Page 1
Operating Manual
6890.5010
Monitor for direction of rotation and standstill
Product features:
Simple and compact unit to monitor forward / reverse motion and standstill of machines
Universal pulse inputs for use with all common incremental encoders and sensors
(HTL, RS422 or TTL)
Two potential-free changeover relay outputs as well as two fast-responding
power transistor outputs
Wide input frequency range (up to 500 kHz) and a fast response time
(<1 msec. with f >1 kHz)
Compact housing for simple snap fitting on top hat rails (EN 60715)
Easy to set up by two front DIL switches
17 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
Page 2
Version:
Description:
6890.5010_01a/af/hk_Aug2007
First edition
6890.5010_01b/tj/nw_Feb2014
Correction in chapter 3.3. “Impulse Inputs”
6890.5010_01c_oi/Nov-15/ag
“Safety Instructions” and “Legal notices” supplemented
“Technical Specifications” and manual-design updated
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. Introduction ................................................................................................. 5
3. Connections and Terminal Assignments ...................................................... 5
3.1. Power Supply ......................................................................................................... 6
3.2. Auxiliary Power Output ......................................................................................... 6
3.3. Impulse Inputs ....................................................................................................... 6
3.4. Reset Input ............................................................................................................ 6
3.5. Relay Outputs ........................................................................................................ 6
3.6. Transistor Outputs ................................................................................................. 7
3.7. The front LEDs ....................................................................................................... 7
4. Switch Settings ........................................................................................... 8
4.1. Setup of the Impulse Inputs .................................................................................. 8
4.2. Basic Switching Functions .................................................................................... 9
4.3. Setting of the Standstill Time (T) ........................................................................ 10
4.4. Definition of Direction of Rotation ...................................................................... 11
5. Technical Specifications ............................................................................ 13
6. Dimensions ................................................................................................ 14
6890_5010_01c_oi_e.doc / Mrz-21 Page 2 / 14
Page 3
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 5). The device is not
suitable for operation in explosion-proof areas or areas which are excluded by the EN 61010-1
standard.
6890_5010_01c_oi_e.doc / Mrz-21 Page 3 / 14
Page 4
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 crosssections for wiring are described in the Technical Specifications (see chapter 5).
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.
6890_5010_01c_oi_e.doc / Mrz-21 Page 4 / 14
Page 5
2. Introduction
LED
DIL 1
DIL 2
NO
NC
C
NO
NC
C
X1 (Rel 1) X2 (Rel 2) X3 (digital)
C+
Out 1
Out 2
9
8
1 2 3 4 5 6 7
GND
DCin
A
/A
B
/B
Res.
+5.4 out
GND
X4
17 - 30 V
+
5 V out
+
Reset
6890.5010 has been designed as a monitor module for assembly in electrical control cabinets.
The units are suitable for monitoring the direction of rotation and the zero-motion state with
industrial machine applications.
As remarkable properties, the 6890.5010 units provide a very high input frequency range, a very
fast response time and versatile settings for encoder characteristics and evaluation of the
signals with respect to direction and standstill detection.
3. Connections and Terminal Assignments
The units provide a 9-position screw terminal strip on the bottom side for power supply and
input signals, and three 3-position terminals on the top, for the outputs. The drawing below
explains the function and assignment of the screw terminal strips.
6890_5010_01c_oi_e.doc / Mrz-21 Page 5 / 14
Page 6
3.1. Power Supply
The unit operates with a DC power from 17 to 30 V, applied to terminals 1 and 2 of terminal
strip X4. The power consumption is approx. 30 mA (plus about 30% of the current taken from
the auxiliary 5 V output)
3.2. Auxiliary Power Output
Positions 8 and 9 of terminal strip X4 provide an auxiliary, stabilized 5 VDC output. The real
output voltage is a little higher (e. g. 5.4 V) in order to compensate for voltage drop on
connectors and cables. The auxiliary output is intended for supply of encoders and sensors. The
output current must not exceed 200 mA.
3.3. Impulse Inputs
The unit features the input channels A, /A (A inverted), B and /B (B inverted). For detection the
direction of rotation it is mandatory to apply at least signals A and B, with a distinguishable
phase displacement (in general 90°). Inverted signals /A and /B are only needed with
differential TTL inputs or RS422 input signals.
The inputs can be set by DIL switch to any of the following characteristics:
Impulse formats:
HTL level 10 - 30 V
TTL level (differential) respectively RS422 format (inverted signals included)
TTL level single-ended (without inverted signals)
Switching characteristics:
PNP (switching to +)
NPN (switching to -)
Tristate (Impedance 10 k)
3.4. Reset Input
A Reset input provides shutdown of all internal functions and forces the unit to "standstill"
state. The switching characteristic of the Reset input is always HTL / PNP, i.e. you have to
apply a positive signal (10 to 30 V) to effectuate the Reset state.
3.5. Relay Outputs
There are two output relays available (dry change-over contacts) with a switching capability of
30 VDC / 2 A respectively 230 VAC / 0.3 A. The response time of the relays is in a range of 5
msec.
