Motrona FM 260 Operating Instructions Manual
control – motion – interface
FM 260
Impulse and Frequency Multiplier for Use with
Incremental Encoders and Sensors
Universal inputs for incremental encoder signals A, B, Z or A, /A, B, /B, Z, /Z
with either TTL level or RS422 format or HTL level
Unit to multiply the input impulses with a proportional factor F1
and a reciprocal factor F2, both adjustable in a range of 0.005 to 9.9999
Error-free multiplication with accurate impulse count on input and output,
therefore no cumulative errors, even not with encoder vibration or frequent change of
direction of rotation
Frequency range 1 MHz (input and output), programmable index pulse output
Serial interface and USB port for communication with remote units and PC
Operating Instructions
FM26001c_e.doc / Nov-11 Page 1 / 27
Safety Instructions
Version:
Description
:
This manual is an essential part of the unit and contains important hints about
function, correct handling and commissioning. Non-observance can result in
damage to the unit or the machine or even in injury to persons using the
equipment!
The unit must only be installed, connected and activated by a qualified electrician
It is a must to observe all general and also all country-specific and application-
specific safety standards
When this unit is used with applications where failure or maloperation could cause
damage to a machine or hazard to the operating staff, it is indispensable to meet
effective precautions in order to avoid such consequences
Regarding installation, wiring, environmental conditions, screening of cables and
earthing, you must follow the general standards of industrial automation industry
- Errors and omissions excepted –
FM26001a/af/hk/mb/Juni08 First edition
FM26001b/hk/April09 Hint concerning shape of output signals
FM26001c_pp_11/11 Completion of chapter 8 : encoder outputs
FM26001c_e.doc / Nov-11 Page 2 / 27
Table of Contents
1. Introduction ................................................................................................. 4
2. Application Examples .................................................................................. 5
2.1. PPR numbers which are not available with encoders...........................................5
2.2. Fine tuning of circumference and attrition of a measuring wheel........................5
2.3. Gearboxes with irrational or recurrent gear ratios ...............................................6
3. Terminal Assignments and Connections ...................................................... 7
3.1. Block Diagram .......................................................................................................8
3.2. Power Supply.........................................................................................................8
3.3. Auxiliary Encoder Supply Output...........................................................................8
3.4. Impulse Inputs for Encoders and Sensors.............................................................8
3.5. Control Inputs ........................................................................................................9
3.6. Serial Interface......................................................................................................9
3.7. USB Port ................................................................................................................9
3.8. Impulse Outputs ....................................................................................................9
4. LCD Display and Front Keys ....................................................................... 10
5. Keypad Operation ...................................................................................... 11
5.1. Normal Operation................................................................................................11
5.2. Keypad Interlock..................................................................................................11
5.3. General Setup Procedure ....................................................................................12
5.4. Changing Parameters on the Setting Level.........................................................12
5.5. Return from the Menu, Time-Out Function .........................................................13
5.6. Reset all Parameters to Factory Default Values .................................................13
6. Menu Structure and Parameter Description ............................................... 14
6.1. Survey of Menus .................................................................................................14
6.2. Description of the parameters ............................................................................15
7. Clarification of Command Functions........................................................... 20
8. Technical Specifications and Dimensions .................................................. 21
9. Appendix ................................................................................................... 23
9.1. Serial Communication Protocol...........................................................................23
9.2. Installation of the USB Driver .............................................................................24
9.3. Serial Code List ...................................................................................................26
FM26001c_e.doc / Nov-11 Page 3 / 27
1. Introduction
Factor 1
Factor 2
The FM 260 unit has been designed for use as a programmable impulse multiplier of incremental
encoder signals. Encoder impulses applied to the input will be scaled by means of two adjustable
Factors, and the resulting impulse sequence will appear at the output with only a few microseconds
of delay.
The output frequency fout may be higher or lower than the input frequency fin, depending on the
factor settings. In principle the function of the unit allows conversion of any input frequency inside
the specified range to any other proportional output frequency.
This unit considers every individual impulse, with consideration of the counting direction indicated by
the quadrature A/B input phase. The number of generated output pulses is therefore accurate and
error-free with regard to input count and Factor setting, even with vibrations and changes of the
direction.
fout = fin
(Factor 1 = 0,0005 - 9,9999, Factor 2 = 0,0005 – 9,9999 )
The five-decade resolution of both factors provides precision scaling of the desired output with
regard to the input signal.
Moreover, if applicable, a marker pulse with programmable ppr number can be generated, either
with or without synchronization to an input index pulse.
Setup of the unit requires setting of the few parameters only, which may be done by means of the
front keys and the LCD menu or via PC using the serial link or the USB port of the unit.
For all PC operation the operator software OS32 is suitable (included in delivery).
