CONNECTRIC motrona ZU 252 User manual

control – motion – interface
motrona GmbH
Zwischen den Wegen 32
78239 Rielasingen - Germany
Tel. [phone]
Fax [phone]
[e-mail]
www.motrona.com
ZU25201c_e.doc / Jan-12 Page 1 / 34
ZU 252
Incremental Counter Module
With Analogue Output and Serial Interface
Counter suitable for quadrature signals (A/B, 90º) as well as single channel inputs
Counting inputs selectable to TTL/ RS422 format or to HTL / 10-30 volts format
Maximum counting frequency 1 MHz
Analogue outputs +/-10 V, 0-20 mA and 4-20 mA, polarity following the sign of the
internal counter
Analogue conversion time 1 msec only
RS 232 and RS 485 interfaces for serial readout of the counter
Also suitable for conversion of the sum or the difference of two separate counts
Facility for free linearization of the analogue output by 16 interpolation points
Easy to set up by TEACH procedure, or by PC and Windows software
Operating Instructions

ZU25201c_e.doc / Jan-12 Page 2 / 34
Safety Instructions
This manual is an essential part of the unit and contains important hints about
function, correct handling and commissioning. Non-observance can result in
damage to the unit or the machine or even in injury to persons using the
equipment!
The unit must only be installed, connected and activated by a qualified electrician
It is a must to observe all general and also all country-specific and application-
specific safety standards
When this unit is used with applications where failure or maloperation could cause
damage to a machine or hazard to the operating staff, it is indispensable to meet
effective precautions in order to avoid such consequences
Regarding installation, wiring, environmental conditions, screening of cables and
earthing, you must follow the general standards of industrial automation industry
- Errors and omissions excepted –
Version:
Description
:
ZU
252
0
1a
/ HK/AF/
Apr
.
08
Original version
ZU
252
0
1b
/ HK/AF/
Dez.08
Explanation DIL2/7+8 and other supplements
Z
U
2
5
2
01
c
/
pp/Jan.12
Name changed from
“
Register C
o
de
”
to
“
Serial Value
”

ZU25201c_e.doc / Jan-12 Page 3 / 34
Table of Contents
1. Compatibility Hint ........................................................................................................ 4
2. Introduction.................................................................................................................. 5
3. Applicable Encoders and Sensors ................................................................................ 6
4. Terminal Assignment ................................................................................................... 7
4.1. Incremental encoders TTL / RS 422 ......................................................................7
4.2. Incremental encoder HTL / 12-30V........................................................................8
4.3. Proximity switches, photocells etc........................................................................8
4.4. Control Input..........................................................................................................8
4.5. Analogue outputs ..................................................................................................8
4.6. Serial interfaces ....................................................................................................9
5. DIL Switch Settings.................................................................................................... 10
5.1. Basic mode of operation and power-down memory setting...............................10
5.2. Impulse levels and symmetric / asymmetric input formats ................................11
5.3. Analogue output format ......................................................................................12
5.4. Selecting the RS232 or the RS485 serial interface.............................................13
5.5. Teach function, Test function, loading of default settings .................................13
6. Setup Procedure......................................................................................................... 14
6.1. Operation as single channel counter (without direction signal)
or as positional counter (with direction signal)...................................................15
6.2. Operation as a summing or differential counter with
two independent impulse inputs (A+B, A-B) .......................................................15
7. Readout of the Actual Counter State by Serial Communication................................ 16
8. PC Setup Using the OS3.2 Operator Software............................................................ 17
9. Displays and Softkeys................................................................................................ 18
10. Parameter Settings .................................................................................................... 19
11. Free Programmable Linearization ............................................................................... 25
12. Monitor Functions...................................................................................................... 27
13. Data Readout via Serial Interface .............................................................................. 29
14. Test Functions............................................................................................................ 30
15. Dimensions ................................................................................................................ 31
16. Technical Specifications ............................................................................................ 32
17. Parameter List............................................................................................................ 33
18. Setup Form................................................................................................................. 34

