Motrona ZU252 Owner's Manual

Operating Manual

ZU 252

Incremental counter module with analog output and serial interface

Product features:

 Counter suitable for quadrature signals (A/B, 90º) as well as single channel inputs

 Counting inputs selectable to TTL/ RS422 format or to HTL / 10-30 volts format

 Maximum counting frequency 1 MHz

 Scalable analog output, configurable for voltage or current operation

 Fast analog conversion time of only 1 msec

 RS232 / RS485 interface for serial readout of the counter

 Also suitable for conversion of the sum or the difference of two separate counts

 Facility for free linearization of the analog output by 16 interpolation points

 Easy to set up by TEACH procedure, or by PC and Windows software motrona GmbH, Zeppelinstraße 16, DE - 78244 Gottmadingen, Tel. +49 (0) 7731 9332-0, Fax +49 (0) 7731 9332-30, [email protected], www.motrona.com

Version:

ZU25201a/ HK/AF/ Apr.08

ZU25201b/ HK/AF/Dez.08

ZU25201c/pp/Jan.12

ZU25201d/pp/Apr.12

ZU25201e/af/nw/Sep.13

Zu252_01f/ag/Aug-15

Description:

Original version

Explanation DIL2/7+8 and other supplements

Name changed from “Register Code” to “Serial Value”

Implementation of the “Command List” chapter

Small Corrections

Safety instructions, legal notices and actualized design added.

Analog output note: only mA or V, but not both together.

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.

Zu252_01f_oi_e.doc / Apr-16 Page 2 / 37

Table of Contents

1.

Safety Instructions and Responsibility ......................................................................... 4

1.1

General Safety Instructions .......................................................................................................... 4

1.2

Use according to the intended purpose ....................................................................................... 4

1.3

Installation .................................................................................................................................... 5

1.4

Cleaning, Maintenance and Service Notes ................................................................................. 5

2.

Compatibility Hint ........................................................................................................ 6

3.

Introduction .................................................................................................................. 7

4.

Applicable Encoders and Sensors ................................................................................ 8

5.

Terminal Assignment ................................................................................................... 8

5.1.

Incremental encoders TTL / RS 422 ............................................................................................. 9

5.2.

Incremental encoder HTL / 12-30V .............................................................................................. 9

5.3.

Proximity switches, photocells etc. ............................................................................................10

5.4.

HTL Input “Control” ....................................................................................................................10

5.5.

Analog output .............................................................................................................................10

5.6.

Serial interface ...........................................................................................................................11

6.

DIL Switch Settings .................................................................................................... 12

6.1.

Basic mode of operation and power-down memory setting .....................................................12

6.2.

Impulse levels and symmetric / asymmetric input formats.......................................................13

6.3.

Analog output format .................................................................................................................14

6.4.

Selecting the RS232 or the RS485 serial interface ...................................................................15

6.5.

Teach function, Test function, loading of default settings ........................................................15

7.

Setup Procedure ......................................................................................................... 16

7.1.

Operation as single channel counter (without direction signal) or as positional counter (with direction signal) .........................................................................17

7.2.

Operation as a summing or differential counter with two independent impulse inputs (A+B, A-B) .....................................................................................17

8.

Readout of the Actual Counter State by Serial Communication ................................ 18

9.

PC Setup Using the OS3.2 Operator Software ............................................................ 19

10.

Displays and Softkeys ................................................................................................ 20

11.

Parameter Settings .................................................................................................... 21

12.

Free Programmable Linearization ............................................................................... 27

13.

Monitor Functions ...................................................................................................... 29

14.

Data Readout via Serial Interface .............................................................................. 31

15.

Test Functions ............................................................................................................ 32

16.

Dimensions ................................................................................................................ 33

17.

Technical Specifications ............................................................................................ 34

18.

Parameter List ............................................................................................................ 35

19.

Command List ............................................................................................................ 36

20.

Setup Form ................................................................................................................. 37


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. Nonconforming 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 17 ). The device is not

suitable for operation in explosion-proof areas or areas which are excluded by the EN 61010-1 standard.


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 voltagesources.

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 temperatureranges. 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 17 ).

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.


2.

Compatibility Hint

This product is a successor model of the thousandfold approved converter type ZU251. The new product is suitable for a 100% replacement of the previous model, however some differences must be observed with DIL switch settings and parameter settings.

Some essential advantages of ZU252 compared to ZU251 are:

 Maximum frequency 1 MHz (instead of 500 kHz)

 Capability to accept even single-ended TTL input signals

(i.e. TTL inputs A and B only, without inverted signals /A and /B)

 The analog format settings +/-10V, 0… +10V, 0 … 20 mA and 4 … 20 mA are now adjustable by a supplementary DIL switch (no more PC required)

 Enhanced auxiliary output 5 V / 250 mA for encoder supply


3.

Introduction

ZU 252 represents a small and low-cost, but highly performing converter for industrial applications, where incremental counting of positions or events must be converted to either analog format or serial data. The unit has been designed as a compact module with 12 screw terminals and a 9-position SUB-D connector (female). The housing is suitable for standard DIN rail mounting.

