Control Techniques SM-Encoder Plus, SM-Encoder Output Plus User Manual
User Guide
SM-Encoder Plus
SM-Encoder
Output Plus
Solutions Module for:
Unidrive SP
Digitax ST
Part Number: 0471-0026-04
Issue: 4
www.controltechniques.com
General Information
The manufacturer accepts no liability for any consequences resulting from inappropriate, negligent
or incorrect installation or adjustment of the optional operating parameters of the equipment or from
mismatching the variable speed drive with the motor.
The contents of this guide are believed to be correct at the time of printing. In the interests of a
commitment to a policy of continuous development and improvement, the manufacturer reserves the
right to change the specification of the product or its performance, or the contents of this guide,
without notice.
All rights reserved. No parts of this guide may be reproduced or transmitted in any form or by any
means, electrical or mechanical including photocopying, recording or by an information storage or
retrieval system, without permission in writing from the publisher.
Drive software version
The SM-Encoder Plus and SM-Encoder Output Plus can only be used with the following drive
software versions:
SM-Encoder Plus SM-Encoder Output Plus
Unidrive SP ≥V01.02.00 ≥V01.13.00
Digitax ST ≥V01.00.00 ≥V01.00.00
If a SM-Encoder Output Plus module is fitted to a Unidrive SP with software version earlier than
V01.13.00, the module will operate as a SM-Encoder Plus module.
Copyright © July 2007 Control Techniques Drives Ltd
Issue Code: 4
Contents
1 How to use this guide ................................................... 4
1.1 Intended personnel .................................................................................4
1.2 Information .............................................................................................. 4
2 Safety information ......................................................... 5
2.1 Warnings, Cautions and Notes ...............................................................5
2.2 Electrical safety - general warning .......................................................... 5
2.3 System design and safety of personnel .................................................. 5
2.4 Environmental limits ................................................................................ 6
2.5 Compliance with regulations ................................................................... 6
2.6 Motor ....................................................................................................... 6
2.7 Adjusting parameters .............................................................................. 6
3 Introduction .................................................................... 7
3.1 Features .................................................................................................. 7
3.2 Solutions Module identification ................................................................ 7
3.3 Set-up parameters ..................................................................................8
3.4 Compatible encoder types ......................................................................8
3.5 Simulated outputs (SM-Encoder Output Plus only) ................................. 9
4 Installing the Solutions Module ................................. 10
4.1 General Installation ............................................................................... 10
4.2 Terminal descriptions ............................................................................ 11
4.3 Wiring, Shield connections .................................................................... 12
5 Getting started ............................................................. 17
5.1 Installation ............................................................................................. 17
5.2 Incremental set-up ................................................................................18
5.3 Simulated encoder output set-up .......................................................... 19
5.4 Freeze function .....................................................................................19
5.5 Termination resistors ............................................................................. 19
6 Parameters ................................................................... 20
6.1 Introduction ........................................................................................... 20
6.2 Single line descriptions .........................................................................22
6.3 Parameter descriptions ......................................................................... 28
7 Diagnostics .................................................................. 35
7.1 Displaying the trip history ...................................................................... 35
8 Terminal data ............................................................... 38
8.1 Encoder inputs (PL1) ............................................................................38
8.2 Encoder Outputs (PL2) .........................................................................39
SM-Encoder Plus & SM-Encoder Output Plus User Guide 3
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1 How to use this guide
1.1 Intended personnel
This guide is intended for personnel who have the necessary training and experience in
system design, installation, commissioning and maintenance.
1.2 Information
This guide contains information covering the identification of the Solutions Module,
terminal layout for installation, fitting of the Solutions Module to the drive, parameter
details and diagnosis information. Additional to the aforementioned are the
specifications of the Solutions Module.
4 SM-Encoder Plus & SM-Encoder Output Plus User Guide
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2 Safety information
2.1 Warnings, Cautions and Notes
A Warning contains information, which is essential for avoiding a safety hazard.
WARNING
How to use this
guide
information
Safety
A Caution contains information, which is necessary for avoiding a risk of damage to the
product or other equipment.
CAUT ION
NOTE
A Note contains information, which helps to ensure correct operation of the product.
2.2 Electrical safety - general warning
The voltages used in the drive can cause severe electrical shock and/or burns, and
could be lethal. Extreme care is necessary at all times when working with or adjacent to
the drive.
Specific warnings are given at the relevant places in this User Guide.
2.3 System design and safety of personnel
The drive is intended as a component for professional incorporation into complete
equipment or a system. If installed incorrectly, the drive may present a safety hazard.
