Motrona ZD Series User manual

ZD340_07d_e.doc / Apr-17 Page 1 / 50
Series ZD / ZA / ZR 330 – 644
High Speed Position Counters and
Differential Counters with two Encoder Inputs
•Electronic counter series for high-end applications
•Two independent encoder inputs, each with channels A, /A, B, /B ,
1 MHz of counting capability and individual impulse scaling facility
•Selectable operating modes for fast position or event counter, summing counter,
differential counter, cutting length indicator, diameter calculator and more
•4 preset levels with high-speed power transistor outputs
•RS232 interface and high-speed analogue output available, RS485 (only ZR)
•Choice of 6-decade display (15 mm, 0.56’’) or 8-decade display (10 mm, 0.36’’)
Operating Instructions
3046 Home Road. Powell, OH 43065 P: [phone] F: [phone] www.GenesisAutomationOnline.com [email protected]
www.GenesisAutomationOnline.com

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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 –
General instructions for cabling, screening and grounding can be found in the
SUPPORT section of our website http://www.motrona.com
Version:
Description:
ZD34001b/Mai06/hk/kk/af First edition
ZD34002a/Jul06/af/hk Extended modes of operation
ZD34003a/Aug06/hk Models ZA_xxx and models xx_330 included
ZD34003c/May06/af/hk Analogue output assignment, Preset calculation, Serial appendix
ZD34003d/Feb08/hk Motrona version with small corrections and modifications
ZD34005a/Sept08/hk Dual counter mode (mode 10), small corrections
ZD34005b/Dec08/hk Several amendments, additional clarifications
ZD34007a/Dec10/kk/hk Parameter "Display Update Time", correction of default values, amendments,
serial codes added to parameter lists
ZD34007b/Jan12/sm Additions for using Namur sensors and type definitions
ZD34007c/June12/pp Corrected images in chapter 1 and 7.2
ZD34007d/April17/cn Control Commands update

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Table of Contents
1. Available Models................................................................................................................4
2. Introduction.........................................................................................................................6
3. Electrical Connections.........................................................................................................7
3.1. Power Supply ...................................................................................................................9
3.2. Auxiliary Outputs for Encoder Supply..............................................................................9
3.3. Impulse Inputs for Incremental Encoders ........................................................................9
3.4. Control Inputs Cont.1 – Cont.4 ........................................................................................9
3.5. Switching Outputs K1 – K4............................................................................................10
3.6. Serial Interface ..............................................................................................................10
3.7. Fast Analogue Output ....................................................................................................10
4. Operating Modes of the Counter.......................................................................................11
4.1. “Single Mode” (Encoder 1 only): F07.062 = 0 ...............................................................12
4.2. “Sum Mode” (Encoder 1 + Encoder 2): F07.062 = 1 ......................................................13
4.3. Differential Mode (Encoder 1 – Encoder 2): F07.062 = 2 ..............................................14
4.4. Master Counter and Integrated Batch Counter: F07.062 = 3 ........................................15
4.5. Evaluation of the Real Cutting Length: F07.062 = 4......................................................16
4.6. Diameter Calculation with Winding Rolls: F07.062 = 5 ................................................17
4.7. Radius Calculation with Winding Rolls: F07.062 = 6 ....................................................18
4.8. Cut-to-Length Control Counter: F07.062 = 7 or 8 ..........................................................19
4.9. Monitor for Slip, Torsion, Skew Position, Shaft Fracture: F07.062 = 9.........................21
4.10. Dual Counter, Two Independent Counters for Encoders 1 and 2: F07.062 = 10 ..........22
5. Keypad Operation .............................................................................................................23
5.1. Normal Operation ..........................................................................................................23
5.2. General Setup Procedure...............................................................................................23
5.3. Direct Fast Access to Presets ........................................................................................24
5.4. Change of Parameter Values on the Numeric Level .....................................................25
5.5. Code Protection against Unauthorized Keypad Access ................................................26
5.6. Return from the Programming Levels and Time-Out Function ......................................26
5.7. Reset all Parameters to Factory Default Values ...........................................................26
6. Menu Structure and Description of Parameters ................................................................27
6.1. Summary of the Menu ...................................................................................................27
6.2. Description of the Parameters.......................................................................................30
6.3. Clarification of the Counter Setting Functions..............................................................39
7. Appendix for models ZD 6xx and ZA 6xx ...........................................................................40
7.1. Relay Outputs.................................................................................................................40
7.2. Front Thumbwheel Switches .........................................................................................40
7.3. Specific Parameters for Units with Thumbwheel Switches .........................................41
8. Appendix: Serial Communication Details ..........................................................................43
8.1. Setup of the Counter by PC............................................................................................43
8.2. Automatic and Cyclic Data Transmission......................................................................44
8.3. Communication Protocol................................................................................................44
8.4. Serial Register Codes ....................................................................................................46
9. Specifications ...................................................................................................................48
10. Dimensions.......................................................................................................................49