The impulse input side provides channels A, B and also the inverted lines /A, /B which should be used with TTL/ RS422 input signals. The unit can count and convert the following formats to analog and serial: a. Up/down count with quadrature input (A/B, 90  ).

The polarity of the analog output and the sign of the serial data depend on the sign of the actual counting result b. Single channel impulses on channel A.

Input B sets the counting direction and therefore also the polarity of the output

(LOW = negative, HIGH = positive).

Please observe:

 Open NPN inputs are HIGH

 Open PNP inputs are LOW

 Open RS422 inputs may cause problems, therefore please set unused inputs to HTL by means of the DIL switches c. Dual count of fully independent events on channels A and B, where the output signal represents the sum or the difference of both counts. a.

b.

c.

A

A

A

B B

-

+

B

A and B, quadrature 90° A=impulse, B=static direction signal A and B: independant counting events

The definitions for “zero analog output” and “full scale analog output” definition can be set over the full counting range of +/-8 decades (-99 999 999 to +99 999 999)


4.

Applicable Encoders and Sensors

The converter can accept the following impulse sources:

The ZU252 converter can accept the following impulse sources:

 Quadrature encoders with HTL level output (10 – 30 V) and either PNP or NPN or Push-

Pull or NAMUR characteristics, using A and B outputs wit 90° displacement

 Single channel impulse sources like proximity switches or photocells, providing HTL level at PNP or NPN or Namur characteristics

 TTL / RS422 quadrature encoders with output lines A, /A ,B and /B

 Symmetric single channel sources with TTL / RS422 output, providing differential signals (i.e. A and /A)

 Asymmetric single channel sources with TTL level (without inverted signals, i.e. A only)

In general, HTL encoders will be supplied from the same source as the converter itself.

For supply of TTL encoders, the unit provides an auxiliary output of 5.5 volts

(stabilized, max. 250 mA).

5.

Terminal Assignment

We recommend connecting the Minus wire of the power supply to earth potential.

Please observe that, under poor earthing and grounding conditions, multiple earth connections of screens and GND terminals may cause severe problems. In such cases it may be better to have only one central earthing point for the whole system.

GND terminals 4, 6 and 12 are connected internally. Depending on input voltage and load of the auxiliary voltage output, the total power consumption of the unit is approx. 70 mA

(see specifications in chapter 17 ).

0-20mA / 4-20mA out Analogue out +/-10V

TTL: Input /A HTL: n.c.

TTL: Input A HTL: Input A

TTL: Input /B HTL: n.c.

Control

Aux. 5.5V out (max. 250 mA)

TTL: Input B HTL: Input B

Analogue GND ( - )

+18...30 VDC (typ. 70 mA)

GND ( - ) GND ( - )


5.1.

Incremental encoders TTL / RS 422

If applicable, the encoder can be supplied from the ZU252 converter. Where the encoder is already supplied from a remote source, we recommend fully differential operation, with no

GND connection between encoder and converter (see figures a. and b.)

TTL encoder

Screen

ZU 252 converter

+

A

A

11 (+5.5V)

A

8

A

9 a)

B

B

-

B

B

2

3

12 (GND) b)

+ext

TTL encoder

+

A

A

B

B

-

Screen

ZU 252 converter

11 (+5.5V)

A

A

8

9

B

B

2

3

12 (GND)

-ext

5.2.

Incremental encoder HTL / 12 … 30 V

The encoder may be supplied from the same source as the converter, or from another source.

HTL encoder

+

+24V

Screen

ZU 252 converter

A 9

B

GND

3

12 (GND)


5.3.

Proximity switches, photocells etc.

This connection is fully similar to a HTL incremental encoder. With single-channel operation, input B remains unconnected or can be used to select the output polarity. With use of two independent counting events for forming the sum or the difference, input B operates as the second counting input.

For use of sensors providing 2-wire NAMUR characteristics:

 Set the inputs to HTL and NPN

 Connect the positive wire of the sensor to the corresponding input and the negative wire to GND.

5.4.

HTL Input “Control”

The HTL control input available on terminal 10 provides programmable characteristics and functions for activation of different commands (e.g. Reset, see parameter “Input setting)

5.5.

Analog output

The unit provides a +/-10V voltage output and a 0-20 mA / 4-20 mA current output at a resolution of 14 bits, i.e. the voltage output operates in steps of 1.25 mV and the current output operates in steps of 2.5 µA.

The nominal load of the voltage output is 2 mA, the current output accepts loads between 0

Ohms and 270 Ohms. The analog ground uses a separate terminal, which however internally is connected to the GND potential of the power supply.

Screen

1

+/- 10V

Vout

(Imax = 2 mA)

4

GND

(R = 0 - 270 Ohms)

Iout

7

20 mA

 Important note: “Voltage out” and “Current out” cannot be used together.

Please do never connect mA and V simultaneously!



The calibration depends on “Analog output format” (see chapter 6.3

)


5.6.

Serial interface

The unit provides a RS232 interface and a RS485 interface, however only one of the two can be used at a time. Serial communication allows to read out the counting result and to set parameters and variables by PC, according to need.

+5V

GND int.

RS485 T+

T-

R+

R-

TxD

RxD

RS232 Sub-D-9 (female on unit site)

GND

PC

120 Ohms

120 Ohms

TxD

RxD

RS232:

Please connect only pins 2, 3 and 5 !

