Koganei ZL1 Series User manual

INDEX
Actuators
Features 846
Handling instructions and precautions 848
Diagram of inner circuits 849
Specifications 850
Order codes 851
Dimensions 852
Setting instructions 854
Before use, be sure to read the safety precautions at the front of the general personal catalog.
CAUTION
Linear Magnetic Sensor Controller
RoHS directive compliant products
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845
旧版 0
032016

Linear Magnetic Sensor Controller
Linear Magnetic Sensor Controller
● E xchange with control devices is possible due to standard equipment for analog output (1 to 5 VDC).
● Switch output is possible in four places. Simple position detection is possible.
● Since the sensor head is the same shape as the ZE sensor switch, it is compatible with ac-
tuators equipped with the ZE sensor switch.
Output mode
■Window comparator mode ■Hysteresis mode
Sensor head
ZLS1-□L
Linear magnetic sensor controller
ZL1-□-□
Senses the linear position of the cylinder within the specified range.
NOTE
For information about actuators on which the linear magnetic sensor
controller can be mounted, refer to "Compatible actuators" on page 847.
Switch output display
Indicator color is red
only.
4-digit LED display
The display color can
be changed to green or
red.
Display (%)
OUT1
LCD display
100
60
40
0F
Response differential (fixed)
t
Hand full open Holding workpiece Hand full open Hand full open
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% F.S).
When the controller setting and sensor heat setting positions are as shown below.
OUT1 Threshold value setting Upper limit: 60 Lower limit: 40
Display when hand is full open: 90
Display (%)
OUT1
LCD display
CAUTION: When the effective measuring range signal is OFF (outside the measuring range), OUT also becomes OFF.
100
20
40
0F
t
Hand full open Holding workpiece Hand full open 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: 40 Lower limit: 20
Display when hand is full open: 90
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846
旧版 1
032016

The linear magnetic sensor controller can mounted on the actuators below. For information about mounting
it on other actuators, contact Koganei.
Example of use
Compatible actuators
Air Hand L hand Air hand NHB Flat type air hand
● Workpiece identification by 4-point switching output
●Height check for press-fit items
Swing type
Parallel type
●Compatible actuatorsNote and operation ranges (mm or angle)
Name Model Cylinder bore
6 [0.236] 8 [0.315] 10 [0.394] 12 [0.472] 14 [0.551] 16 [0.630] 18 [0.709] 20 [0.787] 25 [0.984] 32 [1.260]
Air Hand NHC1D   4 [0.157]   6 [0.236] 5 [0.197] 5 [0.197] 
L hand NHL1D 4 [0.157] 4 [0.157]   5 [0.197] 5 [0.197] 5 [0.197] 
Air hand NHB parallel type NHB□PG(L) 4 [0.157] 
6.5 [0.256]
10 [0.394] 14 [0.551] 20 [0.787]
Air hand NHB parallel type NHB□P(A) 4 [0.157] 4 [0.157]   8 [0.315] 12 [0.472] 14 [0.551] 
Air hand NHB swing type NHB□S
-10 to 30°-10 to 30°
 
-10 to 30°

-10 to 30°-10 to 30°

NHB swing 180 degrees NHBDSL(G) 80°85°65°65°
Flat type air hand AFDPG 5 [0.197] 9 [0.354] 7 [0.276] 10 [0.394] 9 [0.354] 
Note: The actuators on which the linear magnetic sensor controller can be mounted are the sensor cylinders with the sensor switch magnets.
Remark: The values above are values that include response differentials. They are reference values. For information about actuators other than those above,
contact Koganei.
ZLS1
1
4
3
2
ZLS1
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847
旧版 2
032016