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1. Available Models
The ZD, ZA and ZR counter series include a range of models with similar functions and
properties, but with different housings, displays and outputs.
ZA counters provide an additional high-speed analogue output which is not available with the
ZD or ZR models. However the ZR models have an additional RS485 interface, but otherwise all
details between ZD, ZA and ZR models are fully similar.
The following table explains the details of type designation and the possible options:
Z = electronic counter
D = display only, no analogue output
A = display and high-speed analogue output
R = display and RS-485 interface
3 = housing 96 x 48 mm (3.780 x 1.890’’)
and 4 high-speed transistor outputs
6 = housing 96 x 96 mm (3.780 x 3.780’’)
with 4 high-speed transistor outputs
and 4 relay outputs
3 = display 8 decades 9.15 mm/0.36’’ size
0 = no thumbwheel switches on front
2 = two thumbwheel sets (4 decade each)
4 = four thumbwheel sets (4 decade each)
ZD 330

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The following models are available:
ZD 330, ZA 330, ZR 330 ZD 340, ZA 340, ZR 340
ZD 630, ZA 630, ZR 630 ZD 640, ZA 640, ZR 640
ZD 632, ZA 632, ZR 632 ZD 642, ZA 642, ZR 642
ZD 634, ZA 634, ZR 634 ZD 644, ZA 644, ZR 644
Number and combination of front thumbwheels according to customer specification, see section 7.2

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2. Introduction
The counters of series ZD, ZA and ZR have been designed to close a gap with multiple counting
applications, which cannot be accomplished by the normal industrial electronic counters
available on the market.
A continual demand for increasing production speeds and higher precision at the same time
results in counting frequencies exceeding the conventional frequency range.
Particularly with fast running procedures it is most important to also have fast response of the
switching outputs or the analogue output.
Many applications require to evaluate the signals of two incremental measuring systems, and
to compare the results with respect to the sum or the difference or the ratio of the two
positions. This is e.g. necessary for calculation of diameters of winding rolls etc.
Still there exist applications where the use of traditional thumbwheel switches offers real
advantages compared to keypad and menu operations.
These are some of the reasons why the new counter series ZD, ZA and ZR have been designed.
•This manual at first provides all basic instructions for operation of the
counter models presented in the previous chapter
•For operation of relay outputs and thumbwheel switches (if applicable)
please observe the supplementary instructions given in the appendix
•For easy PC setup and PC communication with ZD and ZA counters, please
use our “OS32” operator software (free of charge, download from our
homepage www.motrona.com
•Where you like to have free serial access to the unit by PLC or IPC or by a
remote operator terminal, please observe the serial protocol details
described in our separate manual “Serpro”
•Subsequently the manual uses the expression ZD340 as a replacement for
all available models. However, statements are fully valid for the other
models too, except where especially remarked.