ZU 252

T+

T-

R+

R-

120 Ohms

120 Ohms

RS485- Bus

( 4- wire )

T+

T-

R+

R-

ZU 252

120 Ohms

T-

T+

120 Ohms

RS485- Bus

( 2- wire )

ZU 252


6.

DIL Switch Settings

There is one 8-position switch located on the top side (DIL1), and another 8-position switch is located on the bottom side of the unit (DIL2). These switches provide major settings of the desired properties of the unit.

Changes of switch settings will become active only after cycling the power supply of the unit!

Positions 7 and 8 of switch DIL2 are for internal factory use only and must both be set to OFF at any time during normal operation

Teach button

Top side

Switch DIL1

Bottom side

Swit ch DIL2

6.1.

Basic mode of operation and power-down memory setting

Positions 2 and 3 of switch DIL1 on the top side set the mode of operation, and position 4 allows setting of the power-down behavior of the unit:

DIL1

1 2 3 4 5 6 7 8 on on on off off on

Mode of operation

Input A only

Quadrature operation A / B / 90°

Sum A + B or difference A - B off off A = counting input, B = direction control (up/dn)

Position 4 off: Power-down memory off. Upon power up the counter either resets to zero or sets to the value programmed under parameter „Set Value“ *)

Position 4 on: Power-down memory on. Upon power up the counter re-loads the previous value before power down

*) see Parameter „Power-up Mode“


6.2.

Impulse levels and symmetric / asymmetric input formats

Positions 5 and 7 of DIL1 together with positions 3 to 6 of DIL2 allow setting of all imaginable combinations of levels and formats.

 All subsequent tables use the following definitions:

„0“ = switch OFF, „1“ = switch ON and

„x“ = position not important

 Switch settings refer to impulse inputs A / B only, but the

Control Input (terminal 10) provides always HTL / PNP format, i.e. you must apply a positive voltage 10 – 30 volts to activate the function

 Where you use 2-wire sensors with NAMUR characteristics, connect the positive pole of the sensor to the corresponding input terminal, and the negative pole to GND

 Where subsequently you read (A) or (B), this indicates that the inputs expect asymmetric (single-ended) signals and you will not need the corresponding inverted signals

 Where however you read (A and /A) or (B and /B), this indicates that the inputs expect symmetric differential signals according to RS422 standard, i.e. it is mandatory to apply also the inverted signals

6.2.1.

Standard settings

If you just use encoders or sensors according to common industrial standards, and if also all input signals should have the same level, you just can use one of the following three standard settings and do not need to consider all further alternatives of switch settings.

DIL1 DIL2

5 6 7 3 4 5 6

Input Characteristics

0 0 0 0 0 0

Asymmetric HTL input (A, B),

10 - 30 V level, NPN (switching to -) or

Push-Pull or NAMUR characteristics

Encoder Type

Standard HTL encoders,

Proximity switches,

Photo switches etc.

1

0

0

1

0

0

0

0

0

0

0

0

Asymmetric HTL input (A, B),

10 - 30 V level, PNP (switching to +) or

Push-Pull characteristics

Symmetric TTL signals or

RS422 signals (A, /A), (B, /B)

(differential, including inverted signal)

PNP Proximity switches,

Photo switches etc.

Standard TTL encoders providing A, /A, B, /B output channels


6.2.2.

Settings for special applications

Where you find that the standard settings shown before are not suitable for your application, please go through the following setting options and find out the input levels and characteristics you need.

DIL1 DIL2

5 6 7 3 4 5 6

Characteristics of input A x x 0 0 0 1

Characteristics of input B x x x x x x x x

0

0

0

0

0

0

1

1

1

1

0

0

0

1

0

1

TTL level (A)

HTL level (A and /A)

TTL level (A)

TTL level (A and /A)

HTL level NPN (A)

TTL level (B)

HTL level (B and /B)

TTL level (B and /B)

TTL level (B)

HTL level PNP (B) x x x x x x x x x x x x

0

0

1

1

1

1

1

1

0

0

0

0

1

1

0

0

1

1

0

1

0

1

0

1

HTL level NPN (A)

HTL level NPN (A)

HTL level PNP (A)

HTL level PNP (A)

HTL level PNP (A)



TTL level (B)


TTL level (B)

HTL level NPN (B)

HTL level NPN (B) x x x x x x

1

1

1

1

1

1

0

0

1

0

1

0

TTL level (A)


TTL level (A)

HTL level NPN (B)

HTL level PNP (B)

HTL level PNP (B)

6.3.

Analog output format

The desired output format of the analog output can be set by positions 1 and 2 of switch DIL2

DIL2 Output format

1 2

0 0

Voltage 0 … +10 V

0 1

Voltage +/- 10 V

1 0

1 1

Current 4 – 20 mA

Current 0 – 20 mA

With this setting the format depends on the parameter „Analog

Mode“ which can be set by PC. Since the factory default setting of parameter “Analogue Mode” is “1”, the format will be a 0 … +10 V output under default conditions.


6.4.

Selecting the RS232 or the RS485 serial interface

Position 1 of switch DIL1 selects between the RS232 interface and the RS485 interface. For

connection details please go back to section 5.6

.