The drive uses high voltages and currents, carries a high level of stored electrical
energy, and is used to control equipment which can cause injury.
Close attention is required to the electrical installation and the system design to avoid
hazards, either in normal operation or in the event of equipment malfunction. System
design, installation, commissioning / start up and maintenance must be carried out by
personnel who have the necessary training and experience. They must read this safety
information and this User Guide carefully.
The STOP and SECURE DISABLE / SAFE TORQUE OFF functions of the drive do not
isolate dangerous voltages from the output of the drive or from any external option unit.
The supply must be disconnected by an approved electrical isolation device before
gaining access to the electrical connections.
With the sole exception of the SECURE DISABLE / SAFE TORQUE OFF function,
none of the drive functions must be used to ensure safety of personnel, i.e. they
must not be used for safety-related functions.
The SECURE DISABLE function and secure input on Unidrive SP and the SAFE
TORQUE OFF function of the Digitax ST meet the requirements of EN954-1 category 3
for the prevention of unexpected starting of the drive. They may be used in a safetyrelated application. The system designer is responsible for ensuring that the
complete system is safe and designed correctly according to the relevant safety
standards.
Careful consideration must be given to the functions of the drive which might result in a
hazard, either through their intended behaviour or through incorrect operation due to a
fault. In any application where a malfunction of the drive or its control system could lead
to or allow damage, loss or injury, a risk analysis must be carried out, and where
Introduction
Solutions Module
Getting started Parameters Diagnostics Terminal data Index
Installing the
SM-Encoder Plus & SM-Encoder Output Plus User Guide 5
Issue: 4 www.controltechniques.com
necessary, further measures taken to reduce the risk - for example, an over-speed
protection device in case of failure of the speed control, or a fail-safe mechanical brake
in case of loss of motor braking.
2.4 Environmental limits
Instructions in the appropriate drive manual regarding transport, storage, installation
and use of the drive must be complied with, including the specified environmental limits.
Drives must not be subjected to excessive physical force.
2.5 Compliance with regulations
The installer is responsible for complying with all relevant regulations, such as national
wiring regulations, accident prevention regulations and electromagnetic compatibility
(EMC) regulations. Particular attention must be given to the cross-sectional areas of
conductors, the selection of fuses or other protection, and protective earth (ground)
connections.
The appropriate drive manual contains instruction for achieving compliance with specific
EMC standards.
Within the European Union, all machinery in which this product is used must comply
with the following directives:
98/37/EC: Safety of machinery.
89/336/EEC: Electromagnetic Compatibility.
2.6 Motor
Ensure the motor is installed in accordance with the manufacturer’s recommendations.
Ensure the motor shaft is not exposed.
Standard squirrel cage induction motors are designed for single speed operation. If it is
intended to use the capability of the drive to run a motor at speeds above its designed
maximum, it is strongly recommended that the manufacturer is consulted first.
Low speeds may cause the motor to overheat because the cooling fan becomes less
effective. The motor should be fitted with a protection thermistor. If necessary, an
electric forced vent fan should be used.
The values of the motor parameters set in the drive affect the protection of the motor.
The default values in the drive should not be relied upon.
It is essential that the correct value is entered in parameter 0.46 motor rated current.
This affects the thermal protection of the motor.
2.7 Adjusting parameters
Some parameters have a profound effect on the operation of the drive. They must not
be altered without careful consideration of the impact on the controlled system.
Measures must be taken to prevent unwanted changes due to error or tampering.
6 SM-Encoder Plus & SM-Encoder Output Plus User Guide
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3 Introduction
S
3.1 Features
The SM-Encoder Plus and SM-Encoder Output Plus Solutions Modules provide an
interface for an additional encoder to be connected to the drive, to be used as position
and speed feedback for the drive. Typical uses for these Solutions Modules would be to
input a speed/position reference from a line speed encoder, or to digitally lock the drive
to a master reference using the position controller in drive menu 13.
The SM-Encoder Output Plus has all the features of the SM-Encoder Plus module but
also provides an encoder power supply output and simulated encoder outputs.
NOTE
3.2 Solutions Module identification
The SM-Encoder Plus does not have any simulated encoder outputs or an encoder
power supply output available.