Handling instructions and precautions
Mounting and piping
Sensor head and connector connection overview
The ZLS1-□sensor head is provided with the mini clamp 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.
6 P 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
raised 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 [1.969 in] from the end,
to expose the lead wires. Do not strip the insulation from the
individual lead wires at this time.
50 mm [1.969 in]
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 [0.354 in]) as far as they
will go by looking into the semi-transparent top cover of the connector.
Note that supplying power while connections are incorrect will
damage the sensor head and controller.
Number on connector 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
6NC Unconnected
5. Taking care not to allow the lead wires to come out of the connector,
use the special 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.
Attaching and detaching of the sensor head and power supply/switching cables
To attach the sensor head and the power supply/switching 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. Insert the sensor head into the switch mounting groove of the air
hand or cylinder to be used. Tighten to a torque of less than 0.2 N
• m
[1.77 in
• lbf].
2. For information of the sensor head insertion direction, refer to the
"Sensor switch mounting" for the air hand or cylinder you are using.
Unconnected
654321
Sensor head
Red
Black White
Brown
Unconnected
654321
Sensor head
Blue
1 2 3 4
ZL1
KOGANEI
SW.OUT
654321
Brown
White
Black
Red
Blue
Gap
Lock lever
Lock lever
8
7
6
5
4
3
2
1
Power supply/switching cable
ZLW-3L
Sensor head
ZLS1-
Protective front cover (available separately)
ZLBK100
Slot
tab
Protrusion
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848
旧版 5
032016

Handling instructions and precautions
Diagram of inner circuits
General precautions
Wiring
1. When using a power supply with a commercially available
switching regulator, be sure to connect a frame ground (F.G.).
2. Be sure to connect a frame ground (F.G.) to the devices when
using devices that generate noise (switching regulator,
inverter motor, etc.) in the vicinity of the installed sensor.
3. After completing wiring work, check to make sure that all
connections are correct.
Other
1. Check fluctuations in the power source to confirm they do not
exceed the ratings before turning on the power.
2. Avoid use during the transitional state (1 second) when the
power is turned on.
3. Never use a needle or any other sharp, pointed object to
perform key operations.
24 VDC
±10%
+
−
D
Main circuit
Linear magnetic sensor controller
Sensor head
Power supply/
switching cable
Note: If you use an extended cable, be aware that voltage decreases due to its resistance.
1
2
3
4
5 OV (blue wire)
LED (red wire)
B_IN (black wire)
A_IN (white wire)
+V (brown wire)
Tr1
Tr2
Tr3
Tr4
Tr5
ZD5
ZD4
ZD3
ZD2
ZD1
3
5
1
6
7
8
4
2
Load
Load
Load
Load
Load
STAB (black wire)
+Vcc (brown wire)
OUT1 (white wire)
OUT2 (red wire)
OUT3 (green wire)
OUT4 (yellow wire)
GND (blue wire)
Analog output (grey wire)
Symbol D : Power supply reverse-polarity protection diode
Z
D1 to Z D5 : Surge voltage absorption zener diode
Tr
1 to Tr 5 : NPN output transistor
Sensor section
内部回路_1_改訂
Main circuit
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849
旧版 6
032016

Linear magnetic sensor controller
Specifications
Connector number
ZL1
●Sensor head
Number on connector 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
6NC Unconnected
●Power supply
Pin number Signal name Lead wire color
1Power supply voltage input (24 V) Brown
2Analog output (1 to 5 V) 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 ZLS1-□L
Power supply voltage 5 VDC±5%
Consumption current 20 mA MAX.
Mounting methods Embedded type
Operation indicator light Red LED lights at optimal sensitivity position (Operation position can be changed by settings)
Lead wires Heat-resistant, oil-resistant vinyl sheath instrumentation cableφ2.9 [0.114] 0.15 mm25-lead with 6 P connectors
Insulation resistance 100 MΩmin. (at 500 VDC megger, between case and lead wire terminal)
Withstand voltage 500 VAC (50/60 Hz) 1 minute (between case and lead wire terminal)
Shock resistance 294.2 m/s2[30 G] (non-repeated)
Protective structure IP67
Vibration resistance 88.3 m/s2[9 G] (total amplitude of 1.5 mm [0.059 in], 10 to 55 Hz)
Ambient temperature 0 to 50°C [32 to 122°F] (non-condensation, non-freezing)
Storage temperature range -10 to 70°C [14 to 158°F] (non-condensation, non-freezing)
Mass 20 g [0.705 oz] (when 1 L lead wire length is 1000 mm [39 in])
●Controller
Item Model ZL1
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 % display within effective measuring range (4 digits, 2-color display: red and green)
Analog output voltage range 1 to 5 VDC (1 KΩoutput impedance)
Analog output repeatability ±1% of F.S (25°C±5°C [77°F±9°F])Note
Insulation resistance 100 MΩmin. (at 500 VDC megger, between case and lead wire terminal)
Withstand voltage 500 VAC (50/60 Hz) 1 minute (between case and lead wire terminal)
Shock resistance 294.2 m/s2[30 G] (non-repeated)
Ambient temperature 0 to 50°C [32 to 122°F] (non-condensation, non-freezing)
Storage temperature range -10 to 70°C [14 to 158°F] (non-condensation, non-freezing)
Mass 40 g [1.411 oz]
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.
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850
旧版 7
032016

