Control Techniques UD52 User manual

User Guide
UD52UD52
SIN-COS encoder
interface
small option module
for Unidrive
Part Number: 0460 - 0085
Issue Number: 3

General Information
The manufacturer accepts no liability for any consequences resulting from
inappropriate, negligent or incorrect installation or adjustment of the
operating parameters of the equipment or from mismatching the Drive
with the motor.
This option module is intended for use only with Control Techniques
Unidrive products. Any other use invalidates the warranty and may cause a
safety hazard.
The contents of this Guide are believed to be correct at the time of
printing. In the interests of a commitment to a policy of continuous
development and improvement, the manufacturer reserves the right to
change the specification of the product or its performance, or the
contents of this Guide, without notice.
All rights reserved. No part of this Guide may be reproduced or
transmitted in any form or by any means, electrical or mechanical including
photocopying, recording or by any information storage or retrieval system,
without permission in writing from the publisher.
Use within the European Union, etc
The following information applies where the end use of the Drive is within
the European Union, the European Economic Area, or other regions which
have implemented Directives of the European Council or equivalent
measures.
The Drive, together with its associated option modules, complies with the
Low Voltage Directive 73/23/EEC.
The installer is responsible for ensuring that the equipment into which the
Drive is incorporated complies with all relevant Directives.
The complete equipment must comply with the EMC Directive 89/336/EEC.
If the Drive is incorporated into a machine, the manufacturer is responsible
for ensuring that the machine complies with the Machinery Directive
89/392/EEC. In particular, the electrical equipment should generally
comply with European Harmonised standard EN60204-1.
Copyright © January 2002 Control Techniques Drives Ltd
Issue Code: 52nu3

UD52 User Guide
Issue code: 52nu3
Contents
Chapter
1Introduction 1
1.1 Main featuresof the UD52 1
1.2 Principle of operation 2
2SafetyInformation 3
3Installing the UD52 6
4Making Connections8
4.1 Locationsof the terminals8
4.2 Functionsof the terminals9
4.3 Serial communications 11
5Setting Up the UD52 12
5.1 Initial setting up 12
5.2 Phase offset 12
5.3 Position information 13
5.4 Simulated-encoder outputs(terminals50, 51, 53, 54) 15
5.5 Freeze inputs(terminals48, 49) 16
5.6 Further setting up 16
6Related Parameters17
6.1Introduction 17
6.2 Programmable software 17
6.3 Parameter descriptions 19
Appendix
ASpecificationsA-1
A.1Inputsand outputsA-1
BAdvanced Functions B-1
B.1 Alternative configurations B-1
B.2 Aligning the encoder mechanicallyB-2
CDiagnostics C-1
C.1Trip codes C-1

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1Introduction
1.1 Main features of the UD52
Note
The UD52canbe used onlywith Drivesequipped with
version 3 (or later) software. (Parameter 0.50 indicates
the software version.)
ApplicationsThe UD52SIN-COS encoder small option moduleis an interface module for
installation in aUnidrive.The UD52operates with encoders having 256,
512, 1024, 2048 or 4096 lines per revolution, and has a maximum operating
frequencyof102.4kHz (3000RPMwith a2048-line encoder).
The UD52can be used in aDrive operating in either the Closed-loopVector
or Closed-loopServo mode in order to obtain speed feedback and very
high resolution shaft position.The UD52is fullycompatible with the
following Stegmann SIN-COS encoders:
SCS60,SCM60,SCS70,SCM70
These encoders are compatible with the two-wire serialcommunications
port in the UD52.
Absolute-
position
information
The UD52can determine the absolute position within arevolution ofa
single-turn encoder, or in manyrevolutions ofamulti-turn encoder.Unlike
the case for astandard encoder, which must be rotated past its marker
pulse in order to obtain absolute-position information, absolute-position
information from a (suitable) SIN-COS encoder is obtained when the Drive is
powered-up.
Speed and position information is displayed in parameters which can be
read on the Drive displayand/or viaserial communications.
Selection of
encoder
function
When aUD52is fitted in the Drive,the Drive automaticallyuses theSIN-COS
encoder as speed and position feedback for the motor.Alternatively, a
standard quadrature encoder can be used for speed and position feedback,
and theSIN-COS encoder used as an incrementalreference.
Simulated
encoder
outputs
The UD52 has simulated encoder outputs which normallyuse theSIN-COS
encoder as the source,but can be reconfigured to use the main encoder
(Encoder 1) connected to the 15-wayD-type on the Drive as the source.
These outputs produce quadrature A/B signals corresponding to the line
counts from the source encoder.Also, these outputs can be configured for
frequencyand direction (F/D)signals.
InstallationThe UD52must be fitted in the small option modulebayofthe Unidrive.
All connections to the Drive are made byamulti-wayconnector.
Connections from external equipment are made byapluggable 16-way
screw-terminalblock on the UD52.

