Motrona ZA Series, ZD 640, ZR Series, ZD 630, ZD 632 Operating Instructions Manual
...
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Series ZD / ZA / ZR 330 – 644
High Speed Position Counters and
Differential Counters with two Encoder Inputs
• Electronic counter series for high-end applications
• Two independent encoder inputs, each with channels A, /A, B, /B ,
1 MHz of counting capability and individual impulse scaling facility
• Selectable operating modes for fast position or event counter, summing counter,
differential counter, cutting length indicator, diameter calculator and more
• 4 preset levels with high-speed power transistor outputs
• RS232 interface and high-speed analogue output available, RS485 (only ZR)
• Choice of 6-decade display (15 mm, 0.56’’) or 8-decade display (10 mm, 0.36’’)
Operating Instructions
ZD340_07d_e.doc / Apr-17 Page 1 / 50
3046 Home Road. Powell, OH 43065 P: (740) 917-5781 F: (740) 917-5791 www.GenesisAutomationOnline.com Sales@GenesisAutomationOnline.com
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 –
General instructions for cabling, screening and grounding can be found in the
SUPPORT section of our website http://www.motrona.com
ZD34001b/Mai06/hk/kk/af First edition
ZD34002a/Jul06/af/hk Extended modes of operation
ZD34003a/Aug06/hk Models ZA_xxx and models xx_330 included
ZD34003c/May06/af/hk Analogue output assignment, Preset calculation, Serial appendix
ZD34003d/Feb08/hk Motrona version with small corrections and modifications
ZD34005a/Sept08/hk Dual counter mode (mode 10), small corrections
ZD34005b/Dec08/hk Several amendments, additional clarifications
ZD34007a/Dec10/kk/hk Parameter "Display Update Time", correction of default values, amendments,
serial codes added to parameter lists
ZD34007b/Jan12/sm Additions for using Namur sensors and type definitions
ZD34007c/June12/pp Corrected images in chapter 1 and 7.2
ZD34007d/April17/cn Control Commands update
ZD340_07d_e.doc / Apr-17 Page 2 / 50
Table of Contents
1. Available Models................................................................................................................4
2. Introduction.........................................................................................................................6
3. Electrical Connections.........................................................................................................7
3.1. Power Supply ...................................................................................................................9
3.2. Auxiliary Outputs for Encoder Supply..............................................................................9
3.3. Impulse Inputs for Incremental Encoders ........................................................................9
3.4. Control Inputs Cont.1 – Cont.4 ........................................................................................9
3.5. Switching Outputs K1 – K4............................................................................................10
3.6. Serial Interface ..............................................................................................................10
3.7. Fast Analogue Output ....................................................................................................10
4. Operating Modes of the Counter.......................................................................................11
4.1. “Single Mode” (Encoder 1 only): F07.062 = 0 ...............................................................12
4.2. “Sum Mode” (Encoder 1 + Encoder 2): F07.062 = 1 ......................................................13
4.3. Differential Mode (Encoder 1 – Encoder 2): F07.062 = 2 ..............................................14
4.4. Master Counter and Integrated Batch Counter: F07.062 = 3 ........................................15
4.5. Evaluation of the Real Cutting Length: F07.062 = 4 ......................................................16
4.6. Diameter Calculation with Winding Rolls: F07.062 = 5 ................................................17
4.7. Radius Calculation with Winding Rolls: F07.062 = 6 ....................................................18
4.8. Cut-to-Length Control Counter: F07.062 = 7 or 8 ..........................................................19
4.9. Monitor for Slip, Torsion, Skew Position, Shaft Fracture: F07.062 = 9.........................21
4.10. Dual Counter, Two Independent Counters for Encoders 1 and 2: F07.062 = 10 ..........22
5. Keypad Operation .............................................................................................................23
5.1. Normal Operation ..........................................................................................................23
5.2. General Setup Procedure...............................................................................................23
5.3. Direct Fast Access to Presets ........................................................................................24
5.4. Change of Parameter Values on the Numeric Level .....................................................25
5.5. Code Protection against Unauthorized Keypad Access ................................................26