Order codes
Additional parts (available separately)
ZL1 - -
Protective front cover
Blank: No protective front cover
C: With protective front cover
Linear Magnetic Sensor Controller
ZLS1 -
Sensor head
Cable length
1L: 1000 mm [39 in]
2L: 2000 mm [79 in]
3L: 3000 mm [118 in]
●Sensor head
ZLW-3L
●Power supply/switching cable
ZLBK100
●Protective front cover
ZL-6M
●Mini clamp wire mount plug, 6 P (for sensor head)
ZL-8M
● Mini clamp wire mount plug, 8 P (for power supply/switching cable)
Power supply/switching cable
Blank: No power supply/switching cable
3L: With power supply/switching cable (length of 3000 mm [118 in])
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851
旧版 8
032016

3000 [118]
φ4.8 [0.189]
(40 [1.575])
8
7
6
5
4
3
2
1
●ZL1-□-□(controller part)
●ZLS1-□L(sensor head part)
●ZLW-3L (power supply/switching cable)
Dimensions mm [in]
30 [1.181]
Power side
Sensor head side
2-φ3.4 [0.134] through holes
4-φ6.5 [0.256]; counterbore
depth 3.3 [0.130]
(Along with the opposite side)
14.7 [0.579]
27.8 [1.094]
4.8 [0.189]
43 [1.693]
51 [2.008]
39.4 [1.551]
1234
45 [1.772] 1.5 [0.059]
9.5 [0.374]
30 [1.181]
ZL1
KOGANEI
SW.OUT
ZL1
KOGANEI
SW.OUT
ZL1
JAPAN
752
6P_CON
+5V
A_IN
B_IN
LED
GND
NC
8P_CON P
1
2
3
4
5
6
7
8
P
1
2
3
4
5
6
24 VDC
ANALOG
STABI
GND
OUT_1
OUT_2
OUT_3
OUT_4
20.1 [0.791]
4.6 [0.181] 4.1 [0.161]
φ2.9 [0.114]
15.6 [0.614]
22.5 [0.886]
M2.5 slotted head set screw
Center point of sensitivity of the sensor: 7.2 [0.283]
Indicator light
1L: 1000 mm [39 in]
2L: 2000 mm [79 in]
3L: 3000 mm [118 in]
654321
Brown
White
Black
Red
Blue
Gap
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旧版 9
032016

20.1 [0.791] Orange
18.5 [0.728]
6 [0.236]
5.05 [0.199]
15.6 [0.614]
●ZLBK100 (protective front cover)
●ZL-6M (mini clamp wire mount plug, 6 P, for sensor head)
●ZL-8M (mini clamp wire mount plug, 8 P, for power supply/switching cable)
Dimensions mm [in]
(5.7 [0.224])
5 [0.197]
(30 [1.181])
(34.7 [1.366])
24.1 [0.949]
Red
18.5 [0.728]
6 [0.236]
5.03 [0.198]
15.6 [0.614]
2 駆動機器図面
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853
旧版 10
032016

CAUTION
1. Incorrect wiring to the sensor head or power/switch cables creates the risk of damage to both the controller and sensor head. Confirm
that wiring is correct before turning on power.
2. Record write conditions that were configured by writing them to flash memory. Note that flash memory has a limited life, and the
number of rewrites is 10,000.
■Nomenclature and functions
No.
Name Description
①Display
Effective measuring range %, setting details, error indicators
②Switch output indicator Lights when switch output is ON (Channels 1 to 4)
③UP key ( ) Use to increase a setting value.
④DOWN key ( ) Use to decrease a setting value.
⑤Mode key ( ) Use when configuring settings.
t
w
r
q
e
ZL1
1 2 3 4
SW.OUT
Setting guidelines
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旧版 11
032016