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1.2 Principle of operation
The UD52 converts the sinusoidal output signals ofaSIN-COS encoder into
square waves and counts the edges (as in the case ofastandard encoder)to
yield position counts at arate offour times the number oflines per
revolution ofthe encoder.The constantlyvarying amplitudes ofthe sine
waves are also measured bythe UD52in order to produce 211 (2048)
interpolated counts between encoder lines.
The overall resolution is the product ofthe number ofinterpolated counts
and the number ofencoder lines.For example,the UD52used with a
512-line (29)encoder can give aresolution of220 (1 048 576) counts per
revolution).

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2Safety Information
2.1 Warnings, Cautions and Notes
A Warning contains information which is essential for avoiding a safety
hazard.
A Cautioncontains information which is necessaryfor avoiding arisk of
damage to the product or other equipment.
A Notecontains information which helps to ensure correct operation ofthe
product.
2.2 Electrical safety –
general warning
The voltages used in the Drive can cause severe electric shock and/or burns,
and could be lethal.Extreme care is necessaryat all times when working
with or adjacent to the Drive.
Specific warnings are given at the relevant places in this User Guide.
The installation must comply with all relevant safety legislation in the
countryofuse.
The Drive contains capacitors that remain charged to apotentiallylethal
voltage after theAC supplyhas been disconnected.Ifthe Drive has been
energized,the AC supplymust be isolated at least ten minutes before work
maycontinue.
2.3 System design
The Drive is intended as acomponent for professional incorporation into
complete equipment or systems.Ifinstalled incorrectlythe Drive may
present asafetyhazard.The Drive uses high voltages and currents, carries
ahigh levelofstored electricalenergy,and is used to controlmechanical
equipment which can cause injury.
Close attention is required tothe electricalinstallation and the system-
design to avoid hazards either in normal operation or in the event of
equipment malfunction.System-design, installation, commissioning and
maintenance must be carried out bypersonnel who have the necessary
training and experience. They must read this safety information and this
User Guide carefully.
To ensure mechanicalsafety,additionalsafetydevices such as
electro-mechanicalinterlocks maybe required.The Drive must not be used
in asafety-critical application without additional high-integrityprotection
against hazards arising from amalfunction.

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2.4 Environmental limits
Instructions in this User Guide regarding transport, storage, installation and
use of Drives must be complied with, including the specified environmental
limits.Drives must not be subjected to excessive physicalforce.
2.5 Compliance with regulations
The installer is responsible for complying with all relevant regulations, such
as national wiring regulations, accident prevention regulations and
electromagnetic compatibility(EMC) regulations.Particular attention must
be given to the cross-sectional areas ofconductors, the selection offuses or
other protection, and protective earth (ground)connections.
The Unidrive Installation Guide contains instructions for achieving compliance
with specific EMC standards.
Within the European Union, all machinery in which this product is used must
comply with the following directives:
89/392/EEC: Safety ofMachinery
89/336/EEC: Electromagnetic Compatibility
2.6 Safety of personnel
The STOPfunction ofthe Drive does not remove dangerous voltages from
the output ofthe Drive or from anyexternal option unit.
The Stopand Start controls or electricalinputs ofthe Drive must not be
relied upon to ensure safetyofpersonnel.Ifasafetyhazard could exist
from unexpected starting ofthe Drive,an interlock that electricallyisolates
the Drive from the AC supplymust be installed to prevent the motor being
inadvertently started.
Careful consideration must be given to the functions ofthe Drive which
might result in ahazard, either through their intended functions (eg.
Auto-start)or through incorrect operation due to afault or trip(eg.
stop/start,forward/reverse,maximum speed).
Under certain conditions, the Drive can suddenlydiscontinue control ofthe
motor.Ifthe loadon the motor could cause the motor speed to be
increased (eg.hoists and cranes), a separate method of braking and
stopping the motor must be used (eg.a mechanical brake).
Before connecting the AC supply to the Drive, it is important that you
understand the operating controls and their operation.Ifin doubt, do not
apply AC power to the Drive.Damage may occur, or lives put at risk.
Carefully follow the instructions in this User Guide.
Before making adjustments to the Drive, ensure all personnel in the areaare
warned.Make notes ofall adjustments that are made.