5.6. Return from the Programming Levels and Time-Out Function ......................................26
5.7. Reset all Parameters to Factory Default Values ...........................................................26
6. Menu Structure and Description of Parameters ................................................................27
6.1. Summary of the Menu ...................................................................................................27
6.2. Description of the Parameters.......................................................................................30
6.3. Clarification of the Counter Setting Functions ..............................................................39
7. Appendix for models ZD 6xx and ZA 6xx ...........................................................................40
7.1. Relay Outputs.................................................................................................................40
7.2. Front Thumbwheel Switches .........................................................................................40
7.3. Specific Parameters for Units with Thumbwheel Switches .........................................41
8. Appendix: Serial Communication Details ..........................................................................43
8.1. Setup of the Counter by PC............................................................................................43
8.2. Automatic and Cyclic Data Transmission......................................................................44
8.3. Communication Protocol................................................................................................44
8.4. Serial Register Codes ....................................................................................................46
9. Specifications...................................................................................................................48
10. Dimensions....................................................................................................................... 49
ZD340_07d_e.doc / Apr-17 Page 3 / 50
1. Available Models
2 = two thumbwheel sets (4 decade each)
4 = four thumbwheel sets (4 decade each)
ZD 330
The ZD, ZA and ZR counter series include a range of models with similar functions and
properties, but with different housings, displays and outputs.
ZA counters provide an additional high-speed analogue output which is not available with the
ZD or ZR models. However the ZR models have an additional RS485 interface, but otherwise all
details between ZD, ZA and ZR models are fully similar.
The following table explains the details of type designation and the possible options:
Z = electronic counter
D = display only, no analogue output
A = display and high-speed analogue output
R = display and RS-485 interface
3 = housing 96 x 48 mm (3.780 x 1.890’’)
and 4 high-speed transistor outputs
6 = housing 96 x 96 mm (3.780 x 3.780’’)
with 4 high-speed transistor outputs
and 4 relay outputs
3 = display 8 decades 9.15 mm/0.36’’ size
0 = no thumbwheel switches on front
ZD340_07d_e.doc / Apr-17 Page 4 / 50
The following models are available:
ZD 330, ZA 330, ZR 330 ZD 340, ZA 340, ZR 340
ZD 630, ZA 630, ZR 630
ZD 632, ZA 632, ZR 632
ZD 640, ZA 640, ZR 640
ZD 642, ZA 642, ZR 642
ZD 634, ZA 634, ZR 634
ZD 644, ZA 644, ZR 644
Number and combination of front thumbwheels according to customer specification, see section 7.2
ZD340_07d_e.doc / Apr-17 Page 5 / 50
2. Introduction
The counters of series ZD, ZA and ZR have been designed to close a gap with multiple counting
applications, which cannot be accomplished by the normal industrial electronic counters
available on the market.
A continual demand for increasing production speeds and higher precision at the same time
results in counting frequencies exceeding the conventional frequency range.
Particularly with fast running procedures it is most important to also have fast response of the
switching outputs or the analogue output.
Many applications require to evaluate the signals of two incremental measuring systems, and
to compare the results with respect to the sum or the difference or the ratio of the two
positions. This is e.g. necessary for calculation of diameters of winding rolls etc.
Still there exist applications where the use of traditional thumbwheel switches offers real
advantages compared to keypad and menu operations.
These are some of the reasons why the new counter series ZD, ZA and ZR have been designed.
• This manual at first provides all basic instructions for operation of the
counter models presented in the previous chapter
• For operation of relay outputs and thumbwheel switches (if applicable)
please observe the supplementary instructions given in the appendix
• For easy PC setup and PC communication with ZD and ZA counters, please
use our “OS32” operator software (free of charge, download from our
homepage www.motrona.com
• Where you like to have free serial access to the unit by PLC or IPC or by a
remote operator terminal, please observe the serial protocol details
described in our separate manual “Serpro”
• Subsequently the manual uses the expression ZD340 as a replacement for
all available models. However, statements are fully valid for the other
models too, except where especially remarked.
