individual settings
for the selected CH
ALL: Sets CH1 to 4 in a row
Use △or ▽key to select
the setting CH
Use △or ▽key to select
the setting CH.
Use △or ▽key to select
the setting CH.
The current position is
displayed. Move to the
setting position. The
indicator corresponding
to the setting CH blinks.
The current position is
displayed. Move to the
L1 setting position. The
indicator corresponding
to the setting CH blinks.
△or ▽
L2 = set to the
displayed value
△or ▽
Set to:
L2 = displayed value +
tolerance value
L1 = displayed value -
tolerance value
ALL: when selected, moves
to the next CH setting
(If not completed to CH4)
Press □
ALL: when selected, moves to the next CH setting
(If not completed to CH4)
Installed cylinder model setting (SET2)
Change this setting in accordance with the cylinder model that the cylinder head will be set into.
Factory setting : 18
Setting :
1 to 20
Set value Installed cylinder model
8 NHBDSL:25
16 NHB□PG:40,50
17 AFDPPG(L):14,18
18
NHB□PG:8,10,16,20,25,30
NHBDSL:12,16,20
AFDPG(L):6,8,12,25
NHB□PGL,NHB□P(A),NHB□S
NHE1D,NHC1D,NHL1D
BDAS,NDAS,PBDAS
CDAS,SGDA,MGA,MGT,TBDA,ARS,
*For information about other cylinders, contact Koganei.
Output mode setting (SET3)
Use this setting to set the output mode for each channel.
Press □Press □Press □
Setting CH is displayed
CH1 to 4: select the setting CH
Use △or ▽key to select
the setting CH.
Set the switch output mode
The indicator corresponding
to the setting CH blinks.
Use △or ▽key to select the switch output
mode from the list below.
<Switch output mode>
: Output OFF
: Window comparator mode (factory setting)
: Hysteresis mode
The set value is displayed for 1 second.
1 second later Return to
5642
5642
5642
ZLL1
ZLL2
ZLL3
Refer to the parameter code embossed on the sensor head, and follow the example
below to enter the parameter code.
The parameter code is embossed at the position shown in the sensor head diagrams on
the right with the format display side facing up.
(Opposite to the “E※※※” impression)
Ex.) For the parameter code “5642”
Parameter 1: 1.56
Parameter 2: 1.42
❻❺
． ．
Press □Press □Press □Return to
Use △or ▽key to change
the setting values.
Input values: 1.30 to 1.70
Use △or ▽key to change
the setting values.
Input values: 1.30 to 1.70
Parameter 1 Parameter 2
Press □Press □Press □Return to
Use the △or ▽key to
congure according to
the installed cylinder.
Input value: 1 to 20

Display cycle setting (SET8)
Use this setting to congure the display cycle.
Adjustment setting (SET9)
Congures the adjustment setting.
Press □Press □1 second later Return to
Use △or ▽key to select
the smoothing setting
from the list below.
<Smoothing setting>
: No smoothing (factory setting)
: 4 times
: 8 times
: 16 times
* Usually, it is not necessary to congure SETA - SETC.
Error Indicators
Indicator Meaning Required action
The sensor head of the
selected channel is not
connected or has been
disconnected.
In the case of disconnection,
turn off power and replace the
sensor head.
Invalid scaling setting.
Recongure the scaling setting
so it satises the required
scaling conditions.
Over voltage being applied to
sensor input. After correcting for the source
of the problem, hold down the
MODE key for more than one
second.
Over voltage being applied to
switch output.
n
(n: applicable channel)
* For other information, detailed specifications, and precautions, see the product
catalog.
* For inquiries about the product, contact your nearest Koganei sales office or the
Overseas Group noted below.
OVERSEAS GROUP
3-11-28, Midori-cho, Koganei City, Tokyo 184-8533, Japan
Tel: [phone] Fax: [phone]
❽❼
Use △or ▽key to select
the display refresh cycle
setting from the list below.
<Display cycle setting>
: 100 ms (factory setting)
: 250 ms
: 500 ms
: 1000 ms
Press □Press □1 second later Return to
Switch output inversion setting (SET4)
This setting can be used to invert the switch output of each channel.
Setting CH is displayed
CH1 to 4: Select the setting CH
Use △or ▽key to select
the setting CH.
Reverse the setting of the
switch output. The indicator
corresponding to the setting
CH blinks.
Use △or ▽key to select the switch
output reverse mode from the list below.
<Switch output reverse mode>
: No reverse (Factory setting)
: Reverse
Press □
Press □
Press □Press □Press □
Press □
Press □
Press □Press □
Press □Press □
Press □
Press □Press □Press □Press □
Press □Press □
The set value is displayed for 1 second.
1 second later
1 second later
1 second later
1 second later
1 second later
Return to
Return to
Sensor head LED indicator light setting SET5)
Congure the sensor head LED indicator display range setting
The sensor head LED indicator turns on within the effective measuring range with the factory setting.
Congure the upper limit
of the sensor head LED
indicator display range.
Use △or ▽key to
change the setting
values.
Input value: 0 to 1000
Congure the lower limit
of the sensor head LED
indicator display range.
Use △or ▽key to
change the setting
values.
Input value: 0 to 1000
Scaling setting (SET6)
Congure the display scaling.
No change after scaling for the analog output (1-5V).
※※※
※※※
※※※
※※※
SCAL: Scaling setting
INIT: Scaling initialization Congure scaling point 1. Move the cylinder to scaling
point 1 (A1)
Move the cylinder to the display
value (B1) of scaling point 1.
Use △or ▽key to
change the setting
values.
Input value: 0 to 1000
Congure scaling point 2. Move the cylinder to scaling
point 2 (A2)
Move the cylinder to the
display value (B2) of scaling
point 2.
Use △or ▽key to
change the setting
values.
Input value: 0 to 1000
Return to
Return to
Return to
｜A1-A2 ｜/｜B1-B2 ｜＞ =1
The scaling setting is initialized and
a value of 0 to 1000 is displayed.
△or ▽
Backlight display setting (SET7)
Use this setting to congure backlight color settings.
Use △or ▽key to select
the backlight color setting
from the list below.
[Backlight color setting]
: Backlight OFF
: When switch output OFF: Green When switch output ON: Red (factory setting)
: When switch output OFF: Red When switch output ON: Green
: Always green
: Always red