Operating Manual

ZX020
Miniature Low Cost Counter for Input Frequencies up to 60 kHz

Product Features:

 Miniature panel housing

 Bright LED display with 6 digits
 Add-on frame for clip or screw mounting
 Counting frequency 15 to 60 kHz (depends on counting mode)
 Selectable filter for use with mechanical inputs
 Adjustable scaling factor and divider
 Protection class IP65 (front side)
 Diverse counting modes (e. g. event, difference, summing or position)
 Easy to set up by menu support
 10 to 30 VDC power supply

motrona GmbH, Zeppelinstraße 16, DE - 78244 Gottmadingen, Tel. +49 (0) 7731 9332-0, Fax +49 (0) 7731 9332-30, info@motrona.com, www.motrona.com
 Version: Description:
Zx02001b/K/hk/Jan02 valid for models before august, 2006
Zx02002a/K/hk/Dec06 60 kHz, Divider, (x4), summing mode
ZX02002b/hk/Aug07 modification of temperature range
Zx02002c/ag/March15 - power down memory removed from the features on page 1
- new design, techn. specifications and safety instructions
Zx020_02d/ag/July15 - “Chapter 2.” updated (setup procedure has been changed)
- “Legal Notices” supplemented
Zx020_02e/ag Correction of the temperature range

Legal notices:
All contents included in this manual are protected by the terms of use and copyrights of motrona GmbH. Any
reproduction, modification, usage or publication in other electronic and printed media as well as in the internet
requires prior written authorization by motrona GmbH.

Table of Contents
1. Safety Instructions and Responsibility ......................................................... 3
1.1. General Safety Instructions ...................................................................................3
1.2. Use according to the intended purpose ................................................................3
1.3. Installation.............................................................................................................4
1.4. Cleaning, Maintenance and Service Notes...........................................................4
2. Front Key Operation ..................................................................................... 5
2.1. Enter the Setup Mode ...........................................................................................5
2.2. Parameter Settings ................................................................................................5
3. Operational parameters ............................................................................... 6
3.1. Input polarity .........................................................................................................6
3.2. Input filter ..............................................................................................................6
3.3. Input Mode of count impulses ..............................................................................6
3.4. Impulse scaling factor ...........................................................................................7
3.5. Decimal point ........................................................................................................7
3.6. Set/Reset mode .....................................................................................................7
3.7. Set point ................................................................................................................8
3.8. End of program ......................................................................................................8
4. Terminal Assignments ................................................................................. 9
5. Delivery includes: ........................................................................................ 9
6. Technical Specifications ............................................................................ 10
7. Dimensions ................................................................................................ 11
7.1. Mounting without use of add-on frames ............................................................11
7.2. Bezel 50 x 25 mm (1.969 x 0.984’’) for clip mounting .........................................11
7.3. Bezel 50 x 25 mm (1.969 x 0.984’’) for screw mounting .....................................11

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1. Safety Instructions and Responsibility
1.1. General Safety Instructions
This operation manual is a significant component of the unit and includes important rules and
hints about the installation, function and usage. Non-observance can result in damage and/or
impairment of the functions to the unit or the machine or even in injury to persons using the
equipment!
Please read the following instructions carefully before operating the device and observe all safety
and warning instructions! Keep the manual for later use.
A pertinent qualification of the respective staff is a fundamental requirement in order to use
these manual. The unit must be installed, connected and put into operation by a qualified
electrician.
Liability exclusion: The manufacturer is not liable for personal injury and/or damage to property
and for consequential damage, due to incorrect handling, installation and operation. Further
claims, due to errors in the operation manual as well as misinterpretations are excluded from
liability.
In addition the manufacturer reserve the right to modify the hardware, software or operation
manual at any time and without prior notice. Therefore, there might be minor differences
between the unit and the descriptions in operation manual.
The raiser respectively positioner is exclusively responsible for the safety of the system and
equipment where the unit will be integrated.
During installation or maintenance all general and also all country- and application-specific safety
rules and standards must be observed.
If the device is used in processes, where a failure or faulty operation could damage the system or
injure persons, appropriate precautions to avoid such consequences must be taken.

1.2. Use according to the intended purpose

The unit is intended exclusively for use in industrial machines, constructions and systems. Non-
conforming usage does not correspond to the provisions and lies within the sole responsibility of
the user. The manufacturer is not liable for damages which has arisen through unsuitable and
improper use.
Please note that device may only be installed in proper form and used in a technically perfect
condition in accordance to the “Technical Specifications” (see chapter 6).
The device is not suitable for operation in explosion-proof areas or areas which are excluded by
the EN 61010-1 standard.

