Motrona FP210 User manual

Operating Manual
motrona GmbH, Zeppelinstraße 16, DE - 78244 Gottmadingen, Tel. [phone], Fax [phone], [email protected], www.motrona.de
Signal converter FP210 / IP210 / PP210 / ZP210
Frequency (FP210)
→
Parallel (25 Bit)
SSI absolute value (IP210)
Start-Stop (PP210)
Pulse counter (ZP210)
Product features:
•Multifunctional unit with several operating modes for incremental encoders or SSI absolute encoders
•For incremental encoders:
Operating modes as frequency converter or position transducer (pulse counter)
Universal incremental inputs (HTL/TTL/RS422) for NPN/PNP/NAMUR encoders and sensors
Functions such as linkages (eg. A+B), scaling, filters,…
Input frequencies up to 1 MHz
•For SSI absolute encoders:
Master or Slave operation with clock frequencies up to 1 MHz
For single turn and multi turn encoders with SSI formats from 10 … 32 Bit
Functions such as bit suppression, round-loop function, scaling, …
•For absolute and magnetostrictive position encoder with Start-Stop-Interface:
Operating modes for master or slave, for position, angle and speed measurement
•USB interface for configuration
•Extremely short conversion times
•Linearization with 24 control points
•Auxiliary voltage output 5 and 24VDC for encoder supply
•Compact rail housing to EN60715
•Easy parameterization via user interface OS (Freeware)

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Die deutsche Beschreibung ist verfügbar unter:
https://www.motrona.com/fileadmin/files/bedienungsanleitungen/Zp210_d.pdf
The English description is available at:
https://www.motrona.com/fileadmin/files/bedienungsanleitungen/Zp210_e.pdf
La description en français est disponible sur:
https://www.motrona.com/fileadmin/files/bedienungsanleitungen/Zp210_f.pdf
The operator software OS (freeware) is available at:
https://www.motrona.com/en/support/software.html
Version:
Description:
ZP210_01a_oi/tgo/mbo April 20
First Version
ZP210_01b_oi/mbo April 20
First Revision
ZP210_02a_oi/tgo/October
Added parameter “Special PIN Function”
Legal notices::
All contents included in this manual are protected by the terms of use and copyrights of motrona
GmbH. Any reproduction, modification, usage or publication in other electronic and printed media
as well as in the internet requires prior written authorization by motrona GmbH.

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Table of Contents
Safety Instructions and Responsibility.......................................................................... 4
General Safety Instructions.............................................................................................................4
Use according to the intended purpose ..........................................................................................4
Installation .......................................................................................................................................5
EMC Guidelines ...............................................................................................................................6
Cleaning, Maintenance and Service Notes.....................................................................................6
Compatibility Hint ........................................................................................................ 7
Introduction.................................................................................................................. 8
Operating Mode...............................................................................................................................8
Function diagram .............................................................................................................................9
Power –LED / Error messages......................................................................................................10
Electrical Connections................................................................................................ 12
DC Power Supply (X1)....................................................................................................................12
Auxiliary voltage output (X2) .........................................................................................................12
Incremental encoder input (X2) .....................................................................................................13
SSI-Absolute encoder input (X2) ...................................................................................................15
Start-stop encoder inputs (X2).......................................................................................................17
Control Inputs (X3) .........................................................................................................................18
Parallel output (X5) / COM + (X3) ..................................................................................................19
„Error“ – Output.................................................................................................................................19
“Data stable” – output ......................................................................................................................19
Serial interface (X4) .......................................................................................................................20
Parameter / Overview-Menu Structure....................................................................... 21
General Menu ................................................................................................................................23
Mode Frequency ............................................................................................................................25
Mode Counter ................................................................................................................................30
Mode SSI........................................................................................................................................32
Mode Start/Stop............................................................................................................................34
Serial Menu ...................................................................................................................................36
Parallel Menu.................................................................................................................................39
Command Menu.............................................................................................................................41
Linearization Menu ........................................................................................................................43
Appendix.................................................................................................................... 44
Data readout via serial interface...................................................................................................44
Parameter list / serial codes .........................................................................................................45
Linearization...................................................................................................................................49
Reading SSI-Value .........................................................................................................................51
Internal processing and calculation of SSI data ...........................................................................52
Operating modes / OP modes of the Start/Stop interface ...........................................................55
Dimensions ....................................................................................................................................57
Technical Specifications:...............................................................................................................58