ZD340_07d_e.doc / Apr-17 Page 6 / 50
3. Electrical Connections
Series "
ZD"Series "
ZA"Series "
ZR"*) Interface 1:
*) Interface 2:
GND
GND
Encoder2 /A
Encoder2 /B
E ncoder1 /A
Encoder1 /B
RxD (RS232)
K4 out
PROG
Cont. 3
Interface 2*)
Interface 1*)
1 2 3 4 5 6 7 8 9 10
X1
17
18 19 20
X2
+Vin
+5,2V aux.out +5,2V aux. out
Encoder1*
*) Examp le shows wiring
for encod ers with 5 v olts
power supply and RS422
line drive r output
Encoder 2*
GND
+24V aux.out + 24V aux. out
Digital
Control
Inputs
RS232
21 22
Encoder 2 B
23
Encoder2 A
+24
+5
/A
+24
+5
/A
Cont1
Cont2
Cont3
Cont4
RxD
TxD
GND
11 12
24
25 26
Encoder1 B
Encoder1 A
19
18
A
24
8
B
23
/B
7
-
20
3
2
A
22
6
B
21
/B
5
-
4
28
27
12
11
14
30
31
27
K2 out
K1 out K3 out
17
1
13
28 29 30 31 32
Cont . 1
Cont. 2 Cont. 4
14
Com+ (K1-K4)
15 16
GND
T xD (RS232)
Co m+ (K1 - K4)
29
K1 out
26
K2 out
25
10
K3 out
9
K4 out
16
15
32
0V, GND
13
GND
Fast
transistor
outputs
Inte rface 2 *)
Inte rface 1 *)
+
-
Power supply
∼ ∼
24 V DC
24 V AC
PROG
- n.c. - Analogue output 0/4 - 20 mA RS 485, B (-)
- n.c. - Analogue output +/- 10 V RS 485, A (+)
ZD340_07d_e.doc / Apr-17 Page 7 / 50
Terminal
Name
Function
01
GND
Common Ground Poten
tial (0V)
02
+5,2V out
Aux. output 5.2V/150 mA for encoder supply
03
+24V out
Aux. output 24V/120 mA for encoder supply
04
GND
Common Ground Potential (0V)
05
Encoder 2, /B
Encoder 2, channel /B (B inverted)
06
Encoder 2, /A
Encoder 2, channel /A (A
inverted)
07
Encoder 1, /B
Encoder 1, channel /B (B inverted)
08
Encoder 1, /A
Encoder 1, channel /A (A inverted)
09
K4 out
Output K4, transistor PNP 30 volts, 350 mA
10
K3 out
Output K3, transistor PNP 30 volts, 350 mA
11
Cont.4
Digital control input
12
Cont.3
Digital control input
13
(PROG)
(for download of new firmware only, not for general use)
14
RxD
Serial RS232 interface, input (Receive Data)
15
Ana.out 20 mA
Analogue current output 0
–
20 mA or 4
–
20 mA (optional)
16
Ana.out +/
-
10V
Analog
ue voltage output
-
10V … 0 … +10V (optional)
17
+Vin
Power supply input, +17
–
40 VDC or 24 VAC
18
+5,2V out
Aux. output 5,2V/150 mA for encoder supply
19
+24V out
Aux. output 24V/120 mA for encoder supply
20
GND
Common Ground Potential (0V)
21
Enc
oder 2, B
Encoder 2, channel B (non
-
inverted)
22
Encoder 2, A
Encoder 2, channel A (non
-
inverted)
23
Encoder 1, B
Encoder 1, channel B (non
-
inverted)
24
Encoder 1, A
Encoder 1, channel A (non
-
inverted)
25
K2 out
Output K2, transistor PNP 30 volts, 350
mA26K1 out
Output K1, transistor PNP 30 volts, 350 mA
27
Cont.2
Digital control input
28
Cont.1
Digital control input
29
Com+ (K1
-
K4)
Common positive input for transistor outputs K1
-K430
TxD
Serial RS232 interface, output (Transmit Data)
31
GND
Co
mmon Ground Potential (0V)
32
GND
Common Ground Potential (0V) for DC or AC power supply
*) 120 mA and 150 mA are per encoder, i.e. total maximum currents are 240 mA and 300 mA
ZD340_07d_e.doc / Apr-17 Page 8 / 50
3.1. Power Supply
The ZD340 counter accepts both, a 17 – 40 volts DC power or a 24 volts AC power for supply
via terminals 17 and 1. The current consumption depends on the level of the input voltage and
some internal conditions; therefore it can vary in a range from 100 – 200 mA (aux. currents
taken from the unit for encoder supply not included).