■Settings
CAUTION
1. Incorrect wiring to the sensor head or power/switch cables creates the risk of damage to both the controller and sensor head. Confirm
that wiring is correct before turning on power.
2. Record write conditions that were configured by writing them to flash memory. Note that flash memory has a limited life, and the
number of guaranteed writes is 10,000.
■Preparation for settings
•Connect the sensor head and power/switching cable to the controller. Refer to "Attaching and detaching of the sensor head and power
supply/switching cables" on page 848.
■Configuring settings
First specify the built-in cylinder type (SET2) and then configure other settings as shown below.
You can change settings using the procedure below.
General flow
Description Initial value
Sets the output range of each
channel. HI: 60 LO:40
Selects the model of mounted
cylinder. 10
Selects the output mode of
each channel. CO4
Can be used to invert the
switch output of each channel. S-0
Changes the sensor head
LED indicator. HI: 60 LO:40
Configures the scaling setting. OFS: 0 FS: 100
Configures the display panel
setting. bL-1
Configures the LCD display
cycle. dT-1
Adjusts the switch output
response time of each channel.
Sd-1
Performs initialization 1.
Performs initialization 2
(display, output check).
Adjusts the maximum output
voltage of analog output.
Note 1: Be sure to specify the model of cylinder for mounting.
Failure to do so creates the risk of erratic operations.
2: Since initialization (SET A, SET B) returns settings to their
initial defaults, all data settings to date are lost.
Detection
mode
→
Button operation
Press →LCD →
Button operation
Release →LCD
Press
→Doing nothing returns to detection mode.
LCD ON/OFF
When a value
is displayed,
enters the
detection
mode.
LCD
backlight
becomes
brighter.
increases
value.
decreases
value.
Changes in
accordance
with setting
details.
Note2
Note1
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旧版 12
032016

Use the procedure below to configure threshold value setting for each channel.
Change the setting in accordance with the cylinder on which the sensor head is installed.
The switch output can be inverted for each channel.
Use the procedure below to change the sensor head LED display position.
Input conditions
0<0FS<FS
0FS<FS<1000
The voltage differential of at least 1 V is required between the
0FS position and the FS position.
If conditions are not satisfied, will appear on the display and
settings will be disregarded.
Scaling is performed at the positions between two specified points.
Note 1: Input conditions: Upper limit value (L2) > Lower limit value (L1) + 1
2:
When the difference between scaling set time 0Fs and Fs is 500 or more,
use the following upper limit value (L2) > Lower limit value (L1) + 10.
Note 1: Once this setting is changed, initialization will be required to return to
its previous setting.
2: Configuring scaling settings causes all threshold values to change to
the following: Upper limit value (L2) = FS; lower limit value (L1) = 0FS.
Change the threshold value settings as required.
3: Configuring scaling settings causes the scaling value setting range to
become 0FS to FS.
Threshold value setting (SET1)
Setting the type of mounted cylinder (SET2)
Switch output inversion setting (SET4)
LED display range setting (SET5)
Scaling setting (SET6)
Window comparator Hysteresis
Upper limit value (L2) ON/OFF position ON position
Lower limit value (L1) ON/OFF position OFF position
Procedure Button operation
Display after operation
Indicator Backlight Remark
1 Green Set the output range of each OUT.
2 (Initial default: 60) OUT flashes Red Set the upper limit setting for flashing indicator.
3 Select the value to be changed.
4 (Initial default: 40) Green Set the lower limit setting for flashing indicator.
5 Select the value to be changed.
6
(Initial default: 60) OUT flashes Red OUT2, OUT3: Repeat steps 2 through 5.
OUT4: Return to sensing mode.
Procedure Button operation Display after operation Remark
1 Selects the type of mounted cylinder.
2
3 (Initial default: 10)
4 Changes the model number of the cylinder that is mounted.
5 Returns to sensing mode after one second.
Use the procedure below to specify the output mode for each channel.
Note: These settings are valid within the effective measuring range (operation range).
Output mode setting (SET3)
Procedure Button operation Display after operation Remark
1 Set the output mode of each OUT.
2 Select the channel of each OUT.
3to CH1:OUT1 CH2:OUT2 CH3:OUT3
CH4:OUT4
4Select the output mode.
5to
: Output off
: Window comparator mode
: Hysteresis modeNote
6*
Displays the set channel number (one second)
Displays the set channel mode (one second)
7 Returns to detection mode after one second.
Procedure Button operation Display after operation Remark
1 Set the contact type of each OUT.
2 Select the channel of each OUT.
3to CH1:OUT1 CH2:OUT2 CH3:OUT3
CH4:OUT4
4Select the contact point type.
5to : Non-inverted (A contact)
: Inverted (B contact)
6*
Displays the set channel number (one second)
Displays the set channel mode (one second)
7 Returns to detection mode after one second.
Procedure Button operation Display after operation Remark
1
2 Set the display lower limit value.
3
(Initial default: 40)
4 Change the value.
5Set the display upper limit value.
6 (Initial default: 60)
7 Change the value.
8 Returns to detection mode after one second.
Procedure Button operation Display after operation Remark
1
2 Move the cylinder to the lower limit position.
3 (Initial default: 0) Set the scaling lower limit value.
4 Change the value.
5 Move the cylinder to the upper limit position.
6 (Initial default: 100) Set the scaling upper limit value.
7 Change the value.
8 Returns to detection mode after one second.
For information about other cylinders, contact Koganei.
Setting guidelines
Compatible cylinder Cylinder bore SET 2 number
NHC1D
Total cylinder bore 10
NHL1D
Total cylinder bore 10
NHB□PG(L)
Total cylinder bore 10
NHB□P(A)
Total cylinder bore 10
NHB□S
Total cylinder bore 10
NHBDSL(G)
Total cylinder bore 10
AFDPG
6.18 [0.243] 15
8.14 [0.32] 12
12 [0.472] 16
Compatible cylinder Cylinder bore SET 2 number
MGA
Total cylinder bore 20
TBDA
Total cylinder bore 18
ARS
Total cylinder bore 16
CDAS
SGDA
6 [0.236] 13
8 [0.315] 14
32 [1.260] 16
Other than above 15
MS
6.10 [0.240] 18
16.20 [0.638] 16
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856
旧版 13
032016

