Motrona MM 640 User manual

control – motion – interface
motrona GmbH
Zwischen den Wegen 32
78239 Rielasingen - Germany
Tel. [phone]
Fax [phone]
[email protected]
www.motrona.com
MM64003a_e.doc / Feb-09 Page 1 / 44
MM 640
Programmable Motion Monitor for Secure and
Redundant Control of Motion Sequences
•Suitable for monitoring of overspeed, underspeed, standstill, direction of rotation,
slip, shaft or gearbox fracture, impermissible motion etc.
•Six logical inputs for plausibility considerations and control of logical conditions
•Two programmable inputs for quadrature encoders A, /A, B, /B with counting
frequencies up to 500 kHz
•Four programmable inputs for function control
•Four relay outputs and four high-speed transistor outputs with programmable
functions and switching characteristics
•Serial RS232 and RS485 interfaces for remote access
Operating Instructions

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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 –
Version: Description:
MM64001a/mb/hk_05/2008 Preliminary version
MM64001b/mb/hk_05/2008 Small corrections and improved explanations
MM64002b/mb/hk_08/2008 First final version, commands for speed selection removed
MM64003a/mb/hk_02/2009 RS485, free assignment of outputs etc.

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Table of Contents
1. Introduction and Application........................................................................................... 4
2. Block Diagram and Terminal Assignment ....................................................................... 5
2.1. Power Supply................................................................................................................................7
2.2. Auxiliary Outputs for Encoder Supply ..........................................................................................7
2.3. Impulse Inputs for Incremental Encoders.....................................................................................7
2.4. Control Inputs Input 1 – Input 4 ...................................................................................................8
2.5. Logical Inputs Login1 - 6...............................................................................................................8
2.6. Relay Outputs and Transistor Outputs.........................................................................................8
2.7. Serial Interface .............................................................................................................................9
3. Relevant Process Data and Setpoints............................................................................10
3.1. Available Actual Values .............................................................................................................10
3.2. Available Setpoints ....................................................................................................................11
3.3. Available Criteria for Combination of Switching Events ...........................................................11
3.4. Generation of an Output Signal .................................................................................................13
4. Setup of the Unit by PC..................................................................................................14
4.1. PC connection .............................................................................................................................14
4.2. The Main Screen ........................................................................................................................14
4.3. Configuration of Events and Switching Functions.....................................................................16
5. Keypad Operation ..........................................................................................................18
5.1. Normal Operation .......................................................................................................................18
5.2. General Setup Procedure............................................................................................................18
5.3. Change of Parameter Values on the Numeric Level..................................................................20
5.4. Code Protection against Unauthorized Keypad Access.............................................................21
5.5. Return from the Programming Levels and Time-Out Function ..................................................21
5.6. Reset all Parameters to Factory Default Values........................................................................21
6. Menu Structure and Description of Parameters.............................................................22
6.1. Summary of the Menu................................................................................................................22
6.2. Description of the Parameters ...................................................................................................24
7. Description of Commands..............................................................................................34
8. Hints for Scaling of the Unit ..........................................................................................36
8.1. Speed Scaling.............................................................................................................................36
8.2. Standstill Definition (Wait-Time) ...............................................................................................37
8.3. Scaling of the Position Counters................................................................................................37
9. Specifications ................................................................................................................38
10. Dimensions ....................................................................................................................39
11. Serial Code List..............................................................................................................40
11.1. Parameters and Settings............................................................................................................40
11.2. Control Commands .....................................................................................................................44
11.3. Actual Process Values ................................................................................................................44