ZU25201c_e.doc / Jan-12 Page 4 / 34
1. Compatibility Hint
This product is a successor model of the thousandfold approved converter type ZU251. The new
product is suitable for a 100% replacement of the previous model, however some differences
must be observed with DIL switch settings and parameter settings.
Some essential advantages of ZU252 compared to ZU251 are:
Maximum frequency 1 MHz (instead of 500 kHz)
Capability to accept even single-ended TTL input signals
(i.e. TTL inputs A and B only, without inverted signals /A and /B)
Setting of analogue formats +/-10V, +10V, 0-20 mA and 4-20 mA can be done by
supplementary DIL switch (no more PC required)
Enhanced auxiliary output 5 V / 250 mA for encoder supply

ZU25201c_e.doc / Jan-12 Page 5 / 34
2. Introduction
ZU 252 represents a small and low-cost, but highly performing converter for industrial
applications, where incremental counting of positions or events must be converted to either
analogue format or serial data. The unit has been designed as a compact module with 12 screw
terminals and a 9-position SUB-D connector (female). The housing is suitable for standard DIN
rail mounting.
The impulse input side provides channels A, B and also the inverted lines /A, /B which should
be used with TTL/ RS422 input signals. The unit can count and convert the following formats to
analogue and serial:
a. Up/down count with quadrature input (A/B, 90).
The polarity of the analogue output and the sign of the serial data depend on the sign of
the actual counting result
b. Single channel impulses on channel A.
Input B sets the counting direction and therefore also the polarity of the output
(LOW = negative, HIGH = positive).
Please observe:
Open NPN inputs are HIGH
Open PNP inputs are LOW
Open RS422 inputs may cause problems, therefore please set unused inputs to HTL
by means of the DIL switches
c. Dual count of fully independent events on channels A and B, where the output signal
represents the sum or the difference of both counts.
A
B
A
B
A
B
A and B, quadrature 90° A=impulse, B=static direction signal A and B: independant counting events
a.
b.
c.
+
-
The definitions for “zero analogue output” and “full scale analogue output” definition can be
set over the full counting range of +/-8 decades (-99 999 999 to [phone])

ZU25201c_e.doc / Jan-12 Page 6 / 34
3. Applicable Encoders and Sensors
The converter can accept the following impulse sources:
The ZU252 converter can accept the following impulse sources:
Quadrature encoders with HTL level output (10 – 30 V) and either PNP or NPN or Push-
Pull or NAMUR characteristics, using A and B outputs wit 90° displacement
Single channel impulse sources like proximity switches or photocells, providing HTL
level at PNP or NPN or Namur characteristics
TTL / RS422 quadrature encoders with output lines A, /A ,B and /B
Symmetric single channel sources with TTL / RS422 output, providing differential
signals (i.e. A and /A)
Asymmetric single channel sources with TTL level (without inverted signals, i.e. A only)
In general, HTL encoders will be supplied from the same source as the converter itself.
For supply of TTL encoders, the unit provides an auxiliary output of 5.5 volts
(stabilized, max. 250 mA).

ZU25201c_e.doc / Jan-12 Page 7 / 34
4. Terminal Assignment
We recommend connecting the Minus wire of the power supply to earth potential.
Please observe that, under poor earthing and grounding conditions, multiple earth connections
of screens and GND terminals may cause severe problems. In such cases it may be better to
have only one central earthing point for the whole system.
GND terminals 4, 6 and 12 are connected internally. Depending on input voltage and load of the
auxiliary voltage output, the total power consumption of the unit is approx. 70 mA
(see specifications).
1
2
3
4
5
6
7
8
9
1
0
1
1
1
2
Analogue out +/-10V
TTL: Input /B HTL: n.c.
TTL: Input B HTL: Input B
Analogue GND ( - )
+18...30 VDC (typ. 70 mA)
GND ( - )
0-20mA / 4-20mA out
TTL: Input /A HTL: n.c.
TTL: Input A HTL: Input A
Control
Aux. 5.5V out (max. 250 mA)
GND ( - )
P
O
W
E
R
4.1. Incremental encoders TTL / RS 422
If applicable, the encoder can be supplied from the ZU252 converter. Where the encoder is
already supplied from a remote source, we recommend fully differential operation, with no
GND connection between encoder and converter (see figures a. and b.)
8
9
2
3
11 (+5.5V)
12 (GND)
+
-
TTL encoder
ZU 252 converter
Screen
A
A
B
B
A
A
B
B
a)
8
9
2
3
11 (+5.5V)
12 (GND)
+
-
TTL encoder
ZU 252 converter
Screen
A
A
B
B
A
A
B
B
b)
+ext
-ext