Figure 3-1 SM-Encoder Plus and SM-Encoder Output Plus
How to use this
guide
Safety information
Introduction
Solutions Module
Installing the
Getting started Parameters Diagnostics Terminal data Index
The SM-Encoder Plus and SM-Encoder Output Plus can be identified by:
1. The label located on the underside of the Solutions Module.
2. The colour coding across the front of the Solutions Module.
SM-Encoder Plus: Brown
SM-Encoder Output Plus: Dark Brown
Figure 3-2 SM-Encoder Plus and SM-Encoder Output Plus label
olutions Module
name
Issue
number
SM-XXXXXXX
Issue: 0
Ser No : 3000005001
STDJ41
Customer
and date code
Serial number
3.2.1 Date code format
The date code is split into two sections: a letter followed by a number.
SM-Encoder Plus & SM-Encoder Output Plus User Guide 7
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The letter indicates the year, and the number indicates the week number (within the
year) in which the Solutions Module was built.
The letters go in alphabetical order, starting with A in 1990 (B in 1991, C in 1992 etc.).
Example:
A date code of L35 would correspond to week 35 of year 2002.
3.3 Set-up parameters
All parameters associated to the SM-Encoder Plus or SM-Encoder Output Plus can be
found in either menu 15, 16, or 17. Each of menus 15, 16, and 17 refer to one of the
available slots into which the Solutions Module can be fitted. Slot 1 = Menu 15, Slot 2 =
Menu 16, Slot 3 = Menu 17.
NOTE
There are only two available slots for Unidrive SP size 0 and Digitax ST.
3.4 Compatible encoder types
The SM-Encoder Plus and SM-Encoder Output Plus are compatible with the following
encoders types:
Incremental encoders Ab, Fd, and Fr
This type of encoder gives incremental position and can only be used for control in
Closed Loop Vector and not Servo mode.
Type Encoder Description Pr x.15
Quadrature incremental encoder.
Ab
With or without marker pulse.
Incremental
Quadrature detection logic determines rotation from the phase relationship of the two
channels.
These encoders are available with a marker pulse, which identifies each individual
rotation of the disc, and is also used to reset the drive position parameter. The
incremental encoder can be used when operating in Closed Loop Vector mode, with the
optional marker pulse not being required for correct operation.
Incremental encoder with frequency and direction outputs.
Fd
With or without marker pulse.
Incremental encoder with forward and reverse outputs.
Fr
With or without marker pulse.
0
1
2
Limitations
Type Encoder Max Input
Ab
Incremental
Fr
Frequency
500kHz* 16,384Fd
Max no. of
Lines (LPR)
* Max input frequency = LPR x rpm / 60
NOTE
The maximum speed in rpm which an encoder connected to the SM-Encoder Plus or
SM-Encoder Output Plus can reach can be calculated from :
Max rpm = (60 x Max input frequency) / Encoder LPR
e.g. For a 4096 line encoder the maximum rpm would be:
(60 x 500 x 10
3
) / 4096 = 7324rpm
8 SM-Encoder Plus & SM-Encoder Output Plus User Guide
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Figure 3-3 Encoder feedback signals
l
360 electrical (encoder)
°
90 separation of A and B
°
min max
Index
alignment
reference
A
/A
B
/B
Z
/Z
Incrementa
signals
Marker
signals
How to use this
guide
Safety information
Introduction
Solutions Module
Installing the
NOTE
Only encoders with lines per revolution that are a power of 2 can be used with the SMEncoder Plus and SM-Encoder Output Plus, e.g. 256, 512, 1024 etc.
The marker pulse duration must be between 45° to 360° electrical (encoder).
3.5 Simulated outputs (SM-Encoder Output Plus only)
The SM-Encoder Output Plus can provide simulated encoder output signals. The
source position is derived from either the encoder input on the module or from the drive
encoder input. The source encoder can be any incremental type or any sincos type of
encoder. If a sincos type is used as the source, the simulation output is derived from the
zero crossings of the sine waves and does not include interpolated information.
Mode x.28
Quadrature outputs 0
Frequency and direction outputs 1
Forward and reverse outputs 2
Quadrature outputs with marker lock 3
Frequency and direction outputs with marker lock 4 to 7
If a mode with marker lock is selected the incremental position is shifted when the first
input marker occurs so that with quadrature mode the marker is aligned with A high and
B high, and with frequency and direction mode the marker is aligned with F high.
The SM-Encoder Output Plus provides the ability to scale down the simulated encoder
output signals.
Getting started Parameters Diagnostics Terminal data Index
SM-Encoder Plus & SM-Encoder Output Plus User Guide 9
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4 Installing the Solutions Module
Before installing or removing a Solutions Module in any drive, ensure the AC supply has
been disconnected for at least 10 minutes and refer to Chapter 2 Safety information on
WARNING
4.1 General Installation
page 5. If using a DC bus supply ensure this is fully discharged before working on any
drive or Solutions Module.
