Control Techniques SM-Encoder Plus User manual

EF
www.controltechniques.com
User Guide
SM-Encoder
Plus
Solutions Module for
Unidrive SP
Part Number: 0471-0026-03
Issue Number: 3

General Information
The manufacturer accepts no liability for any consequences resulting from inappropriate, negligent
or incorrect installation or adjustment of the optional operating parameters of the equipment or from
mismatching the variable speed drive with the motor.
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 parts of this guide may be reproduced or transmitted in any form or by any
means, electrical or mechanical including photocopying, recording or by an information storage or
retrieval system, without permission in writing from the publisher.
Drive software version
The SM-Encoder Plus can only be used with drive software version 01.02.00 onwards.
Copyright © September 2004 Control Techniques Drives Ltd
Issue Code: 3

SM-Encoder Plus User Guide
Issue Number: 3 www.controltechniques.com
Contents
1 How to use this guide ................................................... 4
1.1 Intended personnel ................................................................................. 4
1.2 Information .............................................................................................. 4
2 Safety information ......................................................... 5
2.1 Warnings, Cautions and Notes ............................................................... 5
2.2 Electrical safety - general warning .......................................................... 5
2.3 System design and safety of personnel .................................................. 5
2.4 Environmental limits ................................................................................ 6
2.5 Compliance with regulations ................................................................... 6
2.6 Motor ....................................................................................................... 6
2.7 Adjusting parameters .............................................................................. 6
3 Introduction .................................................................... 7
3.1 Features .................................................................................................. 7
3.2 Solutions Module identification ................................................................ 7
3.3 Set-up parameters .................................................................................. 8
3.4 Compatible with encoder types ............................................................... 8
4 Installing the SM-Encoder Plus .................................. 10
4.1 Solutions Module slots .......................................................................... 10
4.2 Installation ............................................................................................. 10
4.3 Terminal descriptions ............................................................................ 12
4.4 Wiring, Shield connections .................................................................... 12
5 Getting started ............................................................. 17
5.1 Installation ............................................................................................. 17
5.2 SM-Encoder Plus set-up ....................................................................... 18
5.3 Freeze function ..................................................................................... 18
6 Parameters ................................................................... 19
6.1 Introduction ........................................................................................... 19
6.2 Single line descriptions ......................................................................... 21
6.3 Parameter descriptions ......................................................................... 26
7 Diagnostics .................................................................. 32
7.1 Displaying the trip history ......................................................................32
8 Terminal data ............................................................... 35
8.1 Encoder inputs ...................................................................................... 35
Index ............................................................................. 36

4SM-Encoder Plus User Guide
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1 How to use this guide
1.1 Intended personnel
This guide is intended for personnel who have the necessary training and experience in
system design, installation, commissioning and maintenance.
1.2 Information
This guide contains information covering the identification of the Solutions Module,
terminal layout for installation, fitting of the Solutions Module to the drive, parameter
details and diagnosis information. Additional to the aforementioned are the
specifications of the Solutions Module.

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2 Safety information
2.1 Warnings, Cautions and Notes
2.2 Electrical safety - general warning
The voltages used in the drive can cause severe electrical shock and/or burns, and
could be lethal. Extreme care is necessary at all times when working with or adjacent to
the drive.
Specific warnings are given at the relevant places in this User Guide.
2.3 System design and safety of personnel
The drive is intended as a component for professional incorporation into complete
equipment or a system. If installed incorrectly, the drive may present a safety hazard.
The drive uses high voltages and currents, carries a high level of stored electrical
energy, and is used to control equipment which can cause injury.
Close attention is required to the electrical installation 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 by personnel
who have the necessary training and experience. They must read this safety information
and this User Guide carefully.
The STOP and SECURE DISABLE functions of the drive do not isolate dangerous
voltages from the output of the drive or from any external option unit. The supply must
be disconnected by an approved electrical isolation device before gaining access to the
electrical connections.
With the sole exception of the SECURE DISABLE function, none of the drive
functions must be used to ensure safety of personnel, i.e. they must not be used
for safety-related functions.
Careful consideration must be given to the functions of the drive which might result in a
hazard, either through their intended behaviour or through incorrect operation due to a
fault. In any application where a malfunction of the drive or its control system could lead
to or allow damage, loss or injury, a risk analysis must be carried out, and where
necessary, further measures taken to reduce the risk - for example, an over-speed
protection device in case of failure of the speed control, or a fail-safe mechanical brake
in case of loss of motor braking.
A Warning contains information, which is essential for avoiding a safety hazard.
A Caution contains information, which is necessary for avoiding a risk of damage to the
product or other equipment.
A Note contains information, which helps to ensure correct operation of the product.
WARNING
CAUT ION
NOTE