DIL1 / 1 Serial Interface

0 RS232 interface is active (RS485 is switched off)

1 RS485 interface is active (RS232 is switched off)

6.5.

Teach function, Test function, loading of default settings

Positions 6 and 8 of switch DIL1 allow to set the following functions:

DIL1 Function

6 8 x 0 Unit returns to the factory default parameters after power-down x 1 Unit always keeps the parameters according to customer setting

0 x

Push button and yellow LED operate in TEACH mode (see 7 )

1 x

Push button and yellow LED operate in TEST mode, Teach is disabled (see 7 )

After successful commissioning, please make sure to set positions

6 and 8 to “ON”. Otherwise, cycling of the power supply or touching the push button inadvertently would result in overwriting your parameter settings


7.

Setup Procedure

For all basic applications you can use the Teach feature for commissioning of the unit.

Extended functions need a PC for setup and are described under section 9 .

As a first step it is advisable to check the input pulses by means of the LED marked “Status”.

Position 6 of DIL1 must be set to ON for this test.

When you press the TEACH button one time, the yellow LED will be lit after the unit detected a pulse on input A. The LED will be OFF when no input pulse has been detected.

When you press the TEACH button once more, you can also check input B (if applicable). With use of mode A+B and two independent impulse sources, again the yellow LED will be lit after a pulse has been detected on input B.


7.1.

Operation as single channel counter (without direction signal) or as positional counter (with direction signal)

 Settings: Make sure that the DIL switches are set according to the encoder in use, and that position 6 of switch DIL1 is OFF (Teach function active).

 Self test: Upon power up, both front LED’s must be lit first, and the yellow status LED must switch off after the self-test has been concluded successfully (approx.1 sec.).

 Scaling of the analog output with use of the Teach function:

Press the Teach button one time. The status LED will blink in a slow sequence now while the unit waits for setting of the minimum counter state, this is the state where later you expect the analog output to be zero (in general, this will be with counter=0).

Please set the counter to the desired state or move the encoder to the desired position and reset the counter to zero. Then press the Teach button again. This stores your minimum counter definition.

The LED will blink in a fast sequence now and the unit waits for setting of the maximum counter state, this is the state where later you expect full scale analog output.

Please get the counter to the desired state or move your encoder to the desired position.

Then press the teach button once more. This stores your maximum counter definition and the LED will switch off.

After this Teach procedure, your analog output is set to 0–10 volts swing between the minimum and the maximum counter state.

7.2.

Operation as a summing or differential counter with two independent impulse inputs (A+B, A-B)

In principle, the Teach procedure is exactly the same as shown under 6.1, but the minimum and maximum counter states already refer to the sum or the difference of the count on both inputs.


8.

Readout of the Actual Counter State by

Serial Communication

At any time you can read out the actual counter state and more values via serial link. For setting of serial communication parameters etc., you must however apply PC setup anyway, as shown later.

ZU 252 uses the DRIVECOM communication protocol according to the ISO 1745 standard.

Details about the protocol can be found in our document “SERPRO.doc”, available for download on www.motrona.com

The following register codes are available for readout:

C1 C2 Description

: 8 Actual conversion result, scaled as % of full scale output, format xxx.xxx % *)

; 0 Actual count of input A

; 4 Actual count of input B

; 3 Actual output voltage of the analog output, scaling 0 – 10 000 millivolts

*) under consideration of the scaling operands as shown in section 11 .


9.

PC Setup Using the OS3.2 Operator Software

You can apply the full set of functions when you use a PC and our operator software OS3.x for setup of the unit (actual software version is OS3.2).

You can download this software and more instructions from our homepage www.motrona.com

Connect your PC to the converter, using a serial RS232 cable like shown in section 5.6

of this

manual. Make sure the cable only uses pins 2, 3 and 5. Pins 2 and 3 must be crossed.

Run the OS3.x software and you will see the following screen:

If your text and color fields remain empty and the headline says „OFFLINE“, you must verify your serial settings and the DIL switch setting. To do this, select „Comms“ from the menu bar.

 Ex factory, all motrona units use the following serial standard settings:

Unit No. 11, Baud rate 9600, 1 start/ 7 data/ parity even/ 1 stop bit

 If the serial settings of your unit should be unknown, you can run the

„SCAN“ function from the „TOOLS“ menu to find out.


10.

Displays and Softkeys

The edit window for all unit parameters can be found on the left side of the screen.

The INPUTS field shows the softkeys to switch the control commands on or off. Display boxes in the RS column indicate when the corresponding command is set to ON by PC. Display boxes in the PI/O column indicate that the corresponding command is ON by external hardware.

The boxes in the OUTPUTS field provide information about the state of the unit, where “Status

A” and “Status B” are especially useful to check the counting inputs:

 Status A is lit when a counting pulse is detected on input A

 Status B is lit when a counting pulse is detected on input B

(with operation modes A+B or A-B only)

The color bar graph displays the actual output state in a range of +/- 100 % of full scale.

Control keys are available for readout, transmission and storage of parameters.


11.

Parameter Settings

Parameter Description

„Register :8“ Setting:

Multiplier

Divisor

Offset

These operands allow to convert the result to the desired engineering units.