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2.7 Risk analysis
In anyapplication where amalfunction ofthe Drive could lead to damage,
loss oflife or injury, arisk analysis must be carried out, and where necessary,
further measures taken to reduce the risk.This would normallybe an
appropriate form ofindependent safetyback-upsystem using simple
electro-mechanical components.
2.8 Signal connections
The controlcircuits are isolated from the power circuits in the Drive bybasic
insulation only, as specified in IEC664–1. The installer must ensure that the
external control circuits are insulated from human contact byat least one
layer ofinsulation rated for use at the AC supply voltage.
Ifthe control circuits are to be connected to other circuits classified as
Safety Extra Low Voltage (SELV) (eg.to a personal computer), an additional
isolating barrier must be included in order to maintain the SELV
classification.
2.9 Adjusting parameters
Some parameters have aprofound effect on the operation ofthe Drive.
Theymust not be altered without careful consideration ofthe impact on
the controlled system.Measures must be taken to prevent unwanted
changes due to error or tampering.

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3Installing the UD52
Warning
Before using the following procedure, refer to the
Warnings at the beginning of Chapter 2 Installingthe Drivein
the Unidrive InstallationGuide.
1 Ensure the Drive is operating in either the Closed-loopVector or the
Closed-loopServo mode (this is indicated byparameter 11.31 (0.48).
2 Before installing the UD52in the Unidrive,ensure the AC supply has
been disconnected from the Drive for at least 10minutes.
3 Check that the exterior ofthe UD52is not damaged,and that the
multi-wayconnector is free from dirt and debris.Do not install a
damaged or dirtyUD52in the Drive.
4 Remove the terminal cover from the Drive (for removal instructions,
see Installing the Drive in Chapter 2ofthe Unidrive Installation Guide).
5 Position the multi-wayconnector on the rear ofthe UD52 over the
connector in the Drive (see Figure 1), and press on the thumb pad to
push the UD52into place.
6 Re-fit the terminal cover to the Drive.
7 Connect the AC supplyto the Drive.
8 Set parameter .00 at 149 to unlock security.
9 Check that Menu-16 parameters are now available.
10 Check that parameter 16.01 is set at 4.
11 If the checks in steps 8 and 9 fail, perform the following:
• Remove theAC supply from the Drive.
• Wait at least 10 minutes.
• Remove the terminalcover.
• Check that the UD52is fullyinserted.
• Replace the terminalcover.
• Re-apply theAC supply.
• Check again that parameter16.01 is set at 4.

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Figure 1 Installing the UD52 in the Unidrive

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4Making Connections
Warning
The control circuits are isolated from the powercircuits in
the Drive bybasic insulationonly,asspecified inIEC664–1.
The installermustensure thatthe external control circuits
are insulated from human contact by at least one layer of
insulation rated for use at theAC supplyvoltage.
If the control circuits are to be connected to other circuits
classified as Safety Extra Low Voltage (SELV) (eg.to a
personal computer), an additional isolating barrier must be
included in order to maintain the SELV classification.
4.1 Locations of the terminals
Figure 2 Location of the two-part terminal block

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4.2 Functions of the terminals
(Note that \indicatesnot (eg.F\ indicatesnot F)
Terminal NameFunctionComments
40SININ Sine input signal Always required
41SINREFSine input reference
42COSIN Cosine input signal
43 COSREF Cosineinput reference
44 0V 0Vcommon
45 +VENC DCsupply to encoder
46SC DATA Serial comms. EIA485 input and outputUse for Closed-loop
Servo mode or
47SC DATA\Serial comms. EIA485 input and outputwhen absolute position
is required
48FREEZEFreeze SC DATA inputOptional
49FREEZE\Freeze SC DATA\ input
50 A
(F)Simulated-encoder phase quadrature outputA
orfrequencyoutput F
(EIA485serial link)
Optional
51 A\
(F\)Simulated-encoder phase quadrature outputA\
orfrequencyoutput F\
(EIA485serial link)
520V 0Vcommon
53 B
(D) Simulated-encoder phase quadrature outputB
or direction outputD
(EIA485serial link)
54 B\
(D\)Simulated-encoder phase quadrature outputB\
or direction outputD\
(EIA485serial link)
550V 0Vcommon