ZU25201c_e.doc / Jan-12 Page 8 / 34
4.2. Incremental encoder HTL / 12-30V
The encoder may be supplied from the same source as the converter, or from another source.
9
3
12 (GND)
GND
HTL encoder
ZU 252 converter
Screen
+24V
+
A
B
4.3. Proximity switches, photocells etc.
This connection is fully similar to a HTL incremental encoder. With single-channel operation,
input B remains unconnected or can be used to select the output polarity. With use of two
independent counting events for forming the sum or the difference, input B operates as the
second counting input.
For use of sensors providing 2-wire NAMUR characteristics:
Set the inputs to HTL and NPN
Connect the positive wire of the sensor to the corresponding input and the negative
wire to GND.
4.4. Control Input
The control input available on terminal 10 provides programmable characteristics and functions
for activation of different commands (e.g. Reset, see parameter “Input setting)
4.5. Analogue outputs
The unit provides a +/-10V voltage output and a 0-20 mA / 4-20 mA current output at a
resolution of 14 bits, i.e. the voltage output operates in steps of 1.25 mV and the current output
operates in steps of 2.5 µA. The nominal load of the voltage output is 2 mA, the current output
accepts loads between 0 Ohms and 270 Ohms.
The analogue ground uses a separate terminal, which however internally is connected to the
GND potential of the power supply.
GND
4
1
7
+/- 10V
20 mA
(R = 0 - 270 Ohms)
(Imax = 2 mA)
Screen
Vout
Iout

ZU25201c_e.doc / Jan-12 Page 9 / 34
4.6. Serial interfaces
The unit provides a RS232 interface and a RS485 interface, however only one of the two can be
used at a time. Serial communication allows to read out the counting result and to set
parameters and variables by PC, according to need.
5
4
3
2
1
9
8
7
6
GND int.
TxD
RxD
RS232
+5V
T+
T-
R+
R-
RS485
Sub-D-9 (female on unit site)
54321
98 7 6
54321
98 7 6
5
4
3
2
1
9
8
7
6
5
4
3
2
1
9
8
7
6
GND
TxD
RxD
PC
ZU 252
RS232:
Please connect only pins 2, 3 and 5 !
5
4
3
2
1
9
8
7
6
5
4
3
2
1
9
8
7
6
T+
T-
120 Ohms
120 Ohms
RS485- Bus
( 4- wire )
ZU 252
120 Ohms 120 Ohms
R+
R-
T+
T-
R+
R-
5
4
3
2
1
9
8
7
6
5
4
3
2
1
9
8
7
6
T+
T-
120 Ohms 120 Ohms
RS485- Bus
( 2- wire )
ZU 252

ZU25201c_e.doc / Jan-12 Page 10 / 34
5. DIL Switch Settings
There is one 8-position switch located on the top side (DIL1), and another 8-position switch is
located on the bottom side of the unit (DIL2). These switches provide major settings of the
desired properties of the unit.
Changes of switch settings will become active only after cycling the power
supply of the unit!
Positions 7 and 8 of switch DIL2 are for internal factory use only and must
both be set to OFF at any time during normal operation
5.1. Basic mode of operation and power-down memory setting
Positions 2 and 3 of switch DIL1 on the top side set the mode of operation, and position 4
allows setting of the power-down behavior of the unit:
12 3 4 5 6 7 8
on on
on off
off on
off off
Mode of operation
Input A only
Quadrature operation A / B / 90°
Sum A + B or difference A - B
A = counting input, B = direction control (up/dn)
DIL1
Position 4 off: Power-down memory off. Upon power up the counter either resets to zero or sets to the
value programmed under parameter „Set Value“ *)
Position 4 on: Power-down memory on. Upon power up the counter re-loads the previous value before
power down
*) see Parameter „Power-up Mode“
Top side
Switch DIL1
Teach button
Bottom side
Switch DIL2

