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Model TI-5000EX

Serial/Incremental Encoder

Training Manual

Software Version 3.4

Mitchell Electronics, Inc.

180B Mill Street P. O. Box 2626

Athens, OH 45701

March 1, 2011

L. Mitchell

Voice: 740-594-8532

FAX: 740-594-8533

Email: [email protected]

URL: http://www.mitchell-electronics.com

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LIMITED WARRANTY: Seller warrants that the articles furnished hereunder shall be free from defects in material and workmanship for a period of one year from date of shipment. In no event will the seller be liable for incidental or consequential damages arising from the use of this equipment, software, or documentation. The liability of the Seller shall be limited to repair or replacement of, at its option, any defective units returned to the Seller. Equipment or parts subject to improper use or unauthorized repair are not covered by warranty. Repaired or replaced parts shall be covered for the remainder of the original warranty period or an additional ninety (90) days from shipment by the Seller, whichever is longer. No other warranty expressed or implied is made. Copyright 2006 Mitchell Electronics, Inc.

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Table of Contents

1 INTRODUCTION........................................................................................................................................................ 1

1.1 OVERVIEW........................................................................................................................................................... 1 1.2 HOW TO USE THIS MANUAL.................................................................................................................................. 1 1.3 SETUP AND SOFTWARE INSTALLATION................................................................................................................. 2 1.3.1 HARDWARE CONNECTIONS ............................................................................................................................... 2 1.3.2 SOFTWARE INSTALLATION ................................................................................................................................ 2 1.3.2.1 WINTI5000EX PC SOFTWARE INSTALLATION............................................................................................... 3 1.3.2.2 PC USB DRIVER INSTALLATION.................................................................................................................... 3 1.3.2.3 DOWNLOAD PROGRAMS TO THE TI-5000EX USING WINTI5000EX............................................................... 4 1.4 NEW IN THIS RELEASE......................................................................................................................................... 5 1.5 OPTIONS.............................................................................................................................................................. 5

2 OPERATION ........................................................................................................................................................ 7

2.1 BASIC OPERATION............................................................................................................................................... 9 2.1.1 HELP ................................................................................................................................................................ 9 2.1.2 MENUS ............................................................................................................................................................. 9 2.1.2.1 TEST AND MOTOR REPAIR MENU .................................................................................................................. 9 2.1.2.2 SYSTEM SETUP MENU................................................................................................................................... 9 2.1.2.2.1 SYSTEM DATA TAB..................................................................................................................................... 9 2.1.2.2.2 USER OPTIONS TAB ................................................................................................................................. 10 2.1.2.2.3 DOWNLOAD TI-5000EX SOFTWARE TAB................................................................................................. 10 2.1.2.3 HELP MENU................................................................................................................................................. 10 2.1.3 TEST BUTTONS............................................................................................................................................... 11 2.1.3.1 DATA DISPLAY BUTTON............................................................................................................................... 11 2.1.3.2 LINE LEVELS BUTTON ................................................................................................................................. 11 2.1.3.3 COUNT TEST BUTTON ................................................................................................................................. 11 2.1.3.4 CONTINUOUS COUNT TEST BUTTON............................................................................................................ 11 2.1.3.5 PHASE TEST BUTTON.................................................................................................................................. 11 2.1.3.6 MEMORY TEST BUTTON .............................................................................................................................. 12 2.1.4 MISCELLANEOUS BUTTONS ............................................................................................................................ 12 2.1.4.1 SELECT FEEDBACK BUTTON ....................................................................................................................... 12 2.1.4.1.1 ENCODER/RESOLVER RADIO BUTTONS.................................................................................................... 12 2.1.4.1.2 ENCODER MANUFACTURER MENU............................................................................................................ 12 2.1.4.1.3 ENCODER TYPE MENU ............................................................................................................................. 13 2.1.4.1.4 MOTOR MANUFACTURER (MEMORY) MENU.............................................................................................. 13 2.1.4.1.5 COUNTS PER REVOLUTION BUTTON......................................................................................................... 13 2.1.4.2 DISPLAY PINOUT BUTTON............................................................................................................................ 14 2.1.4.3 SAVE REPORT TO FILE BUTTON .................................................................................................................. 14 2.1.4.4 PRINT REPORT BUTTON .............................................................................................................................. 14 2.1.4.5 POLES MENU............................................................................................................................................... 14 2.2 SERIAL ENCODER GENERAL INFORMATION........................................................................................................ 15 2.2.1 DATA DISPLAY................................................................................................................................................ 15 2.2.1.1 ENCODER SELECTION.................................................................................................................................. 15 2.2.1.2 COMMUTATION ............................................................................................................................................ 16 2.2.1.3 POSITION COUNT......................................................................................................................................... 17 2.2.1.4 ENCODER STATUS....................................................................................................................................... 17 2.2.2 COUNT TEST................................................................................................................................................... 18 2.2.2.1 REVOLUTION ............................................................................................................................................... 19 2.2.2.2 COUNT ........................................................................................................................................................ 19 2.2.2.3 TARGET....................................................................................................................................................... 19

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2.2.2.4 ERROR ........................................................................................................................................................ 19 2.2.2.5 COUNT/REV................................................................................................................................................. 19 2.2.2.6 STUCK BITS................................................................................................................................................. 19 2.2.2.7 INTERNAL ERROR ........................................................................................................................................ 20 2.3 GENERIC INCREMENTAL QUADRATURE PULSE ENCODERS................................................................................ 21 2.3.1 DESCRIPTION.................................................................................................................................................. 21 2.3.2 CONNECTION.................................................................................................................................................. 21 2.3.3 SETUP ............................................................................................................................................................ 22 2.3.4 TESTING ......................................................................................................................................................... 22 2.3.5 DATA DISPLAY................................................................................................................................................ 22 2.3.5.1 COMMUTATION ............................................................................................................................................ 23 2.3.5.1.1 NORMAL COMMUTATION........................................................................................................................... 23 2.3.5.1.2 SINE COSINE COMMUTATION ENCODERS ................................................................................................. 25 2.3.5.2 COUNT ........................................................................................................................................................ 26 2.3.5.3 RATE........................................................................................................................................................... 27 2.3.5.4 LINE STATES ............................................................................................................................................... 27 2.3.5.5 INDEX .......................................................................................................................................................... 27 2.3.6 LINE LEVELS................................................................................................................................................... 28 2.3.6.1 REALTIME LEVELS....................................................................................................................................... 29 2.3.6.2 MIN LEVELS................................................................................................................................................. 29 2.3.6.3 MAX LEVELS ............................................................................................................................................... 29 2.3.7 COUNT TEST................................................................................................................................................... 30 2.3.7.1 REVOLUTION ............................................................................................................................................... 30 2.3.7.2 COUNT ........................................................................................................................................................ 30 2.3.7.3 TARGET....................................................................................................................................................... 30 2.3.7.4 ERROR ........................................................................................................................................................ 30 2.3.7.5 COUNT/REV................................................................................................................................................. 30 2.3.7.6 STUCK BITS................................................................................................................................................. 31 2.3.7.7 INTERNAL ERROR ........................................................................................................................................ 31 2.3.8 CONTINUOUS COUNT TEST............................................................................................................................. 32 2.3.9 PHASE ANGLE TEST....................................................................................................................................... 34 2.3.9.1 REALTIME.................................................................................................................................................... 34 2.3.9.2 MAX VAL ..................................................................................................................................................... 35 2.3.9.3 MIN VAL ...................................................................................................................................................... 36 2.4 GENERIC PARALLEL ABSOLUTE ENCODERS...................................................................................................... 37 2.4.1 DATA DISPLAY................................................................................................................................................ 39 2.4.1.1 LINE STATES ............................................................................................................................................... 39 2.4.1.2 BINARY CODE.............................................................................................................................................. 39 2.4.1.3 GRAY CODE ................................................................................................................................................ 40 2.4.1.4 BCD CODE ................................................................................................................................................. 40 2.5 GENERIC RESOLVERS........................................................................................................................................ 41 2.5.1 GENERAL COMMENTS .................................................................................................................................... 41 2.5.2 TYPES SUPPORTED ........................................................................................................................................ 42 2.5.3 CONNECTION.................................................................................................................................................. 42 2.5.4 SETUP ............................................................................................................................................................ 43 2.5.5 TESTING ......................................................................................................................................................... 45 2.5.6 DATA DISPLAY................................................................................................................................................ 45 2.5.6.1 RESOLVER ANGLE READINGS ..................................................................................................................... 46 2.5.6.2 RESOLVER OUTPUT..................................................................................................................................... 46 2.5.6.3 RESOLVER EXCITATION SET POINTS ........................................................................................................... 47 2.6 MANUFACTURER SPECIFIC ENCODER DETAILS.................................................................................................. 48 2.6.1 ALLEN BRADLEY (RELIANCE, ELECTROCRAFT) MOTORS ............................................................................... 49 2.6.1.1 GENERAL COMMENTS ................................................................................................................................. 49 2.6.1.2 TYPES SUPPORTED ..................................................................................................................................... 49 2.6.1.2.1 IDENTIFICATION......................................................................................................................................... 50 2.6.1.3 CONNECTION............................................................................................................................................... 52

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2.6.1.4 ENCODER SELECTION.................................................................................................................................. 52 2.6.1.5 TESTING ...................................................................................................................................................... 52 2.6.1.5.1 DATA DISPLAY.......................................................................................................................................... 52 2.6.1.5.1.1 COMMUTATION...................................................................................................................................... 52 2.6.1.5.1.2 COUNT .................................................................................................................................................. 54 2.6.1.5.1.3 ENCODER STATUS................................................................................................................................. 54 2.6.1.5.1.4 MEMORY STATUS.................................................................................................................................. 54 2.6.1.5.2 COUNT TEST ............................................................................................................................................ 55 2.6.1.5.3 MEMORY TEST ......................................................................................................................................... 55 2.6.1.5.3.1 ALLEN BRADLEY MEMORY TEST........................................................................................................... 55 2.6.2 FANUC MOTORS ............................................................................................................................................. 59 2.6.2.1 GENERAL COMMENTS ................................................................................................................................. 59 2.6.2.2 TYPES SUPPORTED ..................................................................................................................................... 59 2.6.2.2.1 IDENTIFICATION......................................................................................................................................... 60 2.6.2.3 CONNECTION............................................................................................................................................... 60 2.6.2.4 ENCODER SELECTION.................................................................................................................................. 60 2.6.2.4.1 INCREMENTAL AND ABS ENCODERS........................................................................................................ 61 2.6.2.4.2 SERIAL ENCODERS................................................................................................................................... 61 2.6.2.5 TESTING ...................................................................................................................................................... 61 2.6.2.5.1 DATA DISPLAY.......................................................................................................................................... 61 2.6.2.5.1.1 COMMUTATION...................................................................................................................................... 61 2.6.2.5.1.2 COUNT .................................................................................................................................................. 63 2.6.2.5.1.3 LINE STATES ......................................................................................................................................... 63 2.6.2.5.1.4 ENCODER STATUS................................................................................................................................. 64 2.6.2.5.2 COUNT TEST ............................................................................................................................................ 65 2.6.3 HEIDENHAIN SERIAL ENCODERS..................................................................................................................... 66 2.6.3.1 GENERAL COMMENTS ................................................................................................................................. 66 2.6.3.2 TYPES SUPPORTED ..................................................................................................................................... 67 2.6.3.2.1 IDENTIFICATION......................................................................................................................................... 67 2.6.3.3 CONNECTION............................................................................................................................................... 68 2.6.3.4 ENCODER SELECTION.................................................................................................................................. 68 2.6.3.5 TESTING ...................................................................................................................................................... 68 2.6.3.5.1 DATA DISPLAY.......................................................................................................................................... 69 2.6.3.5.1.1 COMMUTATION...................................................................................................................................... 69 2.6.3.5.1.2 COUNT .................................................................................................................................................. 71 2.6.3.5.1.3 ENCODER STATUS................................................................................................................................. 72 2.6.3.5.2 COUNT TEST ............................................................................................................................................ 73 2.6.4 HENGSTLER (UNICO) SSI SERIAL ENCODERS ................................................................................................ 74 2.6.4.1 GENERAL COMMENTS ................................................................................................................................. 74 2.6.4.2 TYPES SUPPORTED ..................................................................................................................................... 74 2.6.4.2.1 IDENTIFICATION......................................................................................................................................... 74 2.6.4.3 CONNECTION............................................................................................................................................... 74 2.6.4.4 ENCODER SELECTION.................................................................................................................................. 75 2.6.4.5 TESTING ...................................................................................................................................................... 75 2.6.4.5.1 DATA DISPLAY.......................................................................................................................................... 75 2.6.4.5.1.1 COMMUTATION...................................................................................................................................... 76 2.6.4.5.1.2 COUNT .................................................................................................................................................. 76 2.6.4.5.1.3 ENCODER STATUS................................................................................................................................. 76 2.6.4.5.2 COUNT TEST ............................................................................................................................................ 77 2.6.5 INDRAMAT DIGITAL MOTORS, SERIAL ENCODERS AND RESOLVERS................................................................ 78 2.6.5.1 GENERAL COMMENTS ................................................................................................................................. 78 2.6.5.2 TYPES SUPPORTED ..................................................................................................................................... 78 2.6.5.2.1 IDENTIFICATION......................................................................................................................................... 78 2.6.5.3 CONNECTION............................................................................................................................................... 79 2.6.5.4 ENCODER SELECTION.................................................................................................................................. 79 2.6.5.5 TESTING ...................................................................................................................................................... 80

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2.6.5.5.1 DATA DISPLAY.......................................................................................................................................... 80 2.6.5.5.1.1 COMMUTATION...................................................................................................................................... 82 2.6.5.5.1.2 POSITION CODE RINGS.......................................................................................................................... 83 2.6.5.5.1.3 COUNT .................................................................................................................................................. 84 2.6.5.5.1.4 REVOLUTIONS CODE RINGS AND REVOLUTIONS.................................................................................... 84 2.6.5.5.1.5 ENCODER STATUS................................................................................................................................. 85 2.6.5.5.2 COUNT TEST ............................................................................................................................................ 86 2.6.5.5.3 MEMORY TEST ......................................................................................................................................... 86 2.6.6 KAWASAKI MOTORS AND SERIAL ENCODERS ................................................................................................. 89 2.6.6.1 GENERAL COMMENTS ................................................................................................................................. 89 2.6.6.2 TYPES SUPPORTED ..................................................................................................................................... 89 2.6.6.2.1 IDENTIFICATION......................................................................................................................................... 89 2.6.6.3 CONNECTION............................................................................................................................................... 90 2.6.6.4 ENCODER SELECTION.................................................................................................................................. 90 2.6.6.5 TESTING ...................................................................................................................................................... 90 2.6.6.5.1 DATA DISPLAY.......................................................................................................................................... 91 2.6.6.5.1.1 COMMUTATION...................................................................................................................................... 91 2.6.6.5.1.2 COUNT .................................................................................................................................................. 92 2.6.6.5.1.3 ENCODER STATUS................................................................................................................................. 92 2.6.6.5.2 COUNT TEST ............................................................................................................................................ 93 2.6.7 MITSUBISHI MOTORS AND SERIAL ENCODERS................................................................................................ 94 2.6.7.1 GENERAL COMMENTS ................................................................................................................................. 94 2.6.7.2 TYPES SUPPORTED ..................................................................................................................................... 94 2.6.7.2.1 IDENTIFICATION......................................................................................................................................... 95 2.6.7.3 CONNECTION............................................................................................................................................... 95 2.6.7.4 ENCODER SELECTION.................................................................................................................................. 96 2.6.7.5 TESTING ...................................................................................................................................................... 96 2.6.7.5.1 DATA DISPLAY.......................................................................................................................................... 96 2.6.7.5.1.1 COMMUTATION...................................................................................................................................... 97 2.6.7.5.1.2 COUNT .................................................................................................................................................. 97 2.6.7.5.1.3 ENCODER STATUS................................................................................................................................. 98 2.6.7.5.2 COUNT TEST ............................................................................................................................................ 98 2.6.8 RENCO ENCODERS....................................................................................................................................... 100 2.6.8.1 GENERAL COMMENTS ............................................................................................................................... 100 2.6.9 REXROTH MOTORS....................................................................................................................................... 101 2.6.9.1 GENERAL COMMENTS ............................................................................................................................... 101 2.6.9.2 TYPES SUPPORTED ................................................................................................................................... 101 2.6.9.2.1 IDENTIFICATION....................................................................................................................................... 102 2.6.9.3 CONNECTION............................................................................................................................................. 103 2.6.9.4 ENCODER SELECTION................................................................................................................................ 103 2.6.9.5 TESTING .................................................................................................................................................... 103 2.6.9.5.1 DATA DISPLAY........................................................................................................................................ 104 2.6.9.5.1.1 COMMUTATION.................................................................................................................................... 104 2.6.9.5.1.2 COUNT ................................................................................................................................................ 105 2.6.9.5.1.3 ENCODER STATUS............................................................................................................................... 105 2.6.9.5.1.4 MEMORY STATUS................................................................................................................................ 105 2.6.9.5.2 COUNT TEST .......................................................................................................................................... 106 2.6.9.5.3 MEMORY TEST ....................................................................................................................................... 106 2.6.9.5.3.1 REXROTH MSK MEMORY TEST........................................................................................................... 106 2.6.9.5.3.2 REXROTH MSM MEMORY TEST .......................................................................................................... 109 2.6.10 SANYO DENKI MOTORS AND SERIAL ENCODERS........................................................................................ 112 2.6.10.1 GENERAL COMMENTS ............................................................................................................................. 112 2.6.10.2 TYPES SUPPORTED................................................................................................................................. 112 2.6.10.2.1.1 ABSOLUTE ENCODER RESET PROCEDURES...................................................................................... 114 2.6.10.2.2 IDENTIFICATION..................................................................................................................................... 114 2.6.10.3 CONNECTION........................................................................................................................................... 115

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2.6.10.4 ENCODER SELECTION ............................................................................................................................. 117 2.6.10.5 TESTING .................................................................................................................................................. 117 2.6.10.5.1 DATA DISPLAY ..................................................................................................................................... 117 2.6.10.5.1.1 COMMUTATION.................................................................................................................................. 118 2.6.10.5.1.2 COUNT .............................................................................................................................................. 118 2.6.10.5.1.3 ENCODER STATUS............................................................................................................................. 119 2.6.10.5.2 COUNT TEST ........................................................................................................................................ 119 2.6.11 STEGMANN SERIAL ENCODERS .................................................................................................................. 120 2.6.11.1 GENERAL COMMENTS ............................................................................................................................. 120 2.6.11.2 TYPES SUPPORTED................................................................................................................................. 120 2.6.11.2.1 IDENTIFICATION..................................................................................................................................... 121 2.6.11.3 CONNECTION........................................................................................................................................... 121 2.6.11.4 ENCODER SELECTION ............................................................................................................................. 122 2.6.11.5 TESTING .................................................................................................................................................. 122 2.6.11.5.1 DATA DISPLAY ..................................................................................................................................... 123 2.6.11.5.1.1 COMMUTATION.................................................................................................................................. 123 2.6.11.5.1.2 COUNT .............................................................................................................................................. 124 2.6.11.5.1.3 ENCODER STATUS............................................................................................................................. 124 2.6.11.5.1.4 MEMORY STATUS.............................................................................................................................. 126 2.6.11.5.2 COUNT TEST ........................................................................................................................................ 126 2.6.11.5.3 MEMORY TEST ..................................................................................................................................... 127 2.6.11.5.4 SNS50/60 ........................................................................................................................................... 127 2.6.12 SUMTAK SERIAL ENCODERS....................................................................................................................... 130 2.6.12.1 GENERAL COMMENTS ............................................................................................................................. 130 2.6.12.2 TYPES SUPPORTED................................................................................................................................. 130 2.6.13 TAMAGAWA SERIAL ENCODERS.................................................................................................................. 131 2.6.13.1 GENERAL COMMENTS ............................................................................................................................. 131 2.6.13.2 TYPES SUPPORTED................................................................................................................................. 131 2.6.13.2.1 IDENTIFICATION..................................................................................................................................... 134 2.6.13.3 CONNECTION........................................................................................................................................... 134 2.6.13.4 ENCODER SELECTION ............................................................................................................................. 134 2.6.13.5 TESTING .................................................................................................................................................. 135 2.6.13.5.1 DATA DISPLAY ..................................................................................................................................... 135 2.6.13.5.1.1 COMMUTATION.................................................................................................................................. 135 2.6.13.5.1.2 COUNT .............................................................................................................................................. 135 2.6.13.5.1.3 ENCODER STATUS............................................................................................................................. 136 2.6.13.5.2 COUNT TEST ........................................................................................................................................ 137 2.6.13.5.3 MEMORY TEST ..................................................................................................................................... 137 2.6.14 YASKAWA ENCODERS (ALLEN BRADLEY) .................................................................................................. 138 2.6.14.1 GENERAL COMMENTS ............................................................................................................................. 138 2.6.14.2 TYPES SUPPORTED................................................................................................................................. 138 2.6.14.2.1 QUADRATURE INCREMENTAL WITH U V W COMMUTATION CHANNELS ................................................. 138 2.6.14.2.2 QUADRATURE INCREMENTAL WITH SINGLE C COMMUTATION CHANNEL............................................... 139 2.6.14.2.2.1 C CHANNEL ENCODER UPDATE TEST ............................................................................................... 139 2.6.14.2.3 ABSOLUTE ENCODERS......................................................................................................................... 141 2.6.14.2.3.1 ABSOLUTE ENCODER UPDATE TEST................................................................................................. 142 2.6.14.2.3.2 ABSOLUTE ENCODER RESET PROCEDURES...................................................................................... 143 2.6.14.2.4 IDENTIFICATION..................................................................................................................................... 144 2.6.14.3 CONNECTION........................................................................................................................................... 145 2.6.14.4 SETUP..................................................................................................................................................... 146 2.6.14.5 TESTING .................................................................................................................................................. 146 2.6.14.5.1 DATA DISPLAY ..................................................................................................................................... 146 2.6.14.5.1.1 COMMUTATION.................................................................................................................................. 146 2.7 RESERVED....................................................................................................................................................... 148 2.8 ACCESSORIES ................................................................................................................................................. 148 2.9 PIN CONFIGURATIONS AND REFERENCE INFORMATION .................................................................................... 149

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2.10 CLEANING...................................................................................................................................................... 153 2.11 SOFTWARE INSTALLATION AND REPAIR ......................................................................................................... 154

3 TESTING AND ENCODER BACKGROUND INFORMATION ........................................................................................ 155

3.1 TERMINOLOGY................................................................................................................................................. 155 3.1.1 INCREMENTAL VERSUS ABSOLUTE............................................................................................................... 155 3.1.1.1 TRADITIONAL ABSOLUTE ........................................................................................................................... 155 3.1.1.2 TRADITIONAL INCREMENTAL ...................................................................................................................... 156 3.1.1.3 INCREMENTAL/ABSOLUTE GRAY AREAS ................................................................................................... 156 3.1.2 SERIAL VERSUS NON-SERIAL....................................................................................................................... 157 3.2 TEST THEORY.................................................................................................................................................. 158 3.2.1 INCREMENTAL ENCODER PHASE ANGLE TESTING ........................................................................................ 158 3.2.2 CHECKING AND SETTING COMMUTATION ...................................................................................................... 159

4 SPECIFICATIONS ................................................................................................................................................. 164

4.1 ELECTRICAL SPECIFICATIONS.......................................................................................................................... 164 4.2 SYSTEM DESCRIPTION..................................................................................................................................... 166

List of Figures Figure 2.1 TI-5000EX Pictorial ................................................................................................................................. 8

List of Tables Table 2.1 Main I/O Terminal Block, J1 Pin Configuration ............................................................................... 149 Table 2.2 Auxiliary I/O Terminal Block, J2 Pin Configuration........................................................................ 149 Table 2.3 Power Supply Connector, J3 Pin Configuration............................................................................. 150 Table 2.4 RS232 DCE Ports 0 and 1, J6 Pin Configuration ............................................................................ 150 Table 2.5 USB Connector, J9 Pin Configuration.............................................................................................. 150 Table 2.6 Control Connector, J10 Pin Configuration ...................................................................................... 151 Table 2.7 Can Bus Connector, J11 Pin Configuration .................................................................................... 151 Table 2.8 Resolver, J12 Pin Configuration........................................................................................................ 151

1 INTRODUCTION

1.1 OVERVIEW The TI-5000EX is a complete solution for testing and debugging feedback devices typically found on modern brushless permanent magnet servo motors. It offers users the ability to:

1. Easily perform tests on pulse based devices such as incremental encoders. 2. Easily read and display counts, speeds, and states of input pulse lines from many devices

(including encoders). 3. Easily perform tests on resolver feedback devices. 4. Run diagnostics on serial encoders.

1.2 HOW TO USE THIS MANUAL This manual is shipped with new units as a bound print version. It is also shipped on the installation CD as a PDF file. When the WinTI5000EX program is installed, the PDF file is accessible from the WinTI5000EX Help menu providing Acrobat Readers is installed on the user’s PC. This PDF copy of the manual may be copied and distributed freely among company personnel. It may be viewed on any PC equipped with Acrobat reader. This manual contains a great deal of important information pertaining to the use of the TI-5000EX and to certain topics in servo motor repair in general. We hope that it will be widely read. Section 2 of this manual describes the TI-5000EX Operation. This section will be all that many users need to effectively apply the unit in their applications. For users who need to know more specifics of how the TI-5000EX makes measurements and how details on how various feedback devices work, Section 3, 'Testing and Encoder Background Information', will be beneficial. It should not be necessary for the typical user to read Section 3, but the additional information may be helpful. The first part of Section 3 covers terminology, and that is recommended reading due to the confusing terminology in use with encoders today. Always make certain that the software revision noted on the front of this manual agrees with the revision shown on the sign-on message on the display when the unit is powered up.

TI-5000 2 INTRODUCTION

1.3 SETUP AND SOFTWARE INSTALLATION The TI-5000EX utilizes a PC for operator interface. It uses an RS232 or USB cable connected to a PC for both operator interface and downloading new software. 1.3.1 HARDWARE CONNECTIONS

The TI-5000EX unit is powered by a wall mount power supply which is supplied with the system. 1. Plug the power supply cable into the TI-5000EX power jack, J3, and plug the power supply into a

110 VAC outlet (if using 240VAC, verify that the power supply supports it). 2. Select the cable harness for the encoder to be tested. Plug the 14 pin terminal block into J1 of the

TI-5000EX (and in some cases J2 if the encoder includes commutation lines or J12 if it is a resolver). Connect the encoder into the mating connector on the other end of the harness.

3. Move the TI-5000EX power switch to the ON position to apply power to the TI-5000EX and the encoder under test.

1.3.2 SOFTWARE INSTALLATION

Note: If you have recently purchases a new unit or software upgrades or updates, please follow the instructions that were sent with the purchase. These instructions could be more recent and would supersede instructions in this manual.

A summary of the software installation is as follows:

1. The TI-5000EX includes 3 programs that are installed with the latest version at the time of purchase, so you will not normally need to load any programs into the TI-5000EX tester when it is a new purchased. A procedure is provided below for loading program upgrades and updates into your TI-5000EX at a later date.

2. You must load the WinTI5000EX program and associated software onto your PC for a new purchase.

This software is contained on the CD Rom that comes with your new system. When you update or upgrade your software, it will often only be necessary to copy the new WinTI5000EX program to your PC.

The TI-5000EX tester must communicate with the PC (desktop or notebook) that is to be used as the operator interface. WinTI5000EX.exe is the operator interface program that runs on the PC. Communications between the tester unit and the PC are accomplished using a PC COM port. The COM port can be either a real RS232 COM port or a USB Virtual COM port. If an RS232 COM port is used, the TI-5000EX must be connected to the female DB9 connector on the PC using the blue RS232 ribbon cable supplied with the tester. In either case, when WinTI5000EX is started, you must go to the System Setup menu and select the COM port that you have decided to use (COM1, COM2, COM3, etc.). This should only be necessary one time, and the configuration file will remember the selection when the program is started in the future. If you communicate between the PC and the TI-5000EX tester using the USB port (rather than the RS232 port), you will need to install the USB drivers onto your PC using the CD Rom. A procedure below describes that installation. USB to serial converter cables are available which will plug into the PC USB port and provide you with a COM port with a female DB9 to which you can connect the blue ribbon cable. To use this device, you will need to follow the instructions that come with it for installing drivers on your PC. When you start WinTI5000EX the first time, you will need to go to the System Setup menu and select the COM port that has been assigned to the


USB to serial converter. Often you will be able to tell which COM port was assigned during the driver installation. Otherwise you can find out from the Windows Device Manager. 1.3.2.1 WINTI5000EX PC SOFTWARE INSTALLATION

1. The software can be installed by double clicking on the install.bat file on the CD. It will install the TI-

5000EX files in a folder called TI5000EX. It will not affect your present TI-5000 installation at all. You can have both systems installed and run either one, but you cannot run both at the same time.

2. WinTI5000EX may have issues when changing logged in users on PCs running Windows XP Pro. To avoid problems with more than one user, copy the TI5000EX folder from the root directory (where it is installed by install.bat) to the Shared Documents folder. This seems to allow access by all users.

1.3.2.2 PC USB DRIVER INSTALLATION

The TI-5000EX has its own USB port which can be set up as a USB Virtual COM port. This is probably the simplest way to go other than a standard RS232 serial port. For this you can use the standard USB cable that comes with your TI-5000EX, and plug one end into the PC USB port and the other end into the TI-5000EX USB port. However, the first time you make this connection you should follow the sequence below for installing the USB drivers This is the sequence for Windows XP. Other versions of Windows may differ somewhat, but they should be close to this.

1. Make sure that the latest distribution files are located on your PC in the folder: C:\TI5000EX. If not, then perform the installation to put them there.

2. Plug the USB cable into the TI-5000EX and into the USB port that you wish to use on the PC, and power up the TI-5000EX.

3. The Found New Hardware Wizard window should open up. “Can Windows connect to Windows

Update to search for software?”. Click “No, not this time” and then click the Next button. 4. The next window will say “What do you want the wizard to do?”. Click on “Install from a list or specific

location (Advanced).” And then click the Next button. 5. In the next window, click on “Search for best driver in these locations.” Then check the box beneath it

labeled “Include this location in the search:”. Then click on the Browse button beneath the check box, and navigate to the C:\TI5000EX folder and click on the TI5000EX_USB_DriverInstaller within it. This is the folder that contains the drivers to be installed. Click OK in the browse window and then click the Next button.

6. A window will pop up that says “Please wait while the wizard installs the software…”. Then another

window will pop us that says: “The software you are installing for this hardware: TI5000EX USB Composite Device has not passed Windows logo testing…”. Click on the Continue Anway button. Wait for the installation to complete, and another window will pop up saying: The wizard has finished installing the software for: TI5000EX USB Composite Device”. This will indicate that this phase of the installation has completed.


Note: The Silabs drivers used for this USB device actually have passed the Windows Logo testing. However, because the USB device in your TI-5000EX uses the Mitchell Electronics, Inc. product identification number (PID), Windows does not recognize the drivers as Silabs.

7. Click the Finish button, and the wizard will disappear. However another new hardware wizard will quickly appear. This is normal because there are two sets of drivers to be installed. Simply repeat steps 3 through 6 again to install the next set of files. When it is finished, the last window will say: “The wizard has finished installing the software for: TI-5000EX USB to UART Bridge Controller”. This will indicate that the installation is complete. Click the Finish button to terminate the wizard.

As described above for the USB to RS232 converter, you will need to select the correct COM port in the System Setup menu. You can use the Windows Device Manager (as described above) to determine the correct COM port. The Device Manager will identify the TI-5000EX device. For example, if you see “TI-5000EX USB to UART Bridge Controller (COM7)”, then you would select COM7 in the WinTI5000EX System Setup menu. The USB port will now be used to communicate with your TI-5000EX in the same way as a conventional RS232 port. You will use it during testing, as well as when downloading new software to your TI-5000EX unit. The USB port in the TI-5000EX is powered by the USB rather than the TI-5000 power supply. This allows you to power down the TI-5000EX without losing the USB connection. Often you will wish to power down the unit when connecting encoders, etc. As long as you do not disconnect the USB cable, the USB port will remain connected. If you need to disconnect the USB port, you should first exit the WinTI5000EX software and power down the TI-5000EX. 1.3.2.3 DOWNLOAD PROGRAMS TO THE TI-5000EX USING WINTI5000EX

New purchases come with the TI-5000EX application program already installed, so this step is not normally necessary. However this section describes how future updates and upgrades can easily be downloaded to the TI-5000EX using the WinTI5000EX downloader function. WinTI5000EX is the Windows based interface for the TI-5000EX encoder test system. It is the program that you run on your PC whenever you use your TI-5000EX tester. To download your program using the WinTI5000EX downloader, the following steps should be followed:

1. Connect the RS232 or USB cable from the TI-5000EX to the PC in the normal manner (it is probably already connected as a result of your day to day use).

2. Insert the upgrade media in to the appropriate drive on the PC (diskette into floppy disk drive A: or CD

ROM into the CD ROM drive) so that you can locate the new file to download. If the new file came via email or internet download, just insure that you can find it in whichever folder it is located on your PC. An example of a filename would be: “TI-5000_010008_000F000000000000.s”. It will start with “TI-5000” and end in “.s”

3. Start WinTI5000EX in the normal manner (using shortcut on desktop or double clicking on

WinTI5000EX.exe from Windows Explorer or MyComputer).

4. Click on System Setup on the Menu Bar, and then click on the Download TI-5000EX Software tab. Follow the instructions in the Instructions/Comments box.

The first instruction will be to select the file to download. This is done by pressing the Select File button. Select the floppy drive A:, CD Rom drive, or appropriate folder as discussed in 2. above, and continue until you find the file that you wish to download. Click on the filename to highlight it and select it. Press OK after the correct file is selected.


The program will next prompt you to click on the Start Download button.

After clicking the Start Download button, you will be prompted to make sure the RS232 cable is connected, turn the TI-5000EX OFF (if it is not already OFF), and then to turn the TI-5000EX unit back ON.

As the board powers up, the downloading begins, and a new prompt appears telling you to wait for the code to download. A progress bar will appear to indicate the progress in the download operation. A Download Completed Successfully box will appear when the download is complete. Press the OK button on this message box.

5. Exit WinTI5000EX and power down the TI-5000EX. Power up the TI-5000EX and restart

WinTI5000EX. Go to the WinTI5000EX System Setup menu and check for the correct version number. Check the Currently Licensed Options frame to make sure that any new encoder support appears in the list. Also make sure that all of your previously licensed options still appear in the list. If the licensed options are incorrect, contact the factory for support.

If the unit does not come up properly, repeat the download procedure. If the unit still does not come up properly, call for factory support.

1.4 NEW IN THIS RELEASE Please see the document accompanying this software release for a description of this and previous version updates. 1.5 OPTIONS Numerous cable and other options are available for the TI-5000EX. Please refer to the current price list for a complete listing of these options.


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TI-5000 7 OPERATION 2 OPERATION

This device has various modes of operation. The Main Menu is used to select the desired mode. When connecting an encoder to the TI-5000EX, go to the Main Menu and switch off the power (using the slide switch, SW1, on the side of the TI-5000EX). Make the connection to the encoder, and switch the power back on. Testing for various encoders follows 3 easy steps.

1. Using the Select Feedback button, select the correct encoder type from the various encoder selections supported by the TI-5000EX.

2. Click on the Data Display test button to determine whether the encoder is providing any data output

at all, determine whether the count is changing by approximately the correct amount as indicated by the feedback selection, and determine for serial encoders whether any error bits are in the alarm state.

3. For serial encoders, proceed to the Serial Count Test to more accurately determine whether the

correct number of counts per revolution is occurring. For quadrature pulse encoders, the Line Level Test, Incremental Count Test, and Phase Angle Test may be performed for further confirmation.

The following sections will provide more detailed information as to how to test various feedback types including incremental encoders, serial encoders, and resolvers.

TI-5000 8 OPERATION

Figure 2.1 TI-5000EX Pictorial

TI-5000 9 OPERATION 2.1 BASIC OPERATION The TI-5000EX operation is controlled by test and setup buttons on the WinTI5000EX windows operator interface display. The tests are selected via the test buttons across the top of the display. The device to be tested and various testing options are selected via the Select Feedback button. Setup options for WinTI5000EX may be accessed via the System Setup Menu at the top of the screen. Various other buttons are available for test control, reporting, information, etc. during the course of the various tests. 2.1.1 HELP

The Help Menu will provide general help for the particular test currently selected. Tool Tip Text Help is available on any display by using the PC mouse to move the pointer over the button or data box in question. After a short delay, the text will appear near the pointer describing the use of the particular Windows control (button, text box, etc.) of interest. This is a very quick way to get help without having to go to the main help or the manual. 2.1.2 MENUS

The menus are selectable at the very top of the screen. The currently available menus are Test and Motor Repair, System Setup, and Help. These will be described below. 2.1.2.1 TEST AND MOTOR REPAIR MENU This menu allows selection of the Data Display, Line Levels, Count Test, Continuous Count Test, Phase Test, and Memory Test. Each of these functions is also accessible by the buttons of the same name. Since the buttons will be the more common method of accessing these functions, they will be discussed below with the appropriate buttons. 2.1.2.2 SYSTEM SETUP MENU This menu shows you the current setup for your TI-5000EX system, and allows you to make certain system selections. The window is organized in 3 tabs: System/Data, User Options, and Download TI-5000EX Software). 2.1.2.2.1 SYSTEM DATA TAB The System Data Tab allows you to see the current software version numbers and dates in the Software Versions frame, identify (and change if desired) the currently selected COM port in the Serial Ports frame, and identify the currently licensed software options for your system in the Currently Licensed Options frame. The Software Versions frame shows the serial number for your TI-5000EX unit. You will need to know this number when purchasing software upgrades because the application software will run correctly only on the correctly serial numbered unit. This serial number is read from the TI-5000EX unit, so you will need to have the RS232/USB cable connected and the unit powered up in order for this data to display correctly. The WinTI5000EX version number and date refer to the WinTI5000EX program that is currently installed on your PC and that you are using at the time you read this data. The TI-5000EX Flash version number and date refer to the application program that is running inside your TI-5000EX unit. You will need to download a new program to your TI-5000EX when you receive a program update or when you purchase a program upgrade

TI-5000 10 OPERATION to add new support options to your system. The Boot Flash and Resolver programs are system programs running inside your TI-5000EX unit. If these programs need to be updated, you will need to return your unit to the factory. The PC COM port to be used to communicate with the TI-5000EX tester hardware is selectable from COM1 through COM16 via the Select COM dropdown menu. This selection includes real COM ports and virtual COM ports supported via the USB port. Normally a real COM port will be mapped in as COM1 or COM2. Virtual COM ports will often start at COM4. You will likely need to use the Windows Device Manager to see which COM Ports are available to the WinTI5000EX program. You must select one of the COM ports that is shown in the device manager, and that port cannot be in use by any other programs. For Windows XP and above, WinTI5000 denotes COM ports that are available with and asterisk ‘*’. You should try selecting one of these COM ports first because they are most likely to be correct. Also note that, if you are using USB, the USB cable must be plugged into the TI-5000EX and the USB drivers already installed in order for the USB COM ports to show up with as asterisk. 2.1.2.2.2 USER OPTIONS TAB This allows a short text file to be created that will show up in reports. 2.1.2.2.3 DOWNLOAD TI-5000EX SOFTWARE TAB This menu allows downloading a new TI-5000EX Flash application file. See Section 1.3 for details 2.1.2.3 HELP MENU The Help Menu provides selections: Help and About. The About selection provides support information for the program. The View Manual selection allows you to view the PDF version of the TI-5000EX manual providing that a copy is residing in your TI-5000 folder (or wherever your WinTI5000EX.exe is installed) and Adobe Acrobat Reader is installed on your PC. If you do not have Acrobat Reader, it can be downloaded via the internet from http://www.adobe.com . The View Cables selection allows you to view the PDF cable sheets for the cables supplied by Mitchell Electronics, Inc. from a CablePDF folder residing in your TI-5000 folder (or wherever your WinTI5000EX.exe is installed). An Adobe Acrobat Reader must be installed on your PC. If you do not have Acrobat Reader, it can be downloaded via the internet from http://www.adobe.com . The Help selections will display Help files to help you use the WinTI5000EX system. Tool Tip Help Text is now available for most button and data box controls. Even though this is not part of the Help Menu, it is a very good way to get help with the WinTI5000EX program. Just move the mouse pointer over the button or data box of interest. After a .5 second delay, help text should appear on the screen near the mouse pointer. After 5 or 6 seconds it will disappear. If you are not finished reading it, move the pointer away from the button or text box and then back to it, and the help text will reappear.

TI-5000 11 OPERATION 2.1.3 TEST BUTTONS

The Test buttons are located just below the menus. These buttons allow execution of the various tests: Data Display, Line Levels, Count Test, Continuous Count Test, Phase Test, and Memory Test. Depending on the feedback selections only some of these buttons will be available. Buttons which are not applicable to a particular selected feedback device will be disabled. The Exit to Windows button is not a test but is included with this group. It allows you to shut down the WinTI5000EX program and return to the Windows operating system. 2.1.3.1 DATA DISPLAY BUTTON Data Display is selected to read an encoder signal and display the count, commutation states and other information. The details for the Data Display vary with the particular encoder, so read the section that applies to the particular encoder or family of encoders for details. 2.1.3.2 LINE LEVELS BUTTON Line Level Check provides for measuring the proper incremental encoder output voltages over a 0 to 14.9 volt range. Warning: Voltages above15.0 VDC may damage the TI-5000EX input circuitry. Measurement of serial encoder outputs is not implemented at this time. See the section on incremental encoders for further details. 2.1.3.3 COUNT TEST BUTTON The Count Test will verify that the encoder is incrementing the correct number of counts per revolution while turning the encoder slowly by hand. This test is the only count test implemented for serial encoders. Refer to the section on a particular encoder or family of encoders for further details. 2.1.3.4 CONTINUOUS COUNT TEST BUTTON The Continuous Count Test will verify that the incremental encoder is incrementing the correct number of counts per revolution for a large number of turns and may be conducted at high speeds. The Continuous Count Test is available only for incremental encoders. It lets the operator ensure that the correct number of counts occur from one index pulse to the next. This test may be run continuously without operator interaction to check for an accumulated error. Refer to the section on incremental encoders for more details. 2.1.3.5 PHASE TEST BUTTON The Phase Test is only available for incremental encoders. This test will measure and display the phase angle from the rising edge of A to the rising edge of B. It will also measure A and B symmetry angles from the rising edge to falling edge of a particular pulse (A or B respectively). See Section 3.2.1 for more discussion on this topic.