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3. Electrical Connections
Series "
Z
D"
Series "
Z
A"
Series "
Z
R"
*) Interface 1:
- n.c. - Analogue output 0/4 - 20 mA RS 485, B (-)
*) Interface 2:
- n.c. - Analogue output +/- 10 V RS 485, A (+)
+5
-
A
/A
B
/B
+5
-
A
/A
B
/B
Encoder1*
Encoder 2*
Cont1
Cont2
Cont3
Cont4
Digital
Control
Inputs
RxD
TxD
GND
RS232
-
+24 V DC
Power supply
Co m+ (K1 - K 4)
K1 out
K2 out
K3 out
K4 out
Fast
transistor
outputs
+24
+24
0V, GND
Interface 1 *)
PROG
18
24
23
20
19
22
21
11
12
6
5
27
28
30
3
31 17 1
4
29
26
25
7
8
32
2
16 Interface 2 *)
15
14
13
10
9
∼ ∼ 24 V AC
*) Example sho ws wiring
for e ncoders with 5volts
power supply and RS422
line driver output
17 18 19 20 21 22 23 24 25 26 27 28 29 30 31 32
1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16
GND
GND
GND
GND
GND
+Vin
+5,2V aux.out +5,2V aux. out
+24V aux.out + 24V aux. out
Encoder2 B
Encoder2 A
Encoder1 B Encoder1 A E ncoder1 /A
Encoder1 /B
Encoder2 /A Encoder2 /B
K2 out K1 out K3 out
K4 out
Cont. 1
Cont. 2 Cont. 4
Cont. 3
Com+ (K1-K4)
T xD (RS232) RxD (RS232)
PROG
X1
X2
Interface 2*) Interface 1*)

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Terminal
Name
Function
01
GND
Common Ground Poten
tial (0V)
02
+5,2V out
Aux. output 5.2V/150 mA for encoder supply
03
+24V out
Aux. output 24V/120 mA for encoder supply
04
GND
Common Ground Potential (0V)
05
Encoder 2, /B
Encoder 2, channel /B (B inverted)
06
Encoder 2, /A
Encoder 2, channel /A (A
inverted)
07
Encoder 1, /B
Encoder 1, channel /B (B inverted)
08
Encoder 1, /A
Encoder 1, channel /A (A inverted)
09
K4 out
Output K4, transistor PNP 30 volts, 350 mA
10
K3 out
Output K3, transistor PNP 30 volts, 350 mA
11
Cont.4
Digital control input
12
Cont.3
Digital control input
13
(PROG)
(for download of new firmware only, not for general use)
14
RxD
Serial RS232 interface, input (Receive Data)
15
Ana.out 20 mA
Analogue current output 0
–
20 mA or 4
–
20 mA (optional)
16
Ana.out +/
-
10V
Analog
ue voltage output
-
10V … 0 … +10V (optional)
17
+Vin
Power supply input, +17
–
40 VDC or 24 VAC
18
+5,2V out
Aux. output 5,2V/150 mA for encoder supply
19
+24V out
Aux. output 24V/120 mA for encoder supply
20
GND
Common Ground Potential (0V)
21
Enc
oder 2, B
Encoder 2, channel B (non
-
inverted)
22
Encoder 2, A
Encoder 2, channel A (non
-
inverted)
23
Encoder 1, B
Encoder 1, channel B (non
-
inverted)
24
Encoder 1, A
Encoder 1, channel A (non
-
inverted)
25
K2 out
Output K2, transistor PNP 30 volts, 350
mA
26
K1 out
Output K1, transistor PNP 30 volts, 350 mA
27
Cont.2
Digital control input
28
Cont.1
Digital control input
29
Com+ (K1
-
K4)
Common positive input for transistor outputs K1
-
K4
30
TxD
Serial RS232 interface, output (Transmit Data)
31
GND
Co
mmon Ground Potential (0V)
32
GND
Common Ground Potential (0V) for DC or AC power supply
*) 120 mA and 150 mA are per encoder, i.e. total maximum currents are 240 mA and 300 mA