6SM-Encoder Plus User Guide
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The SECURE DISABLE function has been approved1as meeting the requirements of
EN954-1 category 3 for the prevention of unexpected starting of the drive. It may be
used in a safety-related application. The system designer is responsible for
ensuring that the complete system is safe and designed correctly according to
the relevant safety standards.
1Independent approval by BIA has been given for sizes 1 to 3.
2.4 Environmental limits
Instructions in the Unidrive SP User Guide regarding transport, storage, installation and
use of the drive must be complied with, including the specified environmental limits.
Drives must not be subjected to excessive physical force.
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 of
conductors, the selection of fuses or other protection, and protective earth (ground)
connections.
The Unidrive SP User Guide contains instruction 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:
98/37/EC: Safety of machinery.
89/336/EEC: Electromagnetic Compatibility.
2.6 Motor
Ensure the motor is installed in accordance with the manufacturer’s recommendations.
Ensure the motor shaft is not exposed.
Standard squirrel cage induction motors are designed for single speed operation. If it is
intended to use the capability of the drive to run a motor at speeds above its designed
maximum, it is strongly recommended that the manufacturer is consulted first.
Low speeds may cause the motor to overheat because the cooling fan becomes less
effective. The motor should be fitted with a protection thermistor. If necessary, an
electric forced vent fan should be used.
The values of the motor parameters set in the drive affect the protection of the motor.
The default values in the drive should not be relied upon.
It is essential that the correct value is entered in parameter 0.46 motor rated current.
This affects the thermal protection of the motor.
2.7 Adjusting parameters
Some parameters have a profound effect on the operation of the drive. They must not
be altered without careful consideration of the impact on the controlled system.
Measures must be taken to prevent unwanted changes due to error or tampering.

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3Introduction
3.1 Features
The SM-Encoder Plus provides an interface for an additional encoder to be connected
to the Unidrive SP, to be used as position and speed feedback for the drive. Typical
uses for the SM-Encoder Plus would be to input a speed/position reference from a line
speed encoder, or to digitally lock the drive to a master reference using the position
controller in drive menu 13.
All three Solutions Module slots can be fitted with SM-Encoder Plus modules.
Figure 3-1 SM-Encoder Plus
3.2 Solutions Module identification
The SM-Encoder Plus can be identified by:
1. The label located on the underside of the Solutions Module.
2. The colour coding across the front of the Solutions Module. All Unidrive SP
Solutions Modules are colour coded, with the SM-Encoder Plus being brown.
Figure 3-2 SM-Encoder Plus label
3.2.1 Date code format
The date code is split into two sections: a letter followed by a number.
The letter indicates the year, and the number indicates the week number (within the
year) in which the Solutions Module was built.
The letters go in alphabetical order, starting with A in 1990 (B in 1991, C in 1992 etc.).
Example:
A date code of L35 would correspond to week 35 of year 2002.
The SM-Encoder Plus does not have any simulated encoder outputs available.
NOTE
SM-Encoder Plus
Issue: 0 STDJ41
Ser No : 3000005001
Solutions Module
name
Customer
and date code
Serial number
Issue
number