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1.3. Installation
The device is only allowed to be installed and operated within the permissible temperature range.
Please ensure an adequate ventilation and avoid all direct contact between the device and hot or
aggressive gases and liquids.
Before installation or maintenance, the unit must be disconnected from all voltage-sources.
Further it must be ensured that no danger can arise by touching the disconnected voltage-
sources.
Devices which are supplied by AC-voltages, must be connected exclusively by switches,
respectively circuit-breakers with the low voltage network. The switch or circuit-breaker must be
placed as near as possible to the device and further indicated as separator.
Incoming as well as outgoing wires and wires for extra low voltages (ELV) must be separated
from dangerous electrical cables (SELV circuits) by using a double resp. increased isolation.
All selected wires and isolations must be conform to the provided voltage- and temperature-
ranges. Further all country- and application-specific standards, which are relevant for structure,
form and quality of the wires, must be ensured. Indications about the permissible wire cross-
sections for wiring are described in the “Technical Specifications” (see chapter 6).
Before first start-up it must be ensured that all connections and wires are firmly seated and
secured in the screw terminals. All (inclusively unused) terminals must be fastened by turning the
relevant screws clockwise up to the stop.
Overvoltages at the connections must be limited to values in accordance to the overvoltage
category II.
For placement, wiring, environmental conditions as well as shielding and earthing/grounding of
the supply lines the general standards of industrial automation industry and the specific shielding
instructions of the manufacturer are valid.
Please find all respective hints and rules on www.motrona.com/download.html
--> “[General EMC Rules for Wiring, Screening and Earthing]”.

1.4. Cleaning, Maintenance and Service Notes

To clean the front of the unit please use only a slightly damp (not wet!), soft cloth. For the rear no
cleaning is necessary. For an unscheduled, individual cleaning of the rear the maintenance staff
or assembler is self-responsible.
During normal operation no maintenance is necessary. In case of unexpected problems, failures
or malfunctions the device must be shipped for back to the manufacturer for checking, adjustment
and reparation (if necessary). Unauthorized opening and repairing can have negative effects or
failures to the protection-measures of the unit.

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2. Front Key Operation
2.1. Enter the Setup Mode
There are two different ways to enter the setup mode:
a) keep both front keys pressed when powering on
b) keep both front keys pressed for 5 seconds, if the power is already on

2.2. Parameter Settings

With an activated setup mode, the display shows:

After releasing the keys, the display shows:

In order to cancel the setup hold the left key pressed and additionally press the right one

By pressing the right key, the display changes to:

To jump into the first parameter, hold the left key pressed and additionally press the right one

After releasing the keys, the display alternates between the parameter title and the setting of
the parameter. After pressing any key, only the parameter value for setting is displayed.

Press the right key, to jump into the next parameter.

For numerical inputs select the decade with the left key and change the value by the right one

To jump into the next parameter, hold the left key pressed and additionally press the right one

After reaching the last menu item “Endpro“, two selections can be done:
„Yes“: will store all new entries, before the unit automatically switches to normal operation.
„No“: will repeat the setup routine. The latest values will remain without saving and can be
checked or modified before they are permanently stored.

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3. Operational parameters
Please enter all of the subsequent parameters, as explained in section 2.

3.1. Input polarity

InpoL
nPn NPN: All inputs must switch to“0“
PnP PNP: All inputs must switch to “+“.
For Namur: Set to NPN, see chapter 4.

3.2. Input filter

Filter
Off Filter off: Counting frequency up to 60 kHz
see “Technical Specifications” (chapter 6)
on Filter on. Maximum counting frequency 30 Hz

3.3. Input Mode of count impulses

Input
Cnt.dir Input A: Count input
Input B: Direction select up/down
Up .dn Differential:
Input A: increments
Input B: decrements
Summing:
Input A: increments
Input B: increments
Quad Quadrature up/down for signals A/B, 2 x 90°
Counts rising edge of input A
Quad 2 Similar to “quad“, but with impulse doubling.
Counts rising and falling edges of input A
Quad 4 Similar to “quad“, but with impulse quadrupling.
Counts all edges of inputs A and B

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3.4. Impulse scaling factor
Factor
00.0001 Multiplies the input pulses with the factor set.
99.9999 Setting range 0.0001 to 99.9999.
Setting “0“ will not be accepted.
Divider
00.0001 Divides the input pulses by the divider set.
99.9999 Setting range 0.0001 to 99.9999.
Setting “0“ will not be accepted.