TI-5000 12 OPERATION 2.1.3.6 MEMORY TEST BUTTON

The Memory Test is only used with certain serial encoders which include memory in the encoder and which are currently supported by the system. Memory Test software licensing will be required to conduct memory tests on these encoders. 2.1.4 MISCELLANEOUS BUTTONS

Depending on the Test that is currently selected using the test buttons, just described, various other buttons will appear on the current test screen. These buttons are discussed in the following sections. Please note that all the buttons discussed may not appear in all of the test screens. 2.1.4.1 SELECT FEEDBACK BUTTON The Select Feedback button allows selection of feedback manufacturer and type along with setting up various parameters that may apply to the various types of feedback that you will be testing. The selection window can be accessed by pressing the Select Feedback button. This button is available from within most tests, and the various selections available on this window are discussed below. 2.1.4.1.1 ENCODER/RESOLVER RADIO BUTTONS The Select Feedback Window includes a Select Encoder frame and a Select Resolver frame. Each of these frames includes a radio button that determines whether an encoder or resolver is to be selected for testing. Note that the radio buttons are shaded pale blue indicating that they are a Windows control that allows a user selection entry. If the Encoder Feedback radio button is selected, the various selections options for encoder feedback, such as manufacturer and type, are enabled and available to the user. If the Resolver Feedback radio button is selected, no further setup is done in the setup window. Additional setup will be done in the Data Display test window. The Data Display is the only test available for resolvers. 2.1.4.1.2 ENCODER MANUFACTURER MENU The first step in encoder feedback selection is to select the encoder manufacturer. This is done using the Encoder Manufacturer dropdown menu. Note that this menu is shaded pale blue to indicate that it is a control that allows user selection entry. Incremental and parallel absolute encoders are so similar regardless of manufacturer, that it generally is not helpful to specify a manufacturer. Instead these types of encoders are selected as a generic type: Generic Incremental Encoder or Generic Parallel Absolute Encoder in the dropdown menu for the manufacturer. The properties of serial encoders are very specific to different manufacturers, so it is necessary to select a particular manufacturer when serial encoders are in use. The menu lists all manufacturers supported by the current software revision so that the user can easily determine which manufacturers are currently supported. However, even though a manufacturer appears in the list, that manufacturer is supported on a given unit only if the unit is licensed for that manufacturer. That can be determined from the System Setup menu. If a manufacturer is not licensed, a message box will pop up during the selection warning that the support license must be purchased before the selection will be available.

TI-5000 13 OPERATION 2.1.4.1.3 ENCODER TYPE MENU When the encoder manufacturer selection has been made, the encoder type can then be selected using the Encoder Type dropdown menu. The contents of this menu are completely dependent upon the encoder manufacturer that has been selected. If the manufacturer selection is Generic Incremental Encoder, the type will default to AB Quadrature and the Type control will be disabled since there is currently no other valid choice. If the selection is Generic Parallel Absolute, the Encoder Type Menu defaults to the one and only selection of 10 Bits Various Formats. For encoder manufacturer name selection (such as Fanuc, Mitsubishi, etc.), the Encoder Type menu will contain the various types of serial encoders that are supported for the selected manufacturer. The user must select the encoder type corresponding to the particular encoder that he wishes to test. 2.1.4.1.4 MOTOR MANUFACTURER (MEMORY) MENU Modern serial encoders are increasingly making use of memory. The encoder memory is typically used to store motor parameters and sometimes even commutation information. This information may be read from the encoder by the drive when the drive powers up so that the drive knows exactly what kind of motor is connected to it. Since this information is essential to the drive, this information must be intact and readable for the motor to function properly on the drive. The TI-5000EX support is being expanded to support checkout of this memory data to the greatest extent possible. If motor alignment data is included in the memory, this data is translated into static alignment lockup angles when possible. The details of the memory storage vary greatly from one motor manufacturer to the next. Even though two manufacturers may be using the same Stegmann Hiperface or Heidenhain Endat encoder, the way data is stored in the memory will generally be completely different. Therefore the Memory selection is based on Motor Manufacturer rather than encoder type. Manufacturers who use a particular brand of encoder will be shown when that encoder has been selected. This selection will be disabled for encoders that do not include memory. 2.1.4.1.5 COUNTS PER REVOLUTION BUTTON The Counts Per Revolution button is disabled for all serial encoders. Serial encoders automatically select the correct counts per revolution when the type is selected. The button will be enabled for Generic Incremental Encoder selection. The user should enter the number of counts per revolution expected from the encoder under test. This will be four times the number of pulses per revolutions (PPR) or number of lines per revolution. If you do not know the correct number to enter, either use your best guess or let it default to a selection. When you run a Count Test, the correct number will be determined by the test and can be entered at that time. Any number below 10,000,000 will be accepted by the software. However, the correct number will be evenly divisible by 4 since the counts per revolution value is always 4 times the number of pulses per revolution. The number of counts per revolution must be correct in order for the Mechanical Angle and Electrical Angle in the Data Display test to display correctly.

TI-5000 14 OPERATION 2.1.4.2 DISPLAY PINOUT BUTTON The Display Pinout button is available from all tests, and it will bring up a window containing the J1 and J2 terminal block pin designations for quick reference. 2.1.4.3 SAVE REPORT TO FILE BUTTON The Save Report to File button is available from all tests, and it will allow saving a report of the current test results to a disk file. It will bring up a window that allows a comment line to be specified for the report. If no comment is desired, simply click the OK button on the window. After the comment window, a file selection window will appear in which the filename and path may be specified for the report file. The report will then be saved to the specified file. 2.1.4.4 PRINT REPORT BUTTON The Print Report button is available from all tests, and it will allow a report for the current test to be sent directly to a printer for printing rather than storing on a disk file. 2.1.4.5 POLES MENU The Poles Menu is selectable in the Data Display test. This control allows you to change the number of poles for the motor associated with the selected feedback. The number of poles (and counts per revolution) must be correct in order for the electrical angle to display correctly in the Data Display test. This angle must be correct if it is to be used for feedback alignment purposes. Pole selections of 2 – 8 are allowed for Indramat motors (although 6 and 8 poles are the only numbers we have encountered). Pole selections of 2 – 16 are allowed for Heidenhain Endat and Stegman Hiperface encoders. All other encoder selections allow pole selections of 2 – 36.

TI-5000 15 OPERATION 2.2 SERIAL ENCODER GENERAL INFORMATION Serial encoders are encoders which provide the position count and/or other information (such as error detection bits, overheat bits, etc.) as a serial data stream to the drive or other external electronics. This serial data is somewhat similar to data from your PC RS232 port, your PC network, etc. The encoder normally maintains the count and other information internally, and transmits the resulting data in a serial format which is typically proprietary to the encoder manufacturer. Some encoders provide both serial data output and quadrature pulse output. For thorough testing, these encoders should be tested as both serial and quadrature pulse incremental encoders. Examples of this would be the Sumtak, Sanyo Denki, and Heidenhain Endat encoders. Please refer Section to 2.6 Manufacturer Specific Encoder Details for more information on this topic. 2.2.1 DATA DISPLAY

Data Display is selected to read an input pulse signal and display the count and other information. The Data Display format will vary depending upon the encoder manufacturer. Some manufacturers include more data in the serial data stream than do others. The display format for Fanuc Alpha I serial encoders is shown below as an example.

2.2.1.1 ENCODER SELECTION The Encoder Selection frame displays the current selection which is Fanuc Serial Pulsecoder Alpha I64 (8 pole), with 65,536 counts per revolution. Normally either a TI-5005 (or TI-5005W, depending on the keying)

TI-5000 16 OPERATION or TI-5006 cable would be used with this encoder depending upon whether it used a 17 pin circular or DB15 connector respectively. 2.2.1.2 COMMUTATION The commutation frame provides information that can be used to set and check encoder commutation alignment for permanent magnet brushless servo motors. The C1, C2, C4 and C8 boxes show the commutation gray code pulses that are commonly used to indicate commutation position for Fanuc encoders. However the next two boxes indicate the position in terms of mechanical and electrical degrees, and this is usually a more accurate measurement to apply to commutation. To the right of the Electrical Angle box is the setting for Poles. It is disabled and set to 8 poles for this Fanuc motor. Because this motor has 8 poles (4 pole pairs), the commutation pattern will repeat 4 times in one revolution of the motor shaft. This means that the commutation gray code bits will go through the same sequence 4 times per revolution. Likewise, the electrical angle reading will go through 360 degrees 4 times in one revolution. Checking the commutation by static lockup of the rotor (applying a DC test voltage to the armature winding to lock the rotor in a specified position) will result in the same commutation gray code or electrical angle reading at all 4 lockup positions (within a close tolerance). Notes are available from Mitchell Electronics, Inc. with procedures that describe checking and setting commutation for many kinds of brushless PM servo motors. The information described above is shown in the Data Display for a Fanuc Alpha A64 which is communicating properly as shown in the figure below.

TI-5000 17 OPERATION 2.2.1.3 POSITION COUNT The Count frame shows the position count in Decimal and HEX (hexadecimal). An initial check to make is to verify that the encoder count changes by approximately the correct number of counts per revolution when the shaft is rotated approximately one revolution. This count display can be used for that purpose. 2.2.1.4 ENCODER STATUS The Encoder Status frame shows information that helps determine whether the encoder is working properly. The first box is labeled INDEX. It will show OK if the encoder has been turned to the position where it will index the count to zero, and it will show ALARM it is has not. This Alpha A64 does need to be indexed, but many other serial encoders do not need to be indexed. They produce the correct position count immediately upon power up with no need to index. For these encoders, this box will be disabled. The next box labeled DATA will indicate RECEIVING if the encoder is communicating properly with the TI-5000EX, and it will indicate NONE if it is not (as seen in the first figure above). An encoder not communicating may be the result of a bad cable or possibly a bad encoder. Nothing can be done with an encoder until the problem has been corrected, if indeed it can be corrected. The next column, labeled Internal Error should read OK indicating no internal error indication in the data. If it reads ALARM, then the encoder is indicating that it has detected an internal error, and normally the resulting data is not dependable. An internal error would cause a drive fault in most cases. This usually requires an encoder repair or replacement to correct. This field may not be in effect for all serial encoders.

The next column, with the heading BATTERY ALARM, will show ALARM if there is a battery error alarm and OK if there is not. It is often possible to alternately connect and disconnect a battery voltage to the encoder to verify that this bit is working properly. This field may not be in effect for all serial encoders. The box labeled OVERHEAT, will show ALARM if there is an overheat error alarm and OK if there is not. It is often possible to alternately connect and disconnect thermal lines to the encoder to verify that this bit is working properly This field may not be in effect for all serial encoders. The box labeled ENCODER ID will show the type of encoder detected by the tester for brands of encoders that provide encoder identification information in the serial data. For encoders that do not indicate identification (or identification is not supported by the TI-5000EX software), this field will be disabled.

TI-5000 18 OPERATION 2.2.2 COUNT TEST

The count test will verify that the encoder is incrementing the correct number of counts per revolution. It works basically the same way for incremental encoders as it does for serial encoders as described in a previous section. The Count Test must be run by turning the encoder slowly by hand. In addition to checking for the correct number of counts/rev, this test checks for “stuck bits”. For testing to be as complete as possible, some of the fundamental differences in quadrature pulse incremental encoders and serial absolute encoders require the testing to be done differently. Quadrature pulse encoders do not actually count. They simply produce pulses, and external electronic circuitry does the counting correctly if the encoder produces the pulses correctly. Testing for incremental encoders relies heavily on testing for the correct number of pulse edges per revolution. Absolute encoders produce a bit pattern to represent the angle. This bit pattern may be produced by internal counting, by absolute tracks on the code wheel, by interpolation of those tracks, or some combination of these things. The possibility exists for an absolute encoder to produce the correct count bit pattern at the end of each revolution but not show some intermediate angles correctly due to bits not changing properly. One or more bits never changing during a revolution would represent such a problem. The Stuck Bit test checks to make sure that each bit used to represent the angle in one revolution does actually change states during the revolution. The Count Test is performed by slowly rotating the encoder by hand through 4 or more revolutions until the box at the bottoms indicates Test Completed. The data in the results boxes will indicate how close to the exact number of counts per revolution were registered, whether any bits failed to change state during a particular revolution (stuck bits), and whether any internal errors were detected during a particular revolution. The data boxes are described in detail below.

TI-5000 19 OPERATION 2.2.2.1 REVOLUTION Each row on the display contains the results of the test for one revolution. The revolution box shows which revolution the test is on at any time during the test. After 4 revolutions, the test is complete. It is a good practice to re-run the test turning the encoder in the opposite direction, but the encoder must be turned in only one direction in each individual test. Changing directions during a test will cause the test to fail. Running the test several times may uncover a problem if the problem is intermittent. 2.2.2.2 COUNT The actual count at the end of each revolution is displayed in the Count box. Ideally this number should increase each time by the number of counts per revolution for the encoder. Due to time delays in receiving the data packet from the encoder, the error is seldom zero. The higher the encoder resolution and the faster it is turned, the higher the error will be. Turning the encoder as slowly as possible gives the best results. Serial encoders that are counting incorrectly normally show large errors, so any error below 500 is considered good. See the section below on the ERROR field for more information. 2.2.2.3 TARGET The Target box provides the target count which would ideally be registered at the end of each revolution. It is against this target that the actual count is compared. 2.2.2.4 ERROR The Error box displays the difference in the data in the Count box minus the Data in the Target box. Since the target count is what we expect and the actual count is what we got, the difference is going to be the error. Due to differences in how that Count Test is performed for incremental encoders and serial encoders, the error is quite different. For incremental encoders, the error for a good encoder should not be more than ±2. For serial encoders, there is a time lag for the data to be transmitted from the encoder and received and interpreted by the tester. This time lag causes a measurement error for serial encoders. This error will be larger for high resolution encoders that are turned quickly, and it will be smallest for low resolution encoders that are turned very slowly. Normally serial encoders that have counting problems will have very large errors, so the error limit to indicate faulty counting is set at 500 counts/rev. 2.2.2.5 COUNT/REV The box called Counts/Rev is the difference between the count at the end of the current revolution and the count at the end of the last revolution. Ideally this should be equal to the number of counts per revolution of the encoder. For incremental encoders, it will usually be within ±2. For incremental encoders, it is useful in determining the number of counts/rev of an encoder for which you have no specifications. 2.2.2.6 STUCK BITS During the count test, the tester checks to make sure that all the bits that are active in one revolution (or at least the first 16 bits for encoders with more than 16 bit resolution) change state at least once during the revolution. If they do, the data in the box shows OK. If a bit does not change states, it is determined to be a

TI-5000 20 OPERATION “stuck bit”. Stuck bits are identified by a ‘1’ in the position of the bit that was stuck, while bits which checked out OK are designated by a ‘0’ in those positions. The bits are displayed in groups of 4 with bits 15 to 12 on the left and 3 to 0 on the right. For instance, the following bit pattern would indicate bit 13 as a stuck bit: 0010 0000 0000 0000 This error was generated by selecting a Mitsubishi OSA14 (14 bit encoder) and actually using an OBA13 (13 bit encoder) during the test. The test expected bit13 to change, but only bits 0-12 change for an OBA13. This means that you should check your setup to make sure you have selected the correct encoder if you encounter stuck bits. 2.2.2.7 INTERNAL ERROR As described in the section on Data Display, many serial encoders include an internal error bit in the serial stream that they transmit to the receiving electronics. Typically a HI error bit will indicate that some self test within the encoder has uncovered an error. The exact meaning of this event depends entirely on the specific encoder and you would need to read information on that encoder to understand the significance. In the Data Display window, the Internal Error box will show ALARM whenever the tester receives data with the error bit HI, but it will go back to displaying OK if the error bit is received LO. It is not uncommon for this bit to be HI only part of the time when there is a problem. This means that it may be difficult to actually catch the bit HI in Data Display. For that reason, during the Count Test the internal error bit is latched HI for a particular revolution if it ever appears HI during that revolution. That means that it will show up with ALARM in the box if it ever went HI during that revolution even if it cleared itself during the revolution. This latching of data keeps you from missing the fact that the internal error alarmed.

TI-5000 21 OPERATION 2.3 GENERIC INCREMENTAL QUADRATURE PULSE ENCODERS Generic incremental quadrature pulse encoders are extremely common on servo motors, and this selection supports their testing on the TI-5000EX. Hall effect devices were very commonly used on early brushless permanent magnet servo motors, and this selection also supports looking at Hall effect line states for static alignment and diagnostics. 2.3.1 DESCRIPTION

Quadrature pulse encoders generate an A and B pulse which are 90 degrees out of phase with each other. These encoders are usually used with external counting circuitry which counts either the pulses or the edges. The resulting count increments or decrements depending upon the direction of rotation since the rotation direction determines whether the A pulse will lead or lag the B pulse. Quadrature pulse encoders have traditionally been referred to as incremental encoders. However, since some manufacturers are now using the terms incremental and absolute to mean something else entirely, in this manual we will call these encoders "Quadrature Pulse" to reduce confusion. When testing these encoders, select “Generic Incremental Encoder” from the Encoder Feedback menu of the Select Feedback window which appears after pressing the Select Feedback button (see previous sections on Basic Operation). Many encoders currently used with servo motors are quadrature pulse encoders. Furthermore, several serial encoders also include a quadrature pulse section. Examples of this would be the Sumtak, Sanyo Denki, and Heidenhain Endat encoders. Thoroughly testing these encoders generally requires testing the serial section by choosing the correct serial model selection and testing the quadrature pulse section by selecting an incremental encoder with the correct number of counts per revolution. Please refer to Section 2.6 Manufacturer Specific Encoder Details for more information on this topic. Besides quadrature pulse, there are encoders that are single channel or single channel with an index (i.e.: they provide only an A line or an A and Z line). These encoders are often used as tachometers to provide a pulse rate proportional to RPM. Technically these encoders cannot be called quadrature pulse because they do not have two pulses that are 90 degrees apart. This also means that they cannot indicate direction. They will increment the count in either direction. In industrial counting systems, another type of pulse called A Count B Direction may be encountered. With this type of pulse, each pulse on the A line will increment or decrement the count by 1 depending upon whether the state of the B Direction line is HI or LO respectively. Stepper motor indexers commonly utilize this type of pulse. The single channel and A count B direction signals are not supported by the current software revision of the TI-5000EX. 2.3.2 CONNECTION

The generic incremental quadrature pulse encoder will have A, B, and Z lines (often both true and complement lines for each) which must be connected to J1 as indicated by the J1 pin configuration in Table 2.1. It will have a 0V common power supply line that must be connected to J1 pin 2. If it operates from 5 VDC power, the 5V line must be connected to J1 pin 1. If it uses something other than 5 V, it may be powered by a bench power supply (if no adapter module for the TI-5000EX is available for it). The + power supply line from the encoder should be connected to the + output of the bench power supply. The – power supply line should be connected to the 0V line from the encoder at J1 pin 2 of the TI-5000EX. J1 pin 1 of the TI-5000EX must not be connected when an external power supply is used. Generic incremental quadrature pulse encoders often have commutation lines (often both true and complement), U, V, and W (sometimes S1, S2, S3 and other designations) for providing startup commutation information to the servo motor drive. These lines should be connected to J2 pins in accordance with the J2 pin configuration.

TI-5000 22 OPERATION When Hall effect devices are connected to the TI-5000EX, the U, V, and W lines should be connected to J2 pins 7, 8, and 9 respectively. The 0V common power supply line to the Hall devices should be connected to J1 pin 2. If the Hall devices can be powered by 5 VDC (which they often can), the + Hall power line should be connected to J1 pin 1. If a higher voltage is required, the + Hall power line should be connected to the + output of an external bench supply. The – output of the external supply should be connected to the Hall 0V line at J1 pin 2. J1 pin 1 must not be connected when an external supply is used or the TI-5000EX may be damaged. 2.3.3 SETUP

Rather than repeat the function of the various test keys in this section, the reader is referred to the discussion of the Data Display, Line Level Test, Count Test and Continuous Count Test buttons previously discussed in Section 2.1.3. 2.3.4 TESTING

Generic Incremental Encoders incorporate Data Display, Line Levels, Incremental Count Test, and Phase Test for a complete test sequence. 2.3.5 DATA DISPLAY

Data Display is selected by clicking the Data Display button to read A, B, and Z line states and the count accumulated by the transitioning of these lines in a quadrature pulse pattern. The following figure shows the Data Display for Generic Incremental Encoders.

TI-5000 23 OPERATION 2.3.5.1 COMMUTATION The commutation information usually appears in the commutation frame, but it really depends upon whether the encoder utilizes sine/cosine commutation. Only a few encoders employ the sine cosine commutation output. The two types of commutation currently displayed are discussed in the next two sections. Clicking on the Sine/Cosine Commutation radio button will change to display to better show the sine/cosine commutation. Clicking on the Normal Commutation radio button will change it back. 2.3.5.1.1 NORMAL COMMUTATION The normal commutation display automatically appears as the default when first entering Data Display, and it will display commutation in the Commutation frame. The boxes with headings H1, H2, H3, H4, H5, and H6 display the states of the lines connected to J2 pins 7, 8, 9, 10, 11, and 12 respectively. This display is used to display the commutation states of both Hall effect switches and encoder commutation lines. Any line that is not connected will show up as ‘H’ since the line is pulled to a HI state by internal pull-up resistors. When using Hall effect outputs, the complement lines often do not exist, so the last 3 outputs will be HI all the time. Just ignore any parts of the display that are not being used. When complement lines are in use, it is important to verify that the true and complement lines are in the opposite states at all times. In any case, it is important that the encoder provide the commutation states in the correct pattern. You should rotate the encoder in the forward direction of the motor to verify the correct commutation pattern along with true and complement states. The Table below shows the standard manner of connecting commutation signals to the J2 connector and indicates under which heading the line state information appears. The table also indicates the standard commutation pattern that you should expect to see. You are free to connect commutation lines in other ways if you prefer. This is the way test cables from Mitchell Electronics, Inc. will be wired because this is compatible with the TI-3000 Run Test System. This commutation pattern will repeat as many times in one motor revolution as there are pole pairs. In other words, this pattern will repeat 4 times on an 8 pole motor. Signal U V W U* V* W* Heading 1 2 3 4 5 6 Pin 7 8 9 10 11 12 H L L L H H H H L L L H L H L H L H L H H H L L L L H H H L H L H L H L The practical use for the commutation line states is for “setting the commutation” or aligning the encoder so that the commutation line pattern is synchronized with position of the rotor magnets relative to the stator armature windings. This can usually be easily verified applying a small DC voltage to the armature leads to lock the rotor and observing the commutation line pattern as the shaft is wiggled slightly from the lockup position. The TI-5260 PM Rotor Lockup Switch is a very convenient and organized way to provide lockup currents to the windings for checking and setting commutation alignment.

TI-5000 24 OPERATION An example would be a Yaskawa motor with U, V, and W lines. If it is locked up with +U –V –W (sometimes called +U to neutral), it should show (in View 1) V HI, W LO, and U ready to toggle with a small wiggle of the rotor. This pattern will repeat over and over. Notice that the Z pulse is independent of the A and B pulses. For practically all encoders, the Z pulse will go HI once per revolution. The portion of the angle for which it is HI, and the states of A and B during which it is HI is very dependent upon the particular encoder manufacturer. The box labeled MECHANICAL ANGLE will display the correct mechanical angle providing the correct number of counts/revolution has been entered. The box labeled ELECTRICAL ANGLE will display the correct electrical angle providing that correct numbers have been entered for counts/revolution and number of motor poles. Currently the TI-5000EX will show a positive count when quadrature signals are received with phase A leading phase B. Many American and European motors will use encoders which have this phase relationship for CW (clockwise) rotation. For many of these same motors, the forward armature direction is also CW. In these cases the displayed electrical angle provides a very convenient way to check and set commutation. On the other hand, the forward armature direction for many Japanese motors is CCW. When turned in the CCW direction the encoder phase is often B leading A which results in a negative count. This means that the displayed electrical angle will decrease instead of increasing when the motor is turned in the forward CCW direction. While this does not rule out using the electrical angle display for commutation setting, it does make the display confusing. The TI-7000 allows the user to set the positive direction of encoder rotation, and this feature may eventually be incorporated into the TI-5000EX.

TI-5000 25 OPERATION 2.3.5.1.2 SINE COSINE COMMUTATION ENCODERS The Normal Commutation display automatically appears as the default when first entering Data Display. If you click the Sin/Cos Commutation radio button, the display will switch to the sine/cosine display shown below. Clicking on the Normal Commutation radio button will switch the display back to the normal commutation.

The C and D channel sinusoidal amplitudes are converted to an angle which is displayed in the Commutation frame under the label MECHANICAL ANGLE. This angle should change smoothly from 0 to 359 degrees in one revolution. Each ¼ turn should cause a 90 degree change in the angle. It is very similar to verifying a resolver. If the number of poles is set correctly, the electrical angle will be displayed under the label ELECTRICAL ANGLE. This is probably not too important since you will want to use the Normal Commutation display to check and set commutation. Also, if you have an encoder in which the C and D channel signals go through 360 degrees more than once, the mechanical and electrical angle interpretation will no longer be correct. This display will show the sine/cosine commutation outputs for encoders which use that type of output, such as the Heidenhain ERN1387 and RON3350 encoders used on Siemens servo motors. The TI-5010 cable is compatible with these encoders on Siemens motors. The TI-5101 1V P-P Adapter Module must be used with sine/cosine encoders in order to multiplex the C and D commutation channels into the TI-5000EX A and B channel inputs. Dipswitch #1 on the TI-5101 must be set to the closed position in order to multiplex the C and D channels properly (note: dipswitch #2 does not matter, so you can set it closed too just to make sure you have the right one). If this is not done, you will see the angle display moving through 360 degrees with a slight encoder rotation instead of a complete revolution. It should require a full revolution to move through

TI-5000 26 OPERATION 360 degrees although there may be some which go through 360 as many times as the number of pole pairs for the motor. Signal levels, interpreted as the sine and cosine of the displayed angle, are displayed in the Encoder Status frame in boxes labeled Cosine and Sine. C and D channel signal levels are displayed as voltages in the boxes labeled C-C* and D – D*. These are the differential voltages between the true and complement lines. The software takes into account the 3.48 gain through the TI-5101, so is the actual differential output voltage of the encoder. The Heidenhain specification is for the peak differential voltage to range between 0.75V p-p and 1.2V p-p. This means that you should see amplitudes in the ranges shown in the following table. The maximum, minimum and nominal values are shown. ANG C-C* Max C-C* Min C-C* Nom D-D* Max D-D* Min D-D* Nom 0 0.00 -0.37 -0.60 -0.50 90 0.60 0.37 0.50 0.00 180 0.00 0.60 0.37 0.50 270 -0.37 -0.60 -0.50 0.00 Remember you are checking the peak differential voltage, so you must move the encoder to the positions shown in the table above. Some Siemens motors may use ERN1381 and RON350 encoders. These are the same as the ERN1387 and RON3350 respectively but without the C and D channels. The models ERN1387 and RON3350 provide 8,192 counts per revolution. If the counts/rev is set to 8192, the Normal Commutation display will also show 360 per revolution in the MECHANICAL ANGLE box, and that angle will agree with the C/D channel angle. However, please note that the original TI-5000 angle reading for the C/D channels did not agree. This is due to the way the C and D channels were assigned as sine/cosine for that unit. The current TI-5000EX uses different assignments so that the C/D channel angle and the angle from the encoder count agree. The relationship between the original TI-5000 and current TI-5000EX is shown in the following table. Original TI-5000 Sin/Cos Angle TI-5000EX Sin/Cos Angle 0 90 90 180 180 270 270 0 The Siemens alignment is based on the Z pulse, so it is more accurate to use the Normal Commutation display rather than the sine/cosine angle for alignment. Also the count angle in the Normal Commutation display can be displayed as an electrical angle. The static alignment procedure is to apply lockup voltages with the polarity –U +V +W, and the electrical angle should be very close to zero degrees at each lockup position. Remember, to get the correct electrical angle, you must enter the correct number of poles. 2.3.5.2 COUNT The display shows the count accumulated by the A and B line transitions in the Count frame in the boxes labeled DECIMAL and HEX. Normally the user will be more interested in the decimal count than the hexadecimal representation. You should see counting activity when you turn the encoder. If you do not, you may have a problem with the A or B lines. Again, the Line Level Test or an oscilloscope may help in diagnosing the problem. When you rotate the encoder one revolution, the count should change by the

TI-5000 27 OPERATION number of counts per revolution specified for that encoder. If you do not have that information, it can be determined by the Count Test described in Section 2.2.2.. 2.3.5.3 RATE The Rate frame shows the encoder rate in counts/sec or RPM. The counts per second may be important when back-driving an encoder with a drive motor for determining whether it is moving too fast to perform certain tests. The RPM may be useful when back-driving a motor for checking magnet and winding integrity. In order for the RPM to read correctly, the correct number of counts/rev must have been entered into the setup. 2.3.5.4 LINE STATES The Line States frame utilizes 3 boxes with headings A, B, and Z to display the states of the A, B, and Z lines coming from the encoder. The A and B lines should change following the quadrature pulse pattern shown below when moved in the direction in which the A pulse leads the B pulse. Signal A B Z Heading A B Z J1 Pin 3 5 7 L L X H L X H H X L H X The A, B, and Z lines will often be available as both true and complements. In this case, it is important to make sure that both lines are changing as required. The Line Level check (to be discussed later) provides this information. The Incremental Count Test and Phase Angle Test further ensure that this pattern is correct and producing the correct counts. 2.3.5.5 INDEX The Encoder Status frame begins with a box labeled INDEX. This box will indicate ALARM if the encoder is not yet indexed and OK after it has been indexed. When you first enter the test, it will indicate ALARM. After you have rotated the encoder past the index pulse, it will change to OK and the count will zero out. If this does not occur, you may have a problem with the Z pulse. You can further check it out using the Line Level Test and/or an oscilloscope. You may wish to force the tester to re-index the encoder on the next index pulse. Click on the “Zero count on next index” button to accomplish this. The INDEX box will change to ALARM until the next index pulse occurs. You may also click the Data Display button to re-index.

TI-5000 28 OPERATION 2.3.6 LINE LEVELS

The Line Levels function provides for measuring the proper incremental encoder (not used on serial) output voltages over a 0 to 14.9 volt range. WARNING - Input voltages above 15 VDC may damage the TI-5000EX input circuitry. This voltage range covers many of the very common incremental encoders. If precise or high speed readings are required, a digital voltmeter or an oscilloscope can be used. However, the Line Levels function can provide a good, quick, convenient indication of the state of each output line. The Line Level Test is only available for incremental encoders. The Line Level display is shown in the following figure.

As the encoder is slowly rotated, the following items can be checked:

1. Each A, B and Z line is changing states and not sticking in the same state constantly. 2. Each A*, B*, and Z* complement line (if the encoder employs them) is changing states and is not

sticking in the same state constantly.

3. Each A*, B*, and Z* complement line is always in the opposite state from its A, B, and Z counterpart. The Z line would normally be difficult to catch in the HI state since it is high for a very short part of the entire rotation. However, the Line Level function also provides the encoder count and will zero the count on the first Z pulse encountered. The INDEXED column will show ALARM until the encoder is rotated past the Z pulse. When this occurs, the INDEXED column shows OK. At this point, if the encoder is rotated back until the count is again approximately zero, the point at which the Z line goes to the HI state can be found.

TI-5000 29 OPERATION The realtime levels should be checked to make sure they are correct voltages. The Instruction box indicates that TTL levels would be 0.8V or below for a LO level and 2.0 V or above for a HI level. If you have specifications for your encoder that show different requirements, then those specifications are what you should apply in evaluating the encoder. 2.3.6.1 REALTIME LEVELS To help ensure that each line is reaching both states, the LO state minimum and HI state maximum values are reported on the lines “LO state” and “HI state” respectively. The minimum and maximum displays are described below. As you turn it, it will pick up each state for the A, A*, B and B* lines very quickly. Again, the Z and Z* lines may not be caught so easily since the Z pulse occurs only once per revolution. If the encoder is rotated in such a way as to make the count pass through zero a number of times, you should be able to catch the Z pulse HI. The first line is the realtime line level display. It shows the present voltage from each encoder line and the encoder count relative to when it was first indexed. The voltages for the true lines are in the columns designated by A, B, Z while the complement line voltages shown in columns designated by A*, B*, Z*. The example display above shows how the real time line level display looks when the Z pulse is HI. The count is at zero, and the HI Z pulse has been found. You can see how the Count display was used to get to zero to find the Z pulse HI. 2.3.6.2 MIN LEVELS The line below the realtime levels is the minimum line level display. It shows the lowest voltage recorded for each encoder line. Every line has been shown to go to a LO state of 0.1 V. What we are looking for here is a line which has not gone to the LO state. That would indicate a problem with the encoder or cable. In the case of the Z or Z* lines, it could mean that the encoder needs to be moved more slowly through the zero count in order to pick up the state of the index line. 2.3.6.3 MAX LEVELS The line below the minimum levels is the maximum line level display. It shows the highest voltage recorded for each encoder line. All lines are 2.0 V or above which are valid HI states. This means that all lines have gone HI during our test. Again, we would be looking for a line that has never gone HI as an indication of a problem. In the case of the Z pulse, try to move as slowly as possible through the zero count so that the TI-5000EX can catch the fast moving state change of the Z pulse.

TI-5000 30 OPERATION 2.3.7 COUNT TEST

The count test will verify that the encoder is incrementing the correct number of counts per revolution. It works basically the same way for incremental encoders as it does for serial encoders as described in a previous section. The Count Test must be run by turning the encoder slowly by hand. The Continuous Count Test may be used while motoring incremental encoders at higher speeds. The Count Test is performed by slowing rotating the encoder by hand through 4 or more revolutions until the box at the bottoms indicates Test Completed. The data in the results boxes will indicate how close to the exact number of counts per revolution were registered, whether any bits failed to change state during a particular revolution (stuck bits), and whether any internal errors were detected during a particular revolution. The data boxes are described in detail below. 2.3.7.1 REVOLUTION Each row on the display contains the results of the test for one revolution. The revolution box shows which revolution the test is on at any time during the test. After 4 revolutions, the test is complete. It is a good practice to re-run the test turning the encoder in the opposite direction, but the encoder must be turned in only one direction in each individual test. Changing directions during a test will cause the test to fail. Running the test several times may uncover a problem if the problem is intermittent. Click on the Restart Test button to re-run the test. 2.3.7.2 COUNT The actual count at the end of each revolution is displayed in the Count box. Ideally this number should increase each time by the number of counts per revolution for the encoder. 2.3.7.3 TARGET The Target box provides the target count which will be registered at the end of each revolution. It is against this target that the actual count is compared. 2.3.7.4 ERROR The Error box displays the difference in the data in the Count box minus the Data in the Target box. Since the target count is what we expect and the actual count is what we got, the difference is going to be the error. Due to differences in how that Count Test is performed for incremental encoders and serial encoders, the error is quite different. For incremental encoders, the error for a good encoder should not be more than ±2. 2.3.7.5 COUNT/REV The box called Counts/Rev is the difference in the count at the end of the current revolution and the count at the end of the last revolution. Ideally this should be equal to the number of counts per revolution of the encoder. For incremental encoders, it will usually be within ±2. For incremental encoders, it is useful in determining the number of counts/rev of an encoder for which you have no specifications.

TI-5000 31 OPERATION 2.3.7.6 STUCK BITS The Stuck Bit test does not apply to incremental encoders. 2.3.7.7 INTERNAL ERROR Error information is normally transmitted by serial encoders, so the internal error field does not apply to incremental encoders.

TI-5000 32 OPERATION 2.3.8 CONTINUOUS COUNT TEST

The purpose of the Continuous Count Test, like the count test, is to ensure that the correct number of counts occur from one index pulse to the next when the encoder is rotated. Unlike the Count Test during which the encoder must be turned slowly by hand for 4 turns, this test may be run at high speed for many revolutions. The encoder may be rotated by hand, or it may be driven by the motor. Also unlike the Count Test, it is unaffected by changes in direction, so it can be run while an incremental encoder is in use on a machine. The Continuous Count Test is available only for the incremental encoder selection.

Like the Count Test, the Continuous Count Test compares the actual number of counts received at each index pulse to the target number of counts. The Revolution box shows 10 revolutions, and since this encoder is 32,768 counts per revolution, we know that the target number of counts after 10 revolutions would be 327,680 which is the number showing in the target box. The Count box shows that 327,680 counts have been received, and the Error box shows 0 which would be the number in the Count box minus the number in the Target box. This would be a perfect result after 10 revolutions. Due to the update rate of the display, you may not see every revolution reported as the RPM increases. This is not a problem as the tester is keeping track of the revolutions even though there is not time to display them all. The TI-5000EX Continuous Count Test can continue to function with a change in encoder rotation direction. This is very helpful in testing an encoder while it is actually running on a machine. On direction change, this test may show an error if the index pulse is very wide in terms of pulses on the A or B channel. If the Continuous Count Test runs long enough, the maximum capacity of the tester to keep track of counts and revolutions will eventually be reached. If the test were to continue to run after reaching these maximum values,

TI-5000 33 OPERATION the test would begin to incorrectly report counting errors. To avoid false error reporting, the software checks for reaching these maximums. The maximums that are detected and the action taken is a follows. Count Maximum – The count maximum will be reached when the absolute value of the encoder count is greater than 2,147,483,648 (2 ** 31 – 1). When this occurs the test is stopped, and the Test Status box displays “Test Stopped – Reached Max Count”. The last test values before the maximum was reached will remain on the display and will be printed on the report. Target Maximum – The target maximum will be reached when the absolute value of the target count is greater than 2,147,483,648 (2 ** 31 – 1). When this occurs the test is stopped, and the Test Status box displays “Test Stopped – Reached Max Target Count”. The last test values before the maximum was reached will remain on the display and will be printed on the report. Revolution Maximum – The revolution maximum will be reached when the absolute value of the number of revolutions is greater than 32,000. When this occurs the test is stopped, and the Test Status box displays “Test Stopped – Reached Max Revolutions”. The last test values before the maximum was reached will remain on the display and will be printed on the report.

TI-5000 34 OPERATION 2.3.9 PHASE ANGLE TEST

This section describes performing the Phase Angle Test. For an explanation into why phase angle tests should be performed and what the results tell you, please see Section 3.2.1. The Phase Angle Test is available only for the incremental encoder selection.

2.3.9.1 REALTIME The 93 in the Readings box indicates that 93 phase measurements have been made so far during the test. That gives you some idea as to how representative the readings are. The longer the test is running, the better representation you have of the phase angles in terms of the min/max readings. The Realtime line reports the phase and symmetry angles in real-time as they happen. The realtime data will be constantly updated as the test proceeds. However the speed at which it is updated is dependent upon the speed at which the encoder turns. The data on the Realtime line will probably be changing constantly because the phase angles tend to vary somewhat as the encoder is rotated. The better quality encoders will exhibit more constant phase and symmetry angles. To get the most accurate readings, it is essential to rotate the encoder at a constant speed (RPM). High resolution encoders often use interpolation to divide their sine wave output into smaller pulses. The interpolation process generally causes phase angles to be jumpier. If the TI-5000EX is reading phase angles at a high rate (controlled in part by the encoder rotational speed), it can be hard for the operator to interpret the readings from jumpy data. Clicking the Take Sample button will take a sample of the real-time data and hold it on the display. This makes it much easer to read. This can be done as many times as desired. The Sample line shows a sample that was saved from a realtime reading when the Take Sample button was

TI-5000 35 OPERATION clicked. An initial sample of the first real-time reading is taken automatically when the Phase Test is first started. The Phase B-A box reports the phase angle between the rising edge of B and the rising edge of A with A leading B. It would ideally be 90 degrees when the encoder is moving in the direction of A leading B, or 270 degrees in the direction of B leading A. See Section 3.2.1 for a description of these phase angles. The A Symmetry box reports the A Symmetry angle, which is the angle from the rising edge of A to the falling edge of A, and it would ideally be 180 degrees. Likewise, the B Symmetry box reports the B Symmetry, which is the angle from the rising edge of B to the falling edge of B, and it too would ideally be 180 degrees. These readings provide a measure of the symmetry of the pulses. A perfectly symmetrical pulse would be HI for the same amount of time that it is LO, and that would result in an angle of 180 degrees. Specifications for these angles vary with encoder manufacturer, but a tolerance of ±22 degrees from the ideal is a fairly typical specification. The lowest rate for phase angle measurements is 25 counts per second. For rates slower than 25 CPS, the RT line will not be updated. Similarly, for pulse rates above 440,000 CPS, there is not enough resolution in the internal timer to resolve phase angles to 1 degree. Therefore, above about 400,000 CPS, a TOO FAST prompt appears on the RT line in place of the phase data. You may wish to calculate the maximum and minimum RPM values corresponding to the max and min count rates. The encoder RPM may be calculated from the number of counts per second and the number of lines per revolution as follows: RPM = (60 * RATE) / (4 * LINE) For example, using a 500 line per revolution encoder, 20 CPS and 400,000 CPS would convert to 0.6 RPM and 12,000 RPM respectively. This gives you the allowable RPM range for reading the phase angle for this particular encoder. You can see from this that as the encoder resolution goes up, the allowable RPM for phase readings will come down. Substituting in 400,000 CPS for the maximum rate and 25 CPS for the minimum rate gives us the following two equations for the max and min RPM: MAXRPM = 6,000,000 / LINE MINRPM = 375 / LINE Rotating the encoder while keeping the speed as constant as possible in the allowable RPM range, should result in good phase angle measurements. 2.3.9.2 MAX VAL The Max Val line shows the maximum values of the phase and symmetry angles since the test started or the last max/min reset. To further help in evaluating jumpy data, the maximum and minimum values are recorded and displayed along with the realtime values. The max and min values may be reset by clicking the Reset Max/Min Values button. The reset process will set the max and min values to the values in the current real-time data reading. The values are automatically reset when the Phase test is first started. If the encoder is stopped during a test, it may cause a wild max or min value to be recorded. This would be a situation in which you would definitely want to perform a reset. Of course the test can be exited and restarted to reset the max/min values as well. The max value readings are most useful when the encoder is turned at a constant speed with a

TI-5000 36 OPERATION motor. The max values will normally show a lot of variation when the encoder is rotated by hand and therefore may not be that useful. The speed differences caused by rotating by hand will cause variation in the readings, and it usually does not tell you much about the quality of the encoder. Therefore, max values should be ignored if the encoder rotational speed is not constant. 2.3.9.3 MIN VAL The Min Val line records the minimum values in the same manner as described above for the maximum values.

TI-5000 37 OPERATION 2.4 GENERIC PARALLEL ABSOLUTE ENCODERS The TI-5000EX provides limited support for Parallel Absolute Encoders. Parallel Absolute encoders are functionally similar to many serial encoders because they maintain an absolute position rather than a relative position like the incremental encoders. As with the serial encoders, their resolution is usually stated as some number of bits for representing the count for one revolution. The major difference is that parallel encoders provide an output line for each data bit. This can add up to a lot of lines, and this is one reason that this type of encoder is not typically used with servo motors. Generally parallel output encoders will be used where an absolute position must be obtained on power-up such as with a tool changer or something of that nature. Even though these encoders are not normally used with a brushless motor to provide commutation and positioning information, they will be found in machine tool products which use servo motors. Therefore, servo motor repair shops may get requests from customers to test this type of encoder.