8SM-Encoder Plus User Guide
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3.3 Set-up parameters
All parameters associated to the SM-Encoder Plus can be found in either menu 15, 16,
or 17. Each of menus 15, 16, and 17 refer to one of the available slots into which the
SM-Encoder Plus can be fitted. Slot 1 = Menu 15, Slot 2 = Menu 16, Slot 3 = Menu 17.
3.4 Compatible with encoder types
The SM-Encoder Plus will allow for the following encoders to be used with Unidrive SP:
Incremental encoders Ab, Fd, and Fr
This type of encoder gives incremental position and can only be used for control in
Closed Loop Vector and not Servo mode.
Ab, Fd, Fr
Quadrature detection logic determines rotation from the phase relationship of the two
channels. These encoders are available with a marker pulse, which identifies each
individual rotation of the disc, and is also used to reset the drive position parameter. The
incremental encoder can be used when operating in Closed Loop Vector mode, with the
optional marker pulse not being required for correct operation.
* Max input frequency = LPR x rpm / 60
Type Encoder Description Pr x.15
Incremental
Ab Quadrature incremental encoder.
With or without marker pulse. 0
Fd Incremental encoder with frequency and direction outputs.
With or without marker pulse. 1
Fr Incremental encoder with forward and reverse outputs.
With or without marker pulse. 2
Limitations
Type Encoder Max Input
Frequency
Max no. of
Lines (LPR)
Incremental
Ab
600kHz* 16,384Fd
Fr
The maximum speed in rpm which an encoder connected to the SM-Encoder Plus can
reach can be calculated from :
Max rpm = (60 x Max input frequency) / Encoder LPR
e.g. For a 4096 line encoder the maximum rpm would be:
(60 x 600 x 103) / 4096 = 8789rpm
NOTE

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Figure 3-3 Encoder feedback signals
Incrementa
l
signals
360 electrical (encoder) °
90 separation of A and B °
A
/A
B
/B
Z
/Z
Marker
signals
Index
alignment
reference
min max
Only encoders with lines per revolution that are a power of 2 can be used with the SM-
Encoder Plus, e.g. 256, 512, 1024 etc.
The marker pulse duration must be between 45° to 360° electrical (encoder).
NOTE

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4 Installing the SM-Encoder Plus
4.1 Solutions Module slots
There are three slots available, which the Solutions Module can be plugged into as
shown in Figure 4-1. The Solutions Module can be plugged into either one of these, but
it is recommended that slot 3 be used for the first Solutions Module then slot 2 and slot
1. This ensures maximum mechanical support for the Solutions Module once fitted.
Figure 4-1 Location of slots 1, 2 and 3 on the Unidrive SP
4.2 Installation
1. Before installing the SM-Encoder Plus in the Unidrive SP, ensure the AC supply has
been disconnected from the drive for at least 10 minutes.
2. Ensure that both the +24V, and +48V backup power supplies are disconnected from
the drive for at least 10 minutes if used.
3. Check that the exterior of the SM-Encoder Plus is not damaged, and that the multi-
way connector is free from dirt and debris.
4. Do not install a damaged or dirty SM-Encoder Plus in the drive.
5. Remove the terminal cover from the drive. (For removal / re-fitting instructions, see
Unidrive SP Solutions Module Installation Sheet provided with the Solutions
Module.)
6. Position the drive connector of the SM-Encoder Plus over the connector of the
appropriate slot in the drive and push downwards until it locks into place.
Before installing the SM-Encoder Plus, refer to Chapter 2 Safety information on page 5.
WARNING
Solutions Module
slot 1 (Menu 15)
Solutions Module
slot 2 (Menu 16)
Solutions Modul
e
slot 3 (Menu 17)

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Figure 4-2 Fitting the SM-Encoder Plus
7. Re-fit the terminal cover to the drive. (For removal / re-fitting instructions, see
Unidrive SP Solutions Module Installation Sheet provided with the Solutions
Module.)
8. Connect the AC supply to the drive.
9. Set Pr 0.49 to L2 to unlock read only security.
10. Check that Menu 15 (slot 1), 16 (slot 2), or 17 (slot 3) parameters are now available.
11. Check that Pr 15.01, Pr 16.01 or Pr 17.01 shows the correct code for the SM-
Encoder Plus (code = 104).
12. If the checks in steps 10 and 11 fail, either the SM-Encoder Plus is not fully inserted,
or the Solutions Module is faulty.
13. If a trip code is now present refer to Chapter 7 Diagnostics on page 32.