ZU25201c_e.doc / Jan-12 Page 11 / 34
5.2. Impulse levels and symmetric / asymmetric input formats
Positions 5 and 7 of DIL1 together with positions 3 to 6 of DIL2 allow setting of all imaginable
combinations of levels and formats.
All subsequent tables use the following definitions:
„0“ = switch OFF, „1“ = switch ON and
„x“ = position not important
Switch settings refer to impulse inputs A / B only, but the
Control Input (terminal 10) provides always HTL / PNP format, i.e.
you must apply a positive voltage 10 – 30 volts to activate the
function
Where you use 2-wire sensors with NAMUR characteristics,
connect the positive pole of the sensor to the corresponding input
terminal, and the negative pole to GND
Where subsequently you read (A) or (B), this indicates that the
inputs expect asymmetric (single-ended) signals and you will not
need the corresponding inverted signals
Where however you read (A and /A) or (B and /B), this indicates that
the inputs expect symmetric differential signals according to RS422
standard, i.e. it is mandatory to apply also the inverted signals
5.2.1. Standard settings
If you just use encoders or sensors according to common industrial standards, and if also all
input signals should have the same level, you just can use one of the following three standard
settings and do not need to consider all further alternatives of switch settings.
DIL1
DIL2
Input Characteristics
Encoder Type
5
6
7
3
4
5
6
0 0 0 0 0 0
Asymmetric HTL input (A, B),
10 - 30 V level, NPN (switching to -) or
Push-Pull or NAMUR characteristics
Standard HTL encoders,
Proximity switches,
Photo switches etc.
1 0 0 0 0 0
Asymmetric HTL input (A, B),
10 - 30 V level, PNP (switching to +) or
Push-Pull characteristics
PNP Proximity switches,
Photo switches etc.
0 1 0 0 0 0
Symmetric TTL signals or
RS422 signals (A, /A), (B, /B)
(differential, including inverted signal)
Standard TTL encoders
providing A, /A, B, /B
output channels

ZU25201c_e.doc / Jan-12 Page 12 / 34
5.2.2. Settings for special applications
Where you find that the standard settings shown before are not suitable for your application,
please go through the following setting options and find out the input levels and characteristics
you need.
DIL1
DIL2
Characteristics of input A
Characteristics of input B
5
6
7
3
4
5
6
x x 0 0 0 1 TTL level (A) TTL level (B)
x x 0 0 1 0 HTL level (A and /A) HTL level (B and /B)
x x 0 0 1 1 TTL level (A) TTL level (B and /B)
x x 0 1 0 0 TTL level (A and /A) TTL level (B)
x x 0 1 0 1 HTL level NPN (A) HTL level PNP (B)
x x 0 1 1 0 HTL level NPN (A) TTL level (B and /B)
x x 0 1 1 1 HTL level NPN (A) TTL level (B)
x x 1 0 0 0 HTL level PNP (A) TTL level (B and /B)
x x 1 0 0 1 HTL level PNP (A) TTL level (B)
x x 1 0 1 0 HTL level PNP (A) HTL level NPN (B)
x x 1 0 1 1 TTL level (A and /A) HTL level NPN (B)
x x 1 1 0 0 TTL level (A) HTL level NPN (B)
x x 1 1 0 1 TTL level (A and /A) HTL level PNP (B)
x x 1 1 1 0 TTL level (A) HTL level PNP (B)
5.3. Analogue output format
The desired output format of the analogue output can be set by positions 1 and 2 of switch DIL2
DIL2
Output format
1
2
0
0
Voltage 0 … +10 V
With this setting the format depends on the parameter
„Analogue Mode“ which can be set by PC. Since the factory
default setting of parameter “Analogue Mode” is “1”, the
format will be a 0 … +10 V output under default conditions.
0
1
Voltage +/
-
10 V
1
0
Current 4
–
20 mA
1
1
Curren
t 0
–
20 mA

ZU25201c_e.doc / Jan-12 Page 13 / 34
5.4. Selecting the RS232 or the RS485 serial interface
Position 1 of switch DIL1 selects between the RS232 interface and the RS485 interface. All
connection details have already been explained in section 4.6.
DIL1 / 1
Serial Interface
0
RS232
interface is active (RS485 is switched off)
1
RS485 interface is active (RS232 is switched off)
5.5. Teach function, Test function, loading of default settings
Positions 6 and 8 of switch DIL1 allow to set the following functions:
DIL1
Function
6
8
x
0
Unit returns to the factory default parameters after power
-
down
x
1
Unit always keeps the parameters according to customer setting
0
x
Push button and yellow LED operate in TEACH mode (see 6.)
1
x
Push button and yellow LED operate in TEST mode,
Teach is disabled (see 6.)
After successful commissioning, please make sure to set positions
6 and 8 to “ON”. Otherwise, cycling of the power supply or touching
the push button inadvertently would result in overwriting your
parameter settings