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SIN
COS SCDATA
Main feedback
SIN - COS encoder
Figure 3 Standard wiring configuration
UD52
SINREF
COSIN
COSREF
0V
+VENC
SCDATA
SCDATA\
SININ
SIN-COS encoder
Sine
output
Cosine
output
0V
Serial
comms.
+V
Figure 4 Grounding and screening recommendations for the UD52
The sinusoidal signals from aSIN-COS encoder are low-voltage analog signals.
Ensure that electricalnoise from the Drive or motor does not adversely
affect the encoder feedback.Ensure that motor cables are shielded (see
Chapter 2Installing the Drive in theInstallation Guide).Refer to Figure 3 for
grounding and screening recommendations for the UD52.
For the simulated encoder connections, refer to the instructions for the
equipment that is to receive the signals.

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4.3 Serial communications
When absolute positioning is required, connect terminals 46, 47 Serial
communications to the appropriate connections on the encoder.
The seriallink allows the Drive (at power-up)to interrogate the SIN-COS
encoder in order to determine the initialabsolute position ofthe encoder
shaft.When the interrogation is completed,the seriallink is disabled.
If the serial link fails, the Drive will trip, showing trip codeSEPEC.
When a SIN-COS encoder is used with aDrive operating in the Closed-loop
Servo mode, absolute-position and phase-offset information is always
required.In the Closed-loopVector mode for controlling an induction
motor, absolute-position and phase-offset information are optional.
When this information is not required, serial communications connections to
the encoder do not need to be made.In this case, set parameter 16.16
SIN-COS encoder – serial comms disable at 1 (otherwise a SEPECtripwill occur
at power-up).
Operating mode Terminals
46,47 Parameter 16.16
Closed-loop Servo mode
Closed-loop Vector mode when absolute-position
information is required
Connect toserialcomms. port
of SIN-COS encoder 0
Closed-loop Vector mode when absolute-position
information is not required Noconnections 1

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5Setting Up the UD52
The instructions in this chapter apply when the Drive is being set up for the
first time with aUD52fitted.
5.1 Initial setting up
The default supply voltage to the encoder from terminal 45 is +5.15V. If the
encoder requires 8V, set parameter 16.15 SIN-COS encoder– voltage select
at 1.
Enter the number oflines per revolution for the SIN-COS encoder in
parameter 16.12 SIN-COS encoder – No. of lines per revolution. Thevaluecan
be onlyapower of2.
5.2 Phase offset
When the Drive is operating in the Closed-loopServo mode,the phase-
offset ofthe SIN-COS encoder in relation to the motor shaft must be
entered in parameter 16.09 SIN-COS encoder – phase offset.
The phase offset can be entered in either ofthe following ways:
• Performing an encoder phasing test.The UD52measures the phase
error automaticallyand enters the value in 16.09.
• Ifthe phase offset is known, you can enter the value manuallyin
parameter 16.09.
See also Aligning the encoder mechanically in Appendix B Advanced functions.
Encoder phasing test (Closed-loop Servo mode)
Warning
During the phasing test, the motor shaft rotates slowly.
Before starting, make sure it will be safe for the motor to
be run.
During the phasing test,the motor shaft rotates in two stages,as follows:
• Initial jump in position by 1Nrevolution
• Subsequent rotation by4Nrevolution
Where Nis the number ofmotor poles.
Examples
No. of poles Initial jumpSubsequent rotation
212revolution 2 revolutions
616revolution 23revolution