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4.3 Terminal descriptions
Figure 4-3 SM-Encoder Plus terminals
Table 4.1 SM-Encoder Plus terminal descriptions
Figure 4-4
4.4 Wiring, Shield connections
Shielding considerations are important for PWM drive installations due to the high
voltages and currents present in the output circuit with a very wide frequency spectrum,
typically from 0 to 20 MHz. Encoder inputs are liable to be disturbed if careful attention
is not given to managing the cable shields.
Encoder mounting methods
There are three methods for mounting an encoder onto a motor:
1. Galvanic isolation between encoder and motor
2. Galvanic isolation between encoder circuit and encoder body
3. No Isolation
Term Encoder
Ab Fd Fr
1A F F
2A\ F\ F\
3B D R
4B\D\R\
5Z
6Z\
70V
8 External power supply decoupling
PL
1
12345678
Terminal 8 should be used to join the external encoder power supply to the encoder as
shown in Figure 4-4. If the drive encoder supply is to be used for two encoders, the user
must ensure the total load does not exceed 300mA for 5V and 8V encoders and 200mA
for 15V encoders.
NOTE
0V +V
Screen
connection
External encode
r
power supply

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4.4.1 Encoder with galvanic isolation from motor
When galvanically isolated the encoder device is mounted to the motor with isolation
fitted between the motor housing / shaft and encoder as shown in Figure 4-5.
Figure 4-5 Galvanic Isolation from motor
An example of this is the Unimotor where isolation from the motor is achieved by
inserting a plastic mounting plate between the motor housing and encoder housing and
a plastic insert fitted in the motor shaft for encoder mounting to the motor shaft. With this
preferred method of mounting noise current is prevented from passing from the motor
housing into the encoder housing, and hence into the encoder cable. The ground
connection of the cable shield is optional, this may be required to comply with safety
measures or to reduce radiated radio frequency emissions from either the drive or
encoder.
4.4.2 Encoder circuit with galvanic isolation from encoder body
In this case the encoder device is mounted directly on the motor housing with contact
being made between the motor housing/shaft and encoder. With this mounting method
the encoder internal circuits are exposed to electrical noise from the motor housing
through the stray capacitance, and they must be designed to withstand this situation.
However this arrangement still prevents large noise currents from flowing from the
motor body into the encoder cable. The ground connection of the cable shield is
optional, this may be required to comply with safety measures or to reduce radiated
radio frequency emissions from either the drive or encoder.
0V
+5V
0V
+5V
0V
+5V
B
B
Z
Z
A
A
Motor
Shaft
Motor
Housing
Encoder
Housing
Isolation
between motor housing
and encoder housing
Encoder
Body
Isolation
between motor shaft
and encoder
Encoder
Connection
Encoder
Circuit

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Figure 4-6 Encoder galvanically isolated from encoder body
4.4.3 No isolation
As shown in Figure 4-7 the encoder 0V connection may be permanently connected to
the housing. This has the advantage that the encoder body can form a shield for its
internal circuits. However it permits noise current from the motor body to flow into the
encoder cable shield. A good quality shielded cable correctly terminated protects the
data against this noise current, but much more care is needed in ensuring correct cable
management than for the isolated cases.
Figure 4-7 No isolation
Motor
Shaft
Motor
Housing
Encoder
Housing
No Isolation
between motor housing
and encoder housing
No Isolation
between motor shaft
and encoder
Encoder
Connection
Stray
Capacitance
Encoder
Body
Encoder
Circuit
0V
+5V
0V
+5V
0V
+5V
B
B
Z
Z
A
A
Galvanic
Isolation
0V
+5V
0V
+5V
0V
+5V
B
B
Z
Z
A
A
Motor
Shaft
Motor
Housing
Encoder
Housing
No Isolation
between motor housing
and encoder housing
No Isolation
between motor shaft
and encoder
Encoder
Connection
Stray
Capacitance
Encoder
Body
Encoder
Circuit
0V
connected
to encoder
housing