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Safety Instructions and Responsibility
General Safety Instructions
This operation manual is a significant component of the unit and includes important rules and hints
about the installation, function and usage. Non-observance can result in damage and/or impairment
of the functions to the unit or the machine or even in injury to persons using the equipment!
Please read the following instructions carefully before operating the device and observe all safety
and warning instructions! Keep the manual for later use.
A pertinent qualification of the respective staff is a fundamental requirement in order to use these
manual. The unit must be installed, connected and put into operation by a qualified electrician.
Liability exclusion: The manufacturer is not liable for personal injury and/or damage to property and
for consequential damage, due to incorrect handling, installation and operation. Further claims, due
to errors in the operation manual as well as misinterpretations are excluded from liability.
In addition the manufacturer reserves the right to modify the hardware, software or operation
manual at any time and without prior notice. Therefore, there might be minor differences between
the unit and the descriptions in operation manual.
The raiser respectively positioner is exclusively responsible for the safety of the system and
equipment where the unit will be integrated.
During installation or maintenance all general and also all country- and application-specific safety
rules and standards must be observed.
If the device is used in processes, where a failure or faulty operation could damage the system or
injure persons, appropriate precautions to avoid such consequences must be taken.
Use according to the intended purpose
The unit is intended exclusively for use in industrial machines, constructions and systems. Non-
conforming usage does not correspond to the provisions and lies within the sole responsibility of the
user. The manufacturer is not liable for damages which have arisen through unsuitable and improper
use.
Please note that device may only be installed in proper form and used in a technically perfect
condition (in accordance to the Technical Specifications). The device is not suitable for operation in
explosion-proof areas or areas which are excluded by the EN 61010-1 standard.

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Installation
The device is only allowed to be installed and operated within the permissible temperature range.
Please ensure an adequate ventilation and avoid all direct contact between the device and hot or
aggressive gases and liquids.
Before installation or maintenance, the unit must be disconnected from all voltage-sources. Further
it must be ensured that no danger can arise by touching the disconnected voltage-sources.
Devices which are supplied by AC-voltages must be connected exclusively by switches, respectively
circuit-breakers with the low voltage network. The switch or circuit-breaker must be placed as near
as possible to the device and further indicated as separator.
Incoming as well as outgoing wires and wires for extra low voltages (ELV) must be separated from
dangerous electrical cables (SELV circuits) by using a double resp. increased isolation.
All selected wires and isolations must be conform to the provided voltage- and temperature-ranges.
Further all country- and application-specific standards, which are relevant for structure, form and
quality of the wires, must be ensured. Indications about the permissible wire cross-sections for
wiring are described in the Technical Specifications.
Before first start-up it must be ensured that all connections and wires are firmly seated and secured
in the screw terminals. All (inclusively unused) terminals must be fastened by turning the relevant
screws clockwise up to the stop.
Overvoltages at the connections must be limited to values in accordance to the overvoltage
category II.

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EMC Guidelines
All motrona devices are designed to provide high protection against electromagnetic interference.
Nevertheless you must minimize the influence of electromagnetic noise to the device and all connected
cables.
Therefore the following measures are mandatory for a successful installation and operation:
•Use shielded cables for all signal and control input and output lines.
•Cables for digital controls (digital I/O, relay outputs) must not exceed a length of 30 m and are
allowed for in building operation only
•Use shield connection clamps to connect the cable shields properly to earth
•The wiring of the common ground lines must be star-shaped and common ground must be
connected to earth at only one single point
•The device should be mounted in a metal enclosure with sufficient distance to sources of
electromagnetic noise.
•Run signal and control cables apart from power lines and other cables emitting electromagnetic
noise.
Please also refer to motrona manual “General Rules for Cabling, Grounding, Cabinet Assembly”. You can
download that manual by the link
https://www.motrona.com/en/support/general-certificates.html
Cleaning, Maintenance and Service Notes
To clean the front of the unit please use only a slightly damp (not wet!), soft cloth. For the rear no
cleaning is necessary. For an unscheduled, individual cleaning of the rear the maintenance staff or
assembler is self-responsible.
During normal operation no maintenance is necessary. In case of unexpected problems, failures or
malfunctions the device must be shipped for back to the manufacturer for checking, adjustment and
reparation (if necessary). Unauthorized opening and repairing can have negative effects or failures to
the protection-measures of the unit.

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Compatibility Hint
This product is a successor model of the thousand fold proven converter type
IP251.
This converter is able to replace functionally the previous model; however some minor differences
have to be observed with regard to the parameter settings.
The main differences between this product and the respective predecessor model are listed below.
Differences of the IP210 compared to the previous model IP251 are:
IP210
IP251
Operating mode
Extension of the parallel converter by
additional operating modes.
(Frequency, counter and start / stop to
parallel converter.)
Possible configurations for incremental
inputs:
RS422 (TTL), HTL Differential, HTL PNP,
HTL NPN or TTL PNP (asymmetrical)
The setting made in the corresponding
parameter then applies to both inputs (A
and B).
Exclusively SSI to parallel converter
without switchable operating mode.
Control Inputs:
Number of inputs: 3 (freely
configurable)
Format: HTL
Number of inputs 1 (Hold)
Format: HTL
Encoder Supply:
Output voltage: 5VDC u. 24VDC
Output current: max. 250 mA
Not available
Serial Interface:
USB interface via mini USB connector
Baud rate: 115200 baud
Format: 8 none 1
RS232/RS485 via 9-position SUB-D
connector
Baud rate: 600, 1200, 2400, 4800, 9600,
19200, or 38400 Baud
Housing:
Dimensions (w x h x d): 23 x 102 x 102 mm
Weight: approx. 100 g
Dimensions (w x h x d): 40 x 79 x 91 mm
Weight: approx. 190 g
Device parameterization:
Only by operator software OS.
By operator software OS and partially
via DIL switches