Setting the backlight color
LCD display cycle setting
Switch output response time setting
Use the procedure below to set the backlight color.
Backlight display setting (SET7)
Procedure Button operation Display after operation Remark
1
2 Backlight setting
3to
4 Returns to detection mode after one second.
Backlight OFF
Switch output OFF: Green Switch output ON: Red
Switch output OFF: Red Switch output ON: Green
Always green
Always red
•
Connection to switch output is linked with switch output channel 1.
5 ms Max
≒20 ms
≒100 ms
≒1000 ms
250 ms
500 ms
1000 ms
Use the procedure below to return settings to their initial defaults. At
the same time, you can also check the status of the display and output.
Use the procedure below to return settings to their initial defaults.
Use the procedure below to set the switch output response time.
Use the procedure below to configure the LCD display cycle setting.
Note: Performing the above operation causes all switch output to become ON
momentarily.
Also, all data is initialized after the above operation is performed. Make written
copies of any settings you have changed before performing the above operation.
Note: All data is initialized after the above operation is performed.
Keep a separate record of settings you have changed.
Initialization 2 (display, output check)
Initialization 1
Switch output response time setting (SET9)
LCD display cycle setting (SET8)
Error indications
Name Error description Error clear
The selected channel's
sensor head is burned out or
not connected.
In case of burn out, turn off
power and then replace the
sensor head.
Invalid setting when
configuring the scaling
setting.
Reconfigure the scaling
setting so it satisfies the
required scaling conditions.
Overvoltage applied to
sensor input. After eliminating the cause
of the error, hold down the
mode key for at least one
second.
(n = applicable channel)
Overcurrent flowing to
switch output.
Use the procedure below to adjust the maximum output voltage of analog output.
Adjustment for the maximum output voltage of analog output (SETC)
Procedure Button operation Display after operation Remark
1 Adjusts the maximum output voltage of analog output.
2
3 Voltage output by analog output.
4Value change
Check the analog output voltage with a
multimeter or some other instrument and
adjust the maximum output voltage.
5 Returns to detection mode after one second.
Procedure Button operation Display after operation Remark
1 Perform initialization. (Check display)
2
Press the 3 buttons at the same time.
While holding down [MODE], press
the following in sequence →.
Procedure Button operation Display after operation Remark
1 Performs initialization.
2
Press the 3 buttons at the same time.
While holding down [MODE], press the
following in sequence: →.
Procedure Button operation Display after operation Remark
1
2 Output delay setting
3to
4 Returns to detection mode after one second.
Procedure Button operation Display after operation Remark
1
2 Sampling cycle setting
3to
4 Returns to detection mode after one second.
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857
旧版 14
032016

2 駆動機器図面
エアシリンダ 三校
858
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032016