ZU25201c_e.doc / Jan-12 Page 14 / 34
6. Setup Procedure
For all basic applications you can use the Teach feature for commissioning of the unit.
Extended functions need a PC for setup and are described under section 8.
As a first step it is advisable to check the input pulses by means of the LED marked “Status”.
Position 6 of DIL1 must be set to ON for this test.
When you press the TEACH button one time, the yellow LED will be lit after the unit detected a
pulse on input A. The LED will be OFF when no input pulse has been detected.
When you press the TEACH button once more, you can also check input B (if applicable). With
use of mode A+B and two independent impulse sources, again the yellow LED will be lit after a
pulse has been detected on input B.

ZU25201c_e.doc / Jan-12 Page 15 / 34
6.1. Operation as single channel counter (without direction signal)
or as positional counter (with direction signal)
Settings: Make sure that the DIL switches are set according to the encoder in use, and
that position 6 of switch DIL1 is OFF (Teach function active).
Self test: Upon power up, both front LED’s must be lit first, and the yellow status LED
must switch off after the self-test has been concluded successfully (approx.1 sec.).
Scaling of the analogue output with use of the Teach function:
Press the Teach button one time. The status LED will blink in a slow sequence now
while the unit waits for setting of the minimum counter state, this is the state where
later you expect the analogue output to be zero (in general, this will be with counter=0).
Please set the counter to the desired state or move the encoder to the desired position
and reset the counter to zero. Then press the Teach button again. This stores your
minimum counter definition.
The LED will blink in a fast sequence now and the unit waits for setting of the maximum
counter state, this is the state where later you expect full scale analogue output.
Please get the counter to the desired state or move your encoder to the desired position.
Then press the teach button once more. This stores your maximum counter definition
and the LED will switch off.
After this Teach procedure, your analogue output is set to 0–10 volts swing between the
minimum and the maximum counter state.
6.2. Operation as a summing or differential counter with
two independent impulse inputs (A+B, A-B)
In principle, the Teach procedure is exactly the same as shown under 6.1, but the minimum and
maximum counter states already refer to the sum or the difference of the count on both inputs.

ZU25201c_e.doc / Jan-12 Page 16 / 34
7. Readout of the Actual Counter State by
Serial Communication
At any time you can read out the actual counter state and more values via serial link. For
setting of serial communication parameters etc., you must however apply PC setup anyway, as
shown later.
ZU 252 uses the DRIVECOM communication protocol according to the ISO 1745 standard.
Details about the protocol can be found in our document “SERPRO.doc”, available for download
under
www.motrona.com
The following register codes are available for readout:
C1
C2
Description
:
8
Actual conver
sion result, scaled as % of full scale output, format xxx.xxx % *)
;
0
Actual count of input
A
;
4
Actual count of input B
;
3
Actual output voltage of the analogue output, scaling 0
–
10 000 millivolts
*) under consideration of the scaling operands as shown in section 10.

ZU25201c_e.doc / Jan-12 Page 17 / 34
8. PC Setup Using the OS3.2 Operator Software
You can apply the full set of functions when you use a PC and our operator software OS3.x for
setup of the unit (actual software version is OS3.2).
You can download this software and more instructions from our homepage
www.motrona.com
Connect your PC to the converter, using a serial RS232 cable like shown in section 4.6 of this
manual. Make sure the cable only uses pins 2, 3 and 5. Pins 2 and 3 must be crossed.
Run the OS3.x software and you will see the following screen:
If your text and color fields remain empty and the headline says „OFFLINE“, you must verify
your serial settings and the DIL switch setting. To do this, select „Comms“ from the menu bar.
Ex factory, all motrona units use the following serial standard settings:
Unit No. 11, Baud rate 9600, 1 start/ 7 data/ parity even/ 1 stop bit
If the serial settings of your unit should be unknown, you can run the
„SCAN“ function from the „TOOLS“ menu to find out.