Relay 1 (terminal X1) is always used to indicate the direction of rotation, according to the actual
A / B phase situation. Relay 2 (terminal X2) can be set by DIL switch to either indicate the other
direction of rotation, or to monitor "standstill"
6890_5010_01c_oi_e.doc / Mrz-21 Page 6 / 14
Page 7
3.6. Transistor Outputs
Both transistor outputs "Out1" und "Out2" (terminal X3) operate in parallel to the relay
functions, but respond much faster (200 µsec only) than the relays.
The outputs are rated to switch DC voltage from 7 - 30 V at maximum currents of
350 mA (each).
The transistor outputs are 100% short-circuit-proof, however not both outputs must be shortcircuited at the same time for a longer duration.
3.7. The front LEDs
The green LED on the front side of the unit signals that the unit is ready for operation. The
yellow LED signals the input frequency, i.e. it will blink or be lit while the unit detects rotation,
and it will be off when the unit detects standstill.
6890_5010_01c_oi_e.doc / Mrz-21 Page 7 / 14
Page 8
4. Switch Settings
Input Signal
Setting DIL 1
RS422 or TTL symmetric
(differential signals A, /A, B und /B)
ON
ONOFF
HTL signal, asymmetric, PNP (switch to +)
(channels A and B only, no inverted signals)
ON
ONOFF
HTL signal, asymmetric, NPN (switch to -)
(channels A and B only, no inverted signals)
This setting is also suitable for NAMUR sensors
(2-wire). Observe special hint below.
ON
ONOFF
TTL signal asymmetric (single-ended)
(only A und B, no inverted signals)
ON
ONOFF
1
OFF: HTL level (all of the 4 input lines)
ON: TTL level (all of the 4 input lines)
2
OFF: Input B is symmetric (needs /B)
ON: Input B is asymmetric (single-ended, no /B)
3
OFF: Input A is symmetric (needs /A)
ON: Input A is asymmetric (single-ended, no /A)
4
---
ON: internal pull-up resistor towards + *)
5
---
ON: internal pull-down resistor towards GND *)
At any time one of the positions 4 and 5 must be "ON".
With 4 and 5 both OFF, the unit may produce undefined operations
Unused inputs should always be set to HTL level
With use of Namur (2-wire) sensors, please connect the positive wire to the
corresponding input, and the negative wire to GND.
With setting HTL and NPN all impulse inputs are tied to the positive potential
of the power supply (+24 V) via internal pull-up resistors. To avoid damage
with use of TTL encoders, it is advisable to first set the unit to TTL level prior
to connection of the encoder to the unit.
4.1. Setup of the Impulse Inputs
Positions 1 to 5 of switch DIL 1 are used to set levels and switching characteristics of the
impulse inputs. Most of all practical applications would require one of the following three
standard settings:
More combinations can be set with consideration of the individual function of each switch
position, according to the following table:
*) Positions 4 and 5 both ON = Tristate, input impedance = 10 kOhms
6890_5010_01c_oi_e.doc / Mrz-21 Page 8 / 14
Page 9
4.2. Basic Switching Functions
DIL 1
DIL 1
6
OFF: Standstill detection without post-trigger
function (see clarification below)
ON: Standstill detection with post-trigger function
(see clarification below)
7
OFF: Relay 2 and Out 2 to signal the opposite
direction of the Rel1/Out1 indication
ON: Relay 2 and Out 2 to signal zero motion
(standstill)
8
OFF: Upon detection of standstill, the
direction signal is cleared (no indication)
ON: Upon detection of standstill, the information of
the last actual direction remains active
T T
(1)
(2)
= Standstill signal OFF = Standstill signal ON
Positions 6, 7 and 8 of switch DIL1 allow selecting the following functions:
The subsequent drawing explains the difference between "post trigger function on" and
"post trigger function off".
In order to get a standstill signal at all, the time distance between two positive edges must
become greater than the setting "T".
Case (1) shows the post-trigger on. The standstill signal immediately switches off again
when another active edge is detected (no matter after which time). In this case, during
slow-down of the machine, the output and the relay might therefore produce multiple onoff cycles before the standstill signal becomes stationary. However this method could be
considered as "more safe", because it would detect any motion, no matter how slow it is.
Case (2) shows the post-trigger off. After the standstill signal has switched on, it will
remain on and only switch off again after two subsequent edges have been detected
where the time distance was less than T.
6890_5010_01c_oi_e.doc / Mrz-21 Page 9 / 14
Page 10
4.3. Setting of the Standstill Time (T)
DIL 2
DIL 2
1 msec
ON
ONOFF
256 msec
ON
ONOFF
2 msec
ON
512 msec
ON
4 msec
ON
1.024 sec
ON
8 msec
ON
2.048 sec
ON
16 msec
ON
4.096 sec
ON
32 msec
ON
8.192 sec
ON
64 msec
ON
16.384 sec
ON
128 msec
ON
32.768 sec
ON
Provided that the standstill function has been assigned to relay 2 and output 2 by setting DIL
switch 1 position 7 to ON, a standstill definition can be set by means of positions 1 - 4 of the
switch DIL 2. The table indicates the pause time between two input pulses that must be
exceeded in order to signal "standstill".