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Procedure
1 Ensure the motor is unloaded (anyload will create errors in the
phase-offset measurement).
2 Set parameter 16.10 SIN-COS encoder phasing test at 1.
3 Enable the Drive.
The motor shaft rotates (as described above)and the measured value of
phase offset is automaticallyentered in parameter 16.09 SIN-COS encoder –
phase offset.
Ifaphasing test is attempted with amotor that has anyofthe following...
• High inertia
• No damping
• Small load on the shaft
...an incorrect value for the phase offset will be measured. Refer to
parameter 5.27 in theUnidrive Advanced User Guide.
Note
If the Drive trips and the display indicates trip code
ENC.PH7, this indicates either of the following:
The SINand COSinput connections from the
encoderare incorrectly made
The phase sequence ofthe motorisreversed
After correcting the connections, repeat the procedure.
Magnetizing current test (Closed-loop Vector)
Refer toAutotune in Chapter 3 Setting Up the Drive in theUnidrive User Guide,
or to parameter 5.12 in theUnidrive Advanced User Guide.Ifthe Drive trips
while Autotune is being performed see the Note above.
5.3 Position information
Counting revolutions
Single-turn encoder
Revolutions are not counted.
Multiple-turns encoder
Revolutions are indicated in parameter 16.03 SIN-COS encoder – revolution
count.When the serial communications link to the encoder is used, at
power-upthe value stored in the encoder is transferred to16.03. When
the value of16.03 reaches a maximum limit that is defined in parameter
16.13 SIN-COS encoder –No. of revolutions, 16.03 is reset and the count
starts again from zero.

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By default, 16.03 will not count.When amulti-turn encoder is used, enter
the required value in 16.13, as follows:
16.13 16.03 countsup
to... 16.13 16.03 countsup to...
008255
119511
2310 1023
37112047
415124095
531138191
6631416383
71271532767
Absolute-position parameters
When the following conditions are met...
• A compatible SIN-COS encoder is used and serial communications
connections are made
• 16.16 SIN-COS encoder – serialcomms.disableis set at 0 (default)
• 16.14 SIN-COS as reference encoder is set at 0 (default)
...the absolute position is indicated by the following parameters:
16.04 SIN-COS encoder incremental position (coarse)
16.05 SIN-COS encoder incremental position (fine)

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Using position information for orientation
The position value in parameter16.04 SIN-COS encoder incremental position
(coarse) (at 16384counts per revolution) is used as an input to the position-
control algorithms in Menu 13.This allows orientation to be performed
within one revolution.
Using position information for digital lock
The digital-lock algorithm uses onlyincremental changes in position
obtained from parameter16.04 and ignores the multi-turn information in
parameter 16.03 SIN-COS encoder – revolution count.
Only incremental digital lock is performed; multi-turn absolute orientation is
not supported.
5.4 Simulated-encoder outputs
(terminals 50, 51, 53, 54)
The simulated-encoder outputs can be connected to external equipment for
monitoring the output ofeither aSIN-COS encoder connected to the UD52
or the main encoder (Encoder 1) that is connected to the 15-wayD-type on
the Drive.Bydefault,the SIN-COS encoder is used as the source.To select
Encoder 1, set parameter 16.06 Simulated-encoder output select at 1.
Quadrature AB, or frequency and direction
Bydefault,the simulated-encoder outputs are phase-quadratureAandB
signals.For frequency(F)and direction (D)signals,set parameter 16.08
Simulated encoder – F/D output enable at 1.
Pulses per revolution
The simulated-encoder outputs are derived from the polaritychanges in the
SIN-COS encoder outputs, giving aresolution offour times the number of
encoder lines per revolution.
The number ofpulses per revolution (PPR)is dependent on the number of
lines per revolution ofthe SIN-COSencoder as well as on the value 16.07
Simulated-encoder output scaling.
Bydefault,the outputs are scaled 1:1.To change the scaling,enter the
required value in parameter 16.07 Simulated-encoder output scaling. The
scaling factor is given by the following:
1
21607[.]

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5.5 Freeze inputs
(terminals 48, 49)
If theFreeze function is required, aUD70large option module must be fitted
in the Drive in order to read the freeze position,and pass the datato the
system controller or PLC.The initiating signal for thefreeze function must
be applied to terminals 48 and 49 on the UD52.
Related UD70 parameters
_Q20%.5 Control word (bit 5)
Set at 1 for the current absolute positions ofthe feedback and reference
encoders to be entered in _Q21% and_Q22% when the Freeze input is
activated.
_Q20%.5 is reset to zero when the values have been entered.
_Q21%Feedback-encoder freeze value
UnitsEncoder lines
Range –231 to231
ResetH = S/VS= N/AP = N/A
_Q22%Reference-encoder freeze value
UnitsEncoder lines
Range –231 to231
ResetH = S/VS= N/AP = N/A
5.6 Further setting up
Refer toParameters descriptions in Chapter 6 Related Parameters for setting
upthe following:
FunctionParameter
Disable interpolation 16.17
Disableupdatingtheposition parameters when reading 16.11