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Introduction
The device is designed as a signal converter with control inputs, which converts the corresponding
sensor or encoder information into a parallel signal. It is also possible to convert serial data to a
parallel format. Its extensive functions and operating modes make it universally applicable.
Operating Mode
Basically all functions have to be configured in the parameter menu. The device can be used in the
following operating modes:
•Operation as frequency converter for incremental input signals
•Operation as position transducer / counter for incremental input signals
•Operation as absolute value converter for SSI signals (replaces IP251)
•Operation as absolute value converter for signals of a start-stop interface

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Function diagram

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Power –LED / Error messages
The device has a green LED on its front foil. This lights up permanently as soon as the supply voltage
of the device has been applied. If an error occurs, the LED flashes at 1 Hz.
If the error no longer exists, the LED automatically lights up again permanently and the parallel output
responds to the current result.
The exact error can be read out via the serial interface via the user interface (OS).
(→Variable: Error_Status, Code: "; 3")
The individual error codes are explained below:
Errorcode:
(Error_Status)
Error identification:
Error description:
0x00000001
Maximum Value
SPECIAL PIN FUNCTION
“Data-Bit / Data-Bit”:
Measured value is greater than + 16777215 (2^24-1)
SPECIAL PIN FUNCTION
“Error” or “Data – Stable”:
Measured value is greater than + 8388607 (2^23-1)
SPECIAL PIN FUNCTION
“Error” and “Data – Stable”:
(or negated accordingly)
Measured value is greater than + 4194303 (2^22-1)
0x00000002
Minimum Value
SPECIAL PIN FUNCTION:
“Data-Bit / Data-Bit”:
Measured value is less than + 16777216 (2^24)
Special PIN FUNCTION
“Error” or “Data – Stable”:
Measured value is less than - 8388608 (2^23)
SPECIAL PIN FUNCTION
“Error” and “Data – Stable”:
(or negated accordingly)
Measured value is less than - 4194304 (2^22)
0x00000004
SSI Encoder Error
SSI error bit set (only for mode: SSI)
0x00000008
Encoder Fault
For internal test purposes only!
0x00000010
Frequency (Input A) out of
range
Maximum or minimum permissible input frequency
at input A has been exceeded or fallen below with
the exponential filter setting used. (only for mode:
Frequency)

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Continuation “Power-LED / Error messages“:
0x00000020
Frequency (Input B) out of
range
Maximum or minimum permissible input frequency
at input B has been exceeded or fallen below with
the exponential filter setting used. (only for mode:
Frequency)
0x00000040
Start/Stop Encoder Error
No "start" and no "stop" pulse detected between
two "init" pulses. (only for mode: Start/Stop)
Check sensor connections!
0x00000080
Position Encoder Outside the
Limit
No "stop" pulse detected between two "init" pulses.
(only for mode: Start/Stop)
Possible cause: No position sensor or position
sensor outside the limits.

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Electrical Connections
The terminal screws should be tightened with a slotted screwdriver (blade width 2mm).
DC Power Supply (X1)
The unit accepts DC supply from 10 to 30 V at the terminals X1 1 and 2. The power consumption
depends on the level of the supply voltage with aprox. 25 mA and the additional current required at
the Auxiliary Voltage Output.
All GND terminals are internally interconnected.
Auxiliary voltage output (X2)
Two auxiliary voltages (24 VDC and 5 VDC) are available as encoder / sensor supply at terminal X2
pins 7, 8 and 9. The 24 VDC output voltage depends on the device supply (see technical data).

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Incremental encoder input (X2)
Terminal X2 pins 3, 4, 5 and 6 provide a connection for various incremental signals.
RS422
HTL DIFFERENTIAL
HTL PNP
HTL NPN

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Continuation “Incremental encoder input (X2)“:
HTL NPN (NAMUR)
TTL (PNP)
Unconnected PNP inputs are always “LOW” and unconnected NPN inputs are always “HIGH”.
All inputs are designed to receive impulses from electrical impulse sources.
Notice for mechanical switching contacts:
When exceptionally mechanical contacts are used, please connect an external capacitor between
GND (-) and the corresponding input (+). A capacity of 10 µF will reduce the input frequency to
20 Hz and miscounting due to contact bouncing will be eliminated.

