Leine Linde ADS Classic User manual

MAY 2012
Part no. 640005, ver 3.0 / Specifications in this manual can be changed without prior notice.
Leine &Linde AB
T [phone] F [phone]
Box 8, SE-645 21 Strängnäs, Sweden
www.leinelinde.com [email protected]
ADS Classic
Advanced Diagnostic System
User manual

CONTENT
GENERAL ......................................................................................... 2
INSTALLATION OF ENCODER ................................................... 2
Assembly .......................................................................................... 3
Disassembly .................................................................................... 4
Electrical connection .................................................................. 4
Alarm output .................................................................................. 5
RS-232 communication ........................................................... 6
ADS PC SOFTWARE ..................................................................... 6
System requirements ................................................................. 7
Installation of software .............................................................. 7
Configuration of software ......................................................... 7
Receiving information from the encoder ............................ 8
Faults ................................................................................................. 9
ACCESSORIES ............................................................................... 11
1

GENERAL
Leine &Linde’s ADS system has been developed to permit the early detection
of fault functions internally in rotating incremental pulse encoders.
The system is based on a rapid logic in conjunction with a micro-
processor which continuously monitors the encoder’s functions and is thus
able to detect a fault function at an early stage. This takes place at such an
early stage that the encoder can continue to perform its function in the
majority of cases, and replacement of the encoder can take place sub-
sequently during a planned maintenance shutdown.
The main control system receives a message from the encoder about a
detected fault function via a signal at the encoder’s alarm output. This alarm
signal is sent to the operator who, with the help of a PC and the analysis
software of the diagnostic system, can communicate with the encoder and
establish the cause of the indicated fault. The operator is also informed of
the frequency, internal temperature and operating period at the time of the
fault. External faults can also be detected. The internal signals in the encoder
are compared with the signal that is generated in the cable. It is possible in
this way, for example, to detect an overload of the output signals from the
encoder. The analysis software can also be used to obtain information about
the total operating time and the max./min. operating temperature.
INSTALLATION OF ENCODER
Important!! When the cover of the encoder is removed, and if there is a risk
that you will come into contact with the electronics, or in conjunction with
the connection of cables, a grounding wrist strap or similar must be worn
in order to equalize the potential and to protect the encoder in this way
against ESD discharges which may damage the encoder.
Incremental encoders of model 861 are designed for assembly directly on the
drive shaft with a torque arm to prevent rotation of the encoder. This permits
simple and rapid assembly and makes the encoder insensitive to axial move-
ment of the drive shaft.
There are two alternative shaft diameters for the encoders: Ø 12 mm or
Ø 16 mm. The encoder is insulated from the drive shaft in order to prevent
currents from finding their way out from the drive shaft through the encoder
with resulting damage to the bearings in both the motor and the encoder.
The drive shafts must be made in accordance with Figure A, and it is im-
portant for the radial run-out on the drive shaft to be minimized, since a
radial run-out on the shaft gives an angular error from the encoder and
causes vibrations which can reduce the service life of the encoder.
M8-thread for disassembly
Figure B
Figure A
Assembly
The encoder is passed onto the drive shaft and is secured by pressing the
front edge of the hollow shaft with an o-ring against the abutment on the
drive shaft when the retaining screw is tightened; see Figure B.
The torque arm can be fitted
in various ways, and there are
holes with an M5 thread on
both the rear and the front
end of the encoder. It is also
possible to have an extra
torque arm angle with an M6
thread fitted to the encoder.
Account should be taken of
the fact that the mechanical
angular error reduces if a
torque arm is fitted perpen-
dicular to the centre of the
encoder and with the greatest
possible distance from the
centre.
The formula for calculating the mechanical angular error is:
Δρmek = ± 90 /π × K/R, where K is the radial run-out of the encoder and R is
the distance between the torque arm bracket and the centre of the encoder;
see Figure C.
Figure C
2 3