3.2. Auxiliary Outputs for Encoder Supply
Terminals 2 and 18 provide an auxiliary output with approx. +5.2 volts DC (300 mA totally).
Terminals 3 and 19 provide an auxiliary output with approx. +24 volts DC (240 mA totally)
3.3. Impulse Inputs for Incremental Encoders
All input characteristics of the impulse inputs can be set by the parameter menu, for each of
the encoders separately. Depending on the application the unit can accept single channel
information (input A only) or quadrature information (A / B, 90°). The following settings are
possible:
• Symmetric input (differential) according to RS422 standard (min. differential voltage 1 V)
• TTL inputs at a level of 3.0 to 5 volts (differential, with inverted signal)
• TTL inputs at a level of 3.0 to 5 volts (single-ended) *)
• HTL signals at a 10 – 30 volts level
(alternatively differential with inverted signals A, /A, B, /B, or single-ended A, B only)
• Impulses from photocells or proximity switches etc. providing a HTL level (10 – 30 volts)
• Proximity switches according to NAMUR (2-wire) standard have an input level of 5,8V
respectively 19,4V. For a save crossover point set the threshold setting of the used input
to the value 200. *)
All encoder input lines are internally terminated by pull-down resistors ( 8,5 kΩ ).
Where encoders with pure NPN outputs are used, corresponding pull-up resistors must be
available inside the encoder or externally to ensure proper function (1 kΩ ... 3,3 kΩ).
3.4. Control Inputs Cont.1 – Cont.4
These inputs can be configured for various remote functions like Reset, Set, Latch, and Inhibit
or switch-over purpose.
All control inputs require HTL level. They can be individually set to either NPN (switch to -) or
PNP (switch to +) characteristics. For applications where edge-triggered action is needed, the
menu allows to set the active edge (rising or falling). Control inputs also accept signals with
Namur (2-wire) standard. For reliable operation the minimum pulse width on the control inputs
should be 50 µsec.
*) requires special settings of the threshold parameters, see “Special parameters F04”
ZD340_07d_e.doc / Apr-17 Page 9 / 50
3.5. Switching Outputs K1 – K4
RS 232
RS 485
ZD340 provides four presets and outputs with programmable switching characteristics.
K1 – K4 are fast-switching and short-circuit-proof transistor outputs with a switching capability
of 5 – 30 volts / 350 mA each. The switching voltage of the outputs must be applied remotely
to the Com+ input (terminal 29)
3.6. Serial Interface
The serial RS232 and RS485 interface can be used for the following purposes:
• Set-up of the unit by PC (if desirable), by means of the OS32 PC software
• Change of parameters during operation
• Readout of actual counter or other values by PLC or PC
The figure below explains the connection between the ZD340 counter and a PC using the
standard Sub-D-9 serial connector, and the connection via RS485 terminals to a PLC.
For details of serial communication, please refer to section 10.
ZD 340
ZA 340
ZR 340
ZR 340
14
30
31
16
15
Where both, RS232 and RS485 interface are in use, you can communicate by the one or
by the other, but not by both interfaces at the same time
RxD RxD
TxDTxD
GND
Screen
A(+)
B(-)
2
PC
3
(Sub-D-9)
5
A
PLC
B
3.7. Fast Analogue Output
An analogue output is available with all ZA models, providing a voltage output of +/- 10 volts
(Load = 3 mA), and a current output of 0 – 20 mA or 4 – 20 mA (load = 0 – 270 Ohms). All output
characteristics like beginning of conversion range, output swing etc. are freely programmable
via menu. The response time of the analogue output is less than 1 msec. (time from encoder
event to analogue out). The resolution is 14 bits.
Please note that extensive serial communication with the unit may temporary increase the
analogue response time.