3.5. Decimal point

dP
0 Sets the decimal point of the display.
0.000 (Max. 3 decimal places)

3.6. Set/Reset mode

resmd
Man.el Manual Set/ Reset function by the red front key
and electrical Set/ Reset by the rear input.
No res All Set/ Reset functions disabled.
El res Electrical Set/ Reset only by input “Reset“.
Manre Manual Set/ Reset only by the red front key.

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3.7. Set point
Setpt
-199999 Upon a Set/ Reset command, the counter sets to
the value entered here.
99.9999 Range -199 999....999 999.

3.8. End of program

Endpro
No Select “No“ to return to the beginning of the
menu for verification of settings.
Yes Select “Yes“ to store data and exit the menu.

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4. Terminal Assignments
(also printed to the top of the unit)

5. Delivery includes:
 Panel mounting clip
 Bezel for screw mounting with panel cut out 50 x 25 mm
 Bezel for clip mounting with panel cut out 50 x 25 mm
 Sealing

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6. Technical Specifications
Power supply: Input voltage: 10 … 30 VDC
Protection circuit: reverse polarity protection
Consumption: max. 50 mA
Connections: Type of connection screw terminal, 1.5 mm² / AWG 16
Incremental input: Characteristic: NPN / PNP / Namur
Switching levels: LOW: 0 V … 0.2 x power supply voltage
HIGH: 0.6 x power supply voltage … 30 V
Channels: A, B and Set/Reset
Counting frequency: 15 … 60 kHz (depends on selected counting mode)
Pulse form: arbitrary (Schmitt-Trigger)
Internal resistance: Ri ≈ 10 kOhm
Pulse time (set/reset): min. 5 ms
Power down memory: Data retention: 10 years
Storage Cycles: 106
Display: Type: 6 digit LED, red
Digit height: 8 mm / 0.3149 inch
Range: -199999 … 999999
Housing: Material: plastic
Mounting: panel
Dimensions: cut out (w x h): 45 x 22 mm
resp. 1.772 x 0.866 inch
outer dimensions (w x h x d): 48 x 24 x 59 mm
resp. 1.889 x 0.9449 x 2.323 inch
Miscellaneous: additional bezels for clip or screw
mounting are included in the delivery
Protection class: front: IP 65 / rear: IP20
Weight: approx. 50 g
Ambient temperature: Operation: -20°... + 55° C / -4° ... 131° F (not condensing)
Storage: -25°... + 70° C / -13° ... 158° F (not condensing)
Conformity & standards: EMC 2004/108/EC: EN 61000-6-2, EN 61000-6-3, EN 61000-6-4
RoHS 2011/65/EU: EN 50581

Maximum counting frequency with respect to operating mode and power supply:

Mode Power supply 24 VDC Power supply 12 VDC

CntDir 60 kHz 20 kHz
Up-Down 25 kHz 15 kHz
Up-Up 25 kHz 15 kHz
Quad 25 kHz 15 kHz
Quad2 25 kHz 15 kHz
Quad4 15 kHz 15 kHz

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 7. Dimensions

7.1. Mounting without use of add-on frames

max. 19.3

22 x45
max. 0.7 6’’

0.874’’ (+ 0.012)
24,0 (.945’ ’)

22,2 ( +0,3)
48,0 (1.890’’) 4,0 (0.157’’) 45,0 (+0,6)
59,0 (2.323’’)
6,5 (0.256’’) 1. 772’’ (+ 0.024 )

7.2. Bezel 50 x 25 mm (1.969 x 0.984’’) for clip mounting

(0.984 x 1.969 ’’)

0.984 +0.020 ’’
26 ,0 (1.024’’)

25 ,0 x 50, 0

25,0 +0,5

53,0 (2.087’’) 1,0 (0 .039’’)

50,0 +0,6
4,0 (0 .157’’) (1.969 +0.024’’)

7.3. Bezel 50 x 25 mm (1.969 x 0.984’’) for screw mounting

A= Senkung Af3, DIN 74
Counterbore Af3, DIN 74 M3
A
(0.984 x 1.969’’)

0.984 +0.020’’

(1. 260 +0 .004)

40 ,0 (1.575’’)
32,0 (1.260’’)

25,0 x 50,0

25,0 +0,5

32,0 + 0,1

A 1,0 (0.039’ ’) M3
4,0 (0.157’ ’) 50,0 +0,6
56,0 ( 2.205’’ )
(1.969 +0.0 24’’)

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