ZU25201c_e.doc / Jan-12 Page 18 / 34
9. Displays and Softkeys
The edit window for all unit parameters can be found on the left side of the screen.
The INPUTS field shows the softkeys to switch the control commands on or off. Display boxes
in the RS column indicate when the corresponding command is set to ON by PC. Display boxes
in the PI/O column indicate that the corresponding command is ON by external hardware.
The boxes in the OUTPUTS field provide information about the state of the unit, where “Status
A” and “Status B” are especially useful to check the counting inputs:
Status A is lit when a counting pulse is detected on input A
Status B is lit when a counting pulse is detected on input B
(with operation modes A+B or A-B only)
The color bar graph displays the actual output state in a range of +/- 100 % of full scale.
Control keys are available for readout, transmission and storage of parameters.

ZU25201c_e.doc / Jan-12 Page 19 / 34
10. Parameter Settings
Parameter
Description
„Register :8“ Setting:
Multiplier
Divisor
Offset
These operands al
low to convert the result to the desired engineering
units.
The conversion affects the numeric value for serial read out from register
<:8> only, but not the scaling of the analogue output.
With the settings Multiplier = 1,0000
Divisor = 1,0000
Offset = 0,0000
the readout from register < :8 > equals to the percentage result (xxx.xxx%)
, where 100,000% has been defined by the TEACH minimum and TEACH
maximum settings
+/-Operand
Readout from <:8> =Measuring result in % of full scale xxOperand
/Operand +
With “Divisor” set to 0 the whole conversion will be skipped, resulting in
lower calculation time and the shortest possible conversion time.
The calculation result from [ Multiplier : Divisor ] must not exceed a value
of 15 000 !
Direction:
C
an be used to invert the polarity of the analogue o
utput signal when
converting quadrature A/B input signals or A=impulse and B=direction.
0 = no inversion of the polarity
1 = inversion of the polarity
A
/
B Mode:
S
ets the counting mode with two independent single
-
channel inputs
0 = no combination
1 = sum A + B
2 = difference A – B
See DIL switch settings in chapter 5.1.
Linearization
Mode:
Sets the mode of linearization.
0: Linearization off, registers P1_x to P16_y do not affect the output
characteristics.
1: Linearization in a range of 0 – 100%
2: Linearization over full range –100% to +100%
See example in chapter „Linearization“

ZU25201c_e.doc / Jan-12 Page 20 / 34
Parameter
Description
Edge Mode:
This setting, with use of quadrature A/B input, allows simple count (x1) or
full quadrature count (x4), by either accepting rising edges from input A
only, or all rising and falling edges from inputs A and B
0 = simple count (x1)
1 = quadrature count (x4)
Input Filter
Programmable hardware filter for the impulse inputs
0Filter off, inputs accept full frequency range
1Filter cuts frequencies higher then 500 kHz
2Filter cuts frequencies higher than 100 kHz
3Filter cuts frequencies higher than 10 kHz
When using the filter, all frequencies higher than indicated above will no
more be evaluated correctly.
Power up Mode
:
Sets the
action of the
counter upon power up
:
0 = Loads the previous value from power down memory
1 = Resets the counter to zero
2 = Sets counter to the value specified by register “Set Value”
Channel A Setting:
Factor A
I
mpulse scaling factor for c
ounter input
A
.
Setting 1.0000 results in one increment with every input pulse, whereas
setting 0.5000 would need 10 input pulses to increment by 5 etc.
Round Loop
A
:
This register limits the counting range to a repeating loop. With setting of
1000, in upwards direction 999 is followed by to 000, and in downwards
direction the counter sets to 1000 when reaching zero.
Setting this register to 000 000 provides counting over the full range.
S
et Value
A
:
Upon external Set
command, the
input A counter
pres
ets to the datum set
here (range +/-100 000 000). The analogue output follows the new counter
state according to its output scaling.
Multiplier A
Multiplier for multiple count of one input impulse on A (001
–
999)
Channel B Setting: (only for operation modes A+B or A-B)
Factor
B
I
mpulse scaling factor for counter input
B
(see Factor A)
Round Loop B:
(see “Round Loop A, but input B)
S
et Value
B
:
(see “Set Value A”, but input B)
Multiplier B
(see “Multiplier A”, but input B)