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SSI-Absolute encoder input (X2)
At terminal X2 pin 1, 2, 3, 4 the SSI connection for the MODE MASTER is available.
At terminal X2 pin 3, 4, 5, 6 the SSI connection for the MODE SLAVE is available.
Connection for MODE Master:

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Continuation “SSI-Absolute encoder input (X2)“:
Connection for MODE Slave:

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Start-stop encoder inputs (X2)
At terminal X2 - Pin 1+2 the RS422 connection for the init pulse in "MODE MASTER" is available.
(Device generates Init pulse itself!).
At terminal X2 - Pin 5+6 the RS422 connection for the init pulse in "MODE SLAVE" is available. (Init
pulse is generated by an external device!).
At terminal X2 - Pin 3 + 4 the RS422 connection for the Sart-Stop pulse is available.
Connection of the RS422 signals:
DPI measurement operation
In the "MODE MASTER", the init pulse is sent to the position sensor on the init line at regular
intervals (SAMPLING TIME (ms)), whose rising edge triggers a measurement.
The pulse width of the init pulse can be set by means of the "INIT PULSE TIME (µs)" parameter.
TInit : 1…9 µs (adjustable)
TStart: ~3…5 µs
TStop: ~3…5 µs

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Control Inputs (X3)
At terminal X3 pins 2,3 and 4 there are three control inputs with HTL PNP characteristic available.
Control Input 1 (Ctrl. In 1) to Control Input 2 (Ctrl. In 2) are freely configurable in the COMMAND
MENU and are used for functions to be triggered externally. eg. for resetting the measurement result
or for freezing the parallel output.
Control input 3 (Ctrl. In 3) is used exclusively for resetting the device parameters to the "default"
values. Thus, it is not freely configurable.
Note: An HTL pulse ("ACTIVE HIGH") at Ctrl. In 3, the device is reset to the factory
settings. The HTL pulse must be present for at least one second.
Wiring of the control inputs:
Unconnected control inputs are always “LOW”.
All inputs are designed to receive impulses from an electronic impulse source.
Notice for mechanical switching contacts:
When exceptionally mechanical contacts are used, please connect an external capacitor between
GND (-) and the corresponding input (+). A capacity of 10 µF will reduce the input frequency to
20 Hz and miscounting due to contact bouncing will be eliminated.

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Parallel output (X5) / COM + (X3)
The parallel outputs are 25 short-circuit proof push-pull outputs. The common, independent supply
voltage of the outputs is applied to terminal X3 - pin 5 (COM +). The supply voltage at COM + should
not exceed +27 V, otherwise the permanent short circuit restistance of the outputs can no longer be
guaranteed.
The voltage drop between COM + and an output in the HIGH state is approx. 1 volt (unloaded).
Bit13 Bit25 Bit12 Bit24 Bit11 Bit23 Bit10 Bit22 Bit9Bit21 Bit8Bit20 Bit7Bit19 Bit6Bit18 Bit5Bit17 Bit4Bit16 Bit3Bit15 Bit2Bit14 Bit1
R = 600 Ohms
GND
COM +
OUT
Typical output circuit:
SUB-D-25
(female on unit site)
13
25
12
24
11
23
10
22
9
21
8
20
7
19
6
18
5
17
4
16
3
15
2
14
1
„Error“ – Output
In the parallel menu using the “SPECIAL PIN FUNCTION” parameter the output bit 25 (or Bit 24 - if a
datastable signal is also configured) can also be set as “Error” signal. In this case, a LOW signal (or
HIGH signal) indicates that an error has been detected.
“Data stable” – output
The output Bit 25 can also be configured as a “Data-stable” signal by using ”SPECIAL PIN
FUNCTION” parameter (in parallel menu). In this case a LOW signal (or HIGH signal) indicates that
parallel output data are stable and will not change. The rising edge (or falling edge) of the signal still
guarantees stable data and can be used for remote Latch of the parallel data.
The LOW duration (or HIGH duration) of the signal is at least 1/3 of the "Parallel Update Time (s)"
set. The sketch below shows the signal path of the "Datastable" output with the "Active Low"
setting. With the "Active High" setting, the signal curve is inverted accordingly.

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Continuation ”Data stable” – output”:
12121
Data stable signal
Zone 1: Parallel output data subject to change
Parallel output data are stable
Zone 2:
Serial interface (X4)
A serial USB interface (mini USB) is available at terminal X4.
The USB interface can be used as follows:
•For parameterization of the device during commissioning
•To change parameters during operation
•For reading out actual values via PC
The serial USB communication is done with a baud rate of " 115200 Baud " and a serial data
format of " 8none1 " and cannot be changed by the user!