To obtain the total angular error, the mechanical angular error must be
added to the resolution fault in the electrical specification.
We recommend that the radial run-out measured on the encoder should
not exceed 0.1 mm.
Calculation example:
The encoder has 2048 ppr, the torque arm is fitted to the torque arm
bracket 69.5 mm from the centre of the encoder, and the measured radial
run-out on the encoder is 0.06 mm.
The mechanical angular error according to the formula is:
Δρmek = ± 90 /π × 0.06 /69.5 = ± 0.025°
The maximum encoder fault according to the specification is ± 50°el,
and it is 360°el on each pulse, which gives:
Δρel =± 360 /2048 × 50 /360 = ± 0.024°
Max. total angular error Δρ = ± 0.025 + 0.024 = ± 0.049°
It is also important for the torque arm to be fitted so that it is free from play.
Play in the torque arm of ± 0.03 mm is equivalent to run-out on the encoder
of 0.06 mm and, as the above calculation example shows, this results in a
significant angular error.
Disassembly
The hole for the retaining screw has an M8 thread, so that the M8 screw can
be used to pull the encoder from the drive shaft if it has become stuck.
Electrical connection
If the encoder is supplied without a cable, the electrical connection must be
made inside the encoder on the screw terminal block. The functions of the
various screw terminal blocks are shown on the encoder label. If the encoder
is supplied with a cable or connector, information about colours, pins and
functions are also shown on the encoder label.
Specification of screw terminal block:
Cable cross-section: 0.14 – 1.5 mm² or AWG 26 – 16
Wire end sleeve cross-section: 0.25 – 1 mm²
Stripping length: 6 mm
Tightening torque: 0.5 – 0.6 Nm
The connection of the cable gland is effected in accordance with the
exploded view in Figure D. It is important to use a screened chassis ground
at both ends in order to obtain the best EMC performance.
Alarm output
In the event of a fault in the encoder,
an alarm signal is given at an optically
isolated output. The alarm signal is
active if an interruption occurs at the
output. If a fault is detected, an inter-
ruption at the output occurs for 500-
600 ms. If the fault remains, the signal
is toggled between an active 500-600
ms and an inactive 200-300 ms. In this
way, an interruption in the supply vol-
tage can be separated from the alarm
signal from the encoder. See Figure E.
Since the alarm signal is given on
an optically isolated output, the sys-
tem which receives the alarm signal
can be galvanically separated from the
other electronics. Example of connec-
tion: See Figure F.
Figure D
500-600ms 200-300ms
Single fault
Constant fault
Power supply
failure
Alarm output
Alarm output
+EV
Alarm-
Alarm+
0V
0kW
Figure E
Figure F
4 5
LED indication
On the back cover of the encoder an LED is located for visual status indica-
tion. A fix green LED indicates that the power is supplied and that the en-
coder is functioning correctly. Fault indications follow the same logic as the
electrical alarm output: If a single fault is detected the LED will blink once,
and if a constant fault is detected the LED will blink continuously.

RS-232 communication
The analysis software is supplied with connection cabling with which a PC
is connected to the encoder through the serial port. We recommend that PC
communication should not be connected during operation.
If the encoder is supplied
with cabling, we recommend
that the connection to the PC
should be effected via a D-SUB
connector (9-pole female), for
example in a terminal box in
accordance with Figure G.
Cable colour Function Pin D-sub
Grey / Pink Rxd 3
Red / Blue Txd 2
Blue 0 V 5
Connected to one another 4
6
8
A standard extension cable, 9-pole D-sub male to 9-pole D-sub female, can be
used between the PC and the above connection.
Note that the length between the encoder and the PC must not exceed 10 m.
ADS PC SOFTWARE
A PC program with which information from the encoder about the operating
conditions and any faults can be received is provided for communication
with the ADS encoder. Your PC is connected to the encoder via the serial port
using the special cable supplied or a standard RS-232 cable in accordance
with the example in the Installation Specification. Communication takes
place with an RS-232 interface. Note that the maximum cable length
between the encoder and the PC is 10 m.
Content
• Diskette with PC software. Part No. 01290021
• Manual Advanced Diagnostic System.
• RS-232 cable 9-pole D-sub female – connector to the encoder.
Part No. 01209083
ADS encoder
Coupling Box
RS 232 communication
Incremental signals
Figure G
System requirements
• PC with at least a 486 processor.
• Windows 95, 98 or NT.
Installation
1. Insert the diskette in the diskette drive.
2. Select the diskette drive in the Program Manager.
3. Start the file..\setup.exe
4. Follow the instructions.
Configuration of software
1. Start \Diagnostik.exe
Select settings.
See Figure H.
2. Set the COM port that you are using.
Set the frequency with which you require the information to be updated
for repeated updating.
Indicate the language that you wish to use, Swedish or English.
It is also possible to communicate via a modem installed in Windows and
an RS-232 modem via the telephone line. The software then calls the
indicated telephone number and starts the communication when the
”Online” key is pressed. We recommend a maximum updating speed of
1.0 s when a modem is in use.
See Figure I.
Figure H
Figure I
6 7