Some applications may require changing settings during operation (e.g. change of the input/output
ratio "on the fly"). This is easily possible via serial link, via USB or by means of a PROFIBUS network
(gateway PB251 needed).
The versatile impulse input of the unit can be set for use with all common standard encoders or
sensors. Independent of the selected input format the output provides always a full set of the signals
A, /A, B, /B and Z, /Z. The output stages are push-pull type and provide an output level of 5 – 30
volts corresponding to the remote supply voltage applied to the output drivers.
Concerning the shape of the output signals, please observe the special hint
given on page 6 of this manual
FM26001c_e.doc / Nov-11 Page 4 / 27
2. Application Examples
2.1. PPR numbers which are not available with encoders
Some applications may require an encoder with a ppr number that is not available on the market, or
which is difficult to get. In such cases the FM 260 multiplier will be able to generate your required
ppr number from the output of any standard encoder.
The example shows how to simulate an encoder with the unusual number of 5431 pulses/rev. from a
standard 4096 ppr encoder, just by setting Factor 1 to 0.5431 and Factor 2 to 0.4096.
This principle even allows encoder operations with non-integer ppr numbers, e.g. to make an encoder
with 100.4 impulses per revolution..
A, /A, B, /B, Z, /Z
Encode r with
4096ppr
In
0,5431
x
0,4096
(Example)
Out
A, /A, B, /B,Z, /Z
5431 ppr
2.2. Fine tuning of circumference and attrition of a measuring wheel
Many times, in extensive production lines, only one single encoder with measuring wheel is
responsible for the control of several different follower machines and controls. Where an attrition of
the wheel would require readjustments in order to keep the accuracy, this would need to happen
individually on every of the following machines and related controls (provided that such kind of
tuning facility is available at all).
With use of a FM 260 multiplier there is an easy way of fine-tuning of the whole line in one central
location only. If applicable, even remote tuning is possible via PLC and serial communication or via
PROFIBUS.
Measuring wheel
Material line
Encoder
FM 260
Fine tuning by changing the factor: x 0,9998 ... 0,9999 ... 1,0000 ... 1,0001 etc.
FM26001c_e.doc / Nov-11 Page 5 / 27
Impulse
Splitter
Folower machine 1
Follower machine 2
Follower machine 3
Control system
PLC
2.3. Gearboxes with irrational or recurrent gear ratios
In practical applications we often find gearings that cannot be properly expressed by a decimal
number (e.g. with a pinion gear of 25 : 9 pinions the decimal expression ratio is 2.7777777.....)
This will cause problems with all position-related or angle-related applications using a decimal ratio
setting. Cumulating errors will result when we set the ratio only with 3 or 4 decimal positions while
the following positions remain unconsidered.
For this reason a user may be forced to mount an extra encoder on the site beyond the gear (which
may be very laborious or even impossible under certain conditions), even though there may already
be an encoder available on the motor site.
Since FM 260 provides a proportional and a reciprocal factor, problems with irrational gear ratios
may be easily solved just by setting the real fraction values according to the number of pinions
involved (i.e. 25 : 9 respectively 2.5000 : 0.9000) rather than imperfect decimal values like 2.777)
Explosive environment or
high-temperature environment
where mounting of an encoder
is problematical or impossible
Motor
Encoder
0.9000
2.5000
FM 260
Pinion gear
25 : 9
Hint concerning the shape of the output signals:
As a result of the digital synthesis of the output frequency, the duty cycle on the output site in
general is different from 1:1. Therefore, also the phase displacement A/B cannot be 90° all the
time. These facts however, in general, do not mean any limitations or restrictions with
practical applications, since the signals will be accepted by practically all industrial counters,
drives or other target units.