The conversion affects the numeric value for serial read out from register

<:8> only, but not the scaling of the analog output.

With the settings Multiplier = 1,0000

Divisor

Offset

= 1,0000

= 0,0000 the readout from register < :8 > equals to the percentage result (xxx.xxx%)

, where 100,000% has been defined by the TEACH minimum and TEACH maximum settings

Readout from <:8>

=

Measuring result in % of full scale x xOperand

/Operand

+

+/-Operand

With “Divisor” set to 0 the whole conversion will be skipped, resulting in lower calculation time and the shortest possible conversion time.

The calculation result from [ Multiplier : Divisor ] must not exceed a value of 15 000 !

Direction:

A/B Mode:

Linearization

Mode:

Can be used to invert the polarity of the analog output signal when converting quadrature A/B input signals or A=impulse and B=direction.

0 = no inversion of the polarity

1 = inversion of the polarity

Sets the counting mode with two independent single-channel inputs

0 = no combination

1 = sum A + B

2 = difference A – B

See DIL switch settings in chapter 5.1

Sets the mode of linearization.

0: Linearization off, registers P1_x to P16_y do not affect the output characteristics.

1: Linearization in a range of 0 – 100%

2: Linearization over full range –100% to +100%

See example in chapter 12 „Free Programmable Linearization“


Parameter

Edge Mode:

Input Filter

Power up Mode:

Description

This setting, with use of quadrature A/B input, allows simple count (x1) or full quadrature count (x4), by either accepting rising edges from input A only, or all rising and falling edges from inputs A and B

0 = simple count (x1)

1 = quadrature count (x4)

Programmable hardware filter for the impulse inputs

0 Filter off, inputs accept full frequency range

1 Filter cuts frequencies higher then 500 kHz

2 Filter cuts frequencies higher than 100 kHz

3 Filter cuts frequencies higher than 10 kHz

When using the filter, all frequencies higher than indicated above will no more be evaluated correctly.

Sets the action of the counter upon power up:

0 = Loads the previous value from power down memory

1 = Resets the counter to zero

2 = Sets counter to the value specified by register “Set Value”

Channel A Setting:

Factor A

Round Loop A:

Impulse scaling factor for counter input A.

Setting 1.0000 results in one increment with every input pulse, whereas setting 0.5000 would need 10 input pulses to increment by 5 etc.

This register limits the counting range to a repeating loop. With setting of

1000, in upwards direction 999 is followed by to 000, and in downwards direction the counter sets to 1000 when reaching zero.

Setting this register to 000 000 provides counting over the full range.

Set Value A: Upon external Set command, the input A counter presets to the datum set here (range +/-100 000 000). The analog output follows the new counter state according to its output scaling.

Multiplier A Multiplier for multiple count of one input impulse on A (001 – 999)

Channel B Setting: (only for operation modes A+B or A-B)

Factor B Impulse scaling factor for counter input B (see Factor A)

Round Loop B:

Set Value B:

Multiplier B

(see “Round Loop A, but input B)

(see “Set Value A”, but input B)

(see “Multiplier A”, but input B)


Parameter

Analogue Setting

Teach Minimum

Teach Maximum

Description

These settings define your minimum and maximum count for input A

(respectively A/B quadrature), where your analog output moves from

0 V to 10 V.

You can enter your minimum and maximum settings as follows:



either by operating the Teach pushbutton (as described under 7.1

). You

will find your Teach result in the Edit window every time after clicking to

“Read”

 or by entering the counter settings directly to the parameter field of your screen, without using the TEACH function. Please store every parameter by the ENTER key, or – after conclusion of all entries – click to “Transmit

All” and then to “Store EEProm” to save your settings.

When using sum mode (A+B) or the differential modes (A-B), these settings already refer to the sum or to the difference of the counter.

Output Mode: Selects the output format of the analog outputs as shown:

V V mA mA

Min.

Max.

Encoder

Min. Max.

Encoder

Min. Max.

Encoder

Min.

Max.

Encoder

Output Mode = 0

-10V ... 0 ... +10V

Analogue Offset:

Analogue Gain:

Output Mode = 1

0 ... +10V

Output Mode = 2

4 ... 20 mA

Output Mode = 3

0 ... 20 mA

Allows adjusting the analog zero output over the full range

(-9999 mV ... 0 ... +9999 mV respectively -19998 µA ... 0 ... +19998 µA)

Sets the maximum output swing of the analog output. Setting of 1000 results in 10 volts respectively 20 milliamps of output swing.


Parameter Description

Serial Communication:

Unit

Number:

Especially with RS 485 applications it is necessary to attach a specific address to each unit, since up to 32 units can be connected to the same bus. You can choose any address number between 11 and 99.

Factory setting = 11

The address must not contain a “0“ because these numbers are reserved for collective addressing.

Setting Baud Serial

Baud

Rate:

0*

1

2

3

9600

4800

2400

1200

4

5

6

600

19 200

38 00

Serial

Format:

Setting

0*

1

2

3

4

* = Factory setting

Data bits

7

7

7

7

7

Parity even even odd odd none

Stop bits

1

2

1

2

1

7

8

5

6

9

Serial Protocol:

Serial Protocol = 0 :

Serial Protocol = 1 :

7

8

8

8 none even odd none none

1

1

2

1

2 8

* = Factory setting

Selects the serial protocol for the cyclic transmission.