In order to check out this type of encoder, the tester must be able to read each line. The TI-5000EX utilizes all of its signal input capability to support up to 10 bits of parallel signals. There are encoders with more than 10 bits and it is possible to check out these encoders 10 bits at a time. If a demand for testing parallel encoders with resolutions higher than 10 bits occurs, then an adapter module may be developed for the TI-5000EX in the future to directly support high resolution parallel absolute encoders. Parallel encoder data may be encoded in various ways. Three of the more common codes are Binary, Gray Code, and Binary Coded Decimal (BCD). Ideally, the technician would tell the tester what kind of code the encoder is using, and the tester would convert the data to a position count using that code. Often however, the technician may not have documentation on the encoder and may not know what kind of code is used by it. Because of this, the TI-5000EX approach is to present the bit pattern in each of these codes at the same time. If the technician happens to know that the encoder produces a gray code, then he will look at the gray code display and ignore the other information. If he does not know what kind of code is produced, he can

TI-5000 38 OPERATION look at all of the codes and decide for himself which code makes sense and therefore is probably the code in use. As an example, let’s consider an 8 bit binary encoder. If we turn it through 10 counts, we would see the following patterns: Bit Pattern Binary Gray Code BCD Decimal Decimal LLLL LLLL 0 0 000 LLLL LLLH 1 1 001 LLLL LLHL 2 3 002 LLLL LLHH 3 2 003 LLLL LHLL 4 7 004 LLLL LHLH 5 6 005 LLLL LHHL 6 4 006 LLLL LHHH 7 5 007 LLLL HLLL 8 15 008 LLLL HLLH 9 14 009 LLLL HLHL 10 12 00A (invalid BCD number) If we look at the 3 BCD digits generated, things look pretty good until we get to the last display. Then we see 00A. If this were truly binary coded decimal, we will get only decimal numbers (0-9) in this display, and that last position should be 010 instead of 00A. Because of this we can rule out BCD. The Gray Code numbers are out of order and jumping all over the place. This tells us that we are not decoding a gray code. The only numbers then that are moving smoothly from 0 to 10 are in the binary column. We can conclude that this is the correct code. Some absolute encoders complement the bits when they apply them to the output lines. In other words, when they want to produce a 0 bit they put the line HI and conversely put it LO for a 1 state. For a complemented output example, the lowest two bits when counting from 0 to 3 would change as follows: HH 0 HL 1 LH 2 LL 3 Again when the behavior of the count is observed, the technician can usually make a judgment on which code makes sense. Normally with binary encoding, both the TRUE and COMPLEMENT representations will make sense. One count goes up while the other count comes down. In this case, it is not really important to decide whether it is actually TRUE or COMPLEMENT data. You will be able to check it out in either case. Normally only the TRUE or the COMPLEMENT but not both will make sense for Gray codes and BCD codes. A Tamagawa OAS66 Absolute Encoder is an example of a 10 bit BCD encoder with complement outputs. This encoder will provide position counts from 0 to 359 which can be directly interpreted as degrees rotation. Some absolute encoders will provide fewer than 10 bits. In these cases, the lines should be connected starting with BIT 0 and working up to the highest bit available. The inputs for the higher bits that are not used should be tied LO (connected to J2 pin 2 ground) if the encoder provides TRUE outputs. If it provides COMPLEMENT outputs, the inputs may be left open and they will pull HI on their own. If it is not known which it is, some experimentation will be necessary. TRUE outputs are probably more common than COMPLEMENT outputs, so TRUE outputs would be a good first guess. Of course if a data sheet is available for the encoder, then no guesswork should be necessary.

TI-5000 39 OPERATION 2.4.1 DATA DISPLAY

For the parallel absolute encoders, the Data Display is the only selection at this time. As described above, all codes are displayed at the same time on the Data Display screen. The encoder connected in this example is a 10 bit binary BEI encoder. On this reading alone, TRUE and COMPLEMENT BCD coding possibilities can be eliminated because they include digits outside the 0-9 range. As the encoder is rotated and more codes are observed, it would become obvious that the binary code readings make sense and the gray code readings do not. You will be able rule out various codes as you see results that do not make sense as you rotate the encoder. This is discussed further in sections below on the various codes. A problem that is often found with absolute encoders is that a single bit or sometimes several bits simply are not changing (stuck bits) as the encoder is rotated. This is most easily observed in the Line States display. This type of problem will also make the count jump rather than changing smoothly. However, the count may also jump if you are looking at the wrong code, so the line states are the most reliable indicator of stuck bits. The binary and BCD encoders may glitch when they are changing from one position count to the next. That is, there may be a momentary incorrect reading as they change. This does not necessarily indicate a problem with this type of encoder. It is caused by the fact that all the bits do not change at exactly the same instant as the position is moved to a new code. Gray code encoders should not have this problem. In fact, gray codes are used specifically to prevent this problem. Gray codes are designed so that only one bit changes when it moves from one position count to the next. By never changing more than one bit, the problem of several bits not changing simultaneously is defeated. 2.4.1.1 LINE STATES The Line States frame displays the states of the 10 lines as a bit pattern for bit 0-9 as a decimal number encoded as true or complement binary. It is this bit pattern that is decoded into the various types of numbers. Even if you cannot make sense of any of the numbers generated by the encoder, you can watch the bit pattern. At a minimum, you would want to see all the lines change state as the encoder is turned. A test showing a line never changing state would probably indicate a faulty output for that line. 2.4.1.2 BINARY CODE The True Binary Code and Complement Binary Code frames display the bit pattern as though it represents binary data. The true data is interpreting a HI bit as being a binary 1, while the complement data is interpreting a LO bit as being a binary 1. Absolute encoders are specified both as true and complement data, so it is important to interpret the data both ways. The left hand section of the display shows the bit pattern as a decimal number encoded as true or complement binary. Both the true and complement numbers in this case are reasonable numbers, so we cannot eliminate either possibility. In this case, we know that this encoder is binary encoded, and we would find that the binary numbers move smoothly through the count as we go from 0 to 1023. This would tell us that the encoder is most likely binary encoded and is working correctly. Both the true and complement numbers will look good, so we really cannot say which it is. Since we can get a good evaluation on it either way, it does not matter in terms of testing. The data is shown represented both as a decimal number and a hexadecimal number. Usually you will be interested in the decimal number, but if you are familiar with hexadecimal representation, that display may be beneficial to you.

TI-5000 40 OPERATION 2.4.1.3 GRAY CODE The True Gray Code and Complement Gray Code frames display data that has been interpreted as gray code data. We look at both true and complement data for the reasons described above for the binary data. In this case, both data representations look good. We cannot conclude that it is not gray code from this single reading. However, as we turn the encoder and watch how the counts change, we would see the gray code data jumping around, and we could conclude that it is not encoded as gray code. 2.4.1.4 BCD CODE The True BCD Code and Complement BCD Code frames display the bit pattern as a binary coded decimal number. The True BCD box indicates the encoding as BCD code. In this case, the true coding works out to be a reasonable number (265), and it is displayed as such and shows VALID in the Code box. However, the Complement BCD box shows one or more illegal BCD digits, so it indicates an INVALID in the Code box. If we are good with converting bit patterns to BCD digits, we would see that bits 0-3 would represent 10 which is illegal since BCD digits can only range from 0-9. Bits 4-7 would translate to 9 which is legal. The 2 bits, 8 and 9 will always represent a legal digit from 0-3. Note that, if we do not know which encoding is in use for this encoder, then the INVALID in the Code box will tell us that it is probably not Complement BCD. However, if Complement BCD is the specified encoding for this encoder, then the INVALID would definitely indicate a problem with this encoder.

TI-5000 41 OPERATION 2.5 GENERIC RESOLVERS The TI-5000EX provides support for resolver check out with built-in resolver hardware (no external adapter module required). The resolver may be connected directly to the TI-5000EX resolver connector, J12. For viewing the resolver signals on an oscilloscope, the TI-3011 Resolver Breakout Board may be plugged into the resolver connector and the resolver connector plugged into the breakout board. The excitation amplitude is adjustable over a range of 0.0 - 8.0V peak, and the excitation frequency is adjustable from 1,000 to 20,000 Hz. in 4 ranges. These settings are made using the Resolver Excitation Setup window as described in a later section. 2.5.1 GENERAL COMMENTS

Since a resolver is basically a transformer in which a voltage input to the excitation winding produces a voltage output to the sine and cosine windings, there is a transformation ratio involved due to the number of turns in these windings. The ratio may be checked approximately during setup by comparing the excitation voltage selected during setup, with the Vector Level in the Data Display (see Data Display screen below). This is approximate because the voltages are only expressed to 0.1 V resolution. Another source of error occurs when there is a phase shift between the excitation signal and the sine and cosine signals. The vector level will be reduced if a phase shift exists. For best accuracy, the excitation frequency should be adjusted such that the sine and cosine signals are either in phase or 180 degrees out of phase with the excitation signal. If from experience, you use the same excitation frequency and voltage routinely for a particular type of resolver, a significant difference in vector level reading would warrant further investigation since a change in transformation ratio would not be expected. When the angle read from a resolver goes through 360 degrees in a single revolution, that resolver is called a single speed or 1 speed resolver. However, resolvers can have various numbers of poles just like motors. While a 2 pole resolver is referred to as a single speed resolver, a 4 pole resolver is a 2 speed resolver and so on with the speed being the same as the number of pole pairs. The resolver angle reading will go through 360 degrees as many times as the speed. Servo motors will commonly use 1, 2, 3 and 4 speed resolvers. Single speed resolvers are commonly used with any number of pole motors. However, resolvers higher than single speed will normally be used on a servo motor with the same number of pole pairs as the resolver speed. For instance, a 4 speed resolver would normally be used with an 8 pole motor. While this is typical, at least one example is known of an 8 pole motor using a 2 speed resolver. Other kinds of applications (besides servo motors) may use resolvers as high as 36 or more speeds. Servo motors, however, are normally limited to the number of pole pairs of the motor (which is seldom above 6). The most common problems that cause incorrect results from a good resolver are incorrect connection to the tester and incorrect excitation. Double check connections and follow the suggestions in the section on connections to ensure that the resolver is connected properly. The most common problems with excitation are excitation amplitude too high or the excitation frequency too low. Both of these situations can lead to waveform distortion, and waveform distortion can result in angle readings that are inaccurate or jumpy, dead spots in the rotation, etc. Follow the procedures in the section on setup to avoid waveform distortion. The question often comes up as to the effect of reversing various resolver leads. The following table shows the effect of lead reversal, and this makes it clear why simply reversing the sine leads is the least complicated way to change the resolver direction. In the following table, when we say “reverse sine” we mean to switch the SIN and SIN* resolver leads on the terminal block. When we say “exchange sine and cosine” we mean to connect the resolver SIN and SIN* leads to the terminal block COS and COS* terminals respectively and connect the resolver COS and COS* leads to the terminal block SIN and SIN* terminals respectively.

TI-5000 42 OPERATION Leads to Change Effect Reverse Sine Reverses direction of increasing angle. Reverse Cosine Reverses direction of increasing angle and advances the angle by 180 degrees. Reverse both Sine and Cosine Advances the angle by 180 degrees without changing the direction. Reverse Excitation Same as reversing sine and cosine. Reverse All leads No effect. Exchange Sine and Cosine Reverses direction of increasing angle and advances the angle by 90 degrees. You can see that the effect of making a combination of changes can be predicted by the individual changes. For instance, reversing the sine leads will reverse the direction. If we then reverse the cosine leads, the direction is reversed again, and the angle is advanced by 180 degrees. The double reversal of direction puts us back to the original direction, and we are advanced by 180 degrees. That is the same thing the table tells us for reversing both the sine and cosine leads. As an example of applying these rules, we could predict that exchanging the sine and cosine leads and reversing the excitation leads would advance the angle by 270 degrees and reverse the rotation. 2.5.2 TYPES SUPPORTED

The TI-5000EX works with resolvers that accept an excitation input and produce outputs whose amplitudes are proportional to the sine and cosine of the mechanical shaft angle. Multi-speed resolvers are compatible. Their angle indication will simply go through 360 degrees multiple times per revolution. The TI-5000EX is not compatible with synchros that produce outputs whose amplitudes are 120 degrees apart. It is not uncommon for resolvers to be wired to use the Phase Analog method of resolving the mechanical angle. With the Phase Analog method, excitation voltages 90 degrees apart in phase are applied to the sine and cosine windings while the resultant output signal is taken from the stator winding (that would normally be used for excitation). This is more of a method of reading the angle than a different type of resolver, and these resolvers are normally compatible with the TI-5000EX providing they are connected in the conventional manner as described in the next section. 2.5.3 CONNECTION

Resolvers will have excitation input and sine and cosine output leads that must be connected to the TI-5000EX. Insert the TI-3011 Breakout Board into the 7 pin terminal block connector, J12, on the right hand side of the unit, and then insert the resolver connector into the breakout board. The resolver can be plugged directly into J12, but using the breakout board will provide some advantages, especially for an initial connection. The breakout board provides the pin numbers and signal names to make it easy to wire your resolver into the 7 pin terminal block, and it provides a simple way to connect an oscilloscope to observe the excitation, sine and cosine signals to verify clean signals with no distortion.

Note: 1. The excitation voltage measured on the oscilloscope from the EXC testpoint will be half the

voltage that is actually applied to the resolver excitation windings. This is due to the fact that the resolver leads are normally connected between EXC and EXC* instead of EXC and GND.

2. The excitation voltage displayed on the TI-5000EX takes into account the factor of 2, and it should be correct (twice the oscilloscope reading).

3. The COS* and SIN* are at GND potential, so they should read correctly on the oscilloscope and that should agree with the readings on the TI-5000EX display.

TI-5000 43 OPERATION The resolver should be connected as follows: Pin Label Use 1 GND Not normally used, but can be connected to an excitation lead. 2 EXC Connect one of the excitation leads to this pin. 3 EXC* Connect the remaining excitation lead to this pin. 4 COS Connect one of the cosine output leads to this pin. 5 COS Connect the remaining cosine output lead to this pin. 6 SIN Connect one of the sine output leads to this pin. 7 SIN Connect the remaining sine output lead to this pin. It is not as important which leads you select for each pin as it is important that you document how you did it. If you have pin configurations from the manufacturer, then you can use their designations. If not, you can make up your own. Either way, you should document how you do it. That will allow you to connect it the same way each time you work on the same type of motor, and any commutation alignment data that you take should be repeatable. Typical resolver lead designations would be as follows:

Typical Designation Typical Color Signal R1 RED/WHI Excitation + R3 BLK/WHI Excitation - S1 RED Cosine + S3 BLK Cosine - S2 YEL Sine + S4 BLU Sine -

If you have no colors to go by or other documentation, you could take resistance readings on the various windings. Normally the sine and cosine windings will be very close to the same resistance, and the excitation winding will be different. 2.5.4 SETUP

Setup for the resolver involves setting the commutation amplitude and frequency. This is accomplished by clicking the Resolver Setup button from the Data Display with resolver as the selected feedback.

TI-5000 44 OPERATION

To ensure proper amplitude and frequency settings, you should connect an oscilloscope to the TI-3011 Breakout Board so that you can observe the excitation, sine, and cosine signals to verify correct levels with good clean sine waves and no distortion. If you have voltage and frequency settings available from previous encounters with a particular resolver, you may not need to observe the waveforms on the oscilloscope and can go right to the desired settings. However, if you get poor readings, you may need to use the oscilloscope to help determine the problem with the resolver. Resolvers require the following setup sequence with the resolver to be tested already connected:

1. To select resolver feedback, click on the Select Feedback button in Data Display, and then click on the Resolver Feedback radio button in the Select Resolver frame of the Select Feedback window. Click the OK button after the resolver selection has been made.

2. Click on the Resolver Setup button in the Data Display to bring up the Resolver Excitation

Setup window. 3. Use the Frequency Range dropdown menu to select the range (1, 2, 3 or 4) which

corresponds to the desired frequency. The frequency covered by each range is shown on the Instructions/Comments box on the display. The ranges are as follows:

Range Frequencies 1 1,000-2,000 Hz. 2 2,000-5,000 Hz. 3 5,000-10,000 Hz. 4 10,000-20,000 Hz.


If you know the frequency specified for your specific resolver or motor, then that will be the frequency that you are selecting. If you do not have that information, you will want to select a frequency which puts the sine and cosine signals either in phase or 180 degrees out of phase with the excitation signal. To look at this phase, you will need to connect an oscilloscope to the TI-3011 Breakout Board as described in the preceding section. When signals are in phase or 180 degrees out of phase, their zero crossings will line up with each other.

4. When the desired range has been selected, use the Frequency Set Point dropdown menu to select the desired frequency within the selected range. On the bottom line under Set, the frequency setting (in Hz.) will be shown. In the Actual Frequency in Hz. and Actual Frequency in KHz. boxes, the actual measured frequency will be show. The frequency set point and actual frequency numbers will normally be fairly close together, but not exact. If the specified frequency is not available from the menu, just select the closest available frequency, which will be plenty close enough.

Note: If the level is set too low to get a good frequency measurement, you may need to adjust the level as described in the next step and then come back to the frequency adjustment.

5. Click the Level Set Point dropdown menu and select a voltage in the 2 to 3 V range. Note

whether the voltage shown in the Vector Level box is between 1.5V and 3V. If it is not, adjust the Level Set Point up or down to get the vector level in that range. A 2.5 V vector level is a good target.

6. If the frequency and level adjustments are not where you want them yet, then repeat those

adjustments until you have the desired results. 2.5.5 TESTING

Generic Resolvers incorporate only the Data Display Test for a complete test. 2.5.6 DATA DISPLAY

Data Display is selected by clicking the Data Display button to read the resolver angle and vector level. The Data Display is the only test available for resolvers.


2.5.6.1 RESOLVER ANGLE READINGS The Resolver Angle Readings frame shows the current resolver angle in degrees and Baldor HEX code angle. Unless you have used a Baldor resolver tester in the past and have lockup data recorded in that format, just ignore the Baldor data and use the angle in degrees. The angle displayed should change in a reasonable manner as the resolver is rotated. For instance if a 1 speed resolver is rotated ¼ revolution, the angle should change by 90 degrees. The angle should change smoothly during the entire rotation. 2.5.6.2 RESOLVER OUTPUT The Resolver Output frame shows the resolver output signals described in different ways. The individual sine and cosine voltage levels are shown in the Sine and Cosine boxes respectively. The cosine will reach a positive peak at 0 degrees and negative peak at 180 degrees, while the sine will reach a positive peak at 90 degrees and a negative peak at 270 degrees. The main thing to watch for here is that the peak voltages reached by the cosine and sine outputs are the same, the positive and negative peaks are the same, and the peaks are the same as the vector level. Within 0.1 or 0.2 volts is close enough to consider it the same voltage. If either the sine or cosine signal is zero all the time or never changes, there is a problem with that resolver channel or possibly with the resolver connections to the tester. An ohmmeter check of that winding may reveal a shorted or open winding. If both signals are zero, then there may be a problem in the excitation windings. Again an ohmmeter check may help determine the problem. The ohmmeter will measure the resistance of the excitation winding on the stator. However, this winding is transformer coupled to an excitation winding on the rotor, and the ohmmeter reading will not tell you anything about the rotor winding.

TI-5000 47 OPERATION The Vector Level box displays a calculated quantity that, for lack of a better name, we call the vector level. Trigonometry tells us that the square root of the sum of the squares of the sine and cosine of any angle is equal to 1. Since the sine and cosine voltages are proportional to the sine and cosine of the angle, the square root of the sum of the squares of these voltages should equal a constant voltage for an ideal resolver. By computing this vector level from the sine and cosine voltages, we have access to a number that can easily point out problems in resolver signals. As the resolver is rotated, the vector level should not vary by more than a couple tenths of a volt. If it does, then the sine and cosine signals are not consistently at the correct amplitudes. This may mean that there is a problem with the resolver, perhaps the signals coming back from the resolver are distorted, or the excitation level may be too high. Using the breakout board to connect an oscilloscope to the excitation, sine and cosine signals will help determine the problem. If the sin/cos signals coming back from the resolver are too low and the vector level is below 1.0 V peak, then the Vector Level box background will change to red indicating a low signal problem. From 1.0 V to 1.4 V, the background will be yellow indicating marginal levels. From 1.5 V to 2.9 V, the background will be green indicating a good range of levels. From 3.0 V to 3.1 V the background is again yellow to indicate a marginally high level. Levels from 3.2 V and above will show a red background to indicate a high level. The excitation level must be adjusted into the acceptable range using the setup procedure described in the setup section. If a good range cannot be achieved, then there is likely a problem with the resolver, and an oscilloscope may help in figuring out the problem. 2.5.6.3 RESOLVER EXCITATION SET POINTS The Resolver Excitation Set Points frame shows the frequency and level set points, in the Frequency and Amplitude boxes respectively, that were selected in the Setup Window.

TI-5000 48 OPERATION 2.6 MANUFACTURER SPECIFIC ENCODER DETAILS The following sections provide details on testing various manufacturers’ serial encoders (and some special quadrature pulse encoders). When you are testing a particular kind of encoder, check this section to see if there are any important testing details listed for it.

TI-5000 49 OPERATION 2.6.1 ALLEN BRADLEY (RELIANCE, ELECTROCRAFT) MOTORS

2.6.1.1 GENERAL COMMENTS AB Series F, H, N, S, and Y use Renco incremental encoders, so please see that section for details. These motors may also be Reliance or Electrocraft brand depending upon their age. Refer to the Renco section for more information. The H series is known to sometimes use Stegmann Hiperface encoders. The Reliance B and P series motors use Ono Sokki (or equivalent) incremental encoders with commutation signals. AB MPS, MPL, MPF, 1326AB and 8720 motors use resolvers, incremental encoder, and Stegmann Hiperface encoders. Refer to the resolver and incremental encoder manual sections for more information. Refer to this section and the Stegmann section for more information on testing motors with the Stegmann Hiperface encoders. These encoders include memory, and Allen Bradley motors utilize this memory area for motor parameters including alignment information. This section will focus on the memory support for these motors. 2.6.1.2 TYPES SUPPORTED The following lists show the Allen Bradley motors with their corresponding Stegmann Hiperface encoders that are currently supported by the TI-5000EX, along with test cable possibilities. Please check the current PDF catalog file and price list files for a complete listing of all cables supporting Allen Bradley motors. This list includes Allen Bradley motors using Stegmann Hiperface encoders. Type Format Counts/Rev Cables Inc / Pos / Rev (see note below) SKS36 Hiperface 512 / 4,096 / NONE TI-5094 (Generic), TI-5057 (AB MPL)

TI-5058 (AB MPL) SKM36 Hiperface 512 / 4,096 / 4096 TI-5094 (Generic), TI-5057 (AB MPF)

TI-5058 (AB MPF) SNS50/60 Hiperface 4,096 / NONE / NONE TI-5069 (Generic), AB 8720 Spindle SRS50/60 Hiperface 4,096 / 32,768 / NONE TI-5069 (Generic), TI-5057 (AB MPF)

TI-5058 (AB MPF), TI-5064 (AB MPL, 1326), TI-5096 (AB H-6300)

SRM50/60 Hiperface 4,096 / 32,768 / 4096 TI-5069 (Generic), TI-5057 (AB MPF) TI-5058 (AB MPF), TI-5064 (AB MPL, 1326) TI-5096 (AB H-6300)

Note 1: Generic means a cable that connects directly to the encoder and works regardless of the type of motor. Note 2: The first count is the number of counts/rev for the incremental signals, the second is the number of counts/rev for the absolute serial position count, and the last count is the number of revolutions that can be counted (for multi-turn encoders only). In addition to the above encoders, a DSL-3J08G0M2XB9, which apparently is a 5V SKM36 encoder, is sometimes used on MPL-A1XX motors. It is not clear whether this is an AB part number or Stegmann. But, the encoder seems to test fine using the SKM36 selection.

TI-5000 50 OPERATION The following list includes conventional incremental encoders with commutation signals and/or Hall effect pickups. Type Format Counts/Rev Cables Ono Sokki Inc./Comm 10,000 TI-5091 (AB B & P Series) Renco Inc./Comm 2,000, 4,000, 8,000 TI-5019Q (AB F, H, and S Series), 10,000 TI-5045Q (AB N Series),

No Cable (AB Y Series) 2.6.1.2.1 IDENTIFICATION F, H, N, S, and Y Series – The part number breakdown for these motors is as follows:

H-4030-P-H00AA (example part number) H - Series designator 4030 - Frame size P - Motor winding KE designator H - Feedback designator Incremental line count F = 1,000 H = 2,000 (standard) K = 5,000 L = 500 M = 3,000 HI Resolution Encoder M2 – Multi-turn (SRM50) S2 – Single-turn (SRS50) 00 - 00 = standard, 04 = brake AA - AA = standard flange, AN = NEMA

B & P Series – Typical B and P series part numbers would be B14H1060 and P21M0304G. In the examples we have seen, the B series motors are 4 poles P series motors are 6 poles.

TI-5000 51 OPERATION MPS, MPL, MPF, 1326AB and 8720 – The part number breakdown for the P series motors is as follows:

MPL-A310P-HK22AA (example part number) MP - Series designator L - Series type A - Voltage rating 3 - Frame size 10 - Magnet Stack length P - Rated Speed H - Feedback H = 2,000 line encoder R = 2 pole (single speed) resolver S = Single-turn HI resolution encoder (SRS50) M = Multi-turn HI resolution encoder (SRM50) E = Single-turn HI resolution encoder (SKS36) V = Single-turn Hi resolution encoder (SKM36) K - Enclosure/Shaft key/Shaft seal 2 - Connectors 2 - Brake 2 = No brake, 4 = 24VDC brake A Mounting flange A Factory designated options, A = standard

Generally it seems that the MPL-A type motors use 4.5-12.0V Stegmann encoders, and the MPL-B type are 7.0-12.0V. Reading the feedback designator tells you what kind of feedback is in use. 1326AB – Part numbers for the 1326AB are as follows:

1326AB-BXXXX-21 Resolver feedback 1326AB-BXXXX-S2L Single-turn encoder (SRS50/60) 1326AB-BXXXX-M2L Multi-turn encoder (SRM50/60)

8720 Spindle Motor – The part number breakdown for the spindle motors is as follows:

8720SM-PPP W F NN S F - MM 8720SM - Base catalog number PPP - Power in KW F - Type of winding NN - Motor curve number S - Speed class F - Feedback 1 = SRS60 2 = SCM60 3 = SNS60

MM - Mod number

TI-5000 52 OPERATION 2.6.1.3 CONNECTION Connection requires using the correct cable as shown in the chart in the Type Supported section. Also the WinTI5000EX ‘Feedback Selection’ frame has a cable dropdown menu from which you can select the cable that you need. After making the cable selection, that selection will appear on the Data Display report which is helpful in documenting the cable used. The TI-5069 and TI-5094 generic cables connect directly to the 8 pin or 9 pin encoder connector, so they should work with all Hiperface encoders (depending on the exact encoder connector used). Download cable sheets from the Customer Page at http://www.mitchell-electronics.com for cable pinouts and wiring details. In most cases, test cables that connect directly to the motor feedback connector are available (the TI-5064 for instance). These cables offer the advantage of testing through the cable harness on the motor (which could be where a problem exists). In the case of the 1326AB motors, when you remove the encoder cover to connect directly to the encoder, the encoder body is free to move. After you align the encoder, it could move when you remove the test cable and install the cover. With the TI-5064 cable, you can check the alignment after the encoder cover has been installed. If properly cabled, the Stegmann Hiperface encoders can be used with the TI-5104 Adapter Module so that it is easier provide the correct power supply voltage and to check the incremental portion with the same connection. See the section on cables for more information. 2.6.1.4 ENCODER SELECTION See the section for the appropriate encoder. 2.6.1.5 TESTING See the section for the appropriate encoder. 2.6.1.5.1 DATA DISPLAY See the section for the appropriate encoder. The following sections describe information shown on the display. 2.6.1.5.1.1 COMMUTATION The electrical angle is best for checking and setting commutation for serial encoders. For a particular lockup polarity, the rotor will lock up in as many different positions as there are pole pairs but the electrical angle indications will be the same at each lockup position. The mechanical angle will be different at each lockup position (except for 2 pole motors where there is only one lockup position), so mechanical angle is not as convenient to use for feedback alignment. For some motors with incremental encoders or Hall effect signals, it is necessary to use the commutation signals for alignment. See section 3.2 for a more detailed description of commutation alignment procedures. The number of poles must be entered correctly for the electrical angle to be displayed correctly. The electrical angle and mechanical angle are derived from the position count. The position count is absolute immediately on power up for Stegmann Hiperface encoders.

TI-5000 53 OPERATION The method of alignment for Allen Bradley motors will vary with motor the motor model. The various models are discussed below. F, H, N, S, and Y Series – A few of these motors use Stegmann Hiperface encoders. Refer to the section below on MPL motors when a Hiperface encoder is used. Most of these motors use Renco encoders. On the older motors, there are Hall effect pickups to provide the commutation signals. Newer motors use a commutation track on the encoder for commutation signals. The alignment is the same in either case. The R, S, and T armature leads are U, V, and W respectively. The TI-5019Q and TI-5045Q cables will connect the corresponding commutation signals to TI-5000EX H1, H2, and H3 respectively. This is important because the A, B, and designations in the AB literature do not correspond with the R, S, and T armature voltages (A=H3, B=H1, C=H2). The first two lockups indicate the proper alignment for the commutation signals. If the encoder has been aligned and indexed, the electrical angle shown should also appear. The third lockup will give you a zero electrical angle if the encoder has been aligned properly and indexed.

Lockup Electrical Angle H1(U) H2(V) H3(W) +U -V 150 H→L H L +U -W 210 L H L→H -U +V +W 0

B & P Series – The B & P series motors use Ono Sokki encoders. These encoders provide the commutation signals as well as the A, B, and Z counting signals. The TI-5091 cable will connect the corresponding commutation signals to TI-5000EX H1, H2, and H3 respectively. The first two lockups indicate the proper alignment for the commutation signals. If the encoder has been aligned and indexed, the electrical angle shown should also appear. The third lockup will give you a zero electrical angle if the encoder has been aligned properly and indexed.

Lockup Electrical Angle H1(U) H2(V) H3(W) +U -V -W 120 H→L H L -W +U +V 180 L H L→H +W -U -V 0 H L H→L

MPS, MPL, MPF, 1326AB and 8720 – The table below shows 2 different lockups that can be used to check or set commutation on Allen Bradley motors with Hiperface serial encoders. The two procedures require applying power to only two armature leads at a time. It is easy to go from +U –V to +U –W just by moving the minus lead from V to W. This should

TI-5000 54 OPERATION cause the motor to jog 60 electrical degrees in the forward direction (CW looking at the shaft for Allen Bradley). Failure to move the correct number of degrees or in the correct direction would be an indication of a significant problem. Setting these angles within ±3 electrical degrees is normally quite sufficient.

Lockup Elect. Angle +U –V 110 (lockup angle read from the memory test – see memory section) +U –W 170 (lockup angle read from the memory test – see memory section) Note: This is an example alignment based on encoder data. These motors do not have a standard alignment. The angles you see will be different.

Unlike most feedback alignment discussed in this manual, Allen Bradley MPL, MPF and 1326 motors using Hiperface encoders do not have a common lockup angle, and in general, they will all lock up at different angles. These motors store a commutation offset in the encoder memory. By using the commutation offset, the encoders do not have to be set to a common alignment. In order to correctly check or set the alignment, you have to run the Memory Test on the encoder, and note the +U –V and +U –W lockup angles provided by the memory test. 2.6.1.5.1.2 COUNT See the section for the appropriate encoder. 2.6.1.5.1.3 ENCODER STATUS See the section for the appropriate encoder. 2.6.1.5.1.4 MEMORY STATUS The Read Memory Status button on the Data Display allows the user to check whether memory is currently in use for a particular encoder. Clicking the button when connected to an SRM50 encoder on an Allen Bradley MPL motor would produce the following display:

Memory Status Field WE AC# CE Bytes 0 YES 0 NO 32 1 YES 0 NO 32 2 YES 0 NO 32 3 YES 0 NO 32 4 Undefined field 0 5 Undefined field 0 6 Undefined field 0 7 Undefined field 0 Total bytes used 128 Total bytes unused 0 Total used + unused 128

This tells us that there are 4 memory fields of 32 bytes each defined in this encoder. All 4 fields are write enabled (WE). The access code is set to 0 (could be 0, 1, 2, or 3). The code enable bit (CE) is not set for the 4 defined fields, so the access code does not have to be used. The total bytes number of memory bytes

TI-5000 55 OPERATION used is 128. The total bytes unused is 0, and this means that all of the available memory is in use. No more data fields could be defined for this memory because it is used up. This data formatting is done by the motor manufacturer and is of little concern to the TI-5000EX user. However, it is useful to look at it to verify that the memory looks normal. For instance if you see that no fields have been defined for an encoder on an Allen Bradley MPL motor, it is very likely that the encoder has been replaced and the correct data has not been programmed into the memory. This would be very important to know because the motor would not run correctly on the Allen Bradley drive. It is also useful to check on unfamiliar motors to determine whether the motor manufacturer is using the memory. This Memory Status data is automatically included on the Data Display report when a Stegmann Hiperface encoder has been selected. 2.6.1.5.2 COUNT TEST See the section for the appropriate encoder. 2.6.1.5.3 MEMORY TEST Encoder memory is used on Allen Bradley MPS, MPL, MPF, and 1326 type PM brushless motors and 8720 series spindle motors (this list may not be all inclusive). As explained previously, the Read Memory Status button on the Data Display can be used to determine whether the memory is in use. When the memory is used, it will normally be programmed with the motor model number and sometimes motor parameters. The drive can read this memory data on power up and determine what kind of a motor is connected to it. Some manufacturers, such as Allen Bradley and Indramat, are now programming a commutation offset value into the memory. This offset tells the drive the difference in the present feedback alignment from the ideal feedback alignment so that the drive can adjust its timing to compensate for an imperfectly aligned feedback device. This relieves the manufacturer of performing a precise alignment during manufacturing. They simply program in the offset for the drive to read. This means that each motor may be aligned somewhat differently, but the repair shop must still align the feedback the way the drive is expecting it to be. The TI-5000EX memory support will display the proper alignment angles based on this memory data so that the repair technician can properly align the feedback. Because the way in which the memory is used differs with the various motor manufacturers, software support must be developed for each brand (and sometimes models) of motors. Therefore TI-5000EX memory support must be purchased for each motor type in addition to the basic Stegmann encoder support.

Note: If a Hiperface encoder is replaced on an AB motor, the motor data must be programmed into the replacement encoder in order for the drive to run the motor. Contact Mitchell Electronics, Inc. for information on software support for programming replacement encoders.

2.6.1.5.3.1 ALLEN BRADLEY MEMORY TEST Allen Bradley MPL, MPF and 1326 motors use the Hiperface encoder memory to store motor parameters. This data is programmed at the factory and cannot be changed by the drive. This data is read by the drive system on power-up prior to moving the motor. If the drive system cannot read the memory or if it gets incorrect data from it, the motor will not run. It is therefore very important to verify that the memory can be read and appears to be correct. The memory also contains information that allows checking the commutation alignment.

TI-5000 56 OPERATION In verifying correct memory data and memory operation, we are looking at two things:

1. Is the data correct and not corrupted? 2. Is it the correct data for this motor?

The first item is done automatically. The data in the encoder is encoded with the ability to check data integrity. The TI-5000EX does this automatically as it reads and displays the various motor parameters. A explanation of possible errors is provided at the end of this section. The second item amounts to making sure that the encoder that is on the motor is the correct one. Sometimes in trouble-shooting, encoders get swapped in an attempt to isolate a problem, and the encoder on the motor you have could be the wrong one entirely. In general the data from the encoder should match the data from the motor nameplate. In this regard, we are looking for gross errors. Minor differences in the encoder data and nameplate data are normal. The display shown below is a memory test from an SRM50 encoder. The motor type number and motor parameters are fairly self explanatory. These numbers should match reasonably well with the nameplate data. At the end of the right column is some information that is useful to the repairman. The number of pole pairs is 4, which indicates a, 8 pole motor. This may not be universal, but it appears that the MPL and MPF motors are 8 poles, while the 1326 motors are 4 poles. The TI-5000EX uses the commutation offset to calculate what the +U –V and +U –W lockup angles should be in electrical degrees for proper feedback alignment, and these angles are reported in the Derived Data frame. Name Plate data: CAT NO. MPL-A310P-MK22AA SERIAL NO. H000659 STALL TORQUE 1.58 Nm MAX SPEED 5000 RPM RATED OUTPUT 0.73 KW Comparing the above nameplate data to the encoder data below, we see that the data agrees quite well.


The 8729 series spindle motors, using SNS50/60 encoders, will produce a similar result. The spindle motors do not have PM rotor, so there is not alignment. The commutation offset and lockup angles do not appear on the report as they are not applicable to spindle motors. Each 32 byte block of data in the encoder is encoded with a checksum which allows the ability to check data integrity. The TI-5000EX does this automatically as it reads and displays the various motor parameters. Any incorrect data in one of the data blocks will result in an incorrect checksum calculated for that block. This will be reported with the text “Error” followed by the calculated checksum and then the data from the checksum field. The word “Error” is all you need to see to know that the information is incorrect. If the data is correct, the checksum field will show the text “OK” (as we see in our example). You should assume that if a checksum error occurs, the AB drive will not run the motor. If data errors occur, it could be for any of the following reasons:

1. Faulty encoder. 2. Faulty or no encoder data. 3. Faulty feedback cable from the feedback connector to the encoder in the motor. 4. Incorrect encoder power supply (failure to use the TI-5104 Indramat Adapter Module for 7V

encoders). 5. Incorrect or faulty TI-5000EX test cable. 6. Faulty TI-5000EX.

Experience so far indicates that it is somewhat rare for the encoder memory to actually have a problem. If you encounter an encoder data error, check the list above to verify that you are doing everything correctly.

TI-5000 58 OPERATION Especially if you are unfamiliar with testing Allen Bradley motors, you might check with Mitchell Electronics, Inc. if you have an encoder (or several encoders) that do not read the data correctly. The TI-5000EX software will attempt to pop up a message to help identify possible data problems or incorrect tester selections. The data from this screen may be saved or printed as a report either in the usual manner with the Save Report to File or Print Report buttons. The Save Encoder Data File button may be used to save a copy of the data to a disk file as Intel hexcode. You may wish to do this to send to Mitchell Electronics, Inc. in the event that there might be a question about the data. You may also wish to have a copy in case you would need to program it into a replacement encoder in the future.

TI-5000 59 OPERATION 2.6.2 FANUC MOTORS

Motors with Fanuc ABS, incremental, and serial encoders are supported by the TI-5000EX. The current revision software supports 6 and 8 pole Fanuc motors on all encoders (that we know of) except the Alpha 16000i. Most Fanuc motors are 8 poles, so the number of poles defaults to 8 whenever a new type of Fanuc encoder is selected. 2.6.2.1 GENERAL COMMENTS Fanuc serial encoders are used only with Fanuc motors. There are significant differences in the various Fanuc models, but the test software takes that into account when displaying the results. The test procedure and commutation pulse patterns are basically the same for the various serial encoders. 2.6.2.2 TYPES SUPPORTED The following list shows the Fanuc encoders that are currently supported by the TI-5000EX: Type Counts/Rev Cables Pulsecoder A 1,048,576 TI-5004, TI-5005, TI-5006 Pulsecoder B 262,144 TI-5004 Pulsecoder B2 32,768 TI-5004 Pulsecoder C 40,000 TI-5005, TI-5006 Pulsecoder Alpha I8 8,192 TI-5070 Pulsecoder Alpha A8 8,192 TI-5070 Pulsecoder Alpha I64 65,536 TI-5005, TI-5006 Pulsecoder Alpha A64 65,536 TI-5004, TI5005, TI-5006 Pulsecoder Alpha 1000A 1,048,576 TI-5005, TI-5006 Pulsecoder Alpha I64i 65,536 TI-5047 Pulsecoder Alpha A64i 65,536 TI-5047 Pulsecoder Alpha 1000iI 1,048,576 TI-5047 Pulsecoder Alpha 1000iA 1,048,576 TI-5047 Pulsecoder Beta I32B 32,768 TI-5006, TI-5070 Pulsecoder Beta A32B 32,768 TI-5006, TI-5070 Pulsecoder Beta I64B 65,536 TI-5047 Pulsecoder Beta A64B 65,536 TI-5047 Pulsecoder Beta A128i 131,072 TI-5047 Pulsecoder ABS * Various TI-5007, TI-5016, TI-5029 Pulsecoder Incremental* Various TI-5007, TI-5016, TI-5029 * These encoders are tested as Generic Incremental and do not show up in the menu. Because the TI-5000EX produces a positive count for A leading B, these encoder will

appear to have a CW direction. Pulsecoder A, B, B2, and C – The Pulsecoder A, B, B2, and C are some of the earlier style encoders. They generally use 17 and 19 pin round MS type and DB15 type connectors.

TI-5000 60 OPERATION Pulsecoder Alpha – The Alpha series motors use the Alpha series encoders. They generally use 17 and 19 pin round MS type and the DB15 type connectors, but some of the built-in Alpha 8 encoders on smaller motors will use AMP D3100 two row connectors. Fanuc has converted the Alpha encoders to a new, more compact package. These encoders commonly employ the 17 pin round MS connector, but it will be on a short cable that plugs into the encoder case via a 14 pin dual row header type connector. Pulsecoder Alpha i – A new series of Alpha i motors utilizes Alpha i encoders. These encoders look very similar to the Alpha encoders in the new package, and the data is very similar. However, they use a small 10 pin circular JAE connector. Pulsecoder Beta – The Beta series motors use built-in Beta encoders. The earlier motors employ the Beta I32B and A32B encoders. These encoders use DB15 connectors but also AMP D3100 two row connectors. BetaM motors use built-in Beta I64B and Beta A64B encoders. These encoders use the small 10 pin circular JAE connector. ABS and Incremental – The ABS and incremental encoders are tested like any other Generic Incremental Encoder. 2.6.2.2.1 IDENTIFICATION The serial pulsecoders will normally have identification such as Pulsecoder A, Pulsecoder C, Pulsecoder Alpha A64, etc. on the label. Otherwise, the part number starting with A860 may have to be used to identify it by a reference to a Fanuc manual or a call to Fanuc. The incremental and ABS encoders are easily identified due to the fact that they will have a 2000P, 3000P, etc. following the A860 part number. This is the number of pulses per revolution for the encoder, and it identifies it as and ABS or incremental. These encoders should be tested as Generic Incremental encoders. 2.6.2.3 CONNECTION Connection requires using the correct cable as shown in the chart in the Type Supported section. Also the WinTI5000EX ‘Feedback Selection’ frame has a cable dropdown menu from which you can select the cable that you need. After making the cable selection, that selection will appear on the Data Display report which is helpful in documenting the cable used. Download cable sheets from the Customer Page at http://www.mitchell-electronics.com for cable pinouts and wiring details. 2.6.2.4 ENCODER SELECTION Click on the Select Feedback button to make the selection. Follow the instructions below for either incremental and ABS or serial encoders.

TI-5000 61 OPERATION 2.6.2.4.1 INCREMENTAL AND ABS ENCODERS

1. Click the Encoder Feedback radio button. 2. Select Generic Incremental Encoder from the Encoder Manufacturer dropdown menu. 3. The encoder type will default to AB Quadrature Count. 4. Click on the Enter Counts Per Revolution button. Multiply the number of pulses per revolution by 4

to get the number of counts/revolution. Fanuc incremental and ABS encoders will have a number such as 2000P, 3000P etc. after the A860 part number, and this is the number of pulses per revolution.

2.6.2.4.2 SERIAL ENCODERS The Fanuc serial encoders require the following setup sequence:

1. Click on the Encoder Feedback radio button. 2. Select Fanuc from the Encoder Manufacturer dropdown menu. 3. Select the encoder type that you have from the Encoder Type dropdown menu.