ZD340_07d_e.doc / Apr-17 Page 10 / 50
4. Operating Modes of the Counter
Operating Mode
0
Single counter mode, encoder 1 only
1
Summing counter mode (encoder 1 + enc
oder 2)
2
Differential counter mode (encoder 1
-
encoder 2)
3
Master counter and batch counter
4
Display of the actual cutting length with cutting "on the fly" applications
5
Roll diameter calculation with winding rolls
6
Roll radius calculation with
winding rolls
7
Cut-to-length control (with deletion of residual errors)
8
Cut-to-length control (with consideration of residual errors)
9
Control of slip, torsion, skew position, shaft fracture etc.
10
Dual counter, two independent counters for encode
r 1 and encoder 2
•
For best survey, all parameters of the unit are arranged in 13 expedient groups, named
“F01” - “F13”. Depending on the application, only a few of these groups may be important,
while all other groups may be irrelevant for your specific application.
This section describes possible applications and operating modes of the counter.
The operation mode can be set under parameter group F07, parameter # F07.062.
The following counting functions are available:
Counter Function
F07.062
It is possible to cycle the display between the five reading modes shown in
the following function tables, by pressing one of the front keys or by using
one of the control inputs (you must have assigned the display scroll function
to one of the keys or the inputs under menu F06, to activate the scrolling of
the display). LEDs L1 and L2 indicate which of the values is actually displayed.
• Scrolling of the display from one reading mode to another will not affect the
function of the preselection outputs K1 – K4
• The analogue output (models ZA) can be assigned to any of the readings
accessible in the display, by a special parameter. Scrolling of the display from
one reading mode to another will not affect the analogue output.
• As far as the selected counter mode also allows reading out the minimum and
maximum values or the positions of the last change of direction, please note
that the unit latches these extreme values in time periods of 1 msec. only.
Therefore the display of memorized extreme positions may include some
inaccuracy with high counting frequencies (real extreme value may lie
between two records)
Full details about parameter arrangement and function can be found under section 6.
ZD340_07d_e.doc / Apr-17 Page 11 / 50
All operating modes provide separate impulse scaling factors for each of the two
Display
L1 (red)
L2 (yellow)
1
Actual counter value
----2
Minimum value since last reset
blinking fast
--3Maximum value since last reset
--
blinking fast
4
Position of last change of direction (up and low)
blinking slow
--5Only lower poin
t of change of direction (F04.030 = 0)
--
blinking slow
encoders. Please observe that the display of the counter will only show whole
numbers (integers) whereas remainders will be carried in the background
Example: Differential Counter:
Encoder1
1000
Impulses
Impulse Scaling
Factor1
x 0,98765 minus
967,65000 - 2469,12000 = -1501 0,47000
Encoder2
2000
Impulses
Impulse Scaling
Factor2
x 1,23456
Display
Remainder
(background)
4.1. “Single Mode” (Encoder 1 only): F07.062 = 0
Only the inputs of encoder 1 are active, signals on the encoder 2 inputs will not be evaluated.
Besides the actual counter value, the unit also records minimum and maximum values as well
as the last positions of change of direction.
All 4 presets are related to the actual counter value.
Only upper point of change of direction (F04.030 = 1)
or
Typical applications:
- fast preset counter
- position counter with m emorized
points of change of direction
- event counter, incrementing or decreme nting
1 2 3 4 5 6
Encoder 1
Cont.1
Reset, Preset, Inhibit etc.
Cont.4
ZD340_07d_e.doc / Apr-17 Page 12 / 50
4.2. “Sum Mode” (Encoder 1 + Encoder 2): F07.062 = 1
Display
L1 (red)
L2 (yellow)
1
Actual sum encoder 1 + encoder 2
----2
Minimum value of the sum (since last reset)
blinking fast
--3Maximum value of the sum (since last reset)
--
blinking fast
4
Actual counter value of encoder 1 alone
blinking slow
--5Actual counter value of encoder 2 alone
--
blinking slow
Both inputs encoder 1 and encoder 2 are active. From both values the unit forms the sum, with
consideration of the individual encoder scaling factors. Where the encoder signal also provides
direction information, this information will be considered by a corresponding sign of the count.
Without direction information (channel A only) both encoder values will be added up. The final
result can once more be scaled into user-friendly engineering units by means of the special
scaling parameters in parameter group F07.