0 : the string starts with the serial address of the unit (“Unit

Number”), followed by a space and the value of the register to be read out. The string ends with a “Line Feed” character and a

“Carriage Return” character.

1 : the unit number is omitted and the string starts with the register value directly. This allows a little faster transmission because of the shorter transmission time.

Unit No.

1 1 +/- X X X X X X LF CR

+/- X X X X X X LF CR


Parameter

Serial Timer:

Serial Value:

Description

This register determines the cycle time in seconds for the cyclic transmission. E. g. with a setting of 0.100 the selected register value will be transmitted every 100 ms. The accuracy of the timer is +/-500 µs.

Setting the register to 0 disables cyclic transmissions.

Selects the register to be transmitted cyclically.

Setting of 00 selects register code :0, setting of 01 selects register code :1 etc.

The communication can operate in either “PC-Mode“ or in “Printer Mode“.

With “PC-Mode“, the unit waits for a request string and responds by a corresponding data string.

For details of the protocol see description “SERPRO“.

With “Printer Mode“ the unit sends data without any request and under

Timer control. As soon as the unit receives a character, it automatically switches to PC Mode and operates according to protocol. When for a period of 20 sec. no character has been received, the unit switches automatically to “Printer Mode“ and restarts cyclic data transmission.

Input Setting:

Input

Configuration

Sets the behavior of the Control input (terminal 10):

0 = static operation with “high” level

1 = dynamic operation by rising edge

2 = dynamic operation by falling edge

3 = dynamic operation by rising edge *)

4 = dynamic operation by falling edge **)

5 = static operation with “low” level

Input Function Sets the function of the Control input (terminal 10):

0 = no function

1 = Set counter A to “Set Value A”

2 = Set counter B to “Set Value B”

3 = Set counter A to “Set Value A” and counter B to “Set Value B”

4 = Inhibit counter A (disable count)

5 = Inhibit counter B (disable count)

6 = Inhibit counters A and B

7 = Activate a serial data transmission cycle

*) Equal to 1 (double command function for reasons of compatibility to the previous model)

**) Equal to 2 (double command function for reasons of compatibility to the previous model)


Parameter

Backup Setting:

Backup A

Backup Rest A

Backup B

Backup Rest B

Description

Upon power-down the unit saves the actual counter values to the registers

Backup A and Backup B.

Since the counters use impulse scaling factors, there may be remainders which need to be considered later for error-free continuation of the count.

These remainders are stored in the corresponding “Rest” registers

Linearisation Setting:

P1_x to P16_x:

P1_y to P16_y:

Interpolation points for linearization (initial values)

Interpolation points for linearization (substitute values)

(see chapter 12 )


12.

Free Programmable Linearization

This programmable feature allows the user to convert the linear counting process to a non- linear analog output. There are 16 programmable interpolation points available, which can be set in any desired distance over the full conversion range. Between two coordinates, the unit uses linear interpolation. Therefore it is advisable to use more points in a range with strong curves and only a few points where the curvature is less.

To specify your desired linearization curve, you must first set the „Linearization Mode“ register to either 1 or 2.

Use registers P1(x) to P16(x) to specify the coordinates on the x-axis. These are the analog output values that the unit normally would generate according to the actual count. The settings are in % of full scale.

Now enter the attached values to registers P1(y) to P16(y). These are the values that the analog output will generate instead of the x- values

Example: the value set to register P2(y) will substitute original value P2(x) etc.

 x-registers must use continuously increasing settings, i.e. P1(x) must have the lowest and P16(x) must have the highest setting

 All entries use a percentage format of xx.xxx% full scale. Setting 0.000% means zero output and setting 100.000% means full scale output.

 With Linearization Mode set to 1, it is a must to set P1(x) to 0% and

P16(x) to 100%. Linearization is defined in the positive range only and the negative range will be a mirror image of the positive range with reference to zero.

 With Linearization Mode set to 2, it is a must to set P1(x) to –100% and

P16(x) to +100%. This enables the user to set curves which are not symmetric to the zero position. y

P1(x)= -100%

P1(y)= 95% y

*) Output mode = 0

*)

P1(x)= 0%

P1(y)=10%

Linearisation Mode = 1

P16(x)=100%

P16(y)= 80% x

P8(x)= 0%

P8(y)= 80% x

P16(x)=+100%

P16(y)= -60%

Linearisation Mode = 2


You can visualize your curve on the PC screen or by means of an external oscilloscope.

For this, select TOOLS, then TEST and there „Analogue Voltage Function“. The unit will now simulate a repeating counting cycle over the full range and generate the analog signal accordingly. When you use the Scope function of the operator software, you must set the serial code „ :1 ” to record the analog output.


13.

Monitor Functions

The monitor function of the OS3.2 PC software allows to display some important data on the PC screen with a continuous refresh cycle.

Select „Monitor“ from the „Tools“ menu to open the basic view of the monitor window. Click to

“Define” to open the definition window. You will find a list with all accessible parameters and actual values, where however the texts may be unfounded.