6890_5010_01c_oi_e.doc / Mrz-21 Page 10 / 14
Page 11
4.4. Definition of Direction of Rotation
DIL 2
DIL 2
1 Imp.
ON
ONOFF
9 Imp.
ON
ONOFF
2 Imp.
ON
10 Imp.
ON
3 Imp.
ON
11 Imp.
ON
4 Imp.
ON
12 Imp.
ON
5 Imp.
ON
13 Imp.
ON
6 Imp.
ON
14 Imp.
ON
7 Imp.
ON
15 Imp.
ON
8 Imp.
ON
16 Imp.
ON
In order to achieve a stable indication of the actual direction of rotation even under vibration and
mechanical oscillation, positions 5 - 8 of switch DIL 2 provide setting of an impulse window.
Before detecting a direction or changing the direction signal, the unit must receive a consecutive
number of impulses in the corresponding direction. The table shows how to set the switches to
define the number of impulses required for detection of the direction.
6890_5010_01c_oi_e.doc / Mrz-21 Page 11 / 14
Page 12
The drawing below explains the operation of the direction outputs upon a change of direction.
Channel A
= Forward motion = Reverse motion
(1)
(2)
Channel B
With case (1) the window has been set to 1 impulse only. As a result the unit immediately
changes the output already after the very first impulse into the opposite direction.
With case (2) a window >1 has been set, wherewith the short change of the phase
between channels A and B does not affect the direction signal.
6890_5010_01c_oi_e.doc / Mrz-21 Page 12 / 14
Page 13
5. Technical Specifications
Power supply:
Input voltage:
Protection circuit:
Ripple:
Consumption:
Connections:
17 … 30 VDC
reverse polarity protection
≤ 10 % bei 24 VDC
approx. 30 mA (unloaded)
screw terminal, 1.5 mm² / AWG 16
Encoder supply:
Output voltage:
Output current:
Connections:
approx. 5.4 V
max. 200 mA
screw terminal, 1.5 mm² / AWG 16
Incremental input:
Characteristic:
Level:
Channels:
Frequency:
Internal resistance:
Connections:
PNP, NPN
RS422: Differential voltage > 1 V
TTL: LOW 0 … 0.5 V, HIGH 2.5 … 5 V
HTL: LOW 0 … 4 V, HIGH 9 … 30 V
A, /A, B, /B or A, B
RS422 and TTL: max. 500 kHz (symmetrical)
HTL and TTL: max. 350 kHz (asymmetrical)
RS422 and TTL: Ri ≈ 10 kOhm
HTL: Ri ≈ 4.7 kOhm
screw terminal, 1.5 mm² / AWG 16
Relay outputs:
Number of relays:
Switching capacity:
Switching delay:
Connections:
2 potential free changeovers
30 VDC / 2 A or 115 VAC / 0.6 A or 230 VAC / 0.3 A
approx. 5 ms
screw terminal, 1.5 mm² / AWG 16
Transistor outputs:
Number of outputs:
Type:
Switching voltage:
Switching current:
Switching delay:
Protection circuit:
Connections:
2
High-Side-Driver
7 … 30 V
max. 350 mA
approx. 200 µs
durable short circuit proof
(not both outputs at the same time!)
screw terminal, 1.5 mm² / AWG 16
Housing:
Material:
Mounting:
Dimensions (w x h x d):
Protection class:
Weight:
plastic
35 mm top hat rail (according to EN 60715)
22.5 x 102 x 102 mm / 0.8858 x 4.0157 x 4.0157 inch
IP20
approx. 100 g
Ambient temperature:
Operation:
Storage:
0 °C … +45 °C / +32 … +113 °F (not condensing)
-25 °C … +70 °C / -13 … +158 °F (not condensing)
Failure rate:
MTBF in years:
91.5 a (long-term usage at 60 °C / 140 °F )
Conformity & standards:
EMC 2004/108/EC:
LV 2006/95/EC:
RoHS 2011/65/EU:
EN 61000-6-2, EN 61000-6-3, EN 61000-6-4
EN 61010-1
EN 50581
6890_5010_01c_oi_e.doc / Mrz-21 Page 13 / 14
Page 14
102 (4.016’’)
91 (3.583’’)
8
2
.
5
(
3
.
2
4
8
’
’
)
1
0
2
(
4
.
0
1
6
’
’
)
22.5
(0.886’’)
1
2
3
4
5
6
7
8
O
F
F
O
N
1
2
3
4
5
6
7
8
O
F
F
O
N
Side view
Top view
Front view
6. Dimensions
6890_5010_01c_oi_e.doc / Mrz-21 Page 14 / 14
Loading...