The encoder types listed in the current software revision are shown in an earlier section. Most Fanuc motors are 8 pole motors, and most of the encoder types specify 8 poles. There is a 6 pole selection available for the Pulsecoder A and the Pulsecoder Alpha A64. To determine the number of poles, apply a small voltage to 2 of the armature leads to lock the rotor, and then count the number of lockup positions to determine the number of pole pairs. For instance, if the rotor locks up in 4 different shaft positions, the motor has 4 pole pairs or 8 poles. 2.6.2.5 TESTING Fanuc Incremental and ABS encoders are tested as Generic Incremental Encoders using Data Display, Line Levels, Incremental Count Test, and Phase Test for a complete test. The Fanuc serial encoders (like most serial encoders) use only the Data Display and the Serial Count Test. The forward armature direction for Fanuc motors is CCW looking at the drive shaft end. 2.6.2.5.1 DATA DISPLAY Data Display is the initial test, and it is started by default when WinTI5000EX is started. When already in another test, it can be started by clicking on the Data Display button among the test buttons at the top of the display. Use it for the following:

1. Turn the encoder to ensure that the encoder is counting approximately the right number of counts per revolution.

2. Use the commutation display to check or set the feedback commutation alignment. 3. Check the encoder status for the following: ensure that the encoder is indexed, communicating

properly with the tester, not reporting internal errors, correctly displaying overheat and battery alarms, and displaying the correct encoder ID (if ID is implemented).

The following sections describe information shown on the display. 2.6.2.5.1.1 COMMUTATION The Fanuc commutation gray code shown as C1 – C8 and the electrical angle can be used to check and set commutation using a static rotor lockup by applying a small lockup voltage to the stator windings. For a

TI-5000 62 OPERATION particular lockup polarity, the rotor will lock up in as many different positions as there are pole pairs but the gray code and electrical angle indications will be the same at each lockup position. The mechanical angle will be different at each lockup position (except for 2 pole motors where there is only one lockup position), so it is not as convenient to use for feedback alignment. See section 3.2 for a more detailed description of commutation alignment procedures. The number of poles must be entered correctly for the electrical angle to be correct. In the case of the Fanuc motors, they will default to 8 unless one of the two 6 pole types is selected. The gray code and electrical angle are derived from a 10 bit commutation count in all serial pulsecoders except the Pulsecoder A, B, and B2 in which case they come from the position count. The mechanical angle comes from the position count for all Fanuc serial pulsecoders. The position count is absolute immediately upon power up only for the Pulsecoder A, B, and B2. On all others it is only absolute after the encoder is indexed, so dashes will appear in the Mechanical Angle box until the encoder is indexed. The Pulsecoder C does not display a mechanical angle. The table below shows 4 different lockups that can be used to check or set commutation on motors with Fanuc serial encoders. The first two are commonly used with the gray codes but can be used with the electrical angle as well. The first procedure requires energizing all 3 armature lines. A slight wiggle of the shaft should result in the C8 indication toggling between 1 and 0. Likewise the second procedure in which only lines V and W are energized results in the C4 indication toggling when the shaft is wiggled. The last two procedures can only be used with the electrical angle since they do not result in unique gray code patterns. It is easy to go from +U –V to +U –W just by moving the minus lead from V to W. This should cause the motor to jog 60 electrical degrees in the forward direction. Failure to move the correct number of degrees or in the correct direction would be an indication of a significant problem. Setting these angles within ±3 electrical degrees is normally quite sufficient. Lockup Elect. Angle Comm Pulses C1 C2 C4 C8 +U –V –W 0 0 0 0 1→0 +V –W 90 0 1 0→1 0 +U –V 330 +U –W 30 The incremental and ABS encoders will be tested as Generic Incremental encoders, but their alignment would follow the table below: Lockup Comm Pulses H1 H2 H3 H4 H5 H6 +U –V –W H H H L→H H H +V –W H L H→L H H H The entire gray code pattern is as follows:

TI-5000 63 OPERATION Serial A,B,Z A, B, B2, Alpha & C 3000P & 2500P C8 C4 C2 C1 C8 C4 C2 C1 H4 H3 H2 H1 0 0 0 0 H H H H 0 0 0 1 H H H L 0 0 1 1 H H L L 0 0 1 0 H H L H 0 1 1 0 H L L H 0 1 1 1 H L L L 0 1 0 1 H L H L 0 1 0 0 H L H H 1 1 0 0 L L H H 1 1 0 1 L L H L 1 1 1 1 L L L L 1 1 1 0 L L L H 1 0 1 0 L H L H 1 0 1 1 L H L L 1 0 0 1 L H H L 1 0 0 0 L H H H It may be worth checking in some situations to verify that this pattern is taking place correctly. 2.6.2.5.1.2 COUNT The Count frame displays the encoder count both as a decimal and hexadecimal number. Users will typically be interested in only the decimal count, but encoder repairmen and other advanced users may find the hexadecimal representation useful. On power up, this count will be zero for the Pulsecoder A and Alpha series when the encoder shaft is at the 9:00 position (i.e.: looking at the end of the shaft with the stamped model number under it, the arrow on the shaft will be pointing to the left). These encoders internally keep up with the count with respect to these references. The Pulsecoder C works differently in that its data reports the difference in the count from the previous reading to the present reading. Therefore, its zero reading will be referenced to its position at power-up. The TI-5000EX software accumulates these difference readings and maintains and reports a total count so that the result is a value similar to the total counts reported for the Pulsecoder A and Alpha series. As mentioned previously, the count represents an absolute position on power up only for the Pulsecoder A, B, and B2. On other encoders, the count represents an absolute position only after the encoder is indexed. It does not represent an absolute position for the Pulsecoder C. Always verify that the encoder count appears to change by the correct number of counts/rev while turning the encoder. If the count is not changing, then there is an encoder problem. As described in a later section, the Count Test may be performed to more accurately determine whether the correct number of counts per revolution is occurring, but this is an important initial evaluation. 2.6.2.5.1.3 LINE STATES The Pulsecoder C is the only supported serial pulsecoder for which a line state is indicated. The line state indicated is the Z or index line. This is not really an index line, like an incremental encoder, but an index bit that goes HI once per revolution. Even though it is not really a line state per se, the Z line state box is a convenient place to show it. The Pulsecoder C sets this bit HI momentarily when moved past the index position, so you will see the indicator flash HI momentarily. Unlike an incremental encoder, it will not stay HI

TI-5000 64 OPERATION if you stop right on the index position. The index pulse occurs when C1, C3, and C4 are HI and C2 is changing between LO and HI. This commutation indication will occur in as many different positions as there are pole pairs, but the index pulse will only occur in one of these positions. Note that this index indication is quite different from the Alpha and Beta series encoders. For the Alpha and Beta encoders, the count is index on the initial revolution after power up, while the Pulsecoder C is reporting an index position on every revolution. 2.6.2.5.1.4 ENCODER STATUS INDEX – The INDEX box is disabled for the Pulsecoder A, B, and B2 because these encoders display the correct count on power up without indexing. It is also disabled for the Pulsecoder C because the TI-5000EX does not index for these encoders. All other serial pulsecoders must be indexed on power up unless they are absolute encoders which have been battery backed up. The absolute encoders will have an ‘A’ in their name while the incremental encoders will have an ‘I’. For instance the Fanuc Alpha I64 is an incremental encoder (incremental is Fanuc’s way of saying ‘not battery backed’ for serial encoders), so it will need to index on every power up. An Alpha A64 encoder is an absolute (absolute is Fanuc’s way of saying ‘battery backed’) so it will need to be indexed on power up only if it had not been connected to a battery. Always verify that the INDEX box changes from ALARM to OK within one revolution of the encoder. DATA - If no data is being sent from the encoder, NONE will be displayed in the DATA box. If the TI-5000EX and the encoder are communicating correctly, RECEIVING will be displayed in the DATA box. The cabling is the first thing to check if the encoder is not communicating, but it can also mean a component failure in the Pulsecoder. INTERNAL ERROR - The INTERNAL ERROR box will show ALARM if there is an internal error alarm and OK if there is not. Several bits in the data stream for the various Pulsecoders respond to the loss of an LED and the resulting counting problems. These bits are consolidated and reported under the INTERNAL box with ALARM if any are HI. If none of these bits are HI, then OK is displayed. Causes for alarms could be a malfunctioning LED, incorrect alignment of the optics, and other problems. Removal of the board in the Pulsecoder is likely to cause some alignment problems. BATTERY - The BATTERY box will show ALARM if there is a battery error alarm and OK if there is not. It is often possible to alternately connect and disconnect battery voltages to the encoder to verify that this bit is working properly. This field is disabled for Alpha and Beta Pulsecoder I (incremental) encoders and the Pulsecoder C because they do not have battery backup capability. The remaining absolute pulsecoders will use this. The Pulsecoders with battery capability should show ALARM in this column if the voltage on the +6VA and 0VA lines is less than approximately 4.6 VDC. If the voltage is above approximately 4.6 VDC, the display should show OK. Many Fanuc encoders use a separate battery cable that is not part of the encoder signal harness. However, some encoders use lines that are part of the signal harness for the battery. The Fanuc serial cables (TI-5004, TI-5006, and TI-5007) bring out the battery line for easy connection. Using a clip lead to jumper the battery wire to J1 pin 1 (+5V) on the TI-5000EX is a good way to supply battery voltage. When this is done and the display changes to OK, sometimes it is necessary to connect the clip lead to J1 pin 2 (GND) in order to make it display ALARM again. Download cable sheets from the Customer Page at http://www.mitchell-electronics.com for cable pinouts and wiring details. OVERHEAT - The OVERHEAT box will show ALARM if there is an overheat error alarm and OK if there is not. It is often possible to alternately connect and disconnect thermal lines to the encoder to verify that this bit is working properly This field may not be in effect for all serial encoders. Thermal contacts inside the Pulsecoder complete a circuit to ground when temperatures are within range. When temperatures become excessive, the contacts open, and the overheat bit is transmitted with the data. The Pulsecoders with the DB15 connectors indicate only their own temperature and do not loop through the motor. Pulsecoders with the circular connectors however, bring this circuit out on the BRN and RED wires (which do not go to the circular connector). In a normal installation these wires are connected through other contacts such as motor overload contacts. These wires can be connected together during testing. When connected together, the

TI-5000 65 OPERATION Pulsecoder should not indicate an overheat condition (providing it is not overheated) with an OK display. If these wires are disconnected from each other, the OVERHEAT box should indicate ALARM. The newer Alpha i and Beta i encoders connect to the motor using two round brass contacts on the face of the encoder (near the shaft coupling). This of course means that the encoder must be mounted on the motor so that the motor overheat contacts mate with these contacts on the encoder. Unlike previous model pulsecoders, these newer style encoders are apparently not looking for a contact closure but are reading a thermistor or some similar device in the motor. If these contacts are shorted, the ALARM indication will not change to OK (and stay that way). However, if a resistor from around 5K to 50K ohms is connected to these contacts, the display will change to OK. A 10K resistor is a commonly available value, and it is probably a good value to use for testing these encoders. ENCODER ID – There is no encoder ID support for Fanuc serial encoders. 2.6.2.5.2 COUNT TEST The Count Test can be started by clicking on the Count Test button among the test buttons at the top of the display. The Count Test it will verify that the encoder is incrementing the correct number of counts per revolution. The Count Test for the Fanuc encoders is not significantly different from that for other encoders, so please refer to the general information on the count test in Section 2.2.2 for further details. The number of bits tested by the Stuck Bit Test varies depending upon the particular model. Encoders with greater than a 16 bit count per revolution will test bit0 to bit15 for activity. Others will test as many bits as are used in the count for one revolution.

TI-5000 66 OPERATION 2.6.3 HEIDENHAIN SERIAL ENCODERS

2.6.3.1 GENERAL COMMENTS The Heidenhain serial encoders listed in the next section are supported by this selection. Heidenhain incremental encoders with A, B, and Z lines should be tested as Generic Incremental encoders. Heidenhain encoders with sine/cosine commutation outputs (like the ERN 1387) are discussed in the section on incremental encoders. Heidenhain encoders commonly show up on Siemens, Bosch, Baldor and Indramat motors among others. The encoders built for the Indramat MDD series motors are significantly different from the standard Heidenhain encoders, and they are described in the Indramat section. Some Heidenhain encoders feature serial outputs, but all Heidenhain encoders have quadrature incremental outputs as well. All encoders appear to have A and B outputs, but not all include a Z index pulse. When a Z pulse is provided, the incremental part of the encoder can be tested like any other incremental encoder (as described in the incremental section). It is typically the serial encoders that do not include an index pulse, and tips are given in this section for testing the incremental section on those encoders. The incremental outputs come in several formats: TTL, HTL, 1V p-p sine, and 11 µA p-p sine. The less common 11 µA format is not supported by the TI-5000EX. The 1V p-p sine outputs should be used with the TI-5101 1 V p-p interface module. This module amplifies the 1V p-p signals up to a range near 5 V which is more acceptable to the TI-5000EX. Usually the A and B signals will work without the amplification, but the Z pulse sometimes will not. The TTL signals will work directly just like any other 5 V incremental encoders. The HTL signals should be limited to less than 15 V to avoid over-voltage to the TI-5000EX inputs. When the incremental encoders include commutation, it comes in the form of a C and D, sine and cosine, outputs. These outputs provide one period of a sine or cosine wave for each revolution of the encoder which can be converted to an angle. This angle can be read using the Sin/Cos 1 Period/Rev function by selecting Incremental Encoder, AB Quadrature Count and then selecting Sin/Cos Commutation in the Data Display window. See Section 2.3.5.1.2 for more information on testing these encoders. The RON3350 and ERN1387 are two such encoders, and the ones used on Siemens 1FT6 motors can be connected to the TI-5000EX using the TI-5010 cable. You can use the TI-5010 cable pin designations as a guide for connecting to other (non-Siemens) motors. Heidenhain supports two serial data formats: SSI and Endat. The TI-5000EX software is compatible with both formats at this time (as indicated in the next section). In addition to the serial lines, the Endat and SSI encoders also include 1V p-p A and B lines (no index pulse is included).

TI-5000 67 OPERATION 2.6.3.2 TYPES SUPPORTED The following list shows the Heidenhain serial encoders that are either currently supported by the TI-5000EX or are under development and will soon be supported: Type Format Serial Incremental Cables Cnt/Rev Cnt/Rev ECI 1317-32 Endat 131,072 128 TI-5059 (B+R) EQI 1325-32 Endat 8,192 128 TI-5031 (Siemens) EQI 1327-32 Endat 32,768 128 TI-5059 (B+R) EQI 1329-32 Endat 131,072 128 TI-5059 (B+R) ECN 1313-512 Endat 8,192 2,048 TI-5059 (Bosch/B+R)

ECN 1313-2048 Endat 8,192 8,192 TI-5031 (Siemens), TI5043 Baldor),

TI-5059 (Bosch/B+R) ECN 125 Endat 33,554,432 0 TI-5662 EQN 1325-2048 Endat 8,192 8,129 TI-5031 (Siemens),

TI5043 (Baldor), TI-5059 (Bosch/B+R) EQN 1325-2048 SSI 8,192 8,192 TI-5049 (Stromag) ERN 1381* Inc N/A 8,192 TI-5010 (Siemens) ERN 1387* Inc N/A 8,192 TI-5010 (Siemens) RON 350* Inc N/A 8,192 TI-5010 (Siemens) ERN 3350* Inc N/A 8,192 TI-5010 (Siemens) * These are not serial encoders – test as incremental. May have sine/cosine comm. lines. Note: Some of the encoders listed above may not be selectable in the current version of software

but may be under development. The dash number (-32, -512, -2048) is not shown in the selection box because it is irrelevant to the serial count.

2.6.3.2.1 IDENTIFICATION The Heidenhain encoders are normally clearly marked, so identification is not a problem. Especially for the serial encoders, check the following:

1. For ECN1313 and EQN1325 encoders, check the label to see whether they are SSI or Endat format. You will probably see Endat most often, but it can be confusing if it is an SSI and you assume it is an Endat.

2. For ECN413, ECN1313, EQN415 and EQN1325 encoders, check to see whether they are labeled

Indramat or have an additional part number that starts with DSF or HSF. These are probably Indramat encoders, and they use a format different from both SSI and Endat. See the Indramat section for more information on these.

3. The part numbers beginning with EC are single-turn encoders and the EQ numbers are multi-turn

encoders. 4. If the third letter is N, such as EQN, the encoder is an optical disk encoder. All of the early Endat

encoders had this type of part number. If the third letter is I, they are a magnetic disk encoder. Many of the newer encoders are this type. These encoders may require some type of alignment for the disk in order to work properly, and they may not work properly when unless they are mounted on a motor shaft. Please consult Heidenhain literature for more details.

TI-5000 68 OPERATION The TI-5000EX does not currently report an encoder ID field for Endat serial encoders, but this feature is planned for future revisions. The SSI encoders are not known to have ID capability. 2.6.3.3 CONNECTION Connection requires using the correct cable as shown in the chart in the Type Supported section. Also the WinTI5000EX ‘Feedback Selection’ frame has a cable dropdown menu from which you can select the cable that you need. After making the cable selection, that selection will appear on the Data Display report which is helpful in documenting the cable used. Download cable sheets from the Customer Page at http://www.mitchell-electronics.com for cable pinouts and wiring details. Cable configurations other than the cables listed are known to exist. There may be cables that are made by OEM machine manufacturers using these encoders. If properly cabled, the serial Endat encoders can be used with the TI-5101 1V p-p adapter so that it is easier to check the incremental portion with the same connection. See the section on cables for more information. 2.6.3.4 ENCODER SELECTION Click on the Select Feedback button to make the selection. The Heidenhain Endat serial encoders require the following setup sequence:

1. Click on the Encoder Feedback radio button. 2. Select Heidenhain from the Encoder Manufacturer dropdown menu. 3. Select the encoder type that you have from the Encoder Type dropdown menu.

The encoder types listed in the current software revision are shown in an earlier section. Siemens motors are most often 6 or 8 pole motors. The number of poles may be selected from the POLES dropdown menu. To determine the number of poles, apply a small voltage to 2 of the armature leads to lock the rotor, and then count the number of lockup positions to determine the number of pole pairs. For instance, if the rotor locks up in 4 different shaft positions, the motor has 4 pole pairs or 8 poles. The number of poles must be entered correctly in order to display the electrical angle correctly. It is essential for the electrical angle to be correct when checking or setting the encoder alignment for correct commutation. See the Count section below for information in verifying the sine and cosine incremental lines. 2.6.3.5 TESTING Heidenhain Incremental encoders are tested as Generic Incremental Encoders using Data Display, Line Levels, Incremental Count Test, and Phase Test for a complete test. Heidenhain serial encoder types listed above (like most serial encoders) use only the Data Display and the Serial Count Test. The forward armature direction for Siemens motors is CW looking at the drive shaft end. 1 V p-p Signals – The 1 V p-p signals must be verified on encoders that incorporate these signals. If the incremental count is not working correctly, that will be an immediate indication of a problem. However, the fact that the incremental count appears to be working is not sufficient. The amplitude of these signals should be checked.

TI-5000 69 OPERATION Amplitude measurement is probably best done with an oscilloscope. Connecting the scope ground clip to J1 pin 2 and checking the amplitude of the individual line at J1 pins 3, 4, 5, and 6, is a good method to use. This should be done coming out of the encoder before the signals go through any adapter modules. Since these are nominally 1 V p-p between true and complement lines, each individual signal will be about 0.5 V p-p. Some encoders may provide a 1 V p-p signal on the true lines (pins 3 and 5) and a DC voltage of about 2.5 VDC on the complement lines (pins 4 and 6). But most will provide 0.5 V p-p on all 4 lines. 2.6.3.5.1 DATA DISPLAY Data Display is the initial test, and it is started by default when WinTI5000EX is started. When already in another test, it can be started by clicking on the Data Display button among the test buttons at the top of the display. Use it for the following:




The following sections describe information shown on the display. 2.6.3.5.1.1 COMMUTATION Checking and setting commutation requires knowing the forward armature direction and the number of motor poles. There a several ways to determine those parameters, but here is a simple procedure using static lockups. These procedures are facilitated by using the TI-5260 PM Rotor Lockup Switch.

1. Lock the rotor using a +U –V polarity. Note the TI-5000EX mechanical angle reading. 2. Switch the minus lead from V to W and note the direction of shaft rotation. That direction is the

forward armature direction for the motor. 3. Note the new mechanical angle reading for the +U –W lockup. 4. As a double check, determine the number of different positions of rotation in which the rotor locks

for the +U –W polarity. 5. The number of poles can be determined by the number of lockups for a single polarity or the change

in mechanical angle when moving from the +U –V to +U –W lockup. The following table summarizes this information:

Number of Poles Number of Lockup Positions Change in Mechanical Angle 2 1 60 degrees 4 2 30 degrees 6 3 20 degrees 8 4 15 degrees 10 5 12 degrees 12 6 10 degrees 14 7 8.6 degrees 16 8 7.5 degrees

The electrical angle can be used to check and set commutation using a static rotor lockup by applying a small lockup voltage to the stator windings. The Fanuc style commutation gray code shown as C1 – C8 can also be used for commutation, but we strongly recommend using the electrical angle as the superior method of alignment for Heidenhain encoders. For a particular lockup polarity, the rotor will lock up in as many

TI-5000 70 OPERATION different positions as there are pole pairs but the gray code and electrical angle indications will be the same at each lockup position. The mechanical angle will be different at each lockup position (except for 2 pole motors where there is only one lockup position), so it is not as convenient to use for feedback alignment. See section 3.2 for a more detailed description of commutation alignment procedures. The number of poles must be entered correctly for the electrical angle to be correct. The gray code, electrical angle and mechanical angle are derived from the position count. The position count is absolute immediately on power up for Heidenhain serial encoders. Siemens - The table below shows 3 different lockups which can be used to check or set commutation on Siemens motors with Heidenhain serial encoders. The first one puts the feedback on a zero electrical angle which some users favor. It requires applying power to all 3 armature lines. The last two procedures require applying power to only two armature leads at a time. It is easy to go from +U –V to +U –W just by moving the minus lead from V to W. This should cause the motor to jog 60 electrical degrees in the forward direction (CW looking at the shaft for Siemens). Failure to move the correct number of degrees or in the correct direction would be an indication of a significant problem. Setting these angles within ±3 electrical degrees is normally quite sufficient.

Lockup Elect. Angle -U +V +W 0 +U –V 150 +U –W 210

Bosch and B+R – The use of Heidenhain serial encoders on Bosch and B+R motors is more complicated than Siemens motors. These motors use the memory provided by the Endat encoders, and they store a commutation offset in the memory. By using the commutation offset, the encoders do not have to be set to a common alignment. Each motor can be aligned differently, and in general they are. If you are familiar with the Indramat digital encoders or Allen Bradley motors with Hiperface encoders, you recognize this scheme. You can use the TI-5000EX to see how the encoder is aligned when you receive the motor, and you can set it back to that alignment after repair, but you cannot verify that that alignment is actually correct without retrieving the commutation information from the encoder memory. Memory Test software that will provide alignment information is currently under development for both of these motors. Kollmorgen AKM – We believe that this is the correct alignment for the Kollmorgen AKM motors.


Lockup Elect. Angle -V +W 0 +U –V 60 +U –W 120

We do not currently have alignment information for Baldor motors using the Endat encoders. 2.6.3.5.1.2 COUNT The Count frame displays the encoder count both as a decimal and hexadecimal number. Users will typically be interested in only the decimal count, but encoder repairmen and other advanced users may find the hexadecimal representation useful. In general this count will not be zero on power up. This is an absolute encoder, and it will remember the count on power up. The number of counts/rev for the various models is shown in the table in an earlier section on types of encoders supported. The ECN encoders are single-turn encoders in that they do not keep track of revolutions. The EQN and EQI encoders are multi-turn encoders, and they will keep track of revolutions (typically 4,096 revolutions). Always verify that the encoder count appears to change by the correct number of counts/rev while turning the encoder. If the count is not changing, then there is an encoder problem. As described in a later section, the Count Test may be performed to more accurately determine whether the correct number of counts per revolution is occurring, but this is an important initial evaluation. Typically serial encoders that include incremental lines are tested both as incremental encoders and serial encoders. Since the Heidenhain serial encoders do not include an index pulse, an incremental encoder count test cannot be performed. Reading the absolute count from EQN 1325 provides a possible method of also checking the integrity of the incremental count. The procedure is as follows:

1. Read the absolute count from the Data display and write it down. 2. Click the Select Feedback button and select an incremental encoder with 8192 counts per turn. 3. Go back to the data display, and it should show a count of zero. Turn the encoder approximately 10

revolutions, and write down the count. 4. Select the EQN1325 serial encoder again. 5. Go back to data display and read the absolute count from the display. Subtract the count recorded

in step 1 from this count. It should compare very closely to the count recorded in step 3. A similar procedure can be used for the ECN 1313, but it is complicated by the fact that the ECN 1313 does not count revolutions. This can be overcome by modifying the above procedure slightly. In step 1, turn the encoder until the absolute count is approximately 1,000. In step 3, turn the encoder 10 1/4 turns clockwise. In step 4, of course, select ECN 1313. In step 5, add 81920 (the count for 10 complete turns) to the absolute reading. This would be the final reading if the ECN 1313 was capable of keeping track of revolutions. Subtracting the count in step 1 from this number should be very close to the count recorded in step 3. The above example is correct for encoders with 8,192 incremental counts/rev. As shown in the identification table, some Endat encoders have only 128 or 2,048 counts/rev. The procedure above will change accordingly with those numbers.

TI-5000 72 OPERATION 2.6.3.5.1.3 ENCODER STATUS INDEX – The INDEX box is disabled for all Heidenhain serial encoders because these encoders display the correct count on power up without indexing. DATA - If no data is being sent from the encoder, NONE will be displayed in the DATA box. If the TI-5000EX and the encoder are communicating correctly, RECEIVING will be displayed in the DATA box. The cabling is the first thing to check if the encoder is not communicating, but it can also mean a component failure in the Pulsecoder. INTERNAL ERROR - The INTERNAL ERROR box will show ALARM if there is an internal error alarm and OK if there is not. The internal alarm is the result of self tests that are done by the encoder electronics. Unlike most other encoders, the Endat encoders latch the errors. That is to say that the INTERNAL ERROR box will continue to show ALARM indefinitely, once an error occurs. Most encoders will no longer show an alarm, if the problem is no longer detected by the encoder. Apparently there are some events, such as power supply glitch or low supply voltage, that can cause an internal error alarm. However, even after the problem is corrected, the INTERNAL ERROR box continues to show alarm. The TI-5000EX can clear the memory location that latches the error by clicking the Reset Alarm button. If an alarm is cleared in this way, and the error continues to come back (for instance after rotating the encoder, cycling power, or allowing some time); then there is probably a problem with the encoder. If it fails to reappear, it may be that the encoder does not have a problem, and the alarm was caused by some temporary circumstance. Heidenhain literature indicates that causes for alarms could be position error, illumination, signal amplitude, etc. ERROR TYPE – The Error Type field will provide a numerical description of the alarm if there is an alarm. The Endat encoders provide a bit pattern that describes the alarm. The Endat documentation shows these possible alarms:

Alarm Number Description 1 Light Source 2 Signal Amplitude 3 Position Value 4 Over Voltage 5 Undervoltage 6 Overcurrent 7 Battery

These alarms are reported by the alarm bit pattern. A given encoder may not implement all of these alarms, and there is another bit pattern in the Endat data that indicates which errors are reported for that particular encoder. The TI-5000EX software takes this bit pattern into account and reports only the errors that are implemented for the encoder under test. More than error one bit may be HI indicating more than one parameter in alarm. In that case the ERROR TYPE box will show the number of each error. For instance, 2 3 would indicate both error 2 – Signal Amplitude and 3 – Position Value errors were reported by the encoder. ENCODER ID – The ENCODER ID will indicate the type of Endat encoder in use based on information read from the Heidenhain section of the encoder memory. This is base primarily on the number of serial counts/rev and whether or not it is a multi-turn encoder. This information may not allow it to completely

TI-5000 73 OPERATION identify the encoder. For instance, it cannot tell the difference between an EQI1325 and an EQN1325. But for the purposes of testing the encoder and alignment, this is not important. If the ID checking software agrees with your encoder selection, it will indicate OK in the ID box. For instance if you select EQI1329, and the ID agrees with that, the ID box will show ‘EQI1329 OK’. If you have selected the wrong encoder, it will show ‘EQI1329 Error’. In that case, you should verify that you have made the wrong selection and make the correct selection. 2.6.3.5.2 COUNT TEST The Count Test can be started by clicking on the Count Test button among the test buttons at the top of the display. The Count Test it will verify that the encoder is incrementing the correct number of counts per revolution. The Count Test for the Heidenhain encoders is not significantly different from that for other encoders, so please refer to the general information on the count test in Section 2.2.2 for further details. The stuck bit test will test bit0 to bit12 for activity for 8,192 count 13 bit Endat encoders.

TI-5000 74 OPERATION 2.6.4 HENGSTLER (UNICO) SSI SERIAL ENCODERS

2.6.4.1 GENERAL COMMENTS The Unico 319-663 encoder appears to be the same as the Hengstler Type RA 58 SSI 24 bit serial encoder. There are 12 bits for counting revolutions and 12 bits for the rotational angle. These bits are put together in one 24 bit gray code data word. There is an alarm bit that follows the 24 bit count. According to the Hengstler catalog, the alarm bit responds to low voltage, high temperature, broken disk or faulty LED. Information on this encoder is available from the Hengstler catalog “Shaft Encoders, Linear and Angular Measuring Systems 2001”. Danaher Controls (Ph. 800-234-8731) can supply the catalog. The encoder power supply is specified between 10V and 30V, so it should be powered from an external supply rather than the TI-5000EX. Connect an external bench supply to the +V and 0V pins of the encoder. Be sure to also connect the 0V line to J1 pin 2 of the TI-5000EX to ensure a common ground system. While the power supply is greater than 5V, the serial signals are 5V levels. 2.6.4.2 TYPES SUPPORTED The following list shows the Hengstler serial encoders that are currently supported by the TI-5000EX: Type Format Counts/Rev Cables Hengstler/Unico SSI 4,096 TI-5636 2.6.4.2.1 IDENTIFICATION These encoders are clearly marked with the part numbers shown in the previous section, so identification should be no problem. The Hengstler part number is Type RA 58. The Unico part number is 319-663 2.6.4.3 CONNECTION A cable for this encoder is not currently offered. The connector is a 12 pin connector of the type used on the Indramat encoders, except the pin rotation is reversed. Cabling for the Hengster/Unico encoders is the TI-5636 as shown below: J1 TB Pin TI-5000EX Signal Signal Encoder Pin Color 2 GND 0V 1 BRN 9 SERIN DATA 2 PNK 10 SERIN* DATA* 10 GRY J2 TB Pin 3 CLK CLOCK 3 YEL 4 CLK* CLOCK* 11 GRN 10-30V 8 WHI 0V Signal 12 BLK Direction* 5 BLU

TI-5000 75 OPERATION The TI-5000EX really only uses the 0V reference and the data and clock true and complement lines. If the Direction* line is left disconnected, the count increases for CW rotation. To reverse the direction connect the Direction* line to the 0V Signal line. 2.6.4.4 ENCODER SELECTION Click on the Select Feedback button to make the selection. The Hengstler serial encoders require the following setup sequence:

1. Click on the Encoder Feedback radio button. 2. Select Hengstler from the Encoder Manufacturer dropdown menu. 3. Select the encoder type that you have from the Encoder Type dropdown menu.

The encoder types listed in the current software revision are shown in an earlier section. The number of poles may be selected from the POLES dropdown menu. To determine the number of poles, apply a small voltage to 2 of the armature leads to lock the rotor, and then count the number of lockup positions to determine the number of pole pairs. For instance, if the rotor locks up in 4 different shaft positions, the motor has 4 pole pairs or 8 poles. The number of poles must be entered correctly in order to display the electrical angle correctly. It is essential for the electrical angle to be correct when checking or setting the encoder alignment for correct commutation. 2.6.4.5 TESTING Hengstler/Unico serial encoder types listed above (like most serial encoders) use only the Data Display and the Serial Count Test. No information on the Unico motor (such as forward armature direction) is available at this time. 2.6.4.5.1 DATA DISPLAY Data Display is the initial test, and it is started by default when WinTI5000EX is started. When already in another test, it can be started by clicking on the Data Display button among the test buttons at the top of the display. Use it for the following:




The following sections describe information shown on the display.

TI-5000 76 OPERATION 2.6.4.5.1.1 COMMUTATION The electrical angle can be used to check and set commutation using a static rotor lockup by applying a small lockup voltage to the stator windings. The number of poles must be entered correctly for the electrical angle to be correct. We do not currently have alignment information for the Unico motors using the Hengstler/Unico encoders. 2.6.4.5.1.2 COUNT The Count frame displays the encoder count both as a decimal and hexadecimal number. Users will typically be interested in only the decimal count, but encoder repairmen and other advanced users may find the hexadecimal representation useful. This is an absolute encoder, and it will remember the count on power up. The Hengstler/Unico serial encoder produces a count of 4,096 (12 bits) per revolution. In addition, they count up to 4,096 full revolutions, so the count can range -8,388,608 (800000 HEX) to +8,388,607 (7FFFFF HEX). (24 bits - 12 bits for count per revolution and 12 bits of revolution count). The data is in gray code, but the TI-5000EX automatically decodes it and displays it as a binary count. As mentioned previously, the count increases when rotated in the CW direction when the Direction* line is disconnected. Connecting the Direction* line to the 0V Signal line reverses the direction. Always verify that the encoder count appears to change by the correct number of counts/rev while turning the encoder. If the count is not changing, then there is an encoder problem. As described in a later section, the Count Test may be performed to more accurately determine whether the correct number of counts per revolution is occurring, but this is an important initial evaluation. 2.6.4.5.1.3 ENCODER STATUS INDEX – The INDEX box is disabled for Hengstler/Unico serial encoders because these encoders display the correct count on power up without indexing. DATA - If no data is being sent from the encoder, NONE will be displayed in the DATA box. If the TI-5000EX and the encoder are communicating correctly, RECEIVING will be displayed in the DATA box. The cabling is the first thing to check if the encoder is not communicating, but it can also mean a component failure in the encoder. INTERNAL ERROR - The currently supported Hengstler/Unico encoders provide one error bit which is reported in the Error field. This bit is reported under the Error column with an "ALARM" message if it is HI. If this bit is LO, an "OK" message results. Hengstler/Unico literature indicates that causes for alarms could be low voltage, high temperature, broken disk or faulty LED. BATTERY - The BATTERY box is disabled for Hengstler/Unico serial encoder because they do not utilize battery backup. OVERHEAT - The OVERHEAT box is disabled for Hengstler/Unico serial encoders because they do not report overheat conditions. ENCODER ID – The ENCODER ID box for the Hengstler/Unico serial encoders because they do not provide ID information.

TI-5000 77 OPERATION 2.6.4.5.2 COUNT TEST The Count Test can be started by clicking on the Count Test button among the test buttons at the top of the display. The Count Test will verify that the encoder is incrementing the correct number of counts per revolution. The Count Test for the Hengstler/Unico encoders is not significantly different from that for other encoders, so please refer to the general information on the count test in Section 2.2.2 for further details. The stuck bit test will test bit0 to bit11 for activity for 4,096 count 12 bit encoders. The stuck bit test is run on the gray code data read from the encoder rather than after conversion to the binary data.

TI-5000 78 OPERATION 2.6.5 INDRAMAT DIGITAL MOTORS, SERIAL ENCODERS AND RESOLVERS

2.6.5.1 GENERAL COMMENTS This section covers the so called digital Indramat motors and feedback. The part numbers begin with MDD, MHD, MKD, and MKE. These motors use complicated serial encoder and resolver feedback systems which include memory data to identify the motor to the drive. The older motors, whose part numbers begin with MAC, are much simpler. They use Hall effect feedback for commutation, and use incremental encoders for position feedback. They also include a tachometer for speed feedback. Refer to previous sections on Generic Incremental Encoders whenever MAC motors are involved. Accessories available for the MAC motors include the TI-5042 cable and the TI-5105 Adapter Module which allow connection to the encoder, Halls, and tach at the same time. This section covers the serial digital feedback devices, and does not cover MAC motors. 2.6.5.2 TYPES SUPPORTED The following list shows the Indramat serial encoders that are currently supported by the TI-5000EX:

Part Number Type Motor Counts/Rev Fbk. Type

DSF0XSN-H E/RCN 212 Heidenhain Single-turn MDD 1024 3 DSF0XMN-H E/RQN 224 Heidenhain Multi-turn MDD 1024 19 D/HSF0XSN-H E/RCN 413 Heidenhain Single-turn MDD/MHD 2048 4 D/HSF0XMN-H E/RQN 425 Heidenhain Multi-turn MDD/MHD 2048 20 D/HSF0XSN-H ECN 1313 Heidenhain Single-turn MHD 2048 4 D/HSF0XMN-H EQN 1325 Heidenhain Multi-turn MHD 2048 20 DSF0XSN-S SCS70 Single-turn - Stegmann MDD 2048 4 DSF0XMN-S SCS70 Multi-turn - Stegmann MDD 2048 20 DSF0XSN-S SCS70 (Spindle) Single-turn - Stegmann 2AD 2048 4 DSF0XMN-S SCS70 (Spingle) Multi-turn - Stegmann 2AD 2048 20 MDD, MKD, MKE Resolver Single-turn MDD/MKD/MKE 0 MDD, MKD, MKE Resolver Multi-turn MDD/MKD/MKE 16 Note: 1. All encoders use the TI-5021 cable 2. Resolver motors use the TI-5040 cable. 2.6.5.2.1 IDENTIFICATION The Indramat encoders are manufactured by both Heidenhain and Stegmann. The encoders will have an Indramat part number that starts with DSF or HSF followed by a number and SN for single-turn or MN for multi-turn. At the end of this number, -H will mean Heidenhain and –S will mean Stegmann. The Stegmann encoders seem to be very common on Indramat spindle motors. On the permanent magnet brushless motors, they do not seem to be used on the MHD series motors, and they seem to be used considerably less than Heidenhain encoders on the MDD motors. This is also indicated by the Indramat motor part number. Here are some example part numbers: MDD 112D-N-020-N2L-130PB0 Heidenhain single-turn MDD 065A-N-040-N2M-095PB0 Heidenhain multi-turn

TI-5000 79 OPERATION MDD 071A-N-030-N2S-095PB0 Stegmann single-turn MDD 071C-N-060-N2T-095GA2 Stegmann multi-turn The Heidenhain encoders include an ECN, RCN, EQN or RQN part number. The older MDD motors can have the ECN/RCN212, EQN/RQN224, ECN/RCN413 and EQN/RQN425 encoders (the newer motors will have the 400 series encoders). According to the manual, the MDD motors can also use resolver feedback, but it does not appear to be very common. The Stegmann encoders will include a Stegmann SCS70 part number. These encoders will appear on the MDD servo motors and the 2AD spindle motors. There is much less memory data in the spindle motor encoders. If you mistakenly select the Stegmann servo motor encoder, the Memory Test will show a large number of errors. The Memory Test software as well as the encoder ID should warn you that you have made an incorrect selection in that situation. The MHD motors will use the Heidenhain ECN/RCN413, EQN/RCN425, ECN1313 and EQN1325 encoders. The MKD motors typically use resolver feedback, but according to the manual, they can come with encoder feedback. The MKE motors seem to be environmentally sealed versions of the MKD motors. To avoid confusion, please note that Heidenhain has encoders using these same part numbers in their standard catalog, and they are completely different. The Heidenhain ECN1313 and EQN1325 ENDAT encoders were discussed in a previous section, and they are not the same as the Indramat encoders. The Endat encoders are used in Siemens, Bosch, Heidenhain, Baldor, B+R, and other motors, and they will not have the DSF part number on them. 2.6.5.3 CONNECTION Connection requires using the correct cable as shown in the chart in the Type Supported section. Also the WinTI5000EX ‘Feedback Selection’ frame has a cable dropdown menu from which you can select the cable that you need. After making the cable selection, that selection will appear on the Data Display report which is helpful in documenting the cable used. Download cable sheets from the Customer Page at http://www.mitchell-electronics.com for cable pinouts and wiring details. The TI-5104 Indramat Adapter Module must be used with all encoders. This module is also used when the memory is read or programmed for resolver feedback. Read the Indramat Alignment Documents carefully to insure correct connections. 2.6.5.4 ENCODER SELECTION Click on the Select Feedback button to make the selection. The Indramat serial encoders require the following setup sequence:

1. Click on the Encoder Feedback radio button. 2. Select Indramat from the Encoder Manufacturer dropdown menu. 3. Select the encoder type that you have from the Encoder Type dropdown menu.

The encoder types listed in the current software revision are shown in an earlier section. Indramat motors are 6 and 8 pole motors. Other numbers of poles would be rare if they exist at all. The number of poles may be selected from the POLES dropdown menu. To determine the number of poles, apply a small voltage to 2 of the armature leads to lock the rotor, and then count the number of lockup

TI-5000 80 OPERATION positions to determine the number of pole pairs. For instance, if the rotor locks up in 4 different shaft positions, the motor has 4 pole pairs or 8 poles. The parameters in the encoder memory also will show the number of pole pairs. The number of poles must be entered correctly in order to display the electrical angle correctly. It is essential for the electrical angle to be correct when checking or setting the encoder alignment for correct commutation. 2.6.5.5 TESTING As mentioned previously, Indramat MAC motors with Heidenhain Incremental encoders are tested as Generic Incremental Encoders using Data Display, Line Levels, Incremental Count Test, and Phase Test for a complete test. Indramat serial encoder types listed above (like most serial encoders) use only the Data Display and the Serial Count Test. The forward armature direction for Indramat motors is CW looking at the drive shaft end. 1 V p-p Signals – The 1 V p-p signals must be verified on encoders that incorporate these signals. If the incremental count is not working correctly, that will be an immediate indication of a problem. However, the fact that the incremental count appears to be working is not sufficient. The amplitude of these signals should be checked. Amplitude measurement is probably best done with an oscilloscope. Connecting the scope ground clip to J1 pin 2 and checking the amplitude of the individual line at J1 pins 3, 4, 5, and 6, is a good method to use. This should be done coming out of the encoder before the signals go through any adapter modules. Since these are nominally 1 V p-p between true and complement lines, each individual signal will be about 0.5 V p-p. Note that for the Indramat/Stegmann encoders, the encoder must be connected to the TI-5000EX and the software on the Data Display reading serial position data. This is important because these encoders will not output the 1 V p-p signals until they receive software commands from the TI-5000EX (or and Indramat drive). 2.6.5.5.1 DATA DISPLAY Data Display is the initial test, and it is started by default when WinTI5000EX is started. When already in another test, it can be started by clicking on the Data Display button among the test buttons at the top of the display. Use it for the following:




When Data Display first starts for the Indramat encoders, a support message box appears to display important support information relevant to the Indramat encoders since they are quite unique. The message content is as follows:

1. Read the Indramat Alignment Note From Mitchell Electronics, Inc. 2. Power down the TI-5000EX before connecting or disconnecting Indramat feedback devices. 3. Disconnect the resolver from the resolver board before reading the resolver board memory.