With ZU252, the following registers may be useful:

C1 C2 Description

: 8 Actual conversion result in % of „full scale“, format xxx.xxx % *)

; 0 Actual count, input A

; 4 Actual count, input B

; 3 Actual analog output, scaling 0 – 10 000 millivolts


Click to the Status field, next to the desired register code (where you read ON or OFF). Now you can toggle this position between ON and OFF by touching any key.

Set all of the register codes to ON which you afterwards would like to trace on the monitor.

Switch all unused register codes to OFF.

To change the text shown with the register code, click to the corresponding text field. The same text will now appear in the “Text Editor” window below the parameter window. Rename the text according to your desire and press ENTER to store the new text in the corresponding monitor line.

When all desired codes have been set to ON and the texts have been renamed according to need, click OK. Where, besides the display data on the screen, you also like to record all data to a file on your hard disc, click first to „Store to File“ and set the corresponding check box.

After staring the monitor you will see the following window, where all values are updated continuously.


14.

Data Readout via Serial Interface

All register codes from chapter 13 . are also available for serial readout by PC or PLC. For

communication the FU252 converter uses the Drivecom Protocol according to ISO 1745. All protocol details can be found in our manual SERPRO_2a.doc which is available for download from our homepage www.motrona.com

To request for a data transmission you must send the following request string to the converter:

EOT AD1 AD2 C1 C2 ENQ

EOT = control character (Hex 04)

AD1 = unit address, High Byte

AD2 = unit address, Low Byte

C1 = register code, High Byte

C2 = register code, Low Byte

ENQ = control character (Hex 05)

The following example shows the request string for readout of the actual conversion result

(code :8) from a unit with unit address 11:

ASCII Code:

Hex Code:

EOT

04

1

31

1

31

:

3A

8

38

ENQ

05

Binary Code: 0000 0100 0011 0001 0011 0001 0011 1010 0011 1000 0000 0101

After a correct request, the unit will respond:

STX C1 C2 x x x x x x x ETX BCC

STX = control character (Hex 02)

C1 = register code, High Byte

C2 = register code, Low Byte xxxxx = readout data

ETX = control character (Hex 03)

BCC = block check character

For all further details see SERPRO_2a.doc.


15.

Test Functions

When you select TEST from the TOOLS menu, you are able to verify the following data, by clicking to the corresponding field:

 Actual counter values

 DIL switch settings

 Internal supply voltages

 Analogue output state


16.

Dimensions

40 mm (1.575’’)

91mm (3.583’’)

74 mm (2.913’’)

Front view Side view Top view


17.

Technical Specifications

Power supply:

Connections:

Encoder supply:

Input voltage:

Protection circuit:

Ripple:

Consumption:

Connector type:

Output voltage:

Output current:

Incremental input:

Control input:

Analog outputs:

Housing:

Ambient temperature:

Signal levels:

HTL characteristic:

HTL internal resistance:

Channels:

Frequency:

Application:

Signal levels:

Pulse time:

Voltage output:

Current output:

Resolution:

Accuracy:

Reaction time

Reset time:

Step width :

Material:

Mounting:

Dimensions (w x h x d):

Protection class:

Weight:

Operation:

Storage:

Conformity & standards: EMC 2004/108/EC:

RoHS 2011/65/EU:

18 … 30 VDC reverse polarity protection

≤ 10 % at 24 VDC approx. 85 mA (unloaded) screw terminals, 1.5 mm² / AWG 16

+ 5.5 VDC max. 250 mA

RS422: Differential voltage > 1 V

TTL: LOW: 0 … 0.5 V / HIGH: 2.5 … 5.3 V

HTL: LOW: 0 … 3 V / HIGH: 10 … 30 V

NPN / PNP

Ri ≈ 4.75 kOhm

A, /A, B, /B max. 1 MHz at RS422 and TTL symmetrical max. 200 kHz at HTL and TTL asymmetrical connection of inductive proximity switches or control commands

HTL: LOW: 0 … 3 V / HIGH: 10 … 30 V min. 3 ms

-10 … +10 V / 0 … 10 V (max. 2 mA)

0 … 20 mA / 4 … 20 mA (burden: max. 270 Ohm)

14 Bit (± 13 Bit)

0.1% (standard operation) approx. 1 ms approx. 1 ms

1.25 mV / 2.5 µA plastic

35 mm top hat rail (according to EN 60715)

40 x 79 x 91 mm / 1.5748 x 3.1102 x 3.5827 inch

IP20 approx. 190 g

0 °C … +45 °C / +32 … +113 °F (not condensing)

-25 °C … +70 °C / -13 … +158 °F (not condensing)

EN 61000-6-2, EN 61000-6-3, EN 61000-6-4

EN 50581


18.

Parameter List

Parameter

Multiplier

Divisor

Offset

Direction

AB Mode

Linearisation Mode

Edge Mode

Input Filter

Power-up Mode

Factor A

Round Loop A

Set Value A

Multiplier A

Factor B

Round Loop B

Set Value B

Multiplier B

Teach Min

Teach Max

Analogue Mode

Analogue Offset

Analogue Gain

Serial Unit No.