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4.4.4 Cable requirements
All mounting methods:
• Shield connection at drive terminal to 0V
• Shield connection at encoder to 0V
• It is recommended that the shielded cable should be run in a continuous length to
the terminal, to avoid the injection of noise at intermediate pigtails and to maximise
the shielding benefit.
• The shield connections ("pigtails") to the drive and encoder should be kept as short
as possible
Mounting with no isolation:
• Shield connected to ground at both ends. The connection must be made by direct
fixing of the cable to the grounded metal parts, i.e. to the encoder body and the
drive grounding bracket, as illustrated in Figure 4.9. "Pigtails" must be avoided. The
outer sheath of the cable should be stripped back enough to allow for the ground
clamp to be fitted. The shield connection should not be broken. The ground clamps
should be located as close as possible to the drive and encoder.
• It is essential that the shielded cable should be run in a continuous length to the
terminal, to avoid the injection of noise at intermediate "pigtails" and to maximise the
shielding benefit.
Cable shield ground connection
For all mounting methods, grounding of the feedback cable shield has added benefits. It
can protect the drive and encoder from induced fast electrical transients, and prevent
radiated radio-frequency emission. However it is essential that it be carried out in the
correct manner as explained above and shown in Figure 4-9.
Recommended Cable
The recommended cable for feedback signals is a twisted pair, shielded with an overall
shield as shown below.
Figure 4-8 Feedback cable, twisted pair
Using this type of cable also allows for the connection of the outer shield to ground and
the inner shields to 0V alone at both drive and encoder end, when required.
In this case under no circumstances must the cable shield connection be omitted at
either end of the cable in this case, since the noise voltage may well be sufficient to
destroy the line driver and receiver chips in the encoder and the drive.
CAUT ION
Connecting the cable shield to ground at both ends carries the risk that an electrical fault
might cause excessive power current to flow in the cable shield and overheat the cable.
There must be an adequately rated safety ground connection between the motor/
encoder and the drive.
WARNING
Twisted
pair
cable
Twisted
p
air shield
Cable
Cable overall shield

16 SM-Encoder Plus User Guide
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Figure 4-9 Feedback cable connections
Ensure that feedback cables are kept as far away as possible from power cables and
avoid parallel routing.
NOTE
Cable
Cable
shield
T
w
i
ste
d
pair
shield
Cable
shield
Twisted
pair
shield
Connection
at motor
Connection
at drive
Ground clamp
o
n
s
hi
e
l
d
Shield
connection
to 0V
Shield
connection
to 0V

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5 Getting started
5.1 Installation
Encoder feedback and communications data is transmitted from an encoder as low
voltage analog or digital signals. Ensure that electrical noise from the drive or motor
does not adversely affect the encoder feedback. Ensure that the drive and motor are
connected as per the instructions given in Chapter 4 Electrical Installation in the
Unidrive SP User Guide, and that the encoder feedback wiring and shielding
recommendations are followed in section 4.4 Wiring, Shield connections on page 12.
The control circuits are isolated from the power circuits in the drive by basic insulation
only, as specified in IEC60664-1. The installer must ensure that the external control
circuits are insulated from human contact by at least one layer of insulation rated for use
at the AC supply voltage.
If the control circuits are to be connected to other circuits classified as Safety Extra Low
Voltage (SELV) (e.g. to a personal computer) an additional isolating barrier must be
included in order to maintain the SELV classification.
WARNING