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1. Introduction and Application
The MM640 motion monitor has been designed for monitoring and control of admissible and
impermissible operating conditions on machinery systems like conveyors, hoisting devices and
many more. This unit is not just a speed monitor, but provides comparison between peripheral
motion, motor motion and scheduled demand values of the control system. The unit is designed
to generate OK signals or alarms upon programmable peripheral conditions. It provides four
relay outputs and four transistor outputs.
6 logical inputs can pick up remote commands or peripheral states, and this information can be
included into the combination of events for setting or resetting alarms.
The example below shows a hoisting unit where a motor moves the load up and down, via
gearbox or other mechanical transmission.
UP
DOWN
Fastspeed
Break
Control System MM 640
Motor
Gearbox
Encoder 1
Encoder 2
In a situation like shown the MM640 unit could e.g. provide the following alarms:
a) The motor is in standstill, but the load is still moving (gearbox problem)
b) The speed command is “UP” but the load does not move at all or even moves into
the wrong direction
c) No speed command is applied and the break is engaged, but still the motor or the load
are moving (break problem)
d) The command is “Slow Speed Down” but the actual speed of the load exceeds the
permissible “Slow Speed” limit
e) the displacement of the load indicated by encoder 2 does not match up with the number
of pulses generated by encoder 1, with consideration of the gearbox ratio (slip problem)
Furthermore the MM640 can take over limit switch functions for the permissible upper and
lower positions of the load etc. All desired functions can be easily configured by PC, just by
clicking a few checkboxes in a “logical AND / OR” matrix on the screen.

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2. Block Diagram and Terminal Assignment
+5
-
A
/A
B
/B
+5
-
A
/A
B
/B
Encoder 1*)
Encoder 2*)
Input 1
Input 2
Input 3
Input 4
Control Inputs
RxD
TxD
GND
RS232
-
+
24 V DC
Power Supply
Com+ (K1 - K4)
Output 1
Output 2
Output 3
Output 4
High-Speed
Transistor
Outputs
+24
+24
18
24
23
20
19
22
21
11
12
6
5
27
28
3
17 1
4
29
26
25
7
8
2
10
9
24 V AC
*) The example uses TTL encoders
with a 5 volts power supply
Login 4
1
NC
C
NO
12
Rel.1
NC
C
NO
Rel.2
NC
C
NO
Rel.3
NC
C
NO
Rel.4
Logical Inputs
Login 5
Login 6
Login 1
Login 2
Login 3
X3
X4
X1 = 1 - 16
X2 = 17 - 32
10
11
9
7
8
6
4
5
3
1
2
14
30
31
2
3
4
5
615
B (-)
A (+)
RS485
17 18 19 20 21 23 24 25 26 27 28 29 30 31 32
1234567 891011 12 13 14 15 16
Rel.1Rel.2Rel.3Rel.4
X1
X2
X3
X4

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Terminal Name Function
01 GND Common Ground Potential (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 Digital output K4, transistor PNP 30 volts, 350 mA
10 K3 out Digital output K3, transistor PNP 30 volts, 350 mA
11 Cont.4 Programmable control input
12 Cont.3 Programmable control input
13 (PROG) (for download of new firmware only, not for general use)
14 RxD Serial RS232 interface, input (Receive Data)
15 RS485 B (-) RS 485 serial interface
16 RS485 A (+) RS 485 serial interface
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 Encoder 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 Digital output K2, transistor PNP 30 volts, 350 mA
26 K1 out Digital output K1, transistor PNP 30 volts, 350 mA
27 Cont.2 Programmable control input
28 Cont.1 Programmable control input
29 Com+ (K1-K4) Common positive input for transistor outputs K1-K4
30 TxD Serial RS232 interface, output (Transmit Data)
31 GND Common 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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2.1. Power Supply
The MM640 monitor 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).
2.2. 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)
2.3. 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
•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
(may need additional remote circuit)
*) requires special settings of the threshold parameters, see “Special parameters F10”
•For applications based on different directions of rotation it is mandatory to
use quadrature encoders with channels A and B or with channels A, /A,
and B, /B (90° phase displacement).
•Where the impulse level is HTL (10 – 30 volts) you can use either single-
ended signals (A and B only) or differential signals (A, /A, B, /B)
•Where the impulse level is TTL, it is strictly recommended to use symmetric
differential signals (with inverted channels /A and /B).
Under industrial environment conditions, single-ended TTL signals may cause
serious problems due to insufficient EMC immunity of the signal lines