The alignment notes provide a detailed procedure for alignment when dealing with both encoders and resolvers, and it is very informative to read. The Data Display continuously reads position data from the

TI-5000 81 OPERATION encoder, and it is best not to connect or disconnect the encoder while this data transfer is occurring. Entering Data Display without the feedback device connected could result in missing important data, so it is best to have the feedback connected before starting. Disconnecting the resolver board while the TI-5000EX is powered could cause transient voltages to develop on the resolver board. This is especially a problem if the resolver is connected to the resolver board during the memory read operation. Always disconnect the resolver from the memory board and power down the TI-5000EX before connecting to the resolver board to avoid the possibility of generating high voltage transients. Data Display should be used as the initial check to see whether the encoder is doing anything at all. The following sections describe information shown on the display. Two examples of the Indramat Data Display are shown below. The first is using the ECN413 selection which shows the multi-turn data disabled. An EQN425 encoder was intentionally used to make this graphic in order to show what the ENCODER ID field looks like with an incorrect selection. The second graphic uses the EQN425 selection, and it shows the additional multi-turn data. It also shows how the ENCODER ID field looks with a correct selection.


2.6.5.5.1.1 COMMUTATION The electrical angle can be used to check and set commutation using a static rotor lockup by applying a small lockup voltage to the stator windings. For a particular lockup polarity, the rotor will lock up in as many different positions as there are pole pairs but the electrical angle indications will be the same at each lockup position. The mechanical angle will be different at each lockup position (except for 2 pole motors where there is only one lockup position), so it is not as convenient to use for feedback alignment. See section 3.2 for a more detailed description of commutation alignment procedures. The number of poles must be entered correctly for the electrical angle to be correct. The electrical angle and mechanical angle are derived from the absolute position information in the serial data. The mechanical and electrical angle data is absolute immediately on power up for Indramat serial encoders. The table below shows 2 different lockups that can be used to check or set commutation on Indramat digital motors with serial encoders. The two procedures require applying power to only two armature leads at a time. It is easy to go from +U –V to +U –W just by moving the minus lead from V to W. This should cause the motor to jog 60 electrical degrees in the forward direction (CW looking at the shaft for Indramat). Failure to move the correct number of degrees or in the correct direction would be an indication of a significant problem. Setting these angles within ±3 electrical degrees is normally quite sufficient.


Lockup Elect. Angle +U –V +U –V lockup angle read from the memory test +U –W +U –W lockup angle read from the memory test

Unlike most feedback alignment discussed in this manual, Indramat digital motors do not have a common lockup angle, and in general, they will all lock up at different angles. Indramat motors store a commutation offset in the encoder memory. By using the commutation offset, the encoders do not have to be set to a common alignment. In order to correctly check or set the alignment, you have to run the Memory Test on the encoder, and record the +U –V and +U –W lockup angles provided by the memory test. The MKD motors utilize a memory board along with the resolver. Again, you must perform a Memory Test to get the lockup angle for that particular motor. When you have the correct lockup angle, you can then lock up the motor and check for that resolver angle in the conventional manner. A document is available from Mitchell Electronics, Inc. with more detail on Indramat alignment procedures. 2.6.5.5.1.2 POSITION CODE RINGS There are significant differences between the Indramat encoders and other serial encoders described in this manual. The serial data returns sine and cosine amplitudes rather than position counts. In this regard, the data is similar to resolver data, and it can be converted to an angle. Furthermore, sine/cosine data is returned for the 1 period/revolution code ring and the 16 periods/revolution code ring for the 200 series encoders and for the 1 period/revolution code ring, 8 periods/revolution code ring and the 64 periods/revolution code ring for the 400 and 1300 series encoders. An absolute position angle can be calculated from the 1 period/rev data. However, this angle can be determined more accurately if it is interpolated using the finer resolution 8, 16, and 64 period/rev data. The TI-5000EX displays the data both ways as will be further explained. As described above, the absolute position angle information is available as both mechanical and electrical angles. To display the electrical angle correctly, the number of poles must be set correctly. The mechanical angle always changes 360 degrees for a full rotation of the encoder. The mechanical angle should roughly agree with the angle in the 1R box. In fact, the 1R box provides the approximate angle, and that angle is further refined by interpolation with the angles in the 1/8R, 1/16R, and 1/64R boxes. While the 200 series encoders produce a 1R and 1/16R position, the 400 and 1300 series encoders produce 1R, 1/8R and 1/64R position data. This allows for even more precise interpolation. It is not necessary to completely understand the interpolation. Rather, it is important to understand that the final angle is made up from the contributions of these various angles, and that even when working correctly, the mechanical angle will typically not agree exactly with the 1R angle. If we are not looking for perfect agreement, then why are the various angles displayed and how should we evaluate them? The following guidelines should help in evaluating the data for the ECN212 and EQN224 encoders:

1. Data in the Mechanical Angle, INCREMENTAL, 1/16R and 1R boxes should all be changing as the encoder is rotated.

2. The Mechanical Angle and 1R boxes should be approximately equal (within a few degrees). 3. As the data in the 1/16R box goes through 360 degrees, the 1R box data should change about 22

degrees (22.5 ideally). 4. As the data in the Mechanical Angle box changes by 360 degrees, the data in the INCREMENTAL

box should change by about 1024 counts. Use following guidelines should help in evaluating the data for the ECN413, ECN1313, EQN425, and EQN1325 encoders:


1. Data in the Mechanical Angle, INCREMENTAL, 1/64R, 1/8R and 1R boxes should all be changing as the encoder is rotated.

2. The Mechanical Angle and 1R boxes should be approximately equal (within a few degrees). 3. As the data in the 1/64R box goes through 360 degrees, the 1/8R box data should change about 45

degrees. Likewise for a 360 degree change in the 1/8R column, the 1R data should change by 45 degrees.

4. As the data in the Mechanical Angle box changes by 360 degrees, the data in the INCREMENTAL box should change by about 2048 counts.

2.6.5.5.1.3 COUNT The data in the INCREMENTAL box is captured as quadrature pulses on the A and B channel inputs. Since there is no index pulse to which it may be referenced, it must be compared with the absolute data to verify that the correct number of counts per revolution is occurring. The ECN212C and EQN224 encoders provide 1024 (10 bit) incremental counts/revolution. The remaining Indramat encoder selections are 2048 (11 bit) incremental counts/revolution. The Data Display should be used as the initial check to see whether the encoder is doing anything at all. There are no alarm bits produced by these encoders. If no data is being sent from the encoder, that problem will be detected and reported in Data Display. An encoder may be connected to the TI-5000EX and rotated by hand through one revolution (determine one revolution by the mechanical angle and watching the shaft) to see whether the count is changing by approximately the correct amount. The count and all angles increase when the encoder is turned in the clockwise (CW) direction. With the Indramat encoders made by Heidenhain, the incremental count and serial data functions are basically independent. With a malfunctioning encoder, it is possible to have a problem in receiving serial data but still see the incremental count change. However, the Indramat encoders made by Stegmann must receive serial data from the drive (or TI-5000EX) in order to enable the incremental outputs. A malfunction in the serial data will likely result in no incremental output signals being produced. 2.6.5.5.1.4 REVOLUTIONS CODE RINGS AND REVOLUTIONS While the ECN212, ECN413 and ECN1313 are single-turn encoders, the EQN224, EQN425, and EQN1325 are multi-turn encoders. The multi-turn encoders include revolution count information in the Revolutions Code Rings frame. The multi-turn encoders are capable of keeping track of 4096 revolutions (0 – 4095). The angle data from the revolution code rings is used to produce a revolutions count which is displayed in the REVOLUTIONS box. For single-turn encoders, the Revolutions Code Rings frame and REVOLUTIONS box will be disabled. The revolutions are measure by 3 code wheels for 200 series encoders and 4 code wheels for 400 and 1300 series encoders. The wheels are driven by a gear train that provides ratios with reference to the main encoder shaft of 16:1, 256:1, and 4096:1 for 200 series and 8:1, 64:1, 512:1, and 4096:1 for the 400 series & Stegmann. The angles from these code wheels are displayed in the 16R, 256R, and 4096R boxes for the 200 series encoders and 8R, 64R, 512R, and 4096R boxes for the 400 series & Stegmann. Again, by mathematically interpolating these code ring angles, the exact number of turns can be determined. This is the number that appears in the REVOLUTIONS box. The following procedure will help determine that the revolution counting sections are working properly:


1. Rotate the encoder 128 revolutions. During the motion verify the following: a. The 1R angle should go through 360 128 times. b. The 16R angle should go through 360 very approximately 8 times. c. The 256R angle should change by approximately 180 degrees. d. The 4096Rev angle should change by approximately 11 degrees (ideally 11.25).

2. At the end of 128 revolutions, verify that the revolution count has changed by 128. This procedure will help determine that the EQN425 and EQN1325 revolution counting sections are working properly:

1. Rotate the encoder 128 revolutions. During the motion verify the following: a. The 1R angle should go through 360 128 times. b. The 8R angle should go through 360 very approximately 16 times. c. The 64R angle should go through 360 very approximately 2 times. d. The 512R angle should change by approximately 90 degrees. e. The 4096R angle should change by approximately 11 degrees (ideally 11.25).

2. At the end of 128 revolutions, verify that the revolution count has changed by 128.

Of course there are many possible variations on this procedure. In general, if you turn it more than 128 revolutions, you will have a better feel for whether all parts are working properly. Conversely, if you turn it fewer times, the test will be less accurate. It is somewhat of a judgment call as to how much time you decide to spend turning the encoder to convince yourself that it is working properly. Each of these angles is scanned at various times, and the information for each may not be current when the encoder is moving. In that regard, do not be alarmed if a wild revolution count is seen from time to time while the encoder is moving. However, the revolution count should be correct whenever the encoder is stopped. When the Indramat motor is equipped with resolver feedback, use the resolver display. At this time, the TI-5000EX does not support reading revolution counts for multi-turn resolver feedback. See the Generic Resolvers section for more on motors with resolver feedback. 2.6.5.5.1.5 ENCODER STATUS INDEX – The INDEX box is disabled for all Indramat serial encoders because there is no indexing with these encoders. The displayed angles are absolute on power up. DATA - If no data is being sent from the encoder, NONE will be displayed in the DATA box. If the TI-5000EX and the encoder are communicating correctly, RECEIVING will be displayed in the DATA box. The cabling is the first thing to check if the encoder is not communicating, but it can also mean a component failure in the encoder. Indramat encoders do not need to be indexed, they provide no internal errors bits, they do not need a battery, and they do not provide overheat information, so there are no fields on the Data Display for any of that information. ENCODER ID – As shown in the Data Display screens above, the ENCODER ID field shows the type of encoder that has been detected from the encoder memory data via the serial data. If the encoder detected agrees with the encoder selected, the encoder type is followed by OK. If the selection does not agree with the type selected, the encoder type is followed by ERROR. In this case, you should check your selection. You probably made the wrong selection. However, it is possible that the encoder has been programmed with the wrong data. In any case, the cause of the error should be investigated.

TI-5000 86 OPERATION 2.6.5.5.2 COUNT TEST Currently there is no Count Test for the Indramat encoders. The procedure described in the preceding section can be used to verify correct counting. 2.6.5.5.3 MEMORY TEST As explained previously, the feedback for Indramat digital motors use a memory device containing motor parameters. This data is programmed in at the factory and cannot be changed by the drive. Some of the default tuning constants may be overridden by the drive, but the data in the encoder is fixed. This device is read by the drive system on power-up prior to moving the motor. If the drive system cannot read the memory or if it gets incorrect data from it, the motor will not run. It is therefore very important to verify that the memory can be read and appears to be correct. The memory also contains information that allows checking the commutation alignment. In verifying correct memory data and memory operation, we are looking at two things:


The first item is done automatically. The data in the encoder is encoded with the ability to check data integrity. The TI-5000EX does this automatically as it reads and displays the various motor parameters. Any parameter that fails this check is not displayed, and “BAD DATA” is displayed in its place. We do not know what the drive requirements are, but the logical guess is that if there is even one bad parameter, the drive will not run the motor. Experience so far indicates that it is somewhat rare for the encoder memory to actually have a problem. Many things such as a bad encoder cable, incorrect connection of the TI-5000EX, etc. could cause a bad data read. Especially if you are unfamiliar with testing Indramat motors, you might check with Mitchell Electronics, Inc. if you have an encoder (or especially, several encoders) that do not read the data correctly. The second item amounts to making sure that the encoder that is on the motor is the correct one. Sometimes in trouble-shooting, encoders get swapped in an attempt to isolate a problem, and the encoder on the motor you have could be the wrong one entirely. In general the data from the encoder should match the data from the motor nameplate. In this regard, we are looking for gross errors. Minor differences in the encoder data and nameplate data are normal. The display shown below is a memory test from an ECN212 encoder. The motor type number and motor parameters are fairly self explanatory. These numbers should match reasonably well with the nameplate data. Toward the end of the right column is some information that is useful to the repairman. The number of pole pairs is 3, which indicates a 6 pole motor. This may not be universal, but it appears that the MDD motors are 6 poles, while the MHD, MKD, and MKE can be either 6 or 8 pole. The feedback type of 3 indicates the ECN212 encoder (as described above). The encoder count of 256 pulses/rev corresponds to 1024 counts/rev as read by the TI-5000EX. The commutation offset number of 238 is what tells the drive how to provide correctly timed armature currents to the motor. The TI-5000EX uses the commutation offset to calculate what the +U –V and +U –W lockup angles should be in electrical degrees for proper feedback alignment, and these angles are reported in the Derived Data frame.

Note: If an encoder is replaced on an Indramat digital motor, the motor data must be programmed into the replacement encoder in order for the drive to run the motor. Contact Mitchell Electronics, Inc. for information on software support for programming replacement encoders.

TI-5000 87 OPERATION Name Plate data: MDD112D-N-020-N2L-130PB0 Natural Convection Natural Convection Surface Cooled Surface Cooled Nominal Torque Nominal Current Nominal Torque Nominal Current MdN 38.00 Nm IdN 43.80 A MdN 57.00 Nm IdN 65.80 A RPM Torque Constant Mass n 2000 min-1 Km 0.87 Nm/A m 59 kg. Comparing the above nameplate data to the encoder data below, we see a typical situation. The nameplate does not include all of the encoder data. Most of the data is very close, but the RPM data is further off than you might expect.

The 8729 series spindle motors seem to have only the Feedback Type and Encoder Count data included. All other data is zero. The report for spindle motors will show ‘NA/SPINDLE’ for all data except the Feedback Type and Encoder Count. The spindle motors do not have PM rotor, so there is no alignment and no lockup angles to report. Each data item has a checksum associated with it for checking data integrity. If the checksum is found to be incorrect, ‘DATA ERROR’ is written into the field in the report in place of the data. If the encoder is from a spindle motor, there are fewer data fields, and errors will be shown for many of the fields if the correct spindle motor selection is not made. Insure that you use one of the Indramat Spindle Motor selections when performing a Memory Test on an encoder from spindle motor.

TI-5000 88 OPERATION If data errors occur, it could be for any of the following reasons:

1. Faulty encoder. 2. Faulty or no encoder data. 3. Faulty feedback cable from the feedback connector to the encoder in the motor. 4. Failure to use the TI-5104 Indramat Adapter Module. 5. Incorrect or faulty TI-5000EX test cable. 6. Faulty TI-5000EX.

An Indramat drive will alarm if there is an encoder data problem, so the problem cannot be ignored. It is not uncommon for the Motor Type field to contain ‘?’ characters. These may be treated as a wildcard in parts of the field that do not affect data, but it is unknown why these characters appear in the data. The Indramat drive seems to accept them without any problem. The TI-5000EX software will attempt to pop up a message to help identify possible data problems. The data from this screen may be either saved or printed as a report in the usual manner with the Save Report to File or Print Report buttons. Saving Data - The Save Encoder Data File button may be used to save a copy of the data to a disk file as Intel hexcode. You may wish to do this to send to Mitchell Electronics, Inc. in the event that there might be a question about the data. You may also wish to have a copy in case you would need to program it into a replacement encoder in the future. WinTI5000EX will make up a proposed filename which includes the Indramat motor part number, the type brand of encoder (Heidenhain or Stegmann), and type of encoder. For example the software might propose: Indramat_ MDD112D-N-020-N2L-130PB0_Heidenhain_DSF0XSN-H_ECN212_Enc.hex You make use this proposed filename as it is, add to it, remove characters from it, or change it entirely as you desire. For example, you might wish to retain this info but add a job number to it such as: Indramat_ MDD112D-N-020-N2L-130PB0_Heidenhain_DSF0XSN-H_ECN212_Enc_Job98765.hex Just type in whatever you desire. If there are ‘?’ characters in the Motor Type, WinTI5000EX will convert those characters to ‘^’ characters because a ‘?’ is not a legal character in a Windows filename.

TI-5000 89 OPERATION 2.6.6 KAWASAKI MOTORS AND SERIAL ENCODERS

2.6.6.1 GENERAL COMMENTS There are several models of Kawasaki serial encoders, and two are currently supported by the TI-5000EX. The H20/M21 8,192 count/rev encoders are used with relatively large robot motors. Connection to these encoders requires only 4 lines: 5 V power, ground, and a pair of RS485 data lines. The cables available are the TI-5011 (4 pin direct connection to the encoder) and the TI-5032 (17 pin circular MS type connector). HE-02 8,192 count/rev encoders are used on somewhat smaller robot motors. They are supported by the TI-5023 (DB25 connector) and TI-5026 (17 pin circular MS type connector) cables. This encoder is the same as the 8192 count Sanyo Denki E03007758. 2.6.6.2 TYPES SUPPORTED The following list shows the Kawasaki serial encoders that are currently supported by the TI-5000EX: Type Counts/Rev Cables H20/M21 8,192 TI-5011 or TI-5032 HE-02 8,192 TI-5023 or TI-5026 2.6.6.2.1 IDENTIFICATION The following motor models use H20M21 encoders: Model Description P20B10200LCL62 4 poles P60B13150HCX23 8 poles P80B22450RCX2A 8 poles P80B22450RCX2R 8 poles Sanyo Denki uses the P series part numbers for their motors too, and they show the bold character as the encoder identifier. The last two, L and X, are not in the Sanyo Denki literature but appear in the part numbers for Kawasaki motors using H20M21 encoders. There is some inconsistency in some of the descriptions in the manuals, but this should provide some useful guidance. The assignments are as follows: Letter Encoder S00 Wire saving incremental, 2000 or 6000 PPR S07 Wire saving incremental, 2048 PPR SA0 Wire saving incremental, 2000 or 6000 PPR, rigid shaft J Absolute encoder with motor flange of 60 mm or less A00 ABS-E encoder with motor flange of 76 mm or more AA0 ABS-E encoder with motor flange of 76 mm or more, rigid shaft M ABS-RIII, 8192 PPR super capacitor unavailable N ABS-RII, 8192 PPR super capacitor unavailable V ABS-RII super capacitor built-in L H20M21 X H20M21

TI-5000 90 OPERATION HE-02 encoder part numbers are not as well known. The two part numbers that we have seen so far are listed below: Part# Description BS11SEN20SB MRM21201H 8 poles 2.6.6.3 CONNECTION Connection requires using the correct cable as shown in the chart in the Type Supported section. Also the WinTI5000EX ‘Feedback Selection’ frame has a cable dropdown menu from which you can select the cable that you need. After making the cable selection, that selection will appear on the Data Display report which is helpful in documenting the cable used. Download cable sheets from the Customer Page at http://www.mitchell-electronics.com for cable pinouts and wiring details. 2.6.6.4 ENCODER SELECTION Click on the Select Feedback button to make the selection. The Kawasaki serial encoders require the following setup sequence:

1. Click on the Encoder Feedback radio button. 2. Select Kawasaki from the Encoder Manufacturer dropdown menu. 3. Select the encoder type that you have from the Encoder Type dropdown menu.

The encoder types listed in the current software revision are shown in an earlier section. The Kawasaki motors using H20/M21 encoders are known to come in both 4 and 8 pole versions. Motors using HE-02 encoders are known to come in 4, 6, and 8 pole versions. The number of poles may be selected from the POLES dropdown menu. To determine the number of poles, apply a small voltage to 2 of the armature leads to lock the rotor, and then count the number of lockup positions to determine the number of pole pairs. For instance, if the rotor locks up in 4 different shaft positions, the motor has 4 pole pairs or 8 poles. The number of poles must be entered correctly in order to display the electrical angle correctly. It is essential for the electrical angle to be correct when checking or setting the encoder alignment for correct commutation. 2.6.6.5 TESTING The model H20M21 is a serial encoder and (like most serial encoders) uses only the Data Display and the Count Test. The model HE-02 encoder has both a quadrature pulse section and a serial section. To completely test these encoders, the quadrature pulse section should be tested like any standard quadrature pulse incremental encoder (8,192 counts/rev). Selecting this encoder from the Kawasaki menu allows testing the serial section using the Data Display and Count Test. The forward armature direction for Kawasaki motors (like most Japanese motors) is CCW looking at the drive shaft end.

TI-5000 91 OPERATION 2.6.6.5.1 DATA DISPLAY Data Display is the initial test, and it is started by default when WinTI5000EX is started. When already in another test, it can be started by clicking on the Data Display button among the test buttons at the top of the display. Use it for the following:




The following sections describe information shown on the display. 2.6.6.5.1.1 COMMUTATION The Fanuc style commutation gray code shown as C1 – C8 (HE-02 only) and the electrical angle can be used to check and set commutation using a static rotor lockup by applying a small lockup voltage to the stator windings. We strongly recommend using the electrical angle as the superior method of alignment for Kawasaki encoders. For a particular lockup polarity, the rotor will lock up in as many different positions as there are pole pairs but the gray code and electrical angle indications will be the same at each lockup position. The mechanical angle will be different at each lockup position (except for 2 pole motors where there is only one lockup position), so it is not as convenient to use for feedback alignment. See section 3.2 for a more detailed description of commutation alignment procedures. The number of poles must be entered correctly for the electrical angle to be correct. The gray code, electrical angle and mechanical angle are derived from the position count. The position count is absolute immediately on power up for Kawasaki serial encoders. The table below shows 3 different lockups which can be used to check or set commutation on motors using Kawasaki 4 pole and 8 pole motors with H20M21 and HE-02 serial encoders. The first one puts the feedback on a zero electrical angle which some users favor. It requires applying power to all 3 armature lines. The last two procedures require applying power to only two armature leads at a time. It is easy to go from +U –V to +U –W just by moving the minus lead from V to W. This should cause the motor to jog 60 electrical degrees in the forward direction (CCW looking at the shaft). Failure to move the correct number of degrees or in the correct direction would be an indication of a significant problem. Setting these angles within ±3 electrical degrees is normally quite sufficient.


TI-5000 92 OPERATION 2.6.6.5.1.2 COUNT The Count frame displays the encoder count both as a decimal and hexadecimal number. Users will typically be interested in only the decimal count, but encoder repairmen and other advanced users may find the hexadecimal representation useful. In general this count will not be zero on power up. This is an absolute encoder, and it will remember the count on power up. The number of counts/rev for the various models is shown in the table in an earlier section on types of encoders supported. The H20M21 encoders are multi-turn encoders in that they keep track of revolutions. The position count is 0 to 8,191 (13 bits) and the revolution count is from -32,768 to 32,767 (16 bits). Since the position count and revolution count are not synchronized well with each other, they are displayed separated. The position count is displayed in the COUNT frame, and it will go to 8,191 and then back to 0 to start over (in the decimal representation). The HE-02 uses a 0 to 8,191 (13 bit) position count and keeps track of revolutions from -128 to +127 (256 revolutions). This is displayed in the Count frame as 8 more bits of data (above the 13 position bits) as are most serial encoders. Always verify that the encoder count appears to change by the correct number of counts/rev while turning the encoder. If the count is not changing, then there is an encoder problem. As described in a later section, the Count Test may be performed to more accurately determine whether the correct number of counts per revolution is occurring, but this is an important initial evaluation. Serial encoders that include incremental lines, like the HE-02, are tested both as incremental encoders and serial encoders. 2.6.6.5.1.3 ENCODER STATUS INDEX – The INDEX box is disabled for all Kawasaki serial encoders because these encoders display the correct count on power up without indexing. DATA - If no data is being sent from the encoder, NONE will be displayed in the DATA box. If the TI-5000EX and the encoder are communicating correctly, RECEIVING will be displayed in the DATA box. The cabling is the first thing to check if the encoder is not communicating, but it can also mean a component failure in the encoder. INTERNAL ERROR - The information in this box reports on the error bits. The encoder literature for the H20/M21 describes 3 error bits: Error Code & Msg Description BUSY -1553 Encoder initialize Error Unable to determine absolute data on power on. ABSALM -1556 ABS-track Error Incremental counter data and absolute data do not match. INPALM -1557 INC-pulse error Incremental A and B pulses are abnormal. At this time we cannot be sure that the bit locations and identities have been determined correctly, but we believe that they have. We can force one of the error bits by interrupting the light source in the encoder. We believe that it is the ABSALM error that is produced in that case. Once the error has been produced in this manner, cycling powering to the encoder will restore proper operation. It will probably require testing known bad encoders to verify the error bits absolutely. In any case the Internal bit will display ALARM instead of OK, if any of the 3 bits monitored go HI. No error bits have been positively identified for the HE-02 encoder.

TI-5000 93 OPERATION BATTERY - The BATTERY box is disabled for Kawasaki serial encoder because they do not utilize battery backup. OVERHEAT - The OVERHEAT box is disabled for Kawasaki serial encoders because they do not report overheat conditions. ENCODER ID – The ENCODER ID box is disabled as there is no known identification data with the Kawasaki encoders. 2.6.6.5.2 COUNT TEST The Count Test can be started by clicking on the Count Test button among the test buttons at the top of the display. The Count Test it will verify that the encoder is incrementing the correct number of counts per revolution. The Count Test for the Kawasaki encoders is not significantly different from that for other encoders, so please refer to the general information on the count test in Section 2.2.2 for further details. The stuck bit test will test bit0 to bit12 for activity for 8,192 count 13 bit Kawasaki encoders.

TI-5000 94 OPERATION 2.6.7 MITSUBISHI MOTORS AND SERIAL ENCODERS

2.6.7.1 GENERAL COMMENTS The Mitsubishi serial encoders listed in the next section are supported by this selection. Mitsubishi incremental encoders with A, B, and Z lines should be tested as Generic Incremental encoders. 2.6.7.2 TYPES SUPPORTED The following list shows the Mitsubishi encoders that are currently supported by the TI-5000EX: Type Counts/Rev Cables OBE12 4,096 TI-5027 OBA13 8,192 TI-5027, TI5028, TI-5046, TI-5620 OSA14 16,384 TI5028 OAH14B 16,384 TI5028 OHE4096 4,096 TI5028 OBA/OSA17 131,072 TI-5027, TI5028 OBA/OSA18 262,144 TI-5027, TI5028, TI-5088, TI-5658 OSA/OSE104 1,048,576 TI-5008 OSA/OSE105 1,048,576 TI-5008 OSA?OSE253 1,048,576 TI-5008 OSA/OSE253, OSA/OSE105 and OSA/OSE104 – The OSA253, OSA105, OSA104 and OSE104 encoders appear to use 20 bits to represent one revolution for 1,048,576 counts per revolution. But, according to the literature, they are they provided different resolutions to the drive system. Apparently the OSA253 is referred to as a 25,000 count encoder. The 3 means 3 zeros after the 25. The OSA104 is a 100,000 count encoder while the OSA105 is a 1,000,000 count encoder. It is not clear whether the drive scales the 1,048,576 count’s per rev to 25,000, 100,000 and 1,000,000, or whether it is just more convenient to talk in terms of round numbers. However, since there are 20 bits in use, the TI-5000EX provides the count in terms of 1,048,576 count’s per revolution. The drive can determine which of these encoders is connected to it by the encoder ID. All of these encoders seem to use basically the same circuit board, so they work virtually identically. The OSA253 and OSA105 do not seem to have the external overheat lines coming into the encoders. In this situation, the overheat inputs are jumpered together on the PCB so that the overheat indication does not go into alarm, when the encoder is removed from the motor. The Data Display for these encoders displays overheat, battery, and internal error bits. OBE12, OBA13, OSA14, OAH14B, and OSA17 (OSA18) – The OSA17 is 131,072 counts/rev, OAH14B and OSA14 are both 16,484 counts/rev, the OBA13 is 8,192 counts/rev, and the OBE12 is 4,096 counts/rev. The numerical part of the model number is apparently the number of bits in the count for one revolution. However, the OSA17 and OBA17 encoders have the ability to be programmed as lower resolution encoders. For instance, if a replacement encoder is purchased for an OSA14, it will be an OSA17 (or possibly OSA18). There will typically be a dash number after the OSA17 to indicate this. An OSA17 that has been programmed as an OSA14 will show the encoder ID for the OSA14. If it shows an

TI-5000 95 OPERATION OSA14 ID, then you should select OSA14 from the list. Always check the encoder ID when testing these encoder and make the selection according to the ID. There is a battery bit for the OSA17, OAH14B, OSA14, and OBA13, but there is not even a battery line for the OBE12. It may be that OBA indicates an absolute encoder where battery backup is used, and OBE does not use it. Internal error bits are displayed for all of these except the OAH14B for which an error bit is yet to be identified. None of these encoders show an overheat bit. OHE4096 – The OHE4096 is a Nemicon SBC-4096 encoder (there may be other similar Nemicon part numbers ending in 4096, like SBN-4096). Mitsubishi models HA-SH103, HA-LH12K1, and HA-LH102C-L1 are examples of motors that use this encoder. This is basically a 12 bit serial encoder providing 4,096 counts/revolution. It has no multi-turn count and no battery backup. Unlike most serial encoders, it must be indexed before the count is absolute. Rotate the encoder until the INDEX box changes from ALARM to OK in the Data Display. At that time, the mechanical and electrical angles will be active for commutation alignment. 2.6.7.2.1 IDENTIFICATION The encoders whose part numbers begin with OSA or OSE apparently are the removable type encoders. They can be removed in one piece from the motor by removing 4 mounting screws. There is a coupling connecting the encoder shaft to the motor shaft. On most of these encoders, the part number can be seen on a bar code sticker after the encoder is removed. These stickers are often not visible when the encoder is mounted on the motor. The encoders whose part numbers begin with OBA or OBE apparently are the built-in type encoders. These encoders cannot be removed in one piece from the motor. They must be disassembled from the motor shaft. Usually these encoders can be identified by markings on the large, square IC (integrated circuit) on the encoder PCB which can be seen when the encoder cover is removed. An OBA13 encoder will normally have OBA13 stamped on this IC. Apparently the OSA17 and OBA17 encoders have the ability to be programmed as other types of encoders. Currently, when a replacement for an OSA14 encoder is purchased, it will be identified as an OSA17 instead of OSA14. In most cases it seems to be identified as OSA17-020. In this situation, the OSA14 selection should be use to read the encoder. In a similar manner, some encoders labeled OBA17 have been found to respond better to the OBA13 selection. The TI-5000EX now reports an encoder ID field for Mitsubishi serial encoders. This field provides further support in identifying the correct selection to use for various encoders -even ones that may be programmed to work like a different part number. Use this encoder ID field to help verify that you have selected the correct encoder. 2.6.7.3 CONNECTION Connection requires using the correct cable as shown in the chart in the Type Supported section. Also the WinTI5000EX ‘Feedback Selection’ frame has a cable dropdown menu from which you can select the cable that you need. After making the cable selection, that selection will appear on the Data Display report which is helpful in documenting the cable used. Download cable sheets from the Customer Page at http://www.mitchell-electronics.com for cable pinouts and wiring details. Cable configurations other than the cables listed are known to exist. These may be cables that are made by OEM machine manufacturers using these encoders.

TI-5000 96 OPERATION Mitsubishi encoders generally use an MR and MRR (which we sometimes call REQ and REQ*) as the request lines. The drive or tester uses these lines to send the pulse or data code (that tells the encoder to send data) to the encoder. The encoder then can send the requested data back on the MD and MDR (which we sometimes refer to as SD and SD*) as the data lines. This is a typical 4 wire serial encoder system. Some of the older Mitsubishi encoders must use 4 lines in this manner. But, some Mitsubishi encoders also send the data back on the MR and MRR lines. So, it is possible with these encoders to use only 2 wires. For these encoders, sometimes the cables that connect the drive to the encoder will have only 2 lines, (even though the encoders will still usually have all 4 lines). As long as all 4 lines are brought out to the encoder connector, the 4 wire TI-5000EX/TI-3000 test cables will work. In some cases the MD and MDR lines do not come out from the encoder PCB to the encoder connector. In this situation, the 4 wire test cables will not work. So far we provide the TI-5658 cable for the only case that we know of where only 2 wires come out on the encoder connector. But, there are probably other cases in existence, and there will probably be more cases coming along in the future. It would be good practice to verify that all 4 wires are coming to the connector – especially if you are experiencing problems in communicating with a Mitsubishi serial encoder. When we have more motors using 2 wires identified, they will be listed in the manual. In order to use 2 wire cables, software changes were required for the testers. If you use 2 wire test cables, verify that your tester software version is at the following levels or newer: TI-5000EX V3.4 Beta 16 12/01/10 and TI-3000 V3.1 Beta19. 2.6.7.4 ENCODER SELECTION Click on the Select Feedback button to make the selection. The Mitsubishi serial encoders require the following setup sequence:

1. Click on the Encoder Feedback radio button. 2. Select Mitsubishi from the Encoder Manufacturer dropdown menu. 3. Select the encoder type that you have from the Encoder Type dropdown menu.

The encoder types listed in the current software revision are shown in an earlier section. Most Mitsubishi motors are 8 pole motors. The number of poles may be selected from the POLES dropdown menu. To determine the number of poles, apply a small voltage to 2 of the armature leads to lock the rotor, and then count the number of lockup positions to determine the number of pole pairs. For instance, if the rotor locks up in 4 different shaft positions, the motor has 4 pole pairs or 8 poles. The number of poles must be entered correctly in order to display the electrical angle correctly. It is essential for the electrical angle to be correct when checking or setting the encoder alignment for correct commutation. 2.6.7.5 TESTING Mitsubishi Incremental encoders are tested as Generic Incremental Encoders using Data Display, Line Levels, Incremental Count Test, and Phase Test for a complete test. Mitsubishi serial encoder types listed above (like most serial encoders) use only the Data Display and the Serial Count Test. The forward armature direction for Mitsubishi motors is CCW looking at the drive shaft end. 2.6.7.5.1 DATA DISPLAY

TI-5000 97 OPERATION Data Display is the initial test, and it is started by default when WinTI5000EX is started. When already in another test, it can be started by clicking on the Data Display button among the test buttons at the top of the display. Use it for the following:




The following sections describe information shown on the display. 2.6.7.5.1.1 COMMUTATION The Fanuc style commutation gray code shown as C1 – C8 and the electrical angle can be used to check and set commutation using a static rotor lockup by applying a small lockup voltage to the stator windings. We strongly recommend using the electrical angle as the superior method of alignment for Mitsubishi encoders. For a particular lockup polarity, the rotor will lock up in as many different positions as there are pole pairs but the gray code and electrical angle indications will be the same at each lockup position. The mechanical angle will be different at each lockup position (except for 2 pole motors where there is only one lockup position), so it is not as convenient to use for feedback alignment. See section 3.2 for a more detailed description of commutation alignment procedures. The number of poles must be entered correctly for the electrical angle to be correct. The gray code, electrical angle and mechanical angle are derived from the position count. The position count is absolute immediately on power up for Mitsubishi serial encoders. The table below shows 3 different lockups that can be used to check or set commutation on motors with Mitsubishi serial encoders. The first one puts the feedback on a zero electrical angle which some users favor. It requires applying power to all 3 armature lines. The last two procedures require applying power to only two armature leads at a time. It is easy to go from +U –V to +U –W just by moving the minus lead from V to W. This should cause the motor to jog 60 electrical degrees in the forward direction (CCW looking at the shaft for Mitsubishi). Failure to move the correct number of degrees or in the correct direction would be an indication of a significant problem. Setting these angles within ±3 electrical degrees is normally quite sufficient.


2.6.7.5.1.2 COUNT The Count frame displays the encoder count both as a decimal and hexadecimal number. Users will typically be interested in only the decimal count, but encoder repairmen and other advanced users may find the hexadecimal representation useful. In general this count will not be zero on power up. This is an absolute encoder, and it will remember the count on power up. The number of counts/rev for the various models is shown in the table in an earlier section on types of encoders supported.

TI-5000 98 OPERATION Always verify that the encoder count appears to change by the correct number of counts/rev while turning the encoder. If the count is not changing, then there is an encoder problem. As described in a later section, the Count Test may be performed to more accurately determine whether the correct number of counts per revolution is occurring, but this is an important initial evaluation. 2.6.7.5.1.3 ENCODER STATUS INDEX – The INDEX box is disabled for all Mitsubishi serial encoders because these encoders display the correct count on power up without indexing. DATA - If no data is being sent from the encoder, NONE will be displayed in the DATA box. If the TI-5000EX and the encoder are communicating correctly, RECEIVING will be displayed in the DATA box. The cabling is the first thing to check if the encoder is not communicating, but it can also mean a component failure in the encoder. INTERNAL ERROR - The INTERNAL ERROR box will show ALARM if there is an internal error alarm and OK if there is not. The internal alarm is the result of self tests that are done by the encoder electronics. BATTERY - The BATTERY box will show ALARM if there is a battery error alarm and OK if there is not. The battery alarm will show when the encoder detects a battery voltage of 2.8VDC or less for some encoders and 3.2VDC or less for others. It is often possible to alternately connect and disconnect battery lines to the encoder to verify that this bit is working properly. Drive literature indicates that 3.6VDC lithium batteries are used. The battery line is brought out near the terminal block on the test cable (see test cable charts in section 2.9 for more info). Connecting a 3.6V source between the line and 0V ground (J1 pin2) should make the display change from ALARM to OK. There is a time constant associated with the battery bit, and the battery voltage may need to be applied for a minute or so before the indication changes. Likewise the battery voltage may need to be removed and the battery input connected to 0V ground for a period of time for the ALARM indication to return. OVERHEAT - The OVERHEAT box will show ALARM if there is an overheat error alarm and OK if there is not. This box will be disabled for encoders for which no overheat is detected information, such as the OBA13. It is often possible to alternately connect and disconnect thermal lines to the encoder to verify that this bit is working properly This field may not be in effect for all serial encoders. Thermal contacts inside the encoder complete a circuit to ground when temperatures are within range. When temperatures become excessive, the contacts open, and the overheat bit is transmitted with the data. Encoders with the circular connectors, such as the OSA104, bring this circuit out on the RED wires (which do not go to the circular connector). In a normal installation these wires are connected through other contacts such as motor overload contacts. These wires can be connected together during testing, and the encoder should not indicate an overheat condition (providing it is not overheated) with OK. If these wires are disconnected from each other, the OVERHEAT box column should indicate ALARM. ENCODER ID – Data from Mitsubishi serial encoders contain information that identifies the encoder. When the encoder type detected agrees with the encoder type selected, the ENCODER ID box will show the type detected followed by OK. If they disagree, it will show the type detected followed by Error. In that case, you should change your selection to match the type that is indicated. This is especially helpful when you are testing an OSA17-020 encoder that has been programmed to replace an OSA14. A similar case is an OBA17-052 encoder that has been programmed to look like an OBA13. It can be difficult to make the correct selection without using the ID information. 2.6.7.5.2 COUNT TEST

TI-5000 99 OPERATION The Count Test can be started by clicking on the Count Test button among the test buttons at the top of the display. The Count Test it will verify that the encoder is incrementing the correct number of counts per revolution. The Count Test for the Mitsubishi encoders is not significantly different from that for other encoders, so please refer to the general information on the count test in Section 2.2.2 for further details. The number of bits tested by the Stuck Bit Test varies depending upon the particular model. Encoders with greater than a 16 bit count per revolution will test bit0 to bit15 for activity. Others will test as many bits as are used in the count for one revolution.

TI-5000 100 OPERATION 2.6.8 RENCO ENCODERS

The Renco encoders supported by the TI-5000EX are tested as Generic Incremental Encoders and do not have a separate test. A section for them is included in this manual because, in the implementation used on Electrocraft motors, they have an important difference from standard quadrature pulse incremental encoders. 2.6.8.1 GENERAL COMMENTS Allen Bradley/Reliance/Electrocraft - Renco encoders encountered in servo motor repair are generally quadrature pulse incremental encoders. It is not uncommon for the Renco encoders to include U, V, and W commutation pulses as well. One such encoder, the RCH20D-2000/3-8MM-5/0-LD/VC-I-M6-S P/N 79994-004, is used with Electrocraft motors (and subsequently Reliance and AB due to corporate acquisitions). This encoder on these motors is supported by the TI-5019Q and 5045Q cables which will allow it to be tested as a quadrature pulse 8,000 count/rev encoder. This cable also provides a display of the U, V, and W (also designated S1, S2, and S3 or A, B, and C) commutation pulses as signals 1, 2, and 3 (4, 5, and 6 unused) in the Data Display function. In addition there is an analog output line (pin H) which produces distinct voltages for the 6 commutation steps. In one variation of the analog output, the commutation states and corresponding nominal analog voltages should be as follows: U V W Analog Voltage (1) (2) (3) (VDC) H L H 3.30 H L L 2.63 H H L 4.15 L H L 1.40 L H H 2.08 L L H 0.80 When the motor is back driven and the analog voltage is viewed on an oscilloscope, it generates a stair step pattern. Each change in the stair step corresponds to a change in the commutation lines. Consult the manufacturer’s literature for details on specific models and series. AB/Reliance/Electrocraft motors that are known to use this encoder are Series F, H, N S, and Y. Giddings and Lewis – At least some G & L motors are very similar to the AB/Reliance/Electrocraft motors discussed above. Other Variations - Another Renco encoder used with servo motors is the RHS21D-P1-2000-8MM-5-CS-LD-M1-0-P-S P/N 79994-023. It may be used with Electrocraft or Giddings and Lewis motors. It produces A, B, and Z pulses but does not provide commutation pulses. It is supported by the TI-5018 cable which will allow it to be tested as a quadrature pulse 8,000 count/rev encoder. Note that the pin configuration for the 8 pin Amp connector is different than the configuration published by Renco for standard RHS series encoders. Standard Renco encoders use pin 2 for ground. The configuration used for this encoder is apparently proprietary to the motor manufacturer. The pin configurations for these Renco encoders are shown in Section 2.9 and may be helpful if you encounter these encoders. See Section 2.6.1 for more information on various Allen Bradley motors using Renco encoders.