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5.2 SM-Encoder Plus set-up
The following parameter set-up should be followed when operating with an Incremental
Encoder.
5.3 Freeze function
The SM-Encoder Plus has a freeze function, but does not have freeze inputs. The
freeze function can be activated using either the SM-Applications or SM-Universal
Encoder Plus. When a freeze signal is applied, the freeze flag (Pr x.39) is set to "ON".
When activated, the non-marker position data (Pr x.29 and Pr x.30) is transferred into
Pr x.35 and Pr x.36.
The freeze flag does not reset itself. Before carrying out consecutive freeze functions,
the SM-Encoder Plus freeze flag must be cleared by the user (Pr x.39 = "OFF").
Incremental encoders, Ab, Fd and Fr
Action Detail
Before power-up
Ensure:
• Drive enable signal is not given (terminal 31)
• Run signal is not given
• Solutions Module is fitted in appropriate slot
• Feedback device is connected
Power up drive
Ensure:
• Drive displays ‘inh’
If the drive trips see Chapter 7 Diagnostics on page 32
Error detection
Ensure:
• When operating with an SM-Encoder Plus in slot 1,2 or 3, the error detection for the
drive encoder is disabled. Pr 3.40 = 0 when no drive encoder is connected.
Slot identification
Identify which Solutions Module slot and menu are being used
• Slot 1 – Menu 15
• Slot 2 – Menu 16
• Slot 3 – Menu 17
Select Solutions
Module
Enter:
• Speed feedback selector Pr 13.04
0: Drive encoder
1: Slot 1 encoder
2: Slot 2 encoder
3: Slot 3 encoder
4: Local reference
Set-up encoder
parameters
Enter:
• Encoder type Pr x.15
0(Ab) 1(Fd) 2(Fr)
Set-up encoder
lines per revolution
• Equivalent lines per revolution Pr x.10
Set according to encoder, see below for restrictions
Initialisation Ensure:
Position feedback is initialised Pr x.45
Encoder Pr x.10 Equivalent lines per revolution
Ab Number of lines per revolution
Fd, Fr Number of lines per revolution / 2
If a SM-Universal Encoder Plus is used as a freeze input, it must be set to freeze the
drive position by setting Pr x.40 to “On”. Also, before consecutive freeze operations can
be performed in the SM-Encoder Plus, the SM-Universal Encoder Plus freeze flag (Pr
x.39) must be cleared together with the SM-Encoder Plus freeze flag (Pr x.39).
E.g. If slot 3 has a SM-Universal Encoder Plus fitted and slot 2 has an SM-Encoder Plus
fitted, Pr 16.39 and Pr 17.39 need to be set to “OFF” before another freeze function can
be performed on the SM-Encoder Plus.
NOTE

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6 Parameters
6.1 Introduction
The parameters listed in this chapter are used for programming and monitoring the SM-
Encoder Plus.
The SM-Encoder Plus is classed as a dumb module as it does not have its own
processor and as a result all parameters are updated by the drive processor.
The SM-Encoder Plus parameters are read/written by the drive background task or at
the combined update time for time critical parameters. The combined update time
depends on the number and type of dumb modules fitted to the drive. For each dumb
module the update rate of these parameters is specified as either 4 or 8ms. The
combined update time is the total of the update times for all dumb modules fitted. (E.g. if
two modules with 4ms and 8ms update times are fitted to the drive, then the combined
update time for the time critical parameters of each module will be 12ms.)
Dumb module Update time
SM-I/O Plus 8ms
SM-Encoder Plus 4ms
SM-Resolver 4ms
The same parameter structure is available in menu 15, 16 and 17 referring to slots 1, 2
and 3.
Before attempting to adjust any parameters, refer to Chapter 2 Safety information on
page 5.
NOTE
WARNING

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Table 6.1 Key to parameter coding
Coding Attribute
RW Read/write: can be written by the user
RO Read only: can only be read by the user
Bit 1 bit parameter
Bi Bipolar parameter
Uni Unipolar parameter
Txt Text: the parameter uses text strings instead of numbers.
FI Filtered: some parameters which can have rapidly changing values are
filtered when displayed on the drive keypad for easy viewing.
DE Destination: indicates that this parameter can be a destination parameter.
RA
Rating dependant: this parameter is likely to have different values and
ranges with drives of different voltage and current ratings. This parameters
is not transferred by smart cards when the rating of the destination drive is
different from the source drive.
NC Not cloned: not transferred to or from smart cards during cloning.
PT Protected: cannot be used as a destination.
US User save: saved in drive EEPROM when the user initiates a parameter
save.
PS Power-down save: automatically saved in drive EEPROM at power-down.