The installation of a Solutions Module is illustrated in Figure 4-1.
Figure 4-1 Fitting a Solutions Module
2
The Solutions Module connector is located on the underside of the module (1). Push
this into the Solutions Module slot located on the drive until it clicks into place (2). Note
that some drives require a protective tab to be removed from the Solutions Module slot.
For further information, refer to the appropriate drive manual.
1
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4.2 Terminal descriptions
r
4.2.1 SM-Encoder Plus
Figure 4-2 SM-Encoder Plus terminals
PL1
12345678
Table 4.1 SM-Encoder Plus terminal descriptions
Ter m En coder
Ab Fd Fr
1A F F
2A\ F\ F\
3B D R
4B\D\R\
5Z
6Z\
70V
8 External power supply decoupling
How to use this
guide
Safety information Introduction
Solutions Module
Installing the
NOTE
Terminal 8 should be used to join the external encoder power supply to the encoder as
shown in Figure 4-3. If the drive encoder supply is to be used for two encoders, the user
must ensure the total load does not exceed 300mA for 5V and 8V encoders and 200mA
for 15V encoders.
Figure 4-3 Encoder cable connections
Screen
connection
External encode
power supply
0V +V
Getting started Parameters Diagnostics Terminal data Index
SM-Encoder Plus & SM-Encoder Output Plus User Guide 11
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4.2.2 SM-Encoder Output Plus
Figure 4-4 SM-Encoder Output Plus terminals
PL1 PL2
12345678 12345678
Table 4.2 SM-Encoder Output Plus PL1 terminal descriptions
Term
1A F F
2A\ F\ F\
3B D R
4B\ D\ R\
5Z
6Z\
70V
8+V
Ab Fd Fr
Encoder inputs
Table 4.3 SM-Encoder Output Plus PL2 terminal descriptions
Term
10V
20V
3AFFAF
4A\F\F\A\F\
5BDRBD
6B\D\R\B\D\
70V
8Z
9Z\
Ab Fd Fr Ab.L Fd.L
Encoder outputs
9
4.3 Wiring, Shield connections
Shielding considerations are important for PWM drive installations due to the high
voltages and currents present in the output circuit with a very wide frequency spectrum,
typically from 0 to 20 MHz. Encoder inputs are liable to be disturbed if careful attention
is not given to managing the cable shields.
Encoder mounting methods
There are three methods for mounting an encoder onto a motor:
1. Galvanic isolation between encoder and motor
2. Galvanic isolation between encoder circuit and encoder body
3. No Isolation
4.3.1 Encoder with galvanic isolation from motor
When galvanically isolated the encoder device is mounted to the motor with isolation
fitted between the motor housing / shaft and encoder as shown in Figure 4-5.
12 SM-Encoder Plus & SM-Encoder Output Plus User Guide
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Figure 4-5 Galvanic Isolation from motor
Isolation
between motor shaft
and encoder
Encoder
Circuit
How to use this
guide
Motor
Housing
Motor
Shaft
Isolation
between motor housing
and encoder housing
+5V
+5V
+5V
0V
A
A
0V
B
B
0V
Z
Z
Encoder
Housing
Encoder
Connection
Encoder
Body
An example of this is the Unimotor where isolation from the motor is achieved by
inserting a plastic mounting plate between the motor housing and encoder housing and
a plastic insert fitted in the motor shaft for encoder mounting to the motor shaft. With this
preferred method of mounting noise current is prevented from passing from the motor
housing into the encoder housing, and hence into the encoder cable. The ground
connection of the cable shield is optional, this may be required to comply with safety
measures or to reduce radiated radio frequency emissions from either the drive or
encoder.
4.3.2 Encoder circuit with galvanic isolation from encoder body
In this case the encoder device is mounted directly on the motor housing with contact
being made between the motor housing/shaft and encoder. With this mounting method
the encoder internal circuits are exposed to electrical noise from the motor housing
through the stray capacitance, and they must be designed to withstand this situation.
However this arrangement still prevents large noise currents from flowing from the
motor body into the encoder cable. The ground connection of the cable shield is
optional, this may be required to comply with safety measures or to reduce radiated
radio frequency emissions from either the drive or encoder.
Safety information Introduction
Solutions Module
Getting started Parameters Diagnostics Terminal data Index
Installing the
SM-Encoder Plus & SM-Encoder Output Plus User Guide 13
Issue: 4 www.controltechniques.com
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