TI-5000 101 OPERATION 2.6.9 REXROTH MOTORS

2.6.9.1 GENERAL COMMENTS Rexroth MSK Series motors use singe-turn and multi-turn serial absolute encoders of both Stegmann Hiperface and Heidenhain Endat brands. Refer to this section and Stegmann section, and the Heidenhain secction for more information on testing motors with the Stegmann Hiperface encoders. These encoders include memory, and the MSK motors utilize this memory area for motor parameters including alignment information. This section will focus on the memory support for these motors The Rexroth MSM series motors use incremental and Tamagawa MFE0017 serial encoders. The incremental encoder is not supported. Please see the section on Tamagawa encoders for more detail. 2.6.9.2 TYPES SUPPORTED The following lists show the Rexroth motors with their corresponding encoders that are currently supported by the TI-5000EX, along with test cable possibilities. Please check the current PDF catalog file and price list files for a complete listing of all cables supporting Rexroth motors. This list includes Rexroth MSK series motors using Heidenhain Endat and Stegmann Hiperface encoders. Type Format Counts/Rev Cables Inc / Pos / Rev ECN1313-2048 Endat 8,192 / 8,192 / NONE TI-5079 (Generic), TI-5093 ECN1325-2048 Endat 8,192 / 8,192 / 4,096 TI-5079 (Generic), TI-5093 SKS36 Hiperface 512 / 4,096 / NONE TI-5094 (Generic), TI-5093 SKM36 Hiperface 512 / 4,096 / 4096 TI-5094 (Generic), TI-5093 This list includes Rexroth MSM series motors using incremental and Tamagawa serial encoders. Type Format Counts/Rev Cables Inc / Pos / Rev MFE0017 Serial NONE/131,072 / 65,535 TI-5080 The MSM series also includes an incremental encoder that is currently not supported. It may be called MFE2500. Rexroth calls it an incremental, but it is a serial encoder. It uses 10,000 counts/rev for the position count. But it does not count revolutions, so it does not need battery backup. More information will be included in the future when it is supported. Note: The first count is the number of counts/rev for the incremental signals, the second is the number of counts/rev for the absolute serial position count, and the last count is the number of revolutions that can be counted (for multi-turn encoders only).

TI-5000 102 OPERATION 2.6.9.2.1 IDENTIFICATION MSK Series – The part number breakdown for these motors is as follows:

MSK-060B-0600-NN-S1-UG0-NNNN. MSK - Product 060 - Motor size B - Motor Length 0600 - Windings Code

NN - Housing Design S1 - Encoder

S1 = Single-turn Hiperface M1 = Multi-turn Hiperface S2 = Single-turn Endat M2 = Multi-turn Endat

U - Electrical connection G - Shaft 0 - Holding brake: 0 = no brake, 1 = brake NNNN - Other design

TI-5000 103 OPERATION MSM Series –

MSM-030B-0300-NN-C0-CG1. MSM - Product 030 - Motor size B - Motor Length 0300 - Windings Code

NN - Cooling Mode C0 - Encoder

C0 = Incremental encoder with 1,024 increments M0 = Multi-turn Absolute Encoder (MDE0017)

C - Electrical connection G - Shaft 1 - Holding brake: 0 = no brake, 1 = brake

2.6.9.3 CONNECTION Connection requires using the correct cable as shown in the chart in the Type Supported section. Also the WinTI5000EX ‘Feedback Selection’ frame has a cable dropdown menu from which you can select the cable that you need. After making the cable selection, that selection will appear on the Data Display report which is helpful in documenting the cable used. The MSK motor feedback connector is compatible with theTI-5093 cable for either the Stegmann or Heidenhain encoders. The TI-5104 Adapter Module should be use with this cable in order to provide 8 VDC supply voltage to the encoder. When the Heidenhain encoders are used, and the MSK encoder wiring includes a 5VDC voltage regulator that reduces the 8 VDC to 5VDC for the Heidenhain encoders. The TI-5094 generic cable connects directly to the 9 pin connector on the Hiperface encoder. It should also be used with the TI-5104 Adapter Module. The TI-5079 generic cable connects directly to the 12 pin connector on the Heidenhain Endat encoder. The TI-5104 Adapter Module should not be used with this cable. The Endat encoders are 5V encoders, and the 8VDC from the module may damage them. The MSM motor feedback connector is compatible with the TI-5080 cable when the MFE0017 serial absolute encoder is used. 2.6.9.4 ENCODER SELECTION See the section for the appropriate encoder. 2.6.9.5 TESTING See the section for the appropriate encoder.

TI-5000 104 OPERATION 2.6.9.5.1 DATA DISPLAY See the section for the appropriate encoder. The following sections describe information shown on the display. 2.6.9.5.1.1 COMMUTATION The electrical angle is best for checking and setting commutation. For a particular lockup polarity, the rotor will lock up in as many different positions as there are pole pairs but the electrical angle indications will be the same at each lockup position. The mechanical angle will be different at each lockup position (except for 2 pole motors where there is only one lockup position), so mechanical angle is not as convenient to use for feedback alignment. See section 3.2 for a more detailed description of commutation alignment procedures. The number of poles must be entered correctly for the electrical angle to be displayed correctly. The electrical angle and mechanical angle are derived from the position count. The position count is absolute immediately on power up for Stegmann Hiperface, Heidenhain Endat, and Tamagawa serial absolute encoders. The two procedures require applying power to only two armature leads at a time. It is easy to go from +U –V to +U –W just by moving the minus lead from V to W. This should cause the motor to jog 60 electrical degrees in the forward direction (CW looking at the shaft for MSK). Failure to move the correct number of degrees or in the correct direction would be an indication of a significant problem. Setting these angles within ±3 electrical degrees is normally quite sufficient. The table below shows 2 different lockups that can be used to check or set commutation on Rexroth MSK motors with Hiperface or Endat serial encoders.

Lockup Elect. Angle +U –V 110 (lockup angle read from the memory test – see memory section) +U –W 170 (lockup angle read from the memory test – see memory section) Note: This is an example alignment based on encoder data. These motors do not have a standard alignment. The angles you see will be different.

Unlike most feedback alignment discussed in this manual, Rexroth MSK motors using Hiperface and Endat encoders do not have a common lockup angle, and in general, they will all lock up at different angles. These motors store a commutation offset in the encoder memory. By using the commutation offset, the encoders do not have to be set to a common alignment. In order to correctly check or set the alignment, you have to run the Memory Test on the encoder, and write down the +U –V and +U –W lockup angles provided by the memory test. Again, for the MSM motors, it is easy to go from +U –V to +U –W just by moving the minus lead from V to W. This should cause the motor to jog 60 electrical degrees in the forward direction (CW looking at the shaft for MSM). Failure to move the correct number of degrees or in the correct direction would be an indication of a significant problem. Setting these angles within ±3 electrical degrees is normally quite sufficient. The table below shows 2 different lockups that can be used to check or set commutation on Rexroth MSM motors with Tamagawa MFE0017 serial encoders.


Lockup Elect. Angle +U –V 240 +U –W 180 +W –U 0 Note: The MSM motors apparently do not store alignment information in the encoder data. These motors apparently have a standard alignment. The above alignment is the only alignment that has been reported so far for these motors.

As with most feedback alignment discussed in this manual, Rexroth MSM motors using Tamagawa encoders do appear to have a common lockup angle. The alignment shown above is the only alignment that we are aware of for these motors. You still need to do a memory test to verify that the memory data is in the encoder and is readable. 2.6.9.5.1.2 COUNT See the section for the appropriate encoder. 2.6.9.5.1.3 ENCODER STATUS See the section for the appropriate encoder. 2.6.9.5.1.4 MEMORY STATUS When Stegmann Hiperface encoders are selected, the Data Display provides a function for reading the memory status. There is no such function for the Heidenhain Endat encoders. The Read Memory Status button on the Data Display allows the user to check whether memory is currently in use for a particular encoder. Clicking the button when connected to an SKS36 encoder on an Rexroth MSK motor would produce the following display:

Memory Status Field WE AC# CE Bytes 0 YES 0 NO 128 1 YES 0 NO 128 2 YES 0 NO 128 3 YES 0 NO 128 5 YES 0 NO 128 6 YES 0 NO 128 7 YES 0 NO 128 8 YES 0 NO 128 Total bytes used 1024 Total bytes unused 0 Total used + unused 1024

This tells us that there are 8 memory fields of 128 bytes each defined in this encoder. All 8 fields are write enabled (WE). The access code is set to 0 (could be 0, 1, 2, or 3). The code enable bit (CE) is not set for the

TI-5000 106 OPERATION 8 defined fields, so the access code does not have to be used. The total bytes number of memory bytes used is 1,024. The total bytes unused is 0, and this means that all of the available memory is in use. No more data fields could be defined for this memory because it is used up. This data formatting is done by the motor manufacturer and is of little concern to the TI-5000EX user. However, it is useful to look at it to verify that the memory looks normal. For instance if you see that no fields have been defined for an encoder on a Rexroth MSK motor, it is very likely that the encoder has been replaced and the correct data has not been programmed into the memory. This would be very important to know because the motor would not run correctly on the Rexroth drive. It is also useful to check on unfamiliar motors to determine whether the motor manufacturer is using the memory. This Memory Status data is automatically included on the Data Display report when a Stegmann Hiperface encoder has been selected. 2.6.9.5.2 COUNT TEST See the section for the appropriate encoder. 2.6.9.5.3 MEMORY TEST Encoder memory is used on Rexroth MSK and MSM PM brushless motors (this list may not be all inclusive). As explained previously, the Read Memory Status button on the Data Display can be used to determine whether the memory is in use when Stegmann Hiperface encoders are used. When the memory is used, it will normally be programmed with the motor model number and sometimes motor parameters. The drive can read this memory data on power up and determine what kind of a motor is connected to it. Some manufacturers, such as Rexroth and Indramat, are now programming a commutation offset value into the memory. This offset tells the drive the difference in the present feedback alignment from the ideal feedback alignment so that the drive can adjust its timing to compensate for an imperfectly aligned feedback device. This relieves the manufacturer of performing a precise alignment during manufacturing. They simply program in the offset for the drive to read. This means that each motor may be aligned somewhat differently, but the repair shop must still align the feedback the way the drive is expecting it to be. The TI-5000EX memory support will display the proper alignment angles based on this memory data so that the repair technician can properly align the feedback. Because the way in which the memory is used differs with the various motor manufacturers, software support must be developed for each brand (and sometimes models) of motors. Therefore TI-5000EX memory support must be purchased for each motor type in addition to the basic Stegmann encoder support.

Note: If a Hiperface encoder is replaced on an Rexroth motor, the motor data must be programmed into the replacement encoder in order for the drive to run the motor. Contact Mitchell Electronics, Inc. for information on software support for programming replacement encoders.

2.6.9.5.3.1 REXROTH MSK MEMORY TEST Rexroth MSK motors use the Hiperface encoder memory to store motor parameters. This data is programmed at the factory and cannot be changed by the drive. This data is read by the drive system on power-up prior to moving the motor. If the drive system cannot read the memory or if it gets incorrect data from it, the motor will not run. It is therefore very important to verify that the memory can be read and appears to be correct. The memory also contains information that allows checking the commutation alignment.

TI-5000 107 OPERATION In verifying correct memory data and memory operation, we are looking at two things:


The first item is done automatically. The data in the encoder is encoded with the ability to check data integrity. The TI-5000EX automatically checks some of this data as it reads and displays the various motor parameters. An explanation of possible errors is provided at the end of this section. The second item amounts to making sure that the encoder that is on the motor is the correct one. Sometimes in trouble-shooting, encoders get swapped in an attempt to isolate a problem, and the encoder on the motor you have could be the wrong one entirely. In general the data from the encoder should match the data from the motor nameplate. In this regard, we are looking for gross errors. Minor differences in the encoder data and nameplate data are normal. The display shown below is a memory test from an SKS36 encoder. The motor part number and motor parameters are fairly self explanatory. These numbers should match reasonably well with the nameplate data. At the end of the right column is some information that is useful to the repairman. The number of pole pairs is 4, which indicates a, 8 pole motor. MSK motors are know to use 6, 8 and 12 poles. There may be other numbers of poles, but those have been seen so far. The TI-5000EX uses the commutation offset to calculate what the +U –V and +U –W lockup angles should be in electrical degrees for proper feedback alignment, and these angles are reported in the Derived Data frame. Name Plate data: PART NO. MSK060C-0300-NN-S1-UG1-NNNN SERIAL NO. 19181 Comparing the above nameplate data to the encoder data below, we see that the data agrees quite well.


Each data item has a checksum associated with it for checking data integrity. If the checksum is found to be incorrect, ‘DATA ERROR’ is written into the field in the report in place of the data. At this time, the TI-5000EX cannot check all the data, but it will report any problems with the portion of the data that it can check. If data errors occur, it could be for any of the following reasons:

1. Faulty encoder. 2. Faulty or no encoder data. 3. Faulty feedback cable from the feedback connector to the encoder in the motor. 4. Failure to use the TI-5104 Indramat Adapter Module. 5. Incorrect or faulty TI-5000EX test cable. 6. Faulty TI-5000EX.

Experience so far indicates that it is somewhat rare for the encoder memory to actually have a problem. If you encounter an encoder data error, check the list above to verify that you are doing everything correctly. Especially if you are unfamiliar with testing Rexroth motors, you might check with Mitchell Electronics, Inc. if you have an encoder (or several encoders) that do not read the data correctly. The TI-5000EX software will attempt to pop up a message to help identify possible data problems or incorrect tester selections. The data from this screen may be saved or printed as a report either in the usual manner with the Save Report to File or Print Report buttons.

TI-5000 109 OPERATION The Save Encoder Data File button may be used to save a copy of the data to a disk file as Intel hexcode. You may wish to do this to send to Mitchell Electronics, Inc. in the event that there might be a question about the data. You may also wish to have a copy in case you would need to program it into a replacement encoder in the future. 2.6.9.5.3.2 REXROTH MSM MEMORY TEST Rexroth MSM motors use the Tamagawa MFE0017 encoder memory to store motor parameters. This data is programmed at the factory and cannot be changed by the drive. This data is read by the drive system on power-up prior to moving the motor. If the drive system cannot read the memory or if it gets incorrect data from it, the motor will not run. It is therefore very important to verify that the memory can be read and appears to be correct. The memory also contains information that allows checking the commutation alignment. In verifying correct memory data and memory operation, we are looking at two things:


The first item is done automatically. The data in the encoder is encoded with the ability to check data integrity. The TI-5000EX automatically tests 2 checksums, and this should determine whether or not the data I good. The second item amounts to making sure that the encoder that is on the motor is the correct one. This is more complicated with the MSM motors that normal because of the process required to get the model number. It has only been tested with the MSM020B MSM030B, and MSM030C models, and other models will like not display correctly. As more models are checked, the software will be updated to accommodate them. The display shown below is a memory test from an MFE0017 encoder. There is actually not very much data used for these motors. But, the checksums should provide a very good indication as to whether the data is good or not. As stated previously, the MSM motors use a standard alignment, and the lockup is not derived from the data. But for convenience, the +U –V and +U –W lockup angles are displayed in the Derived Data frame. These angles should be in electrical degrees for proper feedback alignment. Name Plate data: Motor Model MSM030C-0300-NN-M0-CC0


There are two blocks of data in the encoder memory, and each block has a checksum associated with it which allows the ability to check data integrity. The TI-5000EX does this automatically as it reads and displays the various motor parameters. Any incorrect data in one of the data blocks will result in an incorrect checksum calculated for that block. This will be reported with the text “Error” followed by the calculated checksum and then the data from the checksum field. The word “Error” is all you need to see to know that the information is incorrect. If the data is correct, the checksum field will show the text “OK” (as we see in our example). You should assume that if a checksum error occurs, the Rexroth drive will not run the motor. If data errors occur, it could be for any of the following reasons:

1. Faulty encoder. 2. Faulty or no encoder data. 3. Faulty feedback cable from the feedback connector to the encoder in the motor. 4. Incorrect or faulty TI-5000EX test cable. 5. Faulty TI-5000EX.

Experience so far indicates that it is somewhat rare for the encoder memory to actually have a problem. If you encounter an encoder data error, check the list above to verify that you are doing everything correctly. Especially if you are unfamiliar with testing Rexroth motors, you might check with Mitchell Electronics, Inc. if you have an encoder (or several encoders) that do not read the data correctly. The TI-5000EX software will attempt to pop up a message to help identify possible data problems or incorrect tester selections.

TI-5000 111 OPERATION The data from this screen may be saved or printed as a report either in the usual manner with the Save Report to File or Print Report buttons. The Save Encoder Data File button may be used to save a copy of the data to a disk file as Intel hexcode. You may wish to do this to send to Mitchell Electronics, Inc. in the event that there might be a question about the data. You may also wish to have a copy in case you would need to program it into a replacement encoder in the future.

TI-5000 112 OPERATION 2.6.10 SANYO DENKI MOTORS AND SERIAL ENCODERS

2.6.10.1 GENERAL COMMENTS The Sanyo Denki serial encoders listed in the next section are supported by this selection. Sanyo Denki incremental encoders with A, B, and Z lines should be tested as Generic Incremental encoders. This would include the so called Wire-saving Incremental types. 2.6.10.2 TYPES SUPPORTED The following list shows the Sanyo Denki encoders that are currently supported by the TI-5000EX: Number Type Counts/Rev AB Lines Z Line Cables INC-E TI-5065 E03007758 8,192 Yes Yes TI-5023, TI5026 E07B111335 ABS-E 2048 2,048 Yes Yes TI-5013 E07B151103 ABS-E 32768 32,768 Yes No TI-5056 E07B151306 32,768 Yes Yes User Fabricated (See Section 2.9 Table 2.16) E10B171103 ABS-E 131072 131,072 Yes No TI-5056 R11G4113A ABS-RII 16,384 No No TI-5036 R11ABS ABS-RII 8,192 No No TI-5067 INC-E – The INC-E type is the incremental wire saving encoder, and it can be tested as an AB quadrature incremental encoder. These encoders are known to come in 2,000 pulse (8,000 counts/rev) and 6,000 pulse (24,000 counts/rev) versions, and there are likely other resolutions as well. The wire-saving incremental encoders basically provide A, B, and Z quadrature pulse and index signals with complement lines. When the encoder powers up, these same lines provide U, V, and W signals respectively. The initial U, V, and W signals provide the drive an absolute reference that can be used for startup commutation before the encoder count is indexed by the Z pulse. Once the encoder is indexed, of course the A and B quadrature count provides an absolute position referenced to the Z pulse position. E03007758 – The 8,192 count Sanyo Denki E03007758 encoder provides 13 bit resolution for a single-turn, so 1 turn will change the count by 8,192 (2000 HEX). Another 8 bits above the single-turn count are used to count revolutions, so it can keep track of ± 128 revolutions. This means that the largest positive count will be 1,048,575 (000F FFFF HEX) while the largest negative count is -1,048,576 (FFF0 0000 HEX). It also provides an incremental output with A, B, and Z channels, and these functions of the encoder may be tested using the methods described in the incremental section. The incremental signals will provide 2,048 pulses or 8,192 counts per revolution. This encoder is the same as the Kawasaki HE-02 encoder. E07B111335 – The 2,048 count Sanyo Denki E07B111335 encoder provides 11 bit resolution for a single-turn, so 1 turn will change the count by 2,048 (800 HEX). Another 13 bits above the single-turn count are used to count revolutions, so it can keep track of ± 4,096 revolutions. This means that the largest positive count will be

TI-5000 113 OPERATION 8,388,607 (007F FFFF HEX) while the largest negative count is -8,388,608 (FF80 0000 HEX). The Sumtak also provides an incremental output with A, B, and Z channels, and these functions of the encoder may be tested using the methods described in the incremental section. The incremental signals will provide 2,048 pulses or 8,192 counts per revolution. This encoder is essentially the same as the Sumtak AEC2048 and the Tamagawa TS5643. E07B151103 – The Sanyo Denki E07B151103 encoder provides 15 bit resolution for a single-turn, so 1 turn will change the count by 32,768 (7FFF HEX). Another 11 bits above the single-turn count are used to count revolutions, but the revolution count is limited to 0 to 1,799 revolutions. This means that the largest positive count will be 58,982,399 (0383 FFFF HEX) and the count will not go negative. This Sanyo Denki also provides an incremental output with A and B, channels but no Z channel, and these functions of the encoder may be tested using the methods described in the incremental section. The incremental signals will provide 32,768 counts per revolution. Without a Z pulse the incremental count test will not work, so the serial count must be used as a reference. The following procedure may be used:

1. Read the absolute count from the Data display and record it. 2. Click the Select Feedback button and select an incremental encoder with 32,768 counts per turn. 3. Click OK to go back to the data display, and it should show a count of zero. Turn the encoder

approximately 10 revolutions, and record the count. 4. Select Sanyo Denki E07B151103 serial encoder again. 5. Go back to data display and read the absolute count from the display. Subtract the count recorded

in step 1 from this count. It should compare very closely to the count recorded in step 3. E07B151306 – The Sanyo Denki E07B151306 encoder provides 15 bit resolution for a single-turn, so 1 turn will change the count by 32,768 (7FFF HEX). Another 13 bits above the single-turn count are used to count revolutions, so it can keep track of ± 4,096 revolutions. This means that the largest positive count will be 134,217,727 (07FF FFFF HEX) while the largest negative count is -134,217,728 (F800 0000 HEX). This Sanyo Denki also provides an incremental output with A, B, and Z channels, and these functions of the encoder may be tested using the methods described in the incremental section. The incremental signals will provide 32,768 counts per revolution. No encoder connector has been identified for motors using this encoder, but the wire colors and connection to the TI-5000EX are shown in Section 2.9 Table 2.16. E07B171103 – The Sanyo Denki E07B171103 encoder provides 17 bit resolution for a single-turn, so 1 turn will change the count by 131,072 (0001 FFFF HEX). Another 11 bits above the single-turn count are used to count revolutions, but the revolution count is limited to 0 to 1,799 revolutions. This means that the largest positive count will be 235,929,599 (0E0F FFFF HEX) and the count will not go negative. This Sanyo Denki also provides an incremental output with A, B, channels but no Z channel, and these functions of the encoder may be tested using the methods described in the incremental section. The incremental signals will provide 32,768 counts per revolution. Without a Z pulse the incremental count test will not work, so the serial count must be used as a reference. The following procedure may be used:

1. Read the absolute count from the Data display and write it down. 2. Click the Select Feedback button and select an incremental encoder with 32,768 counts per turn. 3. Click OK to go back to the data display, and it should show a count of zero. Turn the encoder

approximately 10 revolutions, and write down the count. 4. Select Sanyo Denki E07B171103 serial encoder again.


5. Go back to data display and read the absolute count from the display. Subtract the count recorded in step 1 from this count. It should compare very closely to the count recorded in step 3.

R11G4113A – The Sanyo Denki R11G4113A encoder is very similar to the E07B151306 described above. It differs in the fact that it does not provide A, B, and Z quadrature pulses, it provides 14 bit resolution for a single-turn instead of 15 bits, and it requires a -5VDC supply in addition to the normal +5VDC. Because it is 14 bits, 1 turn will change the count by 16,384 (3FFF HEX). Another 13 bits above the single-turn count are used to count revolutions, so it can keep track of ± 4,096 revolutions. This means that the largest positive count will be 67,108,863 (03FF FFFF HEX) while the largest negative count is -67,108,864 (FC00 0000 HEX). An external power supply must be connected to provide -5VDC to pin M. Connect the positive power supply terminal to J1-2 (0V or GND), and connect the – terminal to the GRN wire that is loose at the terminal block end (see the TI-5036 cable description). Make certain that this wire does not inadvertently come into contact with any other wires. The power supply used must have a floating ground. There must be no connection between its negative terminal and ground. R11ABS – The R11ABS is a name we have given to this encoder for lack of official identification. It appears to be the same as the Sanyo Denki R11G4113A except that it is 8,192 counts/rev (13 bits) for a single-turn. Like the R11G4113A, it keeps track of ± 4,096 revolutions. 2.6.10.2.1.1 ABSOLUTE ENCODER RESET PROCEDURES If the Sanyo Denki serial encoders have not been connected to a 5V power supply or battery backup for a period of time, they will need a reset operation. Before the reset operation, the backup mode bit will be in alarm and will stay in alarm even when battery backup is connected. To accomplish a reset operation, must be performed on the encoder. There are several different types of encoders, and the names of the signals and details of the procedure may differ somewhat. The following paragraph will describe resetting the E07B151103 encoder. You may have to experiment somewhat if your encoder does not have the same lines or behave exactly the same as this one. Email [email protected] if you have further questions. When it has been powered down for a long time, the E07B151103 encoder will typically show ALARM for BATTERY WARN and OK for BATTERY ALARM. The CLEAR SIGNAL line can be connected to 5VDC for 5 seconds to clear the multi-turn count, but it does not clear the alarms. Connecting 5VDC to the RESET line for 5 seconds should reset the encoder and clear the alarms. Typically the BATTERY WARN will change to OK, and the BATTERY ALARM WILL change to ALARM. It is in alarm because there is not battery voltage connected. If the Bat+ line is then connected to 5V, both BATTERY WARN and BATTERY ALARM should show OK. Check the pin designations in Section 2.9 for the various Sanyo Denki cable descriptions (listed in Types Supported) for identifying the CLEAR, RESET and BAT lines. 2.6.10.2.2 IDENTIFICATION P Series – Sanyo Denki uses the P series part numbers for some of their motors for which a part number breakdown is provided in their manuals. They show the bold character as the encoder identifier. There is some inconsistency in some of the descriptions in the manuals, but this should provide some useful guidance. The assignments are as follows:

TI-5000 115 OPERATION Letter Encoder S00 Wire saving incremental, 2,000 or 6,000 PPR S07 Wire saving incremental, 2,048 PPR SA0 Wire saving incremental, 2,000 or 6,000 PPR, rigid shaft J Absolute encoder with motor flange of 60 mm or less A00 ABS-E encoder with motor flange of 76 mm or more AA0 ABS-E encoder with motor flange of 76 mm or more, rigid shaft M ABS-RIII, 8,192 PPR super capacitor unavailable N ABS-RII, 8,192 PPR super capacitor unavailable V ABS-RII super capacitor built-in Some example P series models are shown below: Motor Model Feedback P10B13100BXAT0 E10B171104

P20B10500DXS00 ABZ wire saving P30B06040DBV20 R11ABS P50B15020DXV00 R11ABS

6?BM Series – Another series (probably older than the P Series) of Sanyo Denki motors uses part numbers that begin with a 2 digit number followed by ‘BM’, such as 61BM, 62BM, etc. It is unclear how these part numbers breakdown, but the following part numbers are presented with the encoder use with them. The letters in the part numbers that may have to do with the encoder are in bold. While this is not a clear part number breakdown, it may be useful in identifying the feedback device used on these models. Motor Model Feedback 61BM220BBAF0 E07B151103 61BM330BBAF0 E07B151103 61BM330BXAF0 E07B151103 61BM470MXAF5 E07B151103 61BM120BXAT0 E10B171103 61BM330BBAT0 E10B171103 61BM330BXAT0 E10B171103 62BM080FXEU4 ABZUVW Incremental 65BM003HBRTA E0307758 (HE-02) 65BM040FXEGM ABZUVW Incremental 65ZBM010DXS25EEU ABZ Wire Saving 68BM03AHBAG7 E07B151306 68ZBM010DXS25EU R11G4110A13 68ZBM090HCSVT2 R11G4110A13 2.6.10.3 CONNECTION Connection requires using the correct cable as shown in the chart in the Type Supported section. Also the WinTI5000EX ‘Feedback Selection’ frame has a cable dropdown menu from which you can select the cable that you need. After making the cable selection, that selection will appear on the Data Display report which is helpful in documenting the cable used. Download cable sheets from the Customer Page at http://www.mitchell-electronics.com for cable pinouts and wiring details.

TI-5000 116 OPERATION Apparently some Sanyo Denki feedback devices do not come with a connector, and wire colors are used to indicate the various signals. Some are listed below: INC-E Wire-saving Incremental J1 TB Pin Signal Sanyo Color 1 +5 VDC RED 2 GND BLK 3 A BLU 4 A* BRN 5 B GRN 6 B* VIO 7 Z (or C) WHI 8 Z* (or C*) YEL 9 RX GRN/BLK 10 RX* PUR/BLK E07B15130 J1 TB Pin Signal Sanyo Color 1 +5 VDC RED 2 GND BLK 3 A BLU 4 A* BRN 5 B GRN 6 B* PUR 7 Z WHT 8 Z* YEL 9 RX GRN/BLK 10 RX* PUR/BLK FREE CLEAR RED/BLK ABS-E (Request Signal Unavailable) J1 TB Pin Signal Sanyo Color 1 +5 VDC RED 2 GND, BATT GND BLK 3 A WHI/BLU 4 A* BLU 5 B WHI/YEL 6 B* YEL 7 Z (C) WHI/ORG 8 Z* (C*) ORG 9 S WHI/BRN 10 S* BRN FREE Frame GND WHI/GRN FREE RES GRN FREE BATT + WHI/BLK FREE BATT 0V BLK

TI-5000 117 OPERATION ABS-RII (Request Signal Available) J1 TB Pin Signal Cable Color 1 +5 VDC RED 2 GND BLK, YEL 2 BAT- (0V) PUR 9 ES+ BRN 10 ES- BLU 11 ENCREQH ORG 12 ENCREQL GRN FREE -5 VDC GRY FREE BAT+ PNK FREE ECLR WHI 2.6.10.4 ENCODER SELECTION Click on the Select Feedback button to make the selection. The Sanyo Denki serial encoders require the following setup sequence:

1. Click on the Encoder Feedback radio button. 2. Select Sanyo Denki from the Encoder Manufacturer dropdown menu. 3. Select the encoder type that you have from the Encoder Type dropdown menu.

The encoder types listed in the current software revision are shown in an earlier section. Sanyo Denki motors come with various number of poles. The number of poles may be selected from the POLES dropdown menu. To determine the number of poles, apply a small voltage to 2 of the armature leads to lock the rotor, and then count the number of lockup positions to determine the number of pole pairs. For instance, if the rotor locks up in 4 different shaft positions, the motor has 4 pole pairs or 8 poles. The number of poles must be entered correctly in order to display the electrical angle correctly. It is essential for the electrical angle to be correct when checking or setting the encoder alignment for correct commutation. 2.6.10.5 TESTING Sanyo Denki incremental encoders and incremental lines on Sanyo Denki serial encoders are tested as Generic Incremental Encoders using Data Display, Line Levels, Incremental Count Test, and Phase Test for a complete test. Sanyo Denki serial encoder types listed above (like most serial encoders) use only the Data Display and the Serial Count Test. The forward armature direction for Sanyo Denki motors is CCW looking at the drive shaft end. 2.6.10.5.1 DATA DISPLAY Data Display is the initial test, and it is started by default when WinTI5000EX is started. When already in another test, it can be started by clicking on the Data Display button among the test buttons at the top of the display. Use it for the following:


2. Use the commutation display to check or set the feedback commutation alignment.


3. Check the encoder status for the following: ensure that the encoder is indexed, communicating properly with the tester, not reporting internal errors, correctly displaying overheat and battery alarms, and displaying the correct encoder ID (if ID is implemented).

The following sections describe information shown on the display. 2.6.10.5.1.1 COMMUTATION The Fanuc style commutation gray code shown as C1 – C8 and the electrical angle can be used to check and set commutation using a static rotor lockup by applying a small lockup voltage to the stator windings. We strongly recommend using the electrical angle as the superior method of alignment for Sanyo Denki encoders. For a particular lockup polarity, the rotor will lock up in as many different positions as there are pole pairs, but the gray code and electrical angle indications will be the same at each lockup position. The mechanical angle will be different at each lockup position (except for 2 pole motors where there is only one lockup position), so it is not as convenient to use for feedback alignment. See section 3.2 for a more detailed description of commutation alignment procedures. The number of poles must be entered correctly for the electrical angle to be correct. The gray code, electrical angle and mechanical angle are derived from the position count. The position count is absolute immediately on power up for Mitsubishi serial encoders. The table below shows 3 different lockups that can be used to check or set commutation on motors with Sanyo Denki serial encoders. The first one puts the feedback on a zero electrical angle which some users favor. It requires applying power to all 3 armature lines. The last two procedures require applying power to only two armature leads at a time. It is easy to go from +U –V to +U –W just by moving the minus lead from V to W. This should cause the motor to jog 60 electrical degrees in the forward direction (CCW looking at the shaft for Sanyo Denki). Failure to move the correct number of degrees or in the correct direction would be an indication of a significant problem. Setting these angles within ±3 electrical degrees is normally quite sufficient. Here are typical Sanyo Denki lockups for serial encoders.


2.6.10.5.1.2 COUNT The Count frame displays the encoder count both as a decimal and hexadecimal number. Users will typically be interested in only the decimal count, but encoder repairmen and other advanced users may find the hexadecimal representation useful. In general this count will not be zero on power up. This is an absolute encoder, and it will remember the count on power up. The number of counts/rev for the various models is shown in the table in an earlier section on types of encoders supported. Always verify that the encoder count appears to change by the correct number of counts/rev while turning the encoder. If the count is not changing, then there is an encoder problem. As described in a later section, the Count Test may be performed to more accurately determine whether the correct number of counts per revolution is occurring, but this is an important initial evaluation.

TI-5000 119 OPERATION 2.6.10.5.1.3 ENCODER STATUS INDEX – The INDEX box is disabled for all Sanyo Denki serial encoders because these encoders display the correct count on power up without indexing. DATA - If no data is being sent from the encoder, NONE will be displayed in the DATA box. If the TI-5000EX and the encoder are communicating correctly, RECEIVING will be displayed in the DATA box. The cabling is the first thing to check if the encoder is not communicating, but it can also mean a component failure in the encoder. BATTERY ALARM - The BATTERY ALARM bit is not completely understood, but it seems to indicate a situation in which the internal capacitors of the encoder have discharged such that the encoder is in need of a reset (see earlier section for reset). It serves somewhat the function that the INTERNAL ERROR serves for other encoders. While BATTERY ALARM is in ALARM, the revolution count and the position count (within a single-turn) may not be synchronized. When the revolution count goes through zero, the position count may not go though zero. Generally a reset will take care of this problem. BATTERY WARN - The BATTERY WARN box will show ALARM if there is a battery error alarm and OK if there is not. It seems to work similarly to the battery alarm for most other encoders. It only seems to work as expected as long as the encoder is not in need of a reset. The battery voltage range appears to be from about 3.6V to 5.0V. OVERHEAT - The OVERHEAT box will be disabled for Sanyo Denki encoders because no overheat condition is detected. ENCODER ID – There is no encoder ID support for Sanyo Denki serial encoders. 2.6.10.5.2 COUNT TEST The Count Test can be started by clicking on the Count Test button among the test buttons at the top of the display. The Count Test will verify that the encoder is incrementing the correct number of counts per revolution. The Count Test for the Sanyo Denki encoders is not significantly different from that for other encoders, so please refer to the general information on the count test in Section 2.2.2 for further details. The number of bits tested by the Stuck Bit Test varies depending upon the particular model. Encoders with greater than a 16 bit count per revolution will test bit0 to bit15 for activity. Others will test as many bits as are used in the count for one revolution.

TI-5000 120 OPERATION 2.6.11 STEGMANN SERIAL ENCODERS

2.6.11.1 GENERAL COMMENTS The Stegmann serial encoders listed in the next section are supported by this selection. Stegmann incremental encoders with A, B, and Z lines should be tested as Generic Incremental encoders. Stegmann encoders used on Indramat digital motors are discussed in the Indramat section. This section deals with Stegmann Hiperface and SSI encoders. The Stegmann AG100 SSI encoder is used on Indramat MAC motors. The AG661 SSI encoder is used on Siemens 1FT5 series motors. The Stegmann SSI encoders are similar to SSI format encoders from other manufacturers such as Heidenhain and Hengstler. They use clock and data lines, and there are no incremental lines. The newer Stegmann Hiperface encoders are showing up on many brands of motors including Allen Bradley, Baumuller, Berger Lahr (Telemechanique), Control Techniques, Elau, Modicon, Octacom, Rexroth, and SEW Eurodrive to name a few. While the details are different, the Hiperface encoders are similar in function to the Heidenhain Endat encoders. There are serial lines for accessing absolute position data and memory data, and they use analog 1V p-p sine and cosine signals that can be counted like A and B quadrature lines. Also like the Endat encoders, there is no index pulse. Without an index pulse, in order to obtain absolute position information from the incremental count (from the 1V p-p lines), the incremental count must first be referenced to absolute position data read from the serial lines. Tips are given in later sections for testing the incremental section on these encoders. Some Hiperface encoders are specified to operate from 5 VDC, but others are specified in the 7VDC to 12 VDC range. Since even the 5VDC versions will accept up to 12 VDC, it is recommended that the TI-5104 Adapter Module, which provides 8 VDC, be used with the Stegmann Hiperface encoders (Caution: Always check the rating listed on the encoder label to verify the range!). The 8VDC output is within the correct range for all Hiperface encoders that we have encountered. The TI-5104 also provides the additional advantage of amplifying the 1V p-p sine outputs from the incremental lines. The SNS50 and SNS60 encoders are a peculiar variation in the Hiperface encoders. They are so different from the other Hiperface encoders that there is a special section describing them at the end of the Stegmann section. Be sure to read this section if you encounter one of these encoders. These encoders are used on AB 8720 series spindle motors and on Fagor PM brushless motors. 2.6.11.2 TYPES SUPPORTED The following list shows the Stegmann serial encoders that are currently supported by the TI-5000EX, and it lists some representative motors on which they are used as well as test cable possibilities. Please check the current PDF catalog file and price list files for a complete listing of all cables supporting motors using Stegmann encoders.

TI-5000 121 OPERATION Type Format Counts/Rev Cables Inc / Pos / Rev SKS36 Hiperface 512 / 4,096 / NONE TI-5094 (Generic), TI-5057 (AB MPL)

TI-5058 (AB MPL), TI-5093 (Rexroth MSK)

SKM36 Hiperface 512 / 4,096 / 4096 TI-5094 (Generic), TI-5057 (AB MPF) TI-5058 (AB MPF), TI-5093 (Rexroth MSK)

SCS60/70 Hiperface 2,048 / 16,384 / NONE TI-5069 (Generic), TI-5068 (Modicon) SCM60/70 Hiperface 2,048 / 16,384 / 4096 TI-5069 (Generic), TI-5068 (Modicon) SNS50/60 Hiperface 4,096 / NONE / NONE TI-5069 (Generic), TI-5063 (Fagor) SRS50/60 Hiperface 4,096 / 32,768 / NONE TI-5069 (Generic), TI-5057 (AB MPF)

TI-5058 (AB MPF), TI-5064 (AB MPL, 1326), TI-5096 (AB H-6300), TI-5063 (Baumuller)

SRM50/60 Hiperface 4,096 / 32,768 / 4096 TI-5069 (Generic), TI-5057 (AB MPF) TI-5058 (AB MPF), TI-5064 (AB MPL, 1326) TI-5096 (AB H-6300), TI-5063 (Baumuller)

AGI100 SSI NONE / 4,096 / 4,096 TI-5061 (Indramat MAC) AGI661 SSI NONE / 4,096 / 4,096 TI-5061 (Siemens 1FT5) In addition to the above encoders, a DSL-3J08G0M2XB9, which apparently is a 5V SKM36 encoder, is sometimes used on MPL-A1XX motors. It is not clear whether this is an AB part number or Stegmann. But, the encoder seems to test fine using the SKM36 selection. Note: The first count is the number of counts/rev for the incremental signals, the second is the number of counts/rev for the absolute serial position count, and the last count is the number of revolutions that can be counted (for multi-turn encoders only). 2.6.11.2.1 IDENTIFICATION The Stegmann encoders are normally clearly marked, so identification is not a problem. The TI-5000EX does currently report an encoder ID field for Hiperface serial encoders, and this will help assure that the correct selection has been made. The SSI encoders are not known to have ID capability. 2.6.11.3 CONNECTION Connection requires using the correct cable as shown in the chart in the Type Supported section. Also the WinTI5000EX ‘Feedback Selection’ frame has a cable dropdown menu from which you can select the cable that you need. After making the cable selection, that selection will appear on the Data Display report which is helpful in documenting the cable used. The TI-5069 generic cable connects directly to the 8 pin connector on the encoder, so it should work with all Hiperface encoders. Download cable sheets from the Customer Page at http://www.mitchell-electronics.com for cable pinouts and wiring details. Cable configurations other than the cables listed are known to exist. There may be cables that are made by OEM machine manufacturers using these encoders. If properly cabled, the Stegmann Hiperface encoders can be used with the TI-5104 Adapter Module so that it is easier to check the incremental portion with the same connection. See the section on cables for more information.

TI-5000 122 OPERATION 2.6.11.4 ENCODER SELECTION Click on the Select Feedback button to make the selection. The Stegmann serial encoders require the following setup sequence:

1. Click on the Encoder Feedback radio button. 2. Select Stegmann from the Encoder Manufacturer dropdown menu. 3. Select the encoder type that you have from the Encoder Type dropdown menu. 4. Select a Motor Manufacturer name if Memory support exists and you have purchased it.

The encoder types listed in the current software revision are shown in a preceding section. The number of poles may be selected from the POLES dropdown menu. To determine the number of poles, apply a small voltage to 2 of the armature leads to lock the rotor, and then count the number of lockup positions in one revolution to determine the number of pole pairs. For instance, if the rotor locks up in 4 different shaft positions, the motor has 4 pole pairs or 8 poles. The number of poles must be entered correctly in order to display the electrical angle correctly. It is essential for the electrical angle to be correct when checking or setting the encoder alignment for correct commutation. 2.6.11.5 TESTING Stegmann incremental encoders are tested as Generic Incremental Encoders using Data Display, Line Levels, Incremental Count Test, and Phase Test for a complete test. Stegmann serial encoder types listed above (like most serial encoders) use only the Data Display, Serial Count Test and Memory Test if they have memory. 1 V p-p Signals – The 1 V p-p signals must be verified on encoders that incorporate these signals. If the incremental count is not working correctly, that will be an immediate indication of a problem. However, the fact that the incremental count appears to be working is not sufficient. The amplitude of these signals should be checked. Amplitude measurement is probably best done with an oscilloscope. Connecting the scope ground clip to J1 pin 2 and checking the amplitude of the individual line at J1 pins 3, 4, 5, and 6, is a good method to use. This should be done coming out of the encoder before the signals go through any adapter modules. The Hiperface encoders will provide a 1 V p-p signal on the true lines (pins 3 and 5) and a DC voltage of about 2.5 VDC on the complement lines (pins 4 and 6).

TI-5000 123 OPERATION 2.6.11.5.1 DATA DISPLAY Data Display is the initial test, and it is started by default when WinTI5000EX is started. When already in another test, it can be started by clicking on the Data Display button among the test buttons at the top of the display. Use it for the following:


2. Use the commutation display to check or set the feedback commutation alignment. 3. Check the encoder status for the following: ensure that the encoder is communicating properly with

the tester, not reporting internal errors, and displaying the correct encoder ID. The following sections describe information shown on the display. 2.6.11.5.1.1 COMMUTATION The electrical angle is best for checking and setting commutation. For a particular lockup polarity, the rotor will lock up in as many different positions as there are pole pairs, but the electrical angle indications will be the same at each lockup position. The mechanical angle will be different at each lockup position (except for 2 pole motors where there is only one lockup position), so it is not as convenient to use for feedback alignment. See section 3.2 for a more detailed description of commutation alignment procedures. The number of poles must be entered correctly for the electrical angle to be correct. The electrical angle and mechanical angle are derived from the position count. The position count is absolute immediately on power up for Stegmann Hiperface and SSI serial encoders. Some Indramat MAC and Siemens motors use the Stegmann SSI encoders for positioning. These motors use Hall effects for motor commutation, so the encoder does not need to be aligned for commutation purposes. The method of alignment for Hiperface encoders will vary with motor manufacturer. The table below shows 2 different lockups that can be used to check or set commutation on Allen Bradley motors with Hiperface serial encoders. The two procedures require applying power to only two armature leads at a time. It is easy to go from +U –V to +U –W just by moving the minus lead from V to W. This should cause the motor to jog 60 electrical degrees in the forward direction (CW looking at the shaft for Allen Bradley). Failure to move the correct number of degrees or in the correct direction would be an indication of a significant problem. Setting these angles within ±3 electrical degrees is normally quite sufficient.