Besides the actual counter value and the sum, the unit also records minimum and maximum
values of the sum.
Presets K1 and K2 are related to the actual counter value of encoder 1 only.
Presets K3 and K4 are related to the actual sum result (encoder 1 + encoder 2)
1 2 3 4 5 6
+
Encoder 1
Cont.1
Reset, Pres et, Inhibit etc.
Encoder 2
Cont.4
Sum of two
event counts
+
s = s0 + s1 + s2
s0
Two-stage
hydraulic cylinder
1 2 3 4 5 6
Encoder 1
Reset, Preset, Inhibit etc.
Cont.1
s1
Encoder 2
Cont.4
s2
Sum of two
positions
ZD340_07d_e.doc / Apr-17 Page 13 / 50
4.3. Differential Mode (Encoder 1 – Encoder 2): F07.062 = 2
Display
L1 (red)
L2 (yellow)
1
Actual difference encoder 1
-
encoder 2
----2
Minimum value of the differ
ence (since last reset)
blinking fast
--3Maximum value of the difference (since last reset)
--
blinking fast
4
Actual counter value of encoder 1 alone
blinking slow
--5Actual counter value of encoder 2 alone
--
blinking slow
Both inputs encoder 1 and encoder 2 are active. From both values the unit forms the difference,
with consideration of the individual encoder scaling factors.
Where the encoder signal also provides direction information, this information will be
considered by a corresponding sign of the count. Without direction information (channel A only)
encoder 1 will increment and encoder 2 will decrement the counter. The final result can once
more be scaled into user-friendly engineering units by means of the special scaling parameters
in parameter group F07.
Besides the actual counter value and the difference, the unit also records minimum and
maximum values of the difference.
Presets K1 and K2 are related to the actual counter value of encoder 1 only.
Presets K3 and K4 are related to the actual differential result (encoder 1 - encoder 2)
1 2 3 4 5 6
Encoder 1
Cont.1
+
Reset, Pres et, Inhibit etc.
Difference of
two event counts
Encoder 2
Cont.4
-
Gapw idth d = s1 - s2
d
s1
1 2 3 4 5 6
Encoder 1
Cont.1
Reset, Preset, Inhibit etc.
Encoder 2
C ont. 4
s2
Difference of
two positions
ZD340_07d_e.doc / Apr-17 Page 14 / 50
4.4. Master Counter and Integrated Batch Counter: F07.062 = 3
Display
L1 (red)
L2 (yellow)
1
Actual counter value of batch counter
----2
Minimum value of batch counter (since last reset)
blinking fast
--3Maximum value of batch counter (since last reset
)--blinking fast
4
Actual counter value of master counter (encoder 1)
blinking slow
--5Actual counter value of batch counter
--
blinking slow
This counter mode can be used for cut-to lengths applications, cyclic production flows, packing
procedures etc. While the master counter takes care of the correct number of impulses per
product, the background batch counter counts the number of products produced.
This mode assumes that the automatic reset function has been activated for the master
counter, providing restart from zero every time the preset value has been reached.*)
Only the inputs of encoder 1 are active (master counter).
Every time the master counter reaches its preset value, it restarts from zero and the batch
counter increments by 1. ***)
The batch counter can be decremented by separate external signal, when one of the keys or
control inputs has been defined correspondingly. **)
Besides the master counter and the batch counter, the unit also records minimum and
maximum values of the batch count.
Presets K1 and K2 are related to the actual counter value of encoder 1.
Presets K3 and K4 are related to the actual value of the batch counter.
*) Example: If 500 impulses on encoder 1 are necessary for 1 product:
a. Set F01.000 to 500 (preset level 1)
b. Set F10.089 = 1.00 sec. (output pulse time K1)
c. Set F10.097 = 2 or 4 (automatic restart from 0)
**) Select parameter group F06 and assign the special command “13” to any of the keys or
control inputs for remote decrementing of the batch counter
***) As a matter of course the counting sense can also be reversed, i.e. the main counter
loads a preset value, counts down towards zero, increments the batch counter when
reaching zero and sets to the preset value again
ZD340_07d_e.doc / Apr-17 Page 15 / 50
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