At any time it is ensured that
the average frequency over several periods is accurately consistent with the frequency expected from
the input and the ratio setting
the phase displacement will at least be 45° which is more than enough for every industrial phase
discriminator to operate correctly
the number of output pulses corresponds exactly to the number of input pulses with consideration of
the conversion ratio
Typical output signal:
FM26001c_e.doc / Nov-11 Page 6 / 27
3. Terminal Assignments and Connections
Terminal
Appellation
Function
1 2 3 4 5 6 7 8 9 10 11 12 13
Power supply
11 - 30VDC
Aux. output
+5,2V
Impulse inputs
for encoders
and sensors
Control inputs
GND (-)
+Power
GND
+5,2V
A
/A
B
/B
Z
/Z
Cont.1
Cont.2
Cont.3
GND
RxD
TxD
GND
COM+
Cont.4
A
/A
B
/B
Z
/Z
14 15 16 17 18 19 20 21 22 23 24 25
Serial RS232
interface
Remotesupply 5 - 30 V
for output stages
Impulse outputs
Control input
01 GND Minus of power supply, common GND potential
02 +Power Plus of power supply, 11 – 30 volts DC
03 GND Common GND
04 +5,2V Auxiliary output 5,2 V / 200 mA for encoder supply
05 A Impulse input, channel A
06 /A Impulse input, channel /A (=A inverted)
07 B Impulse input, channel B
08 /B Impulse input, channel /B (=B inverted)
09 Z Marker pulse input Z
10 /Z Marker pulse input /Z (=Z inverted)
11 Cont. 1 Control input with programmable function
12 Cont. 2 Control input with programmable function
13 Cont. 3 Control input with programmable function
14 GND Common GND
15 RXD Serial RS232 interface, Receive Data (input)
16 TXD Serial RS232 interface, Transmit Data (output)
17 GND Common GND
18 COM+ Remote supply input for output stages (terminals 19 – 24), 5 – 30 VDC
19 A Impulse output, channel A
20 /A Impulse output, channel /A (=A inverted)
21 B Impulse output, channel B
22 /B Impulse output, channel /B (=B inverted)
23 Z Marker impulse output, Z
24 /Z Marker impulse output, /Z (=Z inverted)
25 Cont. 4 Control input with programmable function
FM26001c_e.doc / Nov-11 Page 7 / 27
3.1. Block Diagram
Power s u pply
11 - 30 VDC
In
Re set, Trim ,
F reeze etc.
RS232
+5,2
/A
/B
Cont1
Cont2
Con t3
Con t4
RxD
T xD
G ND
2
1
4
A
5
6
B
7
8
-
3
Z
9
/Z
10
11
12
13
25
15
16
14
Impulse Processing
Trim + Trim -Factor 2Facto r 1
Sync. pulse
Com +
18
A
19
/A
20
B
21
/B
22
17
23
Marker pulse generatorG ate Func tion
24
/Z
Out
-
Z
3.2. Power Supply
The units require a DC supply from 11 to 30 volts which must be applied to terminals 1 and 2.
Depending on the input voltage level and internal states, the power consumption may vary and lies in
a range of about 65 mA with a 24 volts input (plus encoder currents taken from the auxiliary voltage
output).
3.3. Auxiliary Encoder Supply Output
Terminals 3 and 4 provide an auxiliary output of +5.2 VDC / 200 mA for supply of encoders and
sensors.
3.4. Impulse Inputs for Encoders and Sensors
The setup menu of the unit allows individual setting of the desired characteristics of the signal
inputs. According to the application the units will accept single-channel signals (input A only with no
direction information) as well as dual channel signals A/B including information of the direction of
rotation. The following input formats and levels are acceptable:
symmetric differential input with RS422 format or TTL inputs A, /A, B, /B
asymmetric (single-ended) TTL levels (A and/or B only without inverted channels)
HTL level 10 – 30 volts, alternatively differential (A, /A, B, /B) or single-ended
(A and B only, without inverted channels)
Signals from proximity switches or photocells providing HTL level (10-30 V)
NAMUR (2-wire) signals
The maximum input frequency of the unit is specified to 1 MHz.
The use of the marker pulse inputs Z, /Z is optional.
FM26001c_e.doc / Nov-11 Page 8 / 27
3.5. Control Inputs
235
RxD
RxD
TxD
TxD
GND
PC
(Sub-D-9)
The control inputs provide assignment of programmable functions like keypad-locking, change of the
direction A/B or freezing of the actual output frequency etc.
The inputs require HTL level 10 – 30 V (PNP, switching to +) and the input function can be set to
either "active LOW" or "active HIGH". A minimum pulse duration of 2 msec must be observed with all
commands applied to the control inputs.
3.6. Serial Interface
The serial RS232 interface in general may be used
for easy setup and commissioning of the units (with use of the OS32 operator software)
to change settings and parameters remotely by PC or PLC during the operation
to read out internal states and actual measuring values by PC or PLC
The subsequent drawing shows how to link the unit with a PC, using the standard
9-pin Sub-D-9 connector
Schirm
15
FM 260
16
14
3.7. USB Port
The USB port provides exactly the same range of function as the serial interface. For USB connection
you need a standard USB cable with a "Mini 5-pin" type connector on one site. Before using the USB
port it is necessary to install the driver software on the operator PC. This software is available from
the CD included to delivery, and can also be downloaded from www.motrona.com.
The USB driver software is named CDM 2.04.06 WHQL Certified. zip
Please refer to the appendix chapter 9.2 of this manual for more details about USB driver installation.
3.8. Impulse Outputs
Screw terminals 19 – 24 always provide all of the output signals A, /A, B, /B, Z, /Z, even when you
do not apply inverted signals or marker pulse information to the input.
The output level (5 - 30 volts) is determined by the external voltage applied to terminal 18 (COM+).
The unit uses push-pull output stages for all channels, and the maximum output frequency is 1 MHz.
Please note that neither the input frequency nor the resulting output frequency must
exceed the maximum value of 1 MHz at all times.
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