Lockup Elect. Angle +U –V 110 (lockup angle read from the memory test – see memory section) +U –W 170 (lockup angle read from the memory test – see memory section)

Unlike most feedback alignment discussed in this manual, Allen Bradley MPL, MPF and 1326 motors using Hiperface encoders do not have a common lockup angle, and in general, they will all lock up at different angles. These motors store a commutation offset in the encoder memory. By using the commutation offset, the encoders do not have to be set to a common alignment. In order to correctly check or set the alignment, you have to run the Memory Test on the encoder, and write down the +U –V and +U –W lockup angles provided by the memory test.

TI-5000 124 OPERATION 2.6.11.5.1.2 COUNT As mentioned previously, the Hiperface encoder provides an incremental count using the 1V p-p analog signals. This count is shown in the Incremental Count frame. This count may be zeroed at any time by pressing the Zero Count button. The SSI encoders do not provide an incremental count The Revolution and Position Count frame displays the absolute position count as a decimal number in the POS COUNT box. This count will range from 0 to counts/rev -1. Multi-turn encoders will provide a revolutions count as a decimal number in the REV COUNT box. This box is disabled for single-turn encoders. The HEX COUNT box will display, in hexadecimal format, the position count (for single-turn encoders) and a composite position and revolutions count (where the revolution LSB is the next bit above the MSB of the position count for multi-turn encoders). Most users will be interested only in the decimal count, but encoder repairmen and other advanced users may find the hexadecimal representation useful. In general the absolute count numbers will not be zero on power up. Because it is an absolute encoder, it will remember the count on power up. The number of counts/rev for the various models is shown in the table in an earlier section on types of encoders supported. As an example of single and multi-turn model numbers, the SRS50/60 encoders are single-turn encoders in that they do not keep track of revolutions. The SRM50/60 encoders are multi-turn encoders, and they will keep track of 4,096 revolutions. The “S” and “M” in the names designate single and multi-turn respectively. Always verify that the encoder count appears to change by the correct number of counts/rev while turning the encoder. If the count is not changing, then there is an encoder problem. As described in a later section, the Count Test may be performed to more accurately determine whether the correct number of counts per revolution is occurring, but this is an important initial evaluation. Typically serial encoders that include incremental lines are tested both as incremental encoders and serial encoders. Since the Stegmann Hiperface serial encoders do not include an index pulse, an incremental encoder count test cannot be performed. Comparing the incremental count with the absolute count provides a possible method of also checking the integrity of the incremental count. The procedure is as follows:

1. Move the shaft until the absolute position count in the POS COUNT box reads 0. 2. Click the Zero Count button to force the incremental count to 0. 3. Turn the encoder 10 revolutions. With multi-turn encoders, you can use the data in the REV

COUNT box to keep track, but you will just have to count revolutions for single-turn encoders. 4. Adjust the shaft to get as close as possible to 0 in the POS COUNT box. 5. Write down the incremental count in the INCREMENTAL box. It should be very close to 10 times

the number of incremental counts/rev. 2.6.11.5.1.3 ENCODER STATUS DATA - If no data is being sent from the encoder, NONE will be displayed in the DATA box. If the TI-5000EX and the encoder are communicating correctly, RECEIVING will be displayed in the DATA box. The cabling is the first thing to check if the encoder is not communicating, but it can also mean a component failure in the encoder. There is no good way to determine whether data is being received from the Stegmann SSI encoders, so the DATA box is not implemented for those selections. INTERNAL ERROR - The INTERNAL ERROR box will show ALARM if there is an internal error alarm and OK if there is not. The internal alarm is the result of self tests that are done by the encoder electronics. Stegmann literature lists the causes for alarms which are detailed in the following discussion of error type. ERROR TYPE – When the Hiperface encoder produces an internal alarm, a code indicating the cause of the alarm may be read from the encoder. This code is displayed for Hiperface encoder alarms. For other types

TI-5000 125 OPERATION of encoders, the error type is displayed if it is known. The following list of errors applies to the Hiperface encoders: Code Type Description 00H No error 01H Initialization Analog signals outside specification 02H Initialization Internal angle offset erroneous 03H Initialization Data field partition table destroyed 04H Initialization Analog limit not available 05H Initialization Internal I2C bus not serviceable 06H Initialization Internal checksum error 07H Protocol Encoder reset has occurred as a result of program monitoring 09H Protocol Parity error 0AH Protocol Checksum of the transmitted data is wrong 0BH Protocol Unknown command 0CH Protocol Number of data transmitted wrong 0DH Protocol Command argument transmitted is impermissible 0EH Data Data may not be written to the data field selected 0FH Data Wrong access code 10H Data The size of the specified data field cannot be changed 11H Data Specified word address outside data field 12H Data Access to non-existent data field 01H Position Analog signals outside specification 1FH Position Speed too high, position formation not possible 20H Position Position of single-turn impermissible 21H Position Position error, multi-turn 22H Position Position error, multi-turn 23H Position Position error, multi-turn 28H Position Error absolute valued formation linear measurement system 1CH Other Monitoring the magnitude of the analog signals (process data) 1DH Other Critical encoder current (contamination, transmitter breakdown) 1EH Other Critical encoder temperature 08H Other Counter overflow ENCODER ID – The ENCODER ID will indicate the type of Hiperface encoder in use based on the ID code read from the encoder. This box will be disabled for other types of encoders that do not provide ID data. If the ID checking software agrees with your encoder selection, it will indicate OK in the ID box. For instance if you select SRS50, and the ID agrees with that, the ID box will show ‘SRS50 OK’. If you have selected the wrong encoder, it will show ‘SRS50 Error’. In that case, you should verify that you have made the wrong selection and make the correct selection

TI-5000 126 OPERATION 2.6.11.5.1.4 MEMORY STATUS The Read Memory Status button on the Data Display allows the user to check whether memory is currently in use for a particular encoder. Clicking the button when connected to an SRM50 encoder on an Allen Bradley MPL motor would produce the following display:

Memory Status Field WE AC# CE Bytes 0 YES 0 NO 32 1 YES 0 NO 32 2 YES 0 NO 32 3 YES 0 NO 32 4 Undefined field 0 5 Undefined field 0 6 Undefined field 0 7 Undefined field 0 Total bytes used 128 Total bytes unused 0 Total used + unused 128

This tells us that there are 4 memory fields of 32 bytes each defined in this encoder. All 4 fields are write enabled (WE). The access code is set to 0 (could be 0, 1, 2, or 3). The code enable bit (CE) is not set for the 4 defined fields, so the access code does not have to be used. The total bytes number of memory bytes used is 128. The total bytes unused is 0, and this means that all of the available memory is in use. No more data fields could be defined for this memory because it is used up. This data formatting is done by the motor manufacturer and is of little concern to the TI-5000EX user. However, it is useful to look at it to verify that the memory looks normal. For instance if you see that no fields have been defined for an encoder on an Allen Bradley MPL motor, it is very likely that the encoder has been replaced and the correct data has not been programmed into the memory. This would be very important to know because the motor would not run correctly on the Allen Bradley drive. It is also useful to check on unfamiliar motors to determine whether the motor manufacturer is using the memory. This Memory Status data is automatically included on the Data Display report when a Stegmann Hiperface encoder has been selected. 2.6.11.5.2 COUNT TEST The Count Test can be started by clicking on the Count Test button among the test buttons at the top of the display. This will run a standard Count Test on the absolute position count. The incremental count must be tested as described previously. The Count Test will verify that the encoder is incrementing the correct number of counts per revolution. The Count Test for the Stegmann encoders is not significantly different from that for other encoders, so please refer to the general information on the count test in Section 2.2.2 for further details. The stuck bit test will test bit0 to bit13 for activity for 16,384 count encoders and bit0 to bit14 for activity for 32,768 count encoders. As with all serial encoders, there will be some error shown in the Count Test. The slow data rate from the Hiperface encoders will make the errors somewhat larger than typical serial encoders. Turning the encoders very slowly will help reduce the errors.

TI-5000 127 OPERATION 2.6.11.5.3 MEMORY TEST See the section for the appropriate motor brand. The memory test data is very specific to the particular motor. 2.6.11.5.4 SNS50/60 The Stegmann Hiperface SNS encoders are quite a bit different from the other Hiperface encoders. Here is a list of their peculiarities:

1. These encoders provide serial data lines, like other Hiperface encoders, but they do not provide absolute position information from the serial data. All position data is from the A and B (cosine and sine) channels.

2. As with other Hiperface encoders, memory data may be read from the serial lines, but memory is not

defined by the user as with other Hiperface encoders. The same amount of memory is always defined, and some of the memory is used by Stegmann to provide calibration information for the encoder signals.

3. On power up, the A and B channels will provide a resolution of 4,096 counts/rev using 1024 periods of

cosine and sine waves. 4. Using the serial lines, the encoder may be programmed to output one period of sine and cosine signals

per revolution somewhat similar to a single speed resolver (ignoring the excitation) or the C and D channels of an Heidenhain ERN1387 encoder. The serial lines can be used to program the encoder back to 1024 periods per revolution.

5. The serial lines may be used to program the encoder to output an index pulse once per revolution. In

this mode, the encoder can provide absolute position data (after it is indexed), and it works like any other incremental encoder with A, B, and Z channels. The index pulse uses the serial lines, so in this mode the serial channel can no longer be used for serial data. The encoder will remain in this mode until it is powered down.

Cable Connections – The SNS encoders are compatible with the TI-5069 cable that connects directly to Stegmann Hiperface encoder 8 pin connectors. The cable should be modified so that terminal block pin 7 is jumpered to pin 9 and pin 8 is jumpered to pin 10. This connects the index channel which apparently only exists on the SNS50/60 encoders. Any other Stegmann cables that would be correct for specific motors (such as the TI-5064 for Allen Bradley) would also need this modification. Testing the Encoder – Since this encoder has several different modes, and since you can’t come back out of the Z pulse mode (without cycling the power), it is best if you proceed through this checkout in a specific order. It may also depend on what type of motor is using the encoder as to how important some steps may be. For example, some motors may not use the memory, so the memory test may not be important in those cases. At this time, the memory test can only interpret the data format for the Allen Bradley Spindle motors. Data from other motors will not look like good data when the TI-5000EX system tries to interpret it as Allen Bradley data.

TI-5000 128 OPERATION A spindle motor that is an induction motor, rather than permanent magnet brushless, may not make use of the one period per revolution sine waves or the index pulse. However, unless you are sure a certain function of the motor is not used, you should try to check it out. Suggested Test Sequence – The following sequence will work well in most cases:

1. Connect the encoder to the TI-5000EX using the appropriate Stegmann cable and the TI-5104 Adapter Module.

Note: The cable used should be modified so that the index pulse on the serial channel gets to the Z pulse input of the tester. This means that pins 7, 9, and 11 should be in common with each other and pins 8, 10, and 12 should be in common with each other.

2. Select the Stegmann SNS Hiperface encoder. 3. In the Data Display, the Encoder ID box should say SNS OK. That means that it has read the SNS

encoder ID from the serial lines, and it is telling you that you have selected the correct encoder. Obviously this also tells you that the serial lines are functional and that you are receiving data from the encoder. The normal box for indicating receiving data is not functional for the SNS encoder.

The INTERNAL ERROR box should say OK. If it says ALARM, it will also display a 2 digit hexcode describing the alarm. A code of FF usually means that it is not sending any data. This could mean anything from a cabling problem to a bad encoder. When you turn the encoder (or motor) shaft CW (facing the shaft), the Count should increment and decrement when turn CCW. Remember that this is not absolute position data and cannot be used for alignment. The mechanical and electrical angle boxes will contain dashes because the data is not absolute.

4. The motor is an Allen Bradley and, if you have the Allen Bradley memory options, you can click on the

Memory Test button to perform a memory test. The memory data will be displayed, and you can check for correct checksum results. If it is not an Allen Bradley motor, the data displayed will be meaningless. However, in either case, you can click the Save Encoder Data File button to save the data to your hard drive.

5. Click on the Data Display button to return to the Data Display. Click on the Sin/Cos Commutation radio

button, and the display should change to the sin/cos display. The individual cosine and sine readings are displayed as well as the A and B channel differential voltages that caused them.

There will now be data in the mechanical and electrical angle boxes because the sin/cos signals produce absolute position data. You can record static lockup rotor angles if the motor is a permanent magnet brushless type. You must set the POLES selection to the correct number of poles, and for documentation purposes, you should set the LOCKUP selection to the voltage polarity that you are using for the lockup. These angles will be similar to the angles you will get using the 4096 count, but they will not be exact. In order to get more exact results form the sine/cosine, the correction data from the memory must be used. The software does not currently make corrections using this data.

6. Click on the 4096 Count/Rev radio button to go back to the incremental mode. Again the angles boxes

will contain dashes because the position data is not absolute. Click on the Enable Z Pulse button so that the encoder will begin providing an index pulse. Several of the boxes will become disabled, and the INDEX box will be come enabled and probably show ALARM. Rotate the shaft until the INDEX box changes to OK. This will mean that you have indexed the encoder. If this does not occur after turning an entire revolution, you may have a problem with the encoder or cabling.


When the encoder is indexed, the angle boxes will again show data because the incremental channels are now providing absolute data. This data can be used to check or set alignment by static lockup of the rotor if the motor is a permanent magnet brushless type. You must set the POLES selection to the correct number of poles, and for documentation purposes, you should set the LOCKUP selection to the voltage polarity that you are using for the lockup. This data should agree pretty closely with the data taken from the sin/cos mode. This data should be more accurate because the 4096 counts/rev provides more resolution.

7. Once the index pulse is enabled, a standard Count Test may be performed on the encoder. Click on the Count Test button and perform the Count Test in the normal manner.

8. You can further check the A, B and Z channels by looking at them with a scope. Connect a scope with

the ground clip on J1 pin 2 and the probe on J1 pin 3 (coming into the TI-5104 Adapter module). Connect the other channel probe to pin 4. On pin 4 you should see about 2.5V DC. When you turn the encoder, you should see about 1.0V p-p. This voltage should go approximately 0.5V above and below the DC voltage on pin 4. Repeat the process looking at a DC voltage on pin 6 and a 1.0 V p-p signal on pin 5. Once per revolution you can see the index pulse on the scope. Apparently it is a full sized 5 V signal rather than 1V p-p.

TI-5000 130 OPERATION 2.6.12 SUMTAK SERIAL ENCODERS

2.6.12.1 GENERAL COMMENTS The Sumtak serial encoders listed in the next section are supported by this selection. Sumtak incremental encoders with A, B, and Z lines should be tested as Generic Incremental encoders. 2.6.12.2 TYPES SUPPORTED The following list shows the Sumtak encoders that are currently supported by the TI-5000EX: Type Counts/Rev Cables AEC/AEM 2048 2,048 TI-5013 (Nachi motor) The Sumtak AEC/AEM 2048 serial encoder is essentially the same as the Sanyo Denki E07B111335. Please refer to that section of the manual for further information at this time. Sometimes these encoders are labeled as REC 2048 or REM 2048. They all seem to be basically the same thing.

TI-5000 131 OPERATION 2.6.13 TAMAGAWA SERIAL ENCODERS

2.6.13.1 GENERAL COMMENTS The Tamagawa serial encoders listed in the next section are supported by this selection. Tamagawa incremental encoders with A, B, and Z lines should be tested as Generic Incremental encoders. 2.6.13.2 TYPES SUPPORTED The following list shows the Tamagawa encoders that are currently supported by the TI-5000EX: Type Ser/Inc Counts/Rev Cables Motor SA35 TS5643N 2,048/8,192 TI-5013 Nachi OAH59 TS5645N 2,048/8,192 User Fab. Meiden SA56 TS5647 65,536/NA TI-5066 Matsushita/Toshiba SA48 TS5667 131,072/NA TI-5066 Matsushita/Toshiba SA56 TS5648 1,048,576/NA TI-5066 Matsushita/Toshiba SA48 TS5669 131,072/NA User Fab. OAM74 TS5778 2,048/16,384 TI-5035 Shinko OAM74 TS5778N85 2,048/16,384 TI-5666 Kobelco robot OSA130 TS5781N13 4,096/20,000 TI-5667 Matsushita/Toshiba MFE0017B0MAF 131,072 /NA TI-5074 Nachi TI-5078 Panasonic TI-5080 Rexroth MSM MFE2500P8NBT 10,000/NA TI-5087 Panasonic TS5643 and TS5645 – The 2,048 count TS5643 encoder provides 11 bit resolution for a single-turn, so 1 turn will change the count by 2,048 (800 HEX). Another 13 bits above the single-turn count are used to count revolutions, so it can keep track of ± 4,096 revolutions. This means that the largest positive count will be 8,388,607 (007F FFFF HEX) while the largest negative count is -8,388,608 (FF80 0000 HEX). The TS5643N110 also provides an incremental output with A, B, and Z channels, and these functions of the encoder may be tested using the methods described in the incremental section. The incremental signals will provide 2,048 pulses or 8,192 counts per revolution. The TS5643N110 is essentially the same as the Sumtak AEC2048 and the Sanyo Denki E07B111335. It is often found on Nachi robot motors. The TI-5643N164 (Matsushita motors) and TI-5643N151 (Denso motors) do not have a Z pulse. The TS5645N122 appears to be the basically the same as the TS5645 electronically. Physically they are a different package. These are found on Meiden motors. If disconnected from the +5V power and the battery for some length of time, these encoders will require a reset (connect the RES line to +5V for 5 seconds or so). See the Encoder Status section below. TS5647, TS5667, TS5668 and TS5669 – These are all new style SmartABS encoders and are very similar to each other. They vary from each other primarily in the number of counts and the encoder ID. These are totally serial encoders with no incremental

TI-5000 132 OPERATION lines. The SD and SD* lines handle communications for to and from the encoder. The +5V, 0v, BATT+ and BATT 0V lines are the only other lines required. The 65,536 count TS5647 encoder provides 16 bit resolution for a single-turn, so 1 turn will change the count by 65,536 (10000 HEX). Another 16 bits above the single-turn count are used to count revolutions, so it can keep track of ± 32,768 revolutions. This means that the largest positive count will be 2,147,483,647 (7FFF FFFF HEX) while the largest negative count is -2,147,483,648 (8000 0000 HEX). The 1,048,576 count TS5648 encoder provides 20 bit resolution for a single-turn, so 1 turn will change the count by 1,048,576 (100000 HEX). Another 16 bits above the single-turn count are used to count revolutions, so it can keep track of ± 32,768 revolutions. This would be 36 bits total, but the TI-5000EX can only carry a 32 bit count. This means that the largest positive count will be 2,147,483,647 (7FFF FFFF HEX) while the largest negative count is -2,147,483,648 (8000 0000 HEX). The 131,072 count TS5667 encoder provides 17 bit resolution for a single-turn, so 1 turn will change the count by 131,072 (20000 HEX). Another 16 bits above the single-turn count are used to count revolutions, so it can keep track of ± 32,768 revolutions. This would be 33 bits total, but the TI-5000EX can only carry a 32 bit count. This means that the largest positive count will be 2,147,483,647 (7FFF FFFF HEX) while the largest negative count is -2,147,483,648 (8000 0000 HEX). The TS5669N221 is apparently the same as the TS5667 electronically. It even has the same ID code. The different part number is probably because it is in a different physical package. If disconnected from the +5V power and the battery for some length of time, these encoders will require a reset. For these encoders, use the Reset button on the Data Display. There is no RES line for these encoders. See the Encoder Status section below. TS5778 – The 2,048 count TS5778 encoder provides 11 bit resolution for a single-turn, so 1 turn will change the count by 2,048 (800 HEX). Another 13 bits above the single-turn count are used to count revolutions, so it can keep track of ± 4,096 revolutions. This means that the largest positive count will be 8,388,607 (007F FFFF HEX) while the largest negative count is -8,388,608 (FF80 0000 HEX). The TS5778 also provides an incremental output with A and B (but no Z) channels, and the incremental counts may be tested using the methods described in the incremental section. But, the Count Test and Continuous Count Test will not work without a Z pulse. The incremental signals will provide 4,096 pulses or 16,384 counts per revolution (a version with 2,048 pulses or 8,192 counts per revolution has been reported to us). Without a Z pulse the incremental count test will not work, so the serial count must be used as a reference. The following procedure may be used:

1. Read the absolute count from the Data display and record it. 2. Click the Select Feedback button and select an incremental encoder with 32,768 counts per turn. 3. Click OK to go back to the data display, and it should show a count of zero. Turn the encoder

approximately 10 revolutions, and record the count. 4. Select Tamagawa TS5778 serial encoder again. 5. Go back to data display and read the absolute count from the display. Subtract the count recorded

in step 1 from this count. It should compare very closely to the count recorded in step 3. Shinko motors use a TS5778 encoder. Kobelco robots use a TS5778N85 encoder. The cables for the Shinko and Kobelco are slightly different with the RES line on a different pin. If disconnected from the +5V power and the battery for some length of time, these encoders will require a reset (connect the RES line to +5V for 5 seconds or so). See the Encoder Status section below.

TI-5000 133 OPERATION TS5781 – The 4,096 count TS5781N13 encoder provides 12 bit resolution for a single-turn, so 1 turn will change the count by 4,096 (1000 HEX). Another 14 bits above the single-turn count are used to count revolutions, so it can keep track of 14,400 revolutions. This means that the largest positive count will be 58,982,399 (0383 FFFF HEX) and the count will not go negative. The forward direction for the serial count is CW, which is unusual for a Tamagawa encoder. The TS5781 also provides an incremental output with A, B, and Z channels, and the incremental counts may be tested using the methods described in the incremental section. The incremental signals will provide 5,000 pulses or 20,000 counts per revolution. This encoder is unique in that it requires a 15 VDC power supply. The SRQ line must be pulled up to +15 VDC in order for the encoder to output serial data from the RX and RX* lines. The RX and RX* signals are normal 5V logic signals. The A, B and Z lines produce a 4 V p-p sine wave type signal riding on a 6 VDC DC level. While the TI-5000EX normally expects 5V A, B, and Z signals, the differential input receiver is able to process these levels satisfactorily. The Count Test using the Generic Incremental selection works with this encoder. Some pinouts for these encoders show a battery line to pin N, but the N13 seems to loop pin N back to pin P (it does not go to the encoder). The battery is mounted in a small compartment in the encoder housing in this encoder. Connecting the battery and disconnecting it will switch the EXT BATTERY alarm on and off. If disconnected from the +15V power and the battery for some length of time, these encoders will require a reset (connect the RES line to +15V for 30 seconds or so). See the Encoder Status section below. MFE0017 – The MFE0017 is similar to the SmartABS encoders (TS5647, TS5667, TS5668 and TS5669). The SD and SD* lines handle communications for to and from the encoder. The +5V, 0v, BATT+ and BATT 0V lines are the only other lines required. See ENCODER ID and UPDATE ERROR STATUS BUTTON sections below for notes on how the MFE0017 differs from the TS5647, TS5667, TS5668 and TS5669 encoders. The 131,072 count MFE0017 encoder provides 17 bit resolution for a single-turn, so 1 turn will change the count by 131,072 (20000 HEX). Another 16 bits above the single-turn count are used to count revolutions, so it can keep track of ± 32,768 revolutions. This would be 33 bits total, but the TI-5000EX can only carry a 32 bit count. This means that the largest positive count will be 2,147,483,647 (7FFF FFFF HEX) while the largest negative count is -2,147,483,648 (8000 0000 HEX). If disconnected from the +5V power and the battery for some length of time, these encoders will require a reset. For these encoders, use the Reset button on the Data Display. There is no RES line for these encoders. See the Encoder Status section below. MFE2500 – The MFE2500 come in at least two very different varieties. The MFE2500P8NBT is basically a 10,000 count/rev incremental encoder with serial commutation lines (RX and RX*). The A, B, and Z channels are supported under the Generic Incremental Encoder selection, but there is no direct support for the commutation signals at this time. The MFE2500P8NX apparently is a serial version and is currently unsupported. It is unclear at this point exactly how to identify these encoders from the part number. Apparently the P8 designation means an 8 pole motor. Possibly the X indicates the serial version. The most reliable identifier is

TI-5000 134 OPERATION probably the number of lines. The serial version has a +5VDC, 0V, SD, SD* (serial data), and a shield. It appears that there are no battery lines. The incremental version requires 8 lines for the A, B, Z, and RX channels plus +5V and 0V, so there it will probably be obvious which encoder is in use from the number of lines. 2.6.13.2.1 IDENTIFICATION The Tamagawa encoders are typically clearly marked, so identification is usually not a problem. The TI-5000EX does currently report an encoder ID field for certain SmartABS serial encoders (an ID cannot be read from the MFE0017 at this time), and this will help assure that the correct selection has been made. Other series Tamagawa encoders are not known to have ID capability. 2.6.13.3 CONNECTION Connection requires using the correct cable as shown in the chart in the Type Supported section. Also the WinTI5000EX ‘Feedback Selection’ frame has a cable dropdown menu from which you can select the cable that you need. After making the cable selection, that selection will appear on the Data Display report which is helpful in documenting the cable used. Download cable sheets from the Customer Page at http://www.mitchell-electronics.com for cable pinouts and wiring details. Cable configurations other than the cables listed are known to exist. There may be cables that are made by OEM machine manufacturers using these encoders. 2.6.13.4 ENCODER SELECTION Click on the Select Feedback button to make the selection. The Tamagawa serial encoders require the following setup sequence:

1. Click on the Encoder Feedback radio button. 2. Select Tamagawa from the Encoder Manufacturer dropdown menu. 3. Select the encoder type that you have from the Encoder Type dropdown menu. 4. Select a Motor Manufacturer name if Memory support exists and you have purchased it.

The encoder types listed in the current software revision are shown in a preceding section. The number of poles may be selected from the POLES dropdown menu. To determine the number of poles, apply a small voltage to 2 of the armature leads to lock the rotor, and then count the number of lockup positions in one revolution to determine the number of pole pairs. For instance, if the rotor locks up in 4 different shaft positions, the motor has 4 pole pairs or 8 poles. The number of poles must be entered correctly in order to display the electrical angle correctly. It is essential for the electrical angle to be correct when checking or setting the encoder alignment for correct commutation.

TI-5000 135 OPERATION 2.6.13.5 TESTING Tamagawa incremental encoders are tested as Generic Incremental Encoders using Data Display, Line Levels, Incremental Count Test, and Phase Test for a complete test. Tamagawa serial encoder types listed above (like most serial encoders) use only the Data Display, Serial Count Test and Memory Test if they have memory. Some Tamagawa serial encoders, such as the TS5643 & TS5645 include A, B, and Z incremental channels, and the incremental channels should be tested using the Generic Incremental Encoder selection. 2.6.13.5.1 DATA DISPLAY Data Display is the initial test, and it is started by default when WinTI5000EX is started. When already in another test, it can be started by clicking on the Data Display button among the test buttons at the top of the display. Use it for the following:


2. Use the commutation display to check or set the feedback commutation alignment. 3. Check the encoder status for the following: ensure that the encoder is communicating properly with

the tester, not reporting internal errors, and displaying the correct encoder ID. The following sections describe information shown on the display. 2.6.13.5.1.1 COMMUTATION The electrical angle is best for checking and setting commutation. For a particular lockup polarity, the rotor will lock up in as many different positions as there are pole pairs, but the electrical angle indications will be the same at each lockup position. The mechanical angle will be different at each lockup position (except for 2 pole motors where there is only one lockup position), so it is not as convenient to use for feedback alignment. See section 3.2 for a more detailed description of commutation alignment procedures. The number of poles must be entered correctly for the electrical angle to be correct. The electrical angle and mechanical angle are derived from the position count. The method of alignment for Tamagawa encoders will vary with motor manufacturer, and Tamagawa encoders are used by many different motor manufacturers. There is not general alignment information to provide at this time. While the Tamagawa SmartABS encoders have memory, there is no evidence so far of any motor manufacturers storing the alignment information in the memory. 2.6.13.5.1.2 COUNT The Count frame displays the encoder count both as a decimal and hexadecimal number. Users will typically be interested in only the decimal count, but encoder repairmen and other advanced users may find the hexadecimal representation useful. In general this count will not be zero on power up. This is an absolute encoder, and it will remember the count on power up. The number of counts/rev for the various models is shown in the table in an earlier section on types of encoders supported. Always verify that the encoder count appears to change by the correct number of counts/rev while turning the encoder. If the count is not changing, then there is an encoder problem. As described in a later section, the Count Test may be performed to more accurately determine whether the correct number of counts per revolution is occurring, but this is an important initial evaluation.

TI-5000 136 OPERATION 2.6.13.5.1.3 ENCODER STATUS INDEX – The INDEX box is disabled for all Tamagawa serial encoders because these encoders display the correct count on power up without indexing. INTERNAL ERROR – The SmartABS encoders (TS5647, TS5648, TS5667, TS5669, MFE0017) show an INTERNAL ERROR box which indicates OK when no internal errors exist. When there is an internal error, an abbreviation for each type of error in alarm will be shown in the box. The following is a list these errors: Code Type Description OS Overspeed Occurs when shaft is rotated beyond max RPM for the encoder. FS Full Absolute On power up the encoder operates at reduced resolution while this alarm

is in effect. CE Counting Error The encoder has detected an error in its single-turn count. ME Multi-turn The encoder has detected an error in its multi-turn count. RESET ERRORS RESET MULTI-TURN BUTTON - When these errors occur, the Reset Errors, Reset Multi-turn button should be clicked to attempt to reset the errors. If errors cannot be cleared or seem to keep recurring, then there may be a problem with the encoder. Some errors may be due having the encoder disconnected from the battery backup voltage for an extended period of time. DATA - If no data is being sent from the encoder, NONE will be displayed in the DATA box. If the TI-5000EX and the encoder are communicating correctly, RECEIVING will be displayed in the DATA box. The cabling is the first thing to check if the encoder is not communicating, but it can also mean a component failure in the encoder. BATTERY ALARM – The names of these errors are not consistent, so refer to this table for the explanation. Box Encoder Battery Alarm TS5643, TS5645, TS5647, TS5648, TS5667, TS5669, MFE0017 Ext. Battery TS5778, TS5781N13 This bit will show alarm when the battery voltage drops below about 2.5V. That battery voltage should be 3.6 V. This alarm will clear on its own when the correct battery voltage is connected to the battery leads. BATTERY ERROR – The names of these errors are not consistent, so refer to this table for the explanation. Box Encoder Backup Mode TS5643, TS5645 Battery Alarm TS5778, TS5781N13 Battery Error TS5647, TS5648, TS5667, TS5669, MFE0017 This box will show ALARM if the battery voltage is disconnected for a long enough time that the backup capacitor cannot supply adequate voltage. It must be cleared by a reset. OVERFLOW - The OVERFLOW box will show ALARM when count in the multi-turn counter overflows its range. This alarm must be cleared by a reset.

TI-5000 137 OPERATION ENCODER ID – The encoder ID will be displayed for Tamagawa SmartABS encoders, but the box will be disabled for other Tamagawa types. If the ID read from the encoder agrees with the encoder you have selected, then an OK message will appear such as, “TS5648 OK”. If there is disagreement, then the message will show and error such as, “TS5648 Error”. This would be interpreted to mean that an ID for a TS5648 encoder has been detected, but you have selected some other kind of encoder. In this case, you should correct your selection. If you have made the correct selection, then you may have a faulty encoder. No ID can be displayed for the MFE0017 encoder at this time. UPDATE ERROR STATUS BUTTON – While other SmartABS encoders update their error status on the fly, the MFE0017 cannot. You must click the Update Error Status button to manually update the status information. For instance, you may be getting a Battery Alarm because there is not battery connected. When you connect a battery voltage (3.6V) to the battery line and 0V ground, you expect to see the Battery Alarm information change from ALARM to OK. For the MFE0017 encoder, you must click the Update Error Status button in order to see this happen. 2.6.13.5.2 COUNT TEST The Count Test can be started by clicking on the Count Test button among the test buttons at the top of the display. This will run a standard Count Test on the absolute position count. The incremental count must be tested as described previously. The Count Test will verify that the encoder is incrementing the correct number of counts per revolution. The Count Test for the Tamagawa encoders is not significantly different from that for other encoders, so please refer to the general information on the count test in Section 2.2.2 for further details. The stuck bit test will test bit0 to bit13 for activity for 16,384 count encoders and bit0 to bit14 for activity for 32,768 count encoders. As with all serial encoders, there will be some error shown in the Count Test. There may be a difference in the number revolutions counted for various Tamagawa Smart ABS encoders of the same type. For instance the literature indicates the TS5648N100 would count 65,536 revolutions, but the TS5648N102 appears to count only 14,399 revolutions. The N102 may be a special encoder for Panasonic MTMA motors while the N100 is a standard encoder. This kind of difference could cause the Count Test to fail if the revolution count goes between the minimum and maximum count during a Count Test. A test failure of this type can be ignored if you know that’s what caused it. It is most likely that you will not cross this revolution count boundary during a Count Test. 2.6.13.5.3 MEMORY TEST The Tamagawa SmartABS encoders include memory. Some motor manufacturers are using the memory and others apparently are not. In the future Memory Test functions may be purchased for specific manufacturers. Different manufacturers always make use of the memory in different ways, so support must be developed for each manufacturer. No Memory Test options are available at this time for SmartABS encoders.

TI-5000 138 OPERATION 2.6.14 YASKAWA ENCODERS (ALLEN BRADLEY)

The Yaskawa encoders supported by the TI-5000EX are tested as Generic Incremental Encoders and do not have a separate test. A section for them is included in this manual because they have a number of important differences from standard quadrature pulse incremental encoders. 2.6.14.1 GENERAL COMMENTS There are 3 major types of Yaskawa quadrature type incremental encoders (A, B, and Z lines), and there are serial encoders used on the newer Sigma II motors. The quadrature type encoders are supported by the TI-5000EX, but support for the serial encoders is not yet available. The TI-5000EX does include a Yaskawa selection, but some of the encoders should be tested using the Generic Incremental Encoder selection. 2.6.14.2 TYPES SUPPORTED The 3 major types of Yaskawa encoders currently supported are fundamentally quadrature type, but they have some differences from the typical and require some special treatment. Part numbers often are not clearly marked on the encoder boards, so identification is not always easy. Often there will be an encoder part number on the encoder cover. This section will include part numbers associated with the encoders and motors, and signal lines shown in the cable documentation can be used as an aid in identifying the encoders. Yaskawa encoders are used on Allen Bradley 8500 Series Digital Servo Motors. See the following section on absolute encoders when working with Allen Bradley motors. Type Counts/Rev Cables ABZ & UVW various TI-5015 ABC C Channel 8,192, 16,384, 32,768 TI-5014, TI-5025 ABC 12 bit Absolute 4,096 TI-5017, TI-5024, TI-5039, TI-5041,

TI-5044 ABC 15 bit Absolute 32,768 TI-5017 2.6.14.2.1 QUADRATURE INCREMENTAL WITH U V W COMMUTATION CHANNELS One Yaskawa incremental style includes 3 commutation true lines and 3 commutation complement lines (U, U*, V, V*, W, W*). These encoders are fully supported by the Generic Incremental Encoder Selection. The TI-5000Y support and the TI-5103 Yaskawa Adapter Module are not necessary. A typical part number for this type of encoder would be UTOPI-600VA. As per the chart in the identification section, these are 24,000 counts per revolution. This is the simplest, most straight-forward type of Yaskawa encoder. Many other encoder brands on the market work in a similar manner, and this type can be tested simply as a quadrature pulse incremental encoder. By connecting the commutation lines to the their respective inputs on J2, the commutation line states can be displayed while setting commutation. This encoder is supported by the TI-5015 Cable which is documented in Section 2.9. Part numbers for this type of encoder will start with UTOP whereas part numbers starting with UTOMA would be absolute encoders. If a count test can be performed satisfactorily using the TI-5015 cable and the commutation lines are being displayed properly, then this encoder has most likely been properly identified.

TI-5000 139 OPERATION 2.6.14.2.2 QUADRATURE INCREMENTAL WITH SINGLE C COMMUTATION CHANNEL The second Yaskawa incremental encoder type multiplexes the 3 commutation signals onto one pair of lines -C and C*. These encoders are supported, for the most part, by the Generic Incremental Encoder Selection and the TI-5103 Yaskawa Adapter Module. The TI-5000Y support provides an additional check for C channel update on power up which is explained later in the next section. Some typical part numbers for this type encoder are: UTOPH-81AWF, UTOPH-40AWM, UTOPH-81AUS, and UTOPI-81AUS. Part numbers for this type of encoder will start with UTOP whereas part numbers starting with UTOMA would be absolute encoders. The state of the single pair of C channel lines represents Z, U, V, or W depending upon the states of the A and B lines. As the encoder is rotated and the A and B line states change, the information represented by the C and C* lines changes as well. It is very difficult to visually decode this information with an oscilloscope, but the TI-5000EX equipped with a TI-5103 Yaskawa Adapter Module, can convert the C channel information to U, V, W, and Z signals so you can test this encoder as a standard incremental encoder. The TI-5103 decodes the information from the C and C* lines in hardware, and routes the U, V, W, and Z signals out on separate lines which can be connected to the TI-5000EX and/or viewed with an oscilloscope (such as with the TI-5250 Signal Breakout Box). Some of these encoders utilize a 17 pin circular connector and bring out an index pulse on the K and L lines. In such cases where the index pulse is provided, the encoder can be tested as an incremental encoder without the TI-5103, but the commutation information cannot be tested without the TI-5103. Some motors, such as an SGM-08U3B4L, bring the encoder signals out on a 9 pin AMP connector. The 9 pins are only enough to provide +5 V, GND, A, B, C, and their complements. Since there is no separate index pulse provided, and the index pulse must come from the C and C* lines, the TI-5103 Yaskawa Adapter Module is absolutely necessary for these encoders. For the 17 pin connectors, you must use the TI-5014 Cable which is documented in Section 2.9. If the encoder is using the 9 pin AMP connector, use the TI-5025. There may be other types of connectors in use, and a user fabricated cable must be used in those cases. Contact Mitchell Electronics, Inc. about custom cables if the correct cable is not available. You may encounter some C Channel encoders made by Sony Magnescale, and these have some peculiarities. For other Yaskawa encoders, there is a definite relationship between the commutation pulses and the index (Z) pulse. The position where the index pulse occurs will be very close to one of the positions where the U commutation pulse changes state, the V commutation pulse is LO and the W commutation pulse is HI. For a correctly aligned encoder, this would occur near the –U +V +W lockup position. This relationship between the index pulse and the commutation signals apparently does not exist for the Sony Magnescale encoders. In fact, in several different motors of this type that we have investigated, no relationship was found. The positioning of the index pulse relative to the commutation pulses appeared to be random. Normally, you can use the index pulse to align Yaskawa motors, but we believe that using the commutation pulses is the correct method for motors using the Magnescale encoders. Motors using these encoders tend to be very small. A representative part number is SGM-A5A3TF11X. 2.6.14.2.2.1 C CHANNEL ENCODER UPDATE TEST As described above, the C Channel encoders multiplex the U, V, W and Z signals on to the C channel. This helps minimize the number of feedback wires running between the encoder and drive. As described above, the A and B line states determine the signal that is on the C channel lines at a given time. As the encoder turns, the drive is exposed to all 4 of these signals, and it simply has to latch their states until it is updated again. A problem exists with this system at power up. At power up, the motor is not turning, and the encoder is stationary. That means that the drive is only able to see one piece of information on the C channel lines, and what that information represents will be random depending upon what position the encoder is in and what

TI-5000 140 OPERATION the line states are. But at power up, it is important for the drive to know the state of all 3 U, V, and W signals so it can properly apply voltage to the motor to initially turn it. The encoder logic solves this problem by sending out update signals on the A and B lines at power up. From 20 to 40 ms. after power up, the encoder sends a sequence of A and B signals to the drive. This sequence takes only about 40 uS so it causes no appreciable delay. The order of the sequence and resulting C channel data is as follows:

A B C Count LO LO V 1 LO HI W 2 HI HI Z 3 HI LO U 4 LO LO V 5 LO HI W 6 HI HI Z 7 HI LO U 8 HI HI Z 7 LO HI W 6 LO LO V 5 HI LO U 4 HI HI Z 3 LO HI W 2 LO LO V 1

The important things to notice are:

1. All possible A and B line states are used more than once, so the drive gets to see all the C channel data more than once.

2. The sequence of A and B states represents moving the encoder position 7 counts in one direction,

reaching a 8th count, reversing, and moving back through each of the states in the opposite order which eliminates any net change in the encoder position as seen by the drive.

So the encoder has updated the drive as to the U, V, W, and Z states before the motor has moved. Now the drive is able to move the motor. If the drive does not get this update information, if might not be able to move the motor correctly. It might apply the phase voltages incorrectly and produce an over current alarm. It might see all commutation signals HI or all LO (which are illegal states) and produce an encoder alarm. To be complete we should test for this C Channel update. Using the TI-5103 Yaskawa Adapter Module and the TI-5000Y Yaskawa upgrade option, it is now possible for the TI-5000EX to check for a correct C channel update. The procedure is very straightforward:

1. Using the TI-5014, TI-5025 (or other C Channel encoder cable), connect the C Channel encoder into the TI-5103, and connect the TI-5103 to the TI-5000EX.

Note: Make sure that the TI-5103 JS1 jumper is removed.

2. Power up the TI-5000EX, and select the correct C Channel encoder from the Yaskawa menu. 3. Select Data Display from the Encoder Test Menu. 4. With the encoder perfectly stationary, click on the Cycle Power button to cycle the power to the

encoder. Watch for the RED LED on the TI-5103 module to extinguish (indicating that power to the encoder is interrupted) and again illuminate (meaning that power to the encoder is restored).


5. Move the encoder to a new commutation pattern, again cycle power, and look for illegal commutation states.

6. Repeat the process in all 6 possible commutation states.

Typically with an update problem, the line states will look fine as soon as you move the encoder. Very little encoder motion is required to update the line states, so it is important for the encoder to be perfectly stationary when the power is cycled. Encoders that we have seen exhibiting an update problem seem to show H1, H2 and H3 HI. Often it depends on the encoder position (probably with regards to the commutation signals) as to whether the problem is detected. For instance, a bad encoder that we have behaves as follows. When the encoder is in a position where H1 = HI, H2 = LO, and H3 = LO, the encoder appears to work correctly when the power is cycled. However, if it is moved such that H1 = HI, H2 = LO, and H3 = HI, when the power is cycled, it returns with H1, H2, and H3 all HI. To be complete, cycle the power when the encoder is showing each of the following commutation states: H1 H2 H3 H4 H5 H6 H L L L H H H H L L L H L H L H L H L H H H L L L L H H H L H L H L H L You should never see H1, H2 and H3 all HI or all LO (H4, H5, and H5 should always be opposite H1, H2, and H3). 2.6.14.2.3 ABSOLUTE ENCODERS The third type of Yaskawa encoder is commonly referred to as an absolute encoder. Some of these encoders are used on Allen Bradley 8500 Digital Servo Motors. These encoders are supported to an extent by the Generic Incremental Encoder Selection. The TI-5000Y support and the TI-5103 Yaskawa Adapter Module do allow an additional test to verify that the encoder is transmitting the quadrature pulse position update on power up. This is explained in the section entitled ‘Absolute Encoder Update Test’. Typical part numbers for absolute encoders are UTMAH-B15ASB, UTMAH-B15BSB and UTMAH-B15A5B1. The part number always starts with UTMA instead of UTOP, so they are more easily identified than the first two types discussed. The absolute encoders are available in at least 4 different numbers of counts/revolution: 4,096 (2 to the 12th), 32,768 (2 to the 15th), 65,536 (2 to the 16th), and 131,072 (2 to the 17th). The motor model SGM-04VW14B is an example of a 4,096 count/rev encoder. The 32,768 count/rev. encoders are often called 15 bit absolutes. The 16 and 17 bit ABS encoders are serial encoders and are not currently supported by the TI-5000EX. These encoders are called absolute encoders because they are capable of long term backup by an external battery and short term backup by internal capacitors. Like any quadrature encoder, the A and B quadrature pulses are used by external equipment to maintain a position count. However this count is also maintained in an internal counter and retained via battery backup when the normal power supply to the encoder is turned off. Two counts are maintained internally – a position count and a revolutions count.

