Reliance electric S-D4024 Installation and operation manual

PSC5000 Serial Absolute Encoder Input Card II
S-D4024
Engineering Manual
Engineering Manual 23614-3E
Reliance Electric Limited

The information in this engineering manual is subject to change without notice. Reliance Electric assumes
no responsibility for errors that may appear in this manual.
Throughout this manual, the following notes are used to alert you to safety considerations:
ATTENTION: Identifies information about practices or circumstances that can lead to personal
injury or death, property damage, or economic loss.
Important: Identifies information that is critical for successful application and understanding of the product.
ATTENTION: Only qualified electrical personnel familiar with the construction and operation of
this equipment and the hazards involved should install, adjust, operate, or service this
equipment. Read and understand this manual and other applicable manuals in their entirety
before proceeding. Failure to observe this precaution may result in bodily injury.
ATTENTION: Installing and removing this card or its connecting cables may result in
unexpected machine operation. Power to the machine should be turned off before installing or
removing the card or its connecting cables. Failure to observe this precaution may result in
bodily injury.
ATTENTION: This card contains electrostatic discharge-sensitive components. Careless
handling may result in severe damage on the components. Do not touch the connectors on the
back side of the card. Failure to observe this precaution may result in damage to, or
destruction of the equipment.
© 2003 Reliance Electric Limited
!
!

I
Table of Contents
Chapter 1 Introduction.................................................................................................... 1-1
1.1 Receiving the Shipment.......................................................................... 1-1
1.2 Notes on Handling .................................................................................. 1-1
Chapter 2 Overview......................................................................................................... 2-1
Chapter 3 Hardware of the S-ABS II Card..................................................................... 3-1
3.1 Appearance of the Faceplate of the S-ABS II Card................................ 3-1
3.2 Input Circuits ........................................................................................... 3-2
3.3 External Wiring........................................................................................ 3-3
Chapter 4 Programming ................................................................................................. 4-1
4.1 Organization of Registers ....................................................................... 4-1
4.1.1 Registers 0, 2 and 4 Containing Absolute Position Data ............ 4-1
4.1.2 Register 6 to Show Error Status.................................................. 4-2
4.1.3 Register 7 to Set Forcibly Turning OFF LED .............................. 4-4
4.2 Definition of Registers............................................................................. 4-5
4.2.1 Absolute Position Data Registers................................................ 4-5
4.2.2 Error Status Register ................................................................... 4-5
4.2.3 Register to Set Forcibly Turning OFF LED ................................. 4-6
Chapter 5 Checking Operation of the Status Display LEDs and Prohibiting
the I/O Monitoring Function ......................................................................... 5-1
5.1 Verifying Operation of the Status Display LEDs..................................... 5-1
5.2 Prohibiting I/O Monitoring ....................................................................... 5-1
Chapter 6 Troubleshooting ............................................................................................ 6-1
Appendix A Technical Specifications .............................................................................. A-1
Appendix B Block Diagram ............................................................................................... B-1
Appendix C Pin Arrangement of the Input Connector.................................................... C-1
Appendix D Specifications of Serial Absolute Encoder of IHI....................................... D-1
Appendix E Specifications of Serial Absolute Encoder of Sumtak .............................. E-1
Appendix F Specifications of Serial Absolute Encoders of Nemicon .......................... F-1
Appendix G Bit Format Table of Serial Data from Absolute Encoders......................... G-1
CONTENTS

II
PSC5000 Serial Absolute Encoder Input Card II S-D4024

III
Table of Contents
Figure 3.1 - Faceplate of the SAEI-2 Card .............................................. 3-1
Figure 3.2 - Input Circuit .......................................................................... 3-2
Figure 3.3 - Example of the External Wiring between the Serial
Absolute Encoder and the S-ABS II Card ............................ 3-3
Figure 3.4 - Internal Wiring in the External Battery Box .......................... 3-4
Figure 3.5 - Example of Wiring on Control Panel Side............................ 3-4
Figure B.1 - Block Diagram of the S-ABS II Card .................................... B-1
Figure C.1 - Pin Arrangement of the Input Connector.............................. C-1
List of Figures

IV
PSC5000 Serial Absolute Encoder Input Card II S-D4024

V
Table of Contents
Table 2.1 - Serial Absolute Encoders from Which the SAEI-2 Card
Can Read Data..................................................................... 2-1
Table 4.1 - Registers in the S-ABS II Card............................................. 4-1
Table 6.1 - Troubleshooting.................................................................... 6-1
Table G.1 - Bit Format of Serial Data Provided from Absolute
Encoders Usable for the S-ABS II Card ............................... G-1
List of Tables