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3.1. Power Supply
The ZD340 counter accepts both, a 17 – 40 volts DC power or a 24 volts AC power for supply
via terminals 17 and 1. The current consumption depends on the level of the input voltage and
some internal conditions; therefore it can vary in a range from 100 – 200 mA (aux. currents
taken from the unit for encoder supply not included).
3.2. Auxiliary Outputs for Encoder Supply
Terminals 2 and 18 provide an auxiliary output with approx. +5.2 volts DC (300 mA totally).
Terminals 3 and 19 provide an auxiliary output with approx. +24 volts DC (240 mA totally)
3.3. Impulse Inputs for Incremental Encoders
All input characteristics of the impulse inputs can be set by the parameter menu, for each of
the encoders separately. Depending on the application the unit can accept single channel
information (input A only) or quadrature information (A / B, 90°). The following settings are
possible:
•Symmetric input (differential) according to RS422 standard (min. differential voltage 1 V)
•TTL inputs at a level of 3.0 to 5 volts (differential, with inverted signal)
•TTL inputs at a level of 3.0 to 5 volts (single-ended) *)
•HTL signals at a 10 – 30 volts level
(alternatively differential with inverted signals A, /A, B, /B, or single-ended A, B only)
•Impulses from photocells or proximity switches etc. providing a HTL level (10 – 30 volts)
•Proximity switches according to NAMUR (2-wire) standard have an input level of 5,8V
respectively 19,4V. For a save crossover point set the threshold setting of the used input
to the value 200. *)
All encoder input lines are internally terminated by pull-down resistors ( 8,5 kΩ).
Where encoders with pure NPN outputs are used, corresponding pull-up resistors must be
available inside the encoder or externally to ensure proper function (1 kΩ... 3,3 kΩ).
3.4. Control Inputs Cont.1 – Cont.4
These inputs can be configured for various remote functions like Reset, Set, Latch, and Inhibit
or switch-over purpose.
All control inputs require HTL level. They can be individually set to either NPN (switch to -) or
PNP (switch to +) characteristics. For applications where edge-triggered action is needed, the
menu allows to set the active edge (rising or falling). Control inputs also accept signals with
Namur (2-wire) standard. For reliable operation the minimum pulse width on the control inputs
should be 50 µsec.
*) requires special settings of the threshold parameters, see “Special parameters F04”

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3.5. Switching Outputs K1 – K4
ZD340 provides four presets and outputs with programmable switching characteristics.
K1 – K4 are fast-switching and short-circuit-proof transistor outputs with a switching capability
of 5 – 30 volts / 350 mA each. The switching voltage of the outputs must be applied remotely
to the Com+ input (terminal 29)
3.6. Serial Interface
The serial RS232 and RS485 interface can be used for the following purposes:
•Set-up of the unit by PC (if desirable), by means of the OS32 PC software
•Change of parameters during operation
•Readout of actual counter or other values by PLC or PC
The figure below explains the connection between the ZD340 counter and a PC using the
standard Sub-D-9 serial connector, and the connection via RS485 terminals to a PLC.
For details of serial communication, please refer to section 10.
2
3
5
RxD RxD
TxDTxD
GND
Screen
PC
ZD 340
ZA 340
ZR 340
14
(Sub-D-9)
30
31
RS 232
PLC
ZR 340 16
15
RS 485
A(+)
B(-)
A
B
Where both, RS232 and RS485 interface are in use, you can communicate by the one or
by the other, but not by both interfaces at the same time
3.7. Fast Analogue Output
An analogue output is available with all ZA models, providing a voltage output of +/- 10 volts
(Load = 3 mA), and a current output of 0 – 20 mA or 4 – 20 mA (load = 0 – 270 Ohms). All output
characteristics like beginning of conversion range, output swing etc. are freely programmable
via menu. The response time of the analogue output is less than 1 msec. (time from encoder
event to analogue out). The resolution is 14 bits.
Please note that extensive serial communication with the unit may temporary increase the
analogue response time.