TI-5000 142 OPERATION The basic encoder tests may be run on Absolute encoders by either selecting them from the Yaskawa types if you have the TI-5000Y Yaskawa Option or from Generic Incremental Encoders if you do not. If you have the TI-5000Y Yaskawa Option, the U, V and W states which are derived from the count will be shown on the Data Display and can be used for feedback alignment. If you do not have the Yaskawa Option you can use the electrical angle display available in the Data Display for commutation alignment. The forward armature direction for Yaskawa motors is CCW facing the shaft. The Data Display will show the encoder angle increasing in the same direction when a Yaskawa ABS encoder has been selected (TI-5000Y option), but the encoder angle will increase in the opposite direction if the Generic Incremental Encoder selection has been made. This could be a source of confusion. Using the –U +V +W lockup for the zero angle will help because the zero angle will be in the same position for both the Yaskawa selection and the Generic Incremental Encoder selection. The TI-5000EX cannot provide correct commutation information until the encoder has been indexed. If during the course of working with an absolute encoder, you have any reason to believe the index has been disturbed (such as powering down the encoder and moving it), you should force a new index by pressing the “Zero count on next index” button, verifying that the prompt in the INDEX box changes to ALARM, and moving the encoder until the ALARM prompt in the INDEX box changes back to OK. Even though 32,768 count/rev encoders are fairly high resolution the high speed processing of the TI-5000EX allows Incremental Count Tests to be performed accurately to 3,000 RPM for these encoders. 2.6.14.2.3.1 ABSOLUTE ENCODER UPDATE TEST As mentioned previously, the absolute encoders will send a position count and a revolution count to the drive to update it to the proper absolute position on power-up. The revolution count is sent as serially encoded data on the A line. Testing of the revolution count update is not supported on the TI-5000 at this time. A position count of up to 32,768 is also sent at power-up as quadrature A and B edges. This updates the drive as to the correct angular encoder position on power-up so that the drive can properly commutate the armature lines and provide startup torque to the motor. This is important because normally an incremental encoder cannot provide absolute position information to the drive until the motor has moved the encoder past the index pulse. Since there are no commutation pulses, this is the only way the drive can figure out how to commutate the motor. Using the TI-5103 Yaskawa Adapter Module and the TI-5000Y Yaskawa upgrade option, it is now possible for the TI-5000 to check for a correct position count update. The procedure is very straightforward: 1. Using the TI-5017 (or other absolute encoder cable), connect the absolute encoder into the

TI-5103, and connect the TI-5103 to the TI-5000. Note: Make sure that the TI-5103 JS1 jumper is removed.

2. Power up the TI-5000, and select the correct absolute encoder from the Yaskawa menu. 3. Select Data Display from the Encoder Test Menu, and rotate the encoder until it indexes. 4. Turn the encoder manually approximately ¼ revolution in the direction to produce a positive

count, stop turning, and click on the Cycle Power button to cycle the power to the encoder. 5. After a few seconds when the data appears in the Before Cycle and Cycle Update columns,

make sure that the two numbers do not differ by more than about 8 counts. You may wish to re-index the encoder and repeat the test by turning the encoder ¾ revolution in step 4 just to make sure everything looks good. We believe that a difference of 8 counts in these two numbers is a good tolerance, but there is not a lot of experience at this time. This tolerance may be updated as experience is gained with this test. The encoder will no longer be properly indexed after executing this test, and the ALARM prompt will appear in the Indexed column. Rotate the encoder until the ALARM prompt changes to OK before proceeding with other operations.

TI-5000 143 OPERATION 2.6.14.2.3.2 ABSOLUTE ENCODER RESET PROCEDURES You may encounter an absolute encoder, try to test it as an incremental encoder, and find that it is not producing any quadrature pulses. Assuming it is a good encoder, this probably means the encoder is in need of a reset. It may be due to not having a battery connected for so long that it loses its retained count, but in any case, absolute encoders can get into a condition in which they will not produce quadrature pulses (and therefore cannot be tested) until a reset procedure is performed. The reset procedure is different for a 12 bit versus a 15 bit ABS encoder. The procedure for the 15 bit encoder usually goes smoothly. The 12 bit encoders seem to be harder to reset for some reason. 15 BIT: On the sample 15 bit encoders we have used, there are two LED indicators on the top and bottom of the 2nd encoder printed circuit board. The top LED (1LED) seems to come on and go off during power up when the encoder is working normally. The bottom LED (2LED) seems to flash twice while the 1LED is ON. This probably corresponds with the 2 bursts of data coming from the encoder to update the drive and computer. When the encoder is in need of a reset, 1LED will turn ON when the power comes on, but it will not turn right back OFF like normal. Also in this condition, no quadrature pulses will be generated as the encoder is rotated. In this case, the encoder must be given a RESET and be supplied with a battery backup. The reset procedure is as follows:

1. Disconnect all power from the encoder. Connect a shorting jumper from pin R to pin S, and leave it connected for a minimum of 4 minutes.

2. Disconnect the jumper from pin R to pin S after 4 minutes, and connect a battery (or 5 V supply) with + to pin T and ground to pin S.

3. Proceed to power up the encoder in the normal manner. When the encoder powers up, the LED indicators should behave in the normal manner, and the encoder should produce quadrature pulses when it is rotated. On the first power-up after RESET, it seems to be very important that a voltage be connected to the battery pins before voltage is applied to the normal 5 volt pin. The encoder seems to have some built-in logic that will not allow it to work without this voltage. However, it appears to be required only on the first power-up, and subsequent power-ups apparently work fine without the battery voltage as long as the internal capacitors have not lost their charge. This procedure should cause the encoder to produce quadrature pulses and allow you to perform all the normal tests with the TI-5000EX tester. The TI-5017 Cable is designed for the 15 Bit ABS encoder and brings out the lines required to perform this procedure. 12 BIT: There is a second reset procedure which is required for 12 Bit Absolute encoders. The pin configuration is identical to the 15 Bit Absolute except for the addition of S and S* lines on pins K and L respectively. This encoder is also supported by the TI-5017 Cable. These encoders can be tested as 4,096 count/rev quadrature pulse encoders. Like the 15 bit, they may require a reset before they produce pulses for testing. The procedure that seems to work is similar to but a little more complex than the 15 Bit Absolute. The procedure that has worked for us is as follows:

TI-5000 144 OPERATION 1. With the encoder powered down, connect a battery (or 5 V supply) with + to pin T and ground to pin

S. 2. Connect a shorting jumper from pin R to pin S, and leave it connected for a minimum of 4 minutes. 3. Disconnect the jumper from R to S and connect a shorting jumper from pin R to pin T (that is to the

battery or 5 V supply) for 4 or 5 minutes. 4. With the jumper still connected from pin R to pin T, power up the encoder in the normal manner. 5. Disconnect the jumper from pin R to pin T. Cycle the power, and the encoder should power up with

the LED flashing green then off. The encoder should produce A, B, and Z pulses. If the Red LED does not go off, try cycling the power again.

Notes: 1. Make sure that you leave the battery voltage connected after the reset. If you remove that battery

voltage, you will have to repeat the reset procedure. 2. It seems to be common for this procedure not to work the first time. You may have to repeat the

procedure. I think you can probably repeat steps 3 – 5 rather than going all the way back to step 1. Going back to step 1 is fine, but it does take longer.

3. The R, S and T pins refer to the 17 pin circular connector. If you have a 12 or 15 pin rectangular

AMP connector (other something else), you will need to use the same functional lines. The following table should help with that:

17 Pin connector Pin Function Yaskawa Color R Reset WHI/GRY T 3.6V Batt ORG S 0V Batt ORG/WHI These are the colors that seem to be used in most cases by Yaskawa. 2.6.14.2.4 IDENTIFICATION Some further description of the part numbers may be helpful. The following description will not cover all encoders, but hopefully it will help identify many of them. Identifying the serial encoders that are not yet supported is useful. It looks like motor part numbers that begin with 5 letters, the first 3 of which are ‘SGM’, all use serial encoders. Examples are SGMAH, SGMBH, SGMGH, SGMPH, SGMSH, SGMUH and SGMAS. Often there will be a part number on the encoder. If the encoder part number includes B13, B16 or B17 (13, 16 and 17 bit), then these are serial encoders. An example part number is UTSAE-B17BB. Part numbers including B12 and B15 are supported absolute encoders, and they were discussed in a previous section. The following should be helpful in identifying the supported encoders. We can work from an example – the UTOPH-600UBXXX. The UT indicates a special detector which is an encoder for AC servo motors or AC spindle motors. The OP designation indicates incremental encoder (optical encoder) types as opposed to the MA designation for the absolute encoder (multi-turn). The H means coupled with a plate spring for the motor, whereas E means coupled with couplings for the motor and I means built-in. The 600 indicates the number of pulses per revolution. The part number does not seem to specify whether an encoder of the UT type is a UVW or C Channel encoder. Experience with these encoders seems to indicate this rule of thumb:

1. If the number of pulses/rev in the part number is an even decimal number (can be divided evenly by 10: 25,000, 1,500, 2,000, etc.), it seems to turn out that the encoder is the U,V, W type.


2. If the number of pulses/rev is an even binary number (the number can be created by multiplying 2

times 2 several times: 10 bits - 2 X 2 X 2 X 2 X 2 X 2 X 2 X 2 X 2 X 2 = 1024; 11 bits - 2 X 2 X 2 X 2 X 2 X 2 X 2 X 2 X 2 X 2 X 2 = 2048; 12 bits - 2 X 2 X 2 X 2 X 2 X 2 X 2 X 2 X 2 X 2 X 2 X 2 = 4096, etc.) then the encoder turns out to be a C Channel.

The number of pulses per revolution and the corresponding number of counts per revolution (which is 4 times the pulses per revolution) is indicated in the following chart: Incremental UVW & C Channel Encoders Code Pulses/Rev Counts/Rev Type Cable 100 25,000 100,000 UVW TI-5015 150 1,500 6,000 UVW TI-5015 200 2,000 8,000 UVW TI-5015 250 2,500 10,000 UVW TI-5015 300 3,000 12,000 UVW TI-5015 400 4,000 16,000 UVW TI-5015 500 5,000 20,000 UVW TI-5015 600 6,000 24,000 UVW TI-5015 B50 25,000 100,000 UVW TI-5015 05A 500 2,000 UVW TI-5015 10A 1,024 4,096 C Channel TI-5014, TI-5025 20A 2,048 8,192 C Channel TI-5014, TI-5025 40A 4,096 16,348 C Channel TI-5014, TI-5025 81A 8,192 32,768 C Channel TI-5014, TI-5025 Absolute Encoders Code Bits/Rev Counts/Rev Type Cable B12 12 4,096 12Bit ABS TI-5017, TI-5039, TI-5041, TI-5044 B15 15 32,768 15Bit ABS TI-5017, TI-5039, TI-5041, TI-5044 B13 13 8,192 (serial – not supported) B16 16 65,536 (serial – not supported) B17 17 131,072 (serial – not supported) The UB is the name of the encoder series. The last 3 numbers (indicated by XXX in the example) have to do with the cable length, connector type, customer spec., version, etc.). The 16 and 17 bit absolute encoders are serial encoders, and are not supported by the TI-5000EX at this time. There is currently no selection for a 4,096 Count/Rev (1,024 pulses/rev) C Channel encoder in the Yaskawa support because this encoder has not been available for testing with the software. However, it should be possible to test it as a Generic Incremental Encoder. We believe that the above table is correct, but we have not actually seen all of the UVW encoders listed, and the part number does not specifically differentiate between UVW types and C channel types. We see the counts/rev as the only way to make the distinction between UVW and C Channel. 2.6.14.3 CONNECTION Connection requires using the correct cable as described in preceding sections. Download cable sheets from the Customer Page at http://www.mitchell-electronics.com for cable pinouts and wiring details. Cable configurations other than the cables listed may exist. These are likely cables that are made by OEM machine manufacturers using these encoders.

TI-5000 146 OPERATION 2.6.14.4 SETUP Except for differences noted in preceding sections, the Yaskawa encoders are tested like any other Generic Incremental Encoder. Please refer to the sections pertaining to Setup for Generic Incremental Encoders for further details. 2.6.14.5 TESTING Except for differences noted in preceding sections, the Yaskawa encoders are tested like any other Generic Incremental Encoder. Please refer to the sections on Generic Incremental Encoders for further details on testing. The forward armature direction for Yaskawa motors is CCW looking at the drive shaft end. 2.6.14.5.1 DATA DISPLAY Data Display is the initial test, and it is started by default when WinTI5000EX is started. When already in another test, it can be started by clicking on the Data Display button among the test buttons at the top of the display. Use it for the following:


2. Use the commutation display to check or set the feedback commutation alignment. The following sections describe information shown on the display. Refer to the section on Generic Incremental Encoders for more information on the Data Display. 2.6.14.5.1.1 COMMUTATION The Data Display provides both commutation pulse display and an electrical angle for aligning Yaskawa encoders to the motor. A line to neutral lockup is required for aligning the Yaskawa motors. There are some differences with the various kinds of encoders, and we will discuss them now. U V W Encoder Commutation – For the motors with encoders that bring out the U, V and W commutation signals, you can simply use the commutation signals for alignment. Use the TI-5015 cable and select Generic encoder. The U, V, and W signals will show up on H1, H2, and H3 respectively. As shown below, a +U –V –W lockup should result in V HI, W LO and U at the point where a slight shaft movement will toggle it between HI and LO. We have not seen a case where this does not result in an electrical angle of 180 degrees, but the commutation states must be as described above (whether or not the angle is 180 electrical). The correct number of poles must be entered on the Data Display in order to display the correct electrical angle, but the commutation signals will be correct regardless. C Channel Encoder Commutation – C Channel encoders are aligned similarly to the U V W Encoders. The TI-5103 Yaskawa Adapter Module is used to extract the commutation signals from the C Channel data along with the appropriate cable (TI-5014, TI-5025, etc.). The Generic Encoder selection can be used, but you probably want to use one of the C

TI-5000 147 OPERATION Channel selections if you are licensed for the Yaskawa option. The C Channel selections allow you to run the C Channel Update Test. The U, V, and W signals will show up on H1, H2, and H3 respectively. As shown below, a +U –V –W lockup should result in V HI, W LO and U at the point where a slight shaft movement will toggle it between HI and LO. With optical encoders, this lockup results in an electrical angle of 180 degrees. But, as mentioned above, the magnetic disk encoders do not have a known relation ship between the index pulse and the commutation signals. So, for magnetic encoders, the electrical angle probably will not be 180 degrees. You definitely want to align the encoder based on the commutation signals, and the angle will be whatever value is determined by the disk for that encoder. Don’t worry about the angle. The correct number of poles must be entered on the Data Display in order to display the correct electrical angle, but the commutation signals will be correct regardless. ABS (Absolute) Encoder Commutation – As described above, the ABS encoders do not provide commutation signals, so the alignment is based on the electrical angle. Depending on which encoder you have, select either the 12 or 15 bit encoder from the Yaskawa menu. As a convenience to the technician, the software creates a commutation pattern on the Data Display. As shown below, a +U –V –W lockup should result in V HI, W LO and U at the point where a slight shaft movement will toggle it between HI and LO. This lockup should always result in an electrical angle of 180 degrees. The correct number of poles must be entered on the Data Display in order to display the correct electrical angle. Since the commutation display is derived from the angle, they will be incorrect if the number of poles is not entered correctly. TI-5000EX and TI-3000 Angle Readings – The forward direction of a Yaskawa encoder (direction of increasing count) will always be CW on the TI-5000EX. This is opposite the forward armature direction, CCW, for the Yaskawa motors. The TI-3000 provides the ability to change the encoder direction to make it match the motor direction. The TI-3000 using the B direction setting will result in a 150 degree angle for a +U –V lockup, while the TI-5000EX will read 210 for the same lockup. Both units should read 180 for the +U –V –W lockup. When entering the angle into the TI-3000, always use the angle read on the TI-3000 (normally 150 electrical). The following table shows several alignment possibilities.

Lockup Electrical Angle H1(U) H2(V) H3(W) -U +V +W 0 +U -V -W 180 H→L H L

TI-5000 148 OPERATION 2.7 RESERVED 2.8 ACCESSORIES A wide variety of accessories are available to complement the TI-5000EX test unit such as the TI-5250 Signal Breakout Box, the TI-5260 PM Rotor Lockup Switch, various adapter modules as described in their respective sections above and various cables and software options to meet your feedback testing needs. Most TI-5000EX hardware accessories are also compatible with the Mitchell Electronics, Inc. TI-3000 run Test System. The available accessories are too number to list here and are constantly changing. Please consult the latest price sheet or call for ordering information concerning options and accessories for the TI-5000EX.

TI-5000 149 OPERATION 2.9 PIN CONFIGURATIONS AND REFERENCE INFORMATION See Figure 2.1 for the connector locations on the enclosure. Table 2.1 Main I/O Terminal Block, J1 Pin Configuration TI-5000EX TB Header J1 Signal Parallel Absolute Signal 1 VCC VCC 2 GND GND 3 AIN+ BIT9 4 AIN- 5 BIN+ BIT8 6 BIN- 7 ZIN+ BIT6 8 ZIN- 9 SERIN+ BIT7 10 SERIN- 11 SEROUT+ 12 SEROUT- 13 NC 14 NC Note: Pin 1 is at the end of the terminal block closest to the power supply connector. Table 2.2 Auxiliary I/O Terminal Block, J2 Pin Configuration TI-5000EX TB Header J2 Inc/Ser Parallel Absolute Signal Output 1 AOUT+ 2 AOUT- 3 BOUT+ 4 BOUT- 5 ZOUT+ 6 ZOUT- 7 COMM1 BIT0 8 COMM2 BIT1 9 COMM3 BIT2 10 COMM4 BIT3 11 COMM5 BIT4 12 COMM6 BIT5 Note: Pin 1 is at the end of the terminal block closest to the end of the case and adjacent to J1.

TI-5000 150 OPERATION Table 2.3 Power Supply Connector, J3 Pin Configuration Connection Signal Inner conductor GND Outer conductor +9 VDC Table 2.4 RS232 DCE Ports 0 and 1, J6 Pin Configuration Serial Header DB9 Signal 1 1 CD0 (Out handshake) 2 6 DSR0 (Out handshake) 3 2 RD0 (Data output) 4 7 RTS0 (In handshake) 5 3 TD0 (Data input) 6 8 CTS0 (Out handshake) 7 4 DTR0 (Opt In handshake) 8 9 RI0 (Out handshake) 9 5 GND0 10 NC 11 1 CD1 (Out handshake) 12 6 DSR1 (Out handshake) 13 2 RD1 (Data output) 14 7 RTS1 (In handshake) 15 3 TD1 (Data input) 16 8 CTS1 (Out handshake) 17 4 DTR1 (Opt In handshake) 18 9 RI1 (Out handshake) 19 5 GND1 20 NC Notes: 1. Signals are referred to the DTE end, as is the normal convention. The TI-5000EX is a DCE

device. Table 2.5 USB Connector, J9 Pin Configuration USB Connector Pin Signal 1 VCC 2 DATA- 3 DATA+ 4 GND

TI-5000 151 OPERATION Table 2.6 Control Connector, J10 Pin Configuration Connector J10 Signal 1 U 2 V 3 W 4 ENABLE 5 ENABLE* 6 5V/9V 7 BRAKE 8 GND Table 2.7 Can Bus Connector, J11 Pin Configuration Can Bus Connector Pin Signal 1 CAN LO 2 CAN HI 3 GND Table 2.8 Resolver, J12 Pin Configuration TI-5000EX Terminal Block J12 Signal 1 GND 2 EXC 3 EXC* 4 COS 5 COS* 6 SIN 7 SIN*

TI-5000 152 OPERATION Test Cables – PDF sheets are available for all test cables used by the TI-3000, TI-5000 (obsolete), TI-5000EX, and TI-7000 tester products. These documents provide information on the wiring and connectors used with these cables. In the past the cable wiring has been documented in the user manual for each tester. For the following reasons, this method of documentation has become less satisfactory:

1. New cables are being added to frequently for the manual revisions to effectively keep up with the latest cables.

2. The large number of cables makes it unwieldy to put them all in the manual. 3. The cable sheets provide much more complete documentation since they specify connectors and

assembly notes as well as the wiring. 4. The latest WinTI5000EX software allows the cable sheet PDF files to be viewed or printed using the

Help menu. Test cables will no longer be documented in the tester manuals, and the PDF cable sheets will be available for download from the Mitchell Electronics, Inc. web site. Customers without web access can purchase a CD with the latest cables PDF sheets.

TI-5000 153 OPERATION 2.10 CLEANING The instrument case is made of ABS plastic. The following guidelines are based on information supplied by the plastic resin manufacturer. The resin manufacturer tested and rated the environmental stress cracking effects of many basic chemicals and commercial products. The ratings reflect the effects of continuous exposure (7 days at 73oF) to each chemical substance. This is an extreme case relative to the process of cleaning the instrument case. The following information, therefore, should be viewed as a guideline. Compatible cleaning agents: Mild detergent solutions (3-5%); Ivory, Tide, Top Job, Impact dishwasher liquid, Windex(dilute or rinse quickly). Higher concentrations can be used with prompt rinsing. Incompatible Cleaning Agents: Acetone, Benzene, Isopropyl Alcohol, Methanol, Kerosene, Ethyl Alcohol(100%), Ethylene Chloride.

TI-5000 154 OPERATION 2.11 SOFTWARE INSTALLATION AND REPAIR Software upgrades and updates will be sent to the customer as a file (typically a file on a CD or web site download), which will be user installable. Section 1.3.2 discusses downloading a file to the TI-5000EX. Documentation accompanying the upgrade will discuss the changes made, and provide useful notes. If the revision is very extensive, a new manual may accompany the software. If problems are encountered in using this equipment, please call for assistance. Do not return equipment without first calling for a return authorization number. The RA number should be included on the address label as shown below. In the event equipment is returned, it must be well packed for safe shipping. Address the package as follows: Mitchell Electronics, Inc. 180B Mill St. Athens, OH 45701 Attn: Customer Service RA XXXX Service Phone: (740)594-8532 Support Contacts: Voice: (740)594-8532 FAX: (740)594-8533 Email: [email protected] URL: http://www.mitchell-electronics.com

TI-5000 155 Theory of Operation

3 TESTING AND ENCODER BACKGROUND INFORMATION

The Theory of Operation section will provide technical details concerning system hardware and software. The information in this section is designed to provide detail beyond operating instructions to help the user obtain the maximum benefit from the system. 3.1 TERMINOLOGY This section will attempt to explain various terminologies such as serial, absolute, incremental and so forth. Unfortunately, often the same terms will be used in a different context by different manufacturers, but this section will at least describe what is meant by these terms in reading this manual. 3.1.1 INCREMENTAL VERSUS ABSOLUTE

There is considerable confusion over the use of the incremental and absolute terminology. This is understandable considering the evolution of encoder technology. Hopefully this section will clarify rather than further muddy the waters. At least it will provide a basis for understanding the use of the terms incremental and absolute in this manual. 3.1.1.1 TRADITIONAL ABSOLUTE A traditional absolute encoder will have numerous code rings with different binary weightings which will provide a digital data word representing the absolute position of the encoder within one revolution down to the precision of the least significant bit. This is the type of encoder that we call “Parallel Absolute” in the encoder selection. A simple example would be 3 code rings in which the most significant bit is HI during 1/2 the turn and LO during the other 1/2 turn. The next code ring goes from LO to HI two times during a turn while the least significant bit switches from LO to HI 4 times as shown in the following table: COUNT BIT2 (MSB) BIT1 BIT0 (LSB) A B Z 0 0 0 0 0 0 1 1 0 0 1 1 0 0 2 0 1 0 1 1 0 3 0 1 1 0 1 0 4 1 0 0 0 0 0 5 1 0 1 1 0 0 6 1 1 0 1 1 0 7 1 1 1 0 1 0 There are 8 unique data words to represent the 8 positions which can be reported by this encoder. Adding more bits will divide one revolution into smaller segments, and the encoder will therefore provide higher resolution. It will resolve one rotation into finer segments, but at the expense of adding more output lines to represent the additional bits. Typically this type of absolute encoder will be offered with a gray code output rather than the straight binary code shown above. Gray codes are designed to give the same information, but only one bit changes at a time when moved from one segment to the next. In the above example, all bits change state when moving from segment 7 to segment 0. Due to electronic delays, all bits do not change at the same instant in time, so there may be a short time in which the bits do no correctly represent the position. The gray code eliminates this problem. The distinguishing feature of the absolute encoder is that the encoder reports the absolute position of the encoder to the electronics. It can do this immediately upon power-up with no need for indexing.


3.1.1.2 TRADITIONAL INCREMENTAL A traditional incremental encoder works differently. It provides an A and a B pulse output as shown in the table above. These pulse outputs really provide no usable count information in their own right. Technically they provide a 2 bit gray code which can count from 0 to 3, but this is not how it is used. With the incremental encoder, the counting is done in the external electronics. The beauty of the A/B quadrature pulse pattern shown above is that the change in state can be counted by the electronics, and the direction of the count can be determined by which changes first: A or B. One of the advantages to incremental encoders is that there are always only two lines, A and B (and sometimes their complement lines A* and B*) for any number of counts per turn resolution. The disadvantage is that the point where the counting begins depends on the counter in the external electronics and not on the position of the encoder. Usually the counter is zeroed on power up, and it begins counting from there as the encoder is turned. The encoder could be at any position when power-up occurs. The motion of the encoder simply causes the external counter to increment (or decrement) the count up or down as it moves, and the count is not referenced to its absolute position. In most cases, the incremental encoder must be referenced to the absolute position to be useful. One way this is done is to include an index pulse on an additional line, Z, which will go HI at one point during the encoder revolution. On power-up the encoder can be turned during a "homing" sequence until the index pulse is found by the external electronics. If the external electronics zeros the counter (or sets it to some other known count), the encoder now becomes referenced to the encoder's absolute position. Homing can also be accomplished with reference to proximity switches and other signals that indicate a reference position. The distinguishing feature of the incremental encoder is that the encoder reports an incremental change in position of the encoder to the electronics. The electronics must add this change in position to the absolute position determined by the electronics upon power-up by indexing. 3.1.1.3 INCREMENTAL/ABSOLUTE GRAY AREAS As noted above, the absolute encoder presents the absolute position to the electronics, while the incremental reports to the electronics that it has moved through some increment. The downside to the incremental is the requirement for initial homing to provide absolute position information. What if we worked on our incremental encoder system so that we could remember the homing information through a power cycling, and homing during power-up was not required? Could we be justified in calling our incremental encoder an absolute encoder? Fanuc apparently takes this point of view because they use “absolute” as their terminology for A,B, and Z pulse encoders with battery backup. If the encoder and external counter is powered by a battery so that it truly can provide absolute position information on power up, it is functionally very similar to an absolute encoder. Of course if you want to make connections to this type of encoder and test or otherwise evaluate it, you find that for all practical purposes you have to consider it an incremental encoder because it looks nothing like the traditional absolute encoder described above.


3.1.2 SERIAL VERSUS NON-SERIAL

Serial encoders are encoders that transfer their information to the electronics in a serial data stream. Any of the counting schemes discussed above could transfer their count to the electronics using serial data. The traditional absolute encoder described above would have 16 data lines if it provided 16 bit resolution (counts up to 65535). If each data bit used a true and complement line for noise immunity, this would be 32 lines. The term normally used for this kind of data is "parallel". The Centronix printer printer interface (at one time used on most PC computers) transfers data in a parallel manner, 8 bits at a time. It is fast at the expense of a lot of wires. Serial data provides for the transmission of the data one bit after the other rather than all at once. All 16 bits mentioned above could be sent on one data line, but it could take 16 times as long (all other things equal). Many serial encoders have a request line to interrogate the encoder for data, and a data line for receiving the data from the encoder. If true and complement lines are used in each case, only 4 wires plus power and ground are needed for any resolution. From the standpoint of trouble-shooting, serial encoders present several problems. Often the encoder does not send any data unless it is properly interrogated by the request line. The bit pattern that appears on the data line after interrogation is not simple to interpret and is constantly changing as the encoder moves. It is a complex problem to correctly read and evaluate this information, and it is beyond the capabilities of standard universal test equipment. The TI-5000EX provides this information in an easily interpreted format which makes evaluating serial encoders practical. The term serial encoder is, of course, combined with incremental, absolute, etc. depending upon other details of its design and construction. Just remember that the serial terminology refers to the fact that the information is sent from the encoder to the electronics in a serial fashion, and that is independent of other terminologies applied to it. For instance, the Fanuc Alpha encoders are serial. The Alpha I model is called incremental because it has no battery, but the Alpha A model is called absolute because it has battery backup capability.


3.2 TEST THEORY This section will describe why tests are performed the way they are, and what information is gained by the test. In some cases this is obvious, but in other cases the reasons may not be clear. 3.2.1 INCREMENTAL ENCODER PHASE ANGLE TESTING

The question is often asked as to how important it is to perform the phase angle test. The standard answer is that it is more or less an auxiliary test ranking below the Count Test in importance. The Count Test verifies that the encoder is producing the correct number of counts per revolution. Accurate counting is essential, and it must be verified above all else. However, the phase angle measurement can expose problems with the encoder such as improper assembly, etc. Out of tolerance phase angles may even provide clues to counting problems. Large phase angle errors reduce the rotational speeds at which the encoder can produce acceptable signals for the electronics with which it is used. We can discuss the phase angles with the help of picture of the A and B pulses like you would see on an oscilloscope. ┌───────┐ ┌───────┐ ┌───────┐ ┌─ CH A+ │ │ │ │ │ │ │ ──┘ └───────┘ └───────┘ └──────┘ STATE L │ H H │ L L │ H H │ L L │ H H L │ │ ┌───┼───┐ │ ┌───┼───┐ │ ┌───────┐ │ CH B+ │ │ │ │ │ │ │ │ │ │ │ │ ──┼───┘ │ └───┼───┘ │ └───┼───┘ └──┼─ STATE L │ L │ H │ H │ L │ L │ H │ H L │ L H H L│ COUNT 0 │ 1 │ 2 │ 3 │ 4 │ 5 │ 6 │ 7 8 │ 9 10 11 12│ │ │ │ │ │ │ │ │ │ │ │ │ │ │ │ │ │ │ │ │ │ │ │ │ │ │ │ 0 90 180 270 0 90 180 0 0 A/B Quadrature Lines As with an oscilloscope, the first events are on the left, and the last events are on the right of the picture. We will give the first rising edge of A an angle of 0, and measure everything else relative to it. The falling edge of A is halfway between the two rising edges of A, so it must be at the 180 degree point. With this information we can determine the A symmetry angle. This measurement tells whether the A pulse is symmetrical. In simple terms, this just means is it HI for the same amount of time that it is LO? We determine this by subtracting the angle for the rising edge from the angle for the falling edge (180 - 0 = 180). In this case, it is 180 degrees which is perfect (perfect because the pulse is HI for the same amount of time that it is LO). The A symmetry angle is simply how many degrees the A pulse is HI. We can apply a similar analysis to the B pulse which has a rising edge at 90 degrees and a falling edge at 270 degrees. Again, we determine this by subtracting the angle for the rising edge from the angle for the falling edge (270 - 90 = 180). We get another perfect 180 degree symmetry angle. This tells us that these two signals are perfect by themselves, but we are not quite done. We need to see how they relate to each other, and we do that by measuring the phase angle. This angle is the angle from the rising edge of A to the rising edge of B, and we determine it by subtracting the angle for the rising edge of A from the angle for the rising edge of B (90 - 0 = 90). We have found that the phase angle is also perfect for our perfect encoder. If the encoder is rotated in the opposite direction, we would see that the rising edge


of B occurs at 270 degrees, and our phase angle would be 270 degrees. This is also a perfect answer. These are perfect because the edges are all equally spaced, 90 degrees apart from each others (90+90+90+90 = 36). Now that we have determined these angles, let's step back a minute and see what they mean. We also need to understand why 180 degrees is a perfect symmetry angle, and 90 or 270 is a perfect phase angle. Looking back at the picture, we see that there are 4 edges for each period (each complete 360 degrees) of encoder rotation. Our ideal encoder will evenly space these edges apart in the period. Any other angles will space some of the edges further apart and at the same time crowd others closer together. Spreading apart is fine, but crowding together is a problem. The electronics connected to the encoder will count these edges, and it will have a maximum rate at which it can receive the edges. This maximum rate really amounts to a minimum time separation between edges. As you know, when the encoder rotational speed is increased, the edges will move closer together. Simply put, if incorrect phase angles cause the edges to move closer together, it has the same effect as speeding up the encoder. Incorrect phase angles can cause minimum edge separation times to be reached at significantly lower rotational speeds that for the ideal phase angles. When the time separation between edges reaches the minimum, then the counting circuitry in the receiving electronics will begin missing counts. Of course, the flip side to this situation is that, if the rotational speed is slow enough, the phase angles matter very little because there is still adequate time spacing between edges. Typical encoder specifications for phase angles are ± 22 degrees. This means that the 90 degree phase angle could range between 68 and 112 degrees, and it would meet that manufacturer's specifications. The last topic to consider is how to make good phase angle measurements. The primary requirement is to rotate the encoder at a constant rotational speed. The TI-5000EX tester times the intervals shown in the picture and converts those times to angles. If the encoder speed is accelerating (speed ramping up), then the edges on the right hand end of the picture will be closer together than the edges on the left side, due simply to the increase in speed. This speed increase would cause phase angles and symmetry angles to look incorrect even with our ideal encoder. Since the tolerance on the phase angles is fairly broad, normally it is possible to get a constant enough speed rotating an encoder by hand. However, the best situation would be to rotate it with a constant speed motor. 3.2.2 CHECKING AND SETTING COMMUTATION

Checking and setting commutation is one of the most important tasks you will perform with the TI-5000EX. In most cases, the Commutation frame will display a mechanical and an electrical angle. Often it will also display commutation pulses. In the case of incremental encoders and Hall effect switches, the display will represent the states of actual lines from the feedback coming into J2 pins 7 through 12. The most common line configurations are 3 lines showing U, V, and W; 6 lines showing U, V, W, U*, V*, and W*; and 4 line gray codes. Some feedback devices can be aligned dynamically by back driving the motor and viewing the generated voltage and feedback output on an oscilloscope. Since many feedback devices (such as serial encoders) have no signal to observe during dynamic alignment, the method of static lockup is the remaining option. Because static alignment is more universal and generally a simpler procedure than dynamic alignment, it is recommended for all feedback devices, and it is the method described in this manual. Static lockup is accomplished by applying a small lockup voltage (normally keeping the lockup current below ½ rated current) to 2 or 3 of the armature leads. This will move the rotor to a position for which the feedback display is known. If the feedback display is incorrect, it can be repositioned until it is correct, and this procedure will align the feedback correctly to the rotor. The TI-5260 PM Rotor Lockup Switch greatly simplifies and organizes the lockup procedure The information on the Data Display will differ for various types of feedback, and the procedure may differ as well. Some of the more common variations are shown below.


When Hall effect switches are used, the alignment is almost surely line to line. This will also be the case for some incremental encoders with commutation pulses replacing Hall effect switches in earlier models. Reliance motors with Renco encoders would be an example. The alignment for these feedback devices are best done with the commutation pulse display. The following statement is very important in using commutation states for alignment. It must be understood in order to get the desire result.

A particular pattern of HI and LO commutation states will occur over a range of rotor position angles and will not define a single position angle. In order to define a single position angle, one of the commutation line states must be at a transition point changing between HI and LO. Correct data for alignment using commutation lines will always include a transition point for one of the lines.

Below is a typical line to line alignment showing a transition from HI to LO on H1 and HI and LO line states on H2 and H3 respectively. This example is presented as general guidance, but you must verify the correct alignment for your particular motor. Line to line alignment using commutation pulses is shown below:

Lockup Electrical Angle H1(U) H2(V) H3(W) +U –V H→L H L

Some servo motors with incremental encoder feedback will use line to neutral alignment. These motors are often referred to as “AC servo motors”. It is often easiest to align them using the pulse display as well. In some cases the position relationship between the index pulse and the commutation pulses is known, and the electrical angle can also be used for alignment. The example below shows that relationship for certain Yaskawa motors. If you understand that relationship, you can use the electrical angle, but otherwise the safe method is to use the commutation pulse states. This is presented as general guidance, but you must verify the correct alignment for a particular motor. Line to neutral alignment using commutation pulses is shown below:

Lockup Electrical Angle H1(U) H2(V) H3(W) +U -V -W 180 H→L H L

The Commutation frame, when serial encoders are selected, will show mechanical and electrical angles and often a 4 bit gray code. The 4 bit gray code is a carryover from the Fanuc encoders. It works well for aligning Fanuc encoders, but the electrical angle is a superior choice for other serial encoders. An example is the Mitsubishi serial encoder alignment shown below.



Several things are worth pointing out in the above example. The first lockup results in a zero angle. Some servo technicians like to find a lockup that will provide a zero angle, and this is fine. However, there is nothing magic about a zero angle lockup. For some motors such as Indramat digital, you do not want to think in those terms because it is likely that there is no zero angle lockup. In fact, for these motors the lockup angles are not the same from one motor to the next. The alignment is always dependent upon the motor and drive design, so a zero angle lockup for a motor will only exist if it was designed to have one. Motor and drive designers often do design systems to have common lockups (like zero) so that it simplifies alignment procedures during manufacturing. In this manual, we are suggesting checking both the +U –V and +U –W lockups, and there are several reasons why it is helpful:

1. Using the same two lockups each time standardizes the procedure. 2. Locking up with +U –W after locking up with +U –V, causes the motor to jog in the direction of its

forward armature phase rotation. This allows the technician to check rotation at the same time he checks alignment.

3. The difference in electrical angle from the +U –V to +U –W lockup is always 60 degrees. Checking for that difference allows the technician to make sure that the correct number of poles and counts/rev has been selected.

For a busy technician, getting the correct results is often a matter of sticking to a procedure that is familiar and that provides for catching common mistakes. Some mistakes are listed above, but this procedure will also help catch such mistakes as simply connecting to the wrong armature lead. The lockups shown above will repeat as many times as there are pole pairs. For instance you would see the above lockup in 4 different positions for an 8 pole motor. Checking the lockup for at least 2 positions is another good way of double checking. The Fanuc commutation gray code is shown as C1 – C8. It can be used to check and set commutation using a static rotor lockup by applying a small lockup voltage (normally keeping the lockup current below ½ rated current) as can the mechanical and electrical angle. For a particular lockup polarity, the rotor will lock up in as many different positions as there are pole pairs. The gray code electrical angle indications will be the same at each lockup position while the mechanical angle will be different.


Lockup Elect. Mech. C1 C2 C4 C8 Angle Angle +U –V –W 0 0, 90, 180, 270 (8 pole) 0 0 0 1→0 0, 120, 240 (6 pole) +V –W 90 22.5, 112.5, 202.5, 292.5 (8 pole) 0 1 0→1 0 30, 150, 270 (6 pole) +U –V 330 82.5, 172.5, 262.5, 352.5 (8 pole) 110, 230, 350 (6 pole) +U –W 30 7.5, 97.5, 1872.5, 277.5 (8 pole) 10, 130, 250 (6 pole) Alignment by static lockup can be applied to resolvers as well as to encoders and Hall effect pickups. Since there are differences between resolvers and other types of feedback, the techniques are slightly different as well. A major difference is that resolvers of different speeds will be used with different numbers of poles of motors. Most of the time a resolver will either be a single speed or the same number of speeds as the number of motor pole pairs. In other words, 8 pole motors will normally use either a single speed resolver or a 4 speed resolver. There is at least one known instance of a 2 speed resolver being used on an 8 pole Modicon motor, but this seems to be a rare practice. For the typical situation, you can think of the 1 speed resolver as showing the mechanical angle, and a resolver, with the same number of speeds as motor pole pairs, as showing the electrical angle. For the case of the single speed resolver with multiple numbers of pole pairs, there will be a different angle reading at each lockup position very much as shown above for the mechanical angle with the Fanuc encoders. An example is shown below for a 4 pole Parker motor with a single speed resolver: Lockup Angle Resolver Angle –V +W 0, 180 +U –V 30, 210 +U –W 60, 240 Three different lockups are shown with 6 different angles. You may wonder when you lock it up for instance with +U –V, which angle (30 or 210) should be used for your setting. It does not matter, because you will end up with the same 2 lockup angles either way.


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TI-5000 164 Specifications

4 SPECIFICATIONS

4.1 ELECTRICAL SPECIFICATIONS QUADRATURE PULSE ENCODERS INPUT - Rate Up to 1,000,000 CPS (quad) Max count ± 2,147,483,647 (quad) INCREMENTAL COUNT TEST - Rate Up to 1,000,000 CPS (quad) PHASE - Rate 25 CPS to 400,000 CPS Resolution 1 degree SERIAL ENCODERS Rate Varies with encoder type. RESOLVERS Excitation 1,000 - 20,000 Hz. Speed Up to 3,600 RPM Angle resol. To .1 degree ELECTRICAL INTERFACE Input/Output - 0 - +15 VDC maximum RS232 Serial Interface - Compatible with standard EIA RS232C levels (+3 to +15 and -3 to -15). USB – Standard USB.


POWER SUPPLY DC Supply – Voltage: 9V Current: 1A Physical: Negative center pin, 2.1 X 5.5 mm output connector AC Supply – Wall Mount Power Supply Input Voltage: 230 VAC (120 VAC USA) Input Current: 0.2A Output Voltage: 9 VDC Output Current: 1A Frequency: 50 Hz. Physical: Negative center pin, 2.1 X 5.5 mm output connector, CEE 7/16 Europlug input connector Example: Stancor Model STAF-0329F ENVIRONMENTAL Operating Conditions – Indoor use Altitude up to 2000 m Temperature 5 degrees C to 40 degrees C Maximum relative humidity 80% for temperatures up to 31 degrees C decreasing linearly to 50% relative humidity at 40 degrees C


4.2 SYSTEM DESCRIPTION SYSTEM SPECIFICATIONS Computer: PC Compatible Operating System: Windows95, Windows98, Windows ME, Windows NT, Windows 2000, Windows XP

(recommended), Windows Vista, and Windows 7. Communications: RS232 Serial COM port or USB port. PHYSICAL SPECIFICATIONS - Enclosure 12 oz., 8" X 4" X 2" (19.0 X 10.2 X 4.8 cm), lightweight impact resistant ABS material Weight 0.6 lb (0.280 Kg)