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2.4. Control Inputs 1 – 4
These inputs can be configured for remote functions like Reset, disable of the keyboard or
display selection purpose etc.
All control inputs require HTL level (12 ... 30 volts). The characteristics can be individually set to
either NPN (switch to -) or PNP (switch to +). For applications where edge-triggered action is
needed, the menu allows to set the active edge (rising or falling). The control inputs will also
accept signals with Namur (2-wire) standard.
For reliable operation of the control inputs, minimum impulse duration of
50 μsec. must be ensured.
Please verify that this minimum duration will be kept even at maximum
speed of the machine
2.5. Logical Inputs Login1 - 6
The logical inputs are available for process control. These inputs receive logical information
from the process (e.g. that the actual operator command for a motor is “forward”). The monitor
can use this information together with the encoder feedback to check if the operator command
is executed correctly or not.
Each input is equipped with a programmable switch-on and switch-off delay, in order to allow
an applicable response time to the mechanics before comparing the actual state and the
scheduled state.
All logical inputs operate at HTL level (12 ... 30 volts) with PNP (switch to +) characteristics.
2.6. Relay Outputs and Transistor Outputs
The unit provides four relay outputs and four independent transistor outputs. The user is free to
assign each of the four programmable control functions and each of the four internal status
signals to any of the relays or outputs.
Whilst the relay (dry change-over) will need a switching delay of 5 - 10 msec. the corresponding
transistor output will provide the same information much faster (< 1 msec.)
All desired control functions or switching conditions are programmable by PC.
The OS32 operator software provides integration of any kind of logical combination of input
signals (nominal condition) and feedback signals (real condition) into the process.
After specification of the desired events to be used for control, it is possible to still add any of
the following characteristics to the resulting switching functions:
•Response delay: when the switching event occurs, the output will still wait for a
programmable time until it responds
•Timed or static operation: when the event occurs, the output can provide either dynamic
(timed) operation or static operation

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•All functions may be set to positive response (switch ON upon switching event) or
negative response (switch OFF upon switching event)
•Catch function: all functions may be set to lock in the active position (e.g. remain
continuously ON or continuously OFF) until to acknowledgement by a remote reset
signal
Output 1 to Output 4 are fast-switching, 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)
The relays Rel1 to Rel4 provide dry changeover contacts at a switching capability of maximum
250 V/ 1 A/ 250 VA (AC) or maximum 100 V/ 1A/ 100 W (DC)
2.7. Serial Interface
The serial RS232 interface can be used for the following purposes:
•Set-up of the unit by PC by means of the OS32 PC software
•Change of parameters during operation
•Readout of actual speeds or positions or other counter values by PLC or PC
•Running of functional checks of the monitor, under remote control of a superior system
The figure below shows how to connect the MM640 monitor to a PC or a PLC
2
3
5
RxD RxD
TxD
TxD
GND
screen
PC
MM 640
14
(Sub-D-9)
30
31
PLC
MM 640
16
15
RS 485
A
B
A
B
Both serial interfaces can be connected at the same time.
However only the one or the other must communicate at a time.
It is not possible to communicate simultaneously with both interfaces

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3. Relevant Process Data and Setpoints
3.1. Available Actual Values
Depending on the connected encoders and sensors, the monitor continuously measures and
updates the actual values shown in the list below. This means that every of these actual values
is available at any time for evaluation and can be combined with other functions to switch one
of the outputs ON or OFF.
Value/State Description Requirement
Standstill 1 Digital information (yes/no) for zero motion
of encoder 1 *)
Incremental signal on
Encoder 1 input
Motion signal 1 Digital information (yes/no) for active
motion of encoder 1
Incremental signal on
Encoder 1 input
Speed 1 Actual speed of encoder 1 according to
customer scaling
Incremental signal on
Encoder 1 input
Position 1 Actual position count of encoder 1
according to customer scaling **)
Quadrature encoder for
encoder input 1
Direction 1 Direction of motion (forward or reverse)
of encoder 1
Quadrature encoder for
encoder input 1
Standstill 2 Digital information (yes/no) for zero motion
of encoder 2 *)
Incremental signal on
Encoder 2 input
Motion signal 2 Digital information (yes/no) for active
motion of encoder 2
Incremental signal on
Encoder 2 input
Speed 2 Actual speed of encoder 2 according to
customer scaling
Incremental signal on
Encoder 2 input
Position 2 Actual position count of encoder 2
according to customer scaling **)
Quadrature encoder for
encoder input 2
Direction 2 Direction of motion (forward or reverse)
of encoder 2
Quadrature encoder for
encoder input 2
Difference
Pos 1 - Pos 2
Differential position count between
encoder 1 and encoder 2, according to
customer scaling **)
Quadrature encoders for both,
encoder 1 and encoder 2
*) Standstill can be defined by parameter setting
**) “Zero position” and “Zero difference” can be defined by individual RESET