Receiving information from the encoder
1. Connect an RS-232 cable between the encoder and the serial port on your
PC, and switch on the power supply to the encoder.
2. Press ”Online”, and information about the encoder part number and serial
number, the versions of the hardware and software and the resolution are
then displayed in the information window.
3. Press ”Rep. update”, and information about the operating time, the
frequency of the incremental signals and the temperature internally in
the encoder are then displayed. The information is updated at the speed
entered in the configuration of the software. The highest and lowest
measured temperatures are also displayed. The lowest temperature is
updated only if the temperature is below 0°C. The highest temperature
internally in the encoder must not exceed 100°C (ambient temperature
+ ca. 20°C self-heating), and the lowest must not be below –20°C.
See Figure J.
Any faults that are detected are displayed under ”Stored faults”. Mark the
fault by clicking with the mouse cursor on the fault and click on ”Open” to
obtain more detailed information about the fault.
The fault is presented together with the operating time, frequency and the
internal temperature when the fault is first detected. The same fault is
stored only on a single occasion unless another fault is stored subsequently.
Sufficient memory capacity is available for the storage of 13 faults, and only
the latest faults is stored if a greater number of faults occur.
Faults
1. Fault status 04, State transition fault.
The change of state at channel 1 and 2 is normally changed in accordance
with the green arrows, see Figure K, and the alarm signal is activated if
the state is changed in accordance with the red arrows.
Cause: This fault can occur if the encoder is rotated too fast, if the optics
is damaged or if the bearings are worn out.
00
01
11
10
Figure K
2. Fault status 08, Zero pulse absent.
This is activated if no zero pulse is obtained before the ADS system has
counted twice the resolution the encoder shall have.The encoder must be
rotated through one additional revolution from the point at which the
zero pulse is absent before the fault is activated. This is the case if the
encoder is rotated in the direction that was determined for the first
counting pulse after the zero pulse. If the direction of rotation is changed
so that counting goes towards 0, and if a zero pulse is absent at 0, the
alarm signal will be activated directly.
Cause: This fault can occur if the optics or the electronics are damaged
or if the bearings are worn out.
8 9
00
01
10
11
Figure J

3. Fault status 10, Missing incremental pulses.
All increments between 2 zero pulses is checked, and the resolution must
then be the encoder’s resolution or 0. The fault often occurs in conjunc-
tion with 04, Condition fault, see Point 1.
Cause: This fault can occur if the optics is damaged or if the bearings are
worn out.
4. Fault status 20, Incremental overflow (too many pulses).
All increments between 2 zero points is checked, and the resolution must
then be the encoder’s resolution or 0.
Cause: This fault can occur if the optics are faulty or damaged. Electro-
magnetic disturbances in the environment, which exceed the relevant
standards, can also give rise to this fault.
5. Fault status 30, Failure in LED unit.
Monitoring of the function of the LED unit.
Cause: This fault occurs if the electronics are damaged.
6. Fault status 40, Faulty output signal for the incremental signals.
The incremental signals internally in the encoder are compared with the
signals that are sent out on the cable. If these signals do not match, the
encoder will operate normally internally, but the signal that is sent out
from the encoder will not be correct or will be absent.
External incremental signals are not checked at a signal frequency higher
than 40 kHz, since there is a risk that an alarm signal will be given even if
no fault has occurred.
Cause: This fault occurs if the electronics are damaged, if the encoder
outputs are overloaded or short-circuited, if the ambient temperature is
too high or as a consequence of some other fault in the optics.
7. Fault status 80, Faulty output signal for the zero pulse.
The zero pulse signal internally in the encoder is compared with the
signal that is sent out on the cable. If these signals do not match, the
encoder will operate normally internally, but the signal that is sent out
from the encoder will not be correct or will be absent.
The external zero pulse is not checked at a signal frequency higher than
40 kHz, since there is a risk that an alarm signal will be given even if no
fault has occurred.
Cause: This fault occurs if the electronics are damaged, if the encoder
outputs are overloaded or short-circuited, or if the ambient temperature
is too high.
ACCESSORIES
Description Part number
Torque arm M5 01208013
Torque arm M6 01208014
10 11