Serial Baud Rate

Serial Format

Serial Protocol

Serial Timer

Serial Value

Input Configuration

Input Function

Backup A

Backup B

Rest A

Rest B

P1(x)

P1(y)

P2(x)

P2(y)

P16(x)

P16(y)

Min

-99999

Max Default Positions Sign Ser. Code

99999 10000 +/- 5 4 00

0 99999 10000

-100000000 100000000 0

0 1 0

5

+/- 9

1

4

0

0

01

02

46

0

0

0

0

1

3

2

2

0

0

0

0

1

1

1

1

0

0

0

0

10

08

09

D2

0

1

0

2

99999

100000000

0

10000

0

-100000000 100000000 0

1 999 1

1

0

99999

100000000

10000

0

-100000000 100000000 0

1 999 1

-10000000 100000000 0

1

5

9

+/- 9

3

5

9

+/- 9

3

+/- 9

-10000000 100000000 10000 +/- 9

0 3 1 1

-9999 9999 0 +/- 4

0

0

0

0

10000

99

6

9

1000

11

0

0

1

1

5

2

0

4

0

0

0

4

0

0

0

0

0

0

0

0

0

0

0

04

07

47

48

90

91

92

06

D7

D8

D9

03

14

05

13

12

D5

0

0

0

0

0

1

99999

19

5

7

0

0

8

0

0

-100000000 100000000 0

-100000000 100000000 0

-10000 10000 0

-10000

-100000

+/- 9

+/- 9

+/- 5

10000 0 +/- 5

100000 100000 +/- 6

1

5

2

1

1

-100000

-100000

-100000

-100000

-100000

100000 100000 +/- 6

100000 100000 +/- 6

100000 100000 +/- 6

100000 100000 +/- 6

100000 100000 +/- 6

0

3

0

0

0

0

0

0

0

3

33

34

35

36

A0

30

31

32

11

E2

3

3

3

3

A1

A2

3 A3…(A9)…(C9)

D0

D1


19.

Command List

# Name

0 Inhibit Both

1 Inhibit B

2 Inhibit A

3 Set Both

4 Set B

5 Set A

6 Activate Data

7 Store EEProm

65

66

67

68

Code

61

62

63

64


20.

Setup Form

P2(x):

P3(x):

P4(x):

P5(x):

P6(x):

P7(x):

P8(x):

Date:

Operator:

Register Setting (:8)

General Setting

Input

Analogue Setting

Serial Communication

Input Setting:

Backup-Setting:

Linearization

P1(x):

Multiplier:

DIL Switch 1

Direction:

Linearization Mode:

Input Filter:

Teach Minimum:

Teach Maximum:

Serial Unit No:

Serial Baud Rate:

Serial Format:

Input Configuration:

P1(y):

P2(y):

P3(y):

P4(y):

P5(y):

P6(y):

P7(y):

P8(y):

Factor

Round Loop

Set Value

Multiplier

Backup

Rest

Software:

Serial No.:

Divisor:

P9(x):

P10(x):

P11(x):

P12(x):

P13(x):

P14(x):

P15(x):

P16(x):

AB Mode:

Edge Mode:

Power-up Mode:

Channel A

Serial Timer:

Serial Value:

Channel A

DIL Switch 2

Offset:

Analogue Mode:

Analogue Offset :

Analogue Gain:

Serial Protocol:

Input Function:

P9(y):

P10(y):

P11(y):

P12(y):

P13(y):

P14(y):

P15(y):

P16(y):

Channel B

Channel B

-1- -2- -3- -4- -5- -6- -7- -8- -1- -2- -3- -4- -5- -6- -7- -8-

OFF OFF


Motrona ZU252 Owner's Manual

Operating Manual

Incremental counter module with analog output and serial interface

Table of Contents

1.

Safety Instructions and Responsibility

1.1

General Safety Instructions

1.2

Use according to the intended purpose

1.3

Installation

1.4

Cleaning, Maintenance and Service Notes

2.

Compatibility Hint

3.

Introduction

4.

Applicable Encoders and Sensors

5.

Terminal Assignment

5.1.

Incremental encoders TTL / RS 422

5.2.

Incremental encoder HTL / 12 … 30 V

5.3.

Proximity switches, photocells etc.

5.4.

HTL Input “Control”

5.5.

Analog output

5.6.

Serial interface

6.

DIL Switch Settings

6.1.

Basic mode of operation and power-down memory setting

6.2.

Impulse levels and symmetric / asymmetric input formats

6.3.

Analog output format

6.4.

Selecting the RS232 or the RS485 serial interface

6.5.

Teach function, Test function, loading of default settings

7.

Setup Procedure

7.1.

Operation as single channel counter (without direction signal) or as positional counter (with direction signal)

7.2.

Operation as a summing or differential counter with two independent impulse inputs (A+B, A-B)

8.

Readout of the Actual Counter State by

Serial Communication

9.

PC Setup Using the OS3.2 Operator Software

10.

Displays and Softkeys

11.

Parameter Settings

12.

Free Programmable Linearization

13.

Monitor Functions

14.

Data Readout via Serial Interface

15.

Test Functions

16.

Dimensions

17.

Technical Specifications

18.

Parameter List

19.

Command List

20.

Setup Form

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