VI
PSC5000 Serial Absolute Encoder Input Card II S-D4024

1-1 Introduction
CHAPTER 1
Introduction
The products described in this Engineering Manual are manufactured or distributed
by Reliance Electric Limited.
The PSC5000 Serial Absolute Encoder Input Card II (Model S-D4024) (hereinafter
called "S-ABS II Card") is one of the optional cards for PSC5000 System and
receives serial signals from serial absolute encoder(s) to obtain present position of
motor(s).
This engineering manual describes the functions and specifications of the S-ABS II
Card and provides procedures to program the card in detail. Read and understand
this manual before proceeding.
ATTENTION: Only qualified electrical personnel familiar with the
construction and operation of this equipment and the hazards involved
shall install, adjust, operate or service this equipment. Read and
understand this engineering manual and other applicable manuals in
their entirety before proceeding. Failure to observe this precaution
could result in bodily injury or destruction of the equipment.
1.1 Receiving the Shipment
Upon arrival of the equipment, the user is responsible to thoroughly inspect the
equipment before accepting shipment. If any items are missing or are found
obviously damaged, notify our office or our agent of the fact.
1.2 Notes on Handling
When the S-ABS II Card is installed, adjusted, operated or serviced, caution must be
paid to the following points.
1) The operating temperature range for the S-ABS II Card is 0 to 55 degree C (32
to 131 degree F). Do not operate or store the card at a place under direct
sunlight, close to a heater, or with high humidity.
2) Any heavy shock or vibration shall be avoided from the S-ABS II Card.
3) Prevent foreign material such as paper clips from coming into the PSC5000
System.
4) Because installation of the S-ABS II Card is a hazardous work, only electrical
personnel familiar with the construction and operation of the card and applicable
codes and standards shall perform installation of the card.
5) Turn off the power to the PSC5000 System before inserting or removing the
S-ABS II Card. Inserting or removing the card while the PSC5000 System is
powered ON might cause trouble or damage to the equipment.
!

1-2 PSC5000 Serial Absolute Encoder Input Card II S-D4024
6) The S-ABS II Card uses static-sensitive components. Exercise caution for static
electricity which might cause destruction of the equipment.
7) Do no touch connectors and/or surface of the S-ABS II Card to prevent
electrical connection from being damaged.
8) When you disconnect cable, do not pull cable but connector in order to avoid
damage to cable connection.
9) Do not perform anything not described in this manual. Trouble or destruction of
the equipment could be caused if this instruction is not followed.

2-1 Overview
CHAPTER 2
Overview
The PSC5000 Serial Absolute Encoder Input Card II (S-ABS II Card) is used to read
serial signals (position data) from the serial absolute encoders shown in Table 2.1
and to convert the received signals to double integer data (32-bit data). The data
are updated every 84 microseconds.
Table 2.1 - Serial Absolute Encoders from Which the S-ABS II Card Can Read Data
Model Number of Serial Absolute Encoder
MSW1-4096-13N11-12 Series
AEF-013-2048
NAR-H11M-AD
NAR-H13M-AD (1)
Manufacturer
Ishikawajima-Harima Heavy
Industries Co., Ltd. (IHI)
Sumtak Corporation
NIDEC Nemicon Corporation
NIDEC Nemicon Corporation
(1) Absolute position data provided from this serial absolute encoder are 26-bit data, and the S-ABS II
Card reads only lower 24 bits out of 26 bits excluding upper 2 bits.
An S-ABS II Card has input circuits for three channels independent each other, and
can be connected to up to three serial absolute encoders.
On the front panel of the S-ABS II Card, there are five Status Display LED lamps for
each channel (total 15 LEDs) as shown in Figure 3.1, and when any error is
detected, the LED corresponding to the detected error will be turned ON in red.
Because such error status data are kept in an internal register, it is possible to read
out the status data from the register and to refer to the data with an application
program.
The S-ABS II Card is installed on one of the option slots of the PSC5000 System.
When it is installed, the position information of the absolute encoder can be used for
applications of the PSC5000 controller.
Important: Serial absolute encoders that can be connected to the S-ABS II Card
are as shown in Table 2.1. No other encoders can be used.
Model NAR-H11M-AD encoder cannot recognize errors of data for
revolution number of one revolution or more
Model NAR-H13M-AD encoder recognize neither errors of data for
revolution number of one revolution or more nor external battery alarm.
Also, from this encoder, the S-ABS II Card reads only lower 24 bits of
absolute position data out of 26 bits.
Important: In the same optional card series as the S-ABS II Card, there is another
Serial Absolute Encoder Input Card S-D4009 which is covered by a
separate engineering manual EM-23607. But since the functions and
features of the Serial Absolute Encoder Input Card S-D4009 are
different from those of the S-ABS II Card, the Serial Absolute Encoder
Input Card S-D4009 is not interchangeable with the S-ABS II Card.

2-2 PSC5000 Serial Absolute Encoder Input Card II S-D4024
Important: The S-ABS II Card is for PSC5000 System, and cannot be used for
PSC3000 System.
Important: The S-ABS II Card can be used for the PSC5000 Control Card
operating system Version 1.31 or later.
Important: For programming the S-ABS II Card, PSC5000 Programming Terminal
Version 1.31 or later can be used. Any earlier version of the
Programming Terminal does not support use of the S-ABS II Card.
Important: Be careful that the S-ABS II Card prohibits use of the I/O monitor of the
Programming Terminal. For more information, refer to Section 5.2 of
this manual.
This manual describes the functions and specifications of the S-ABS II Card. It also
includes examples of external wiring and troubleshooting procedures, as well as
programming methods.

3-1 Hardware of the S-ABS II Card
CHAPTER 3
Hardware of the S-ABS II Card
This chapter describes components on faceplate of the S-ABS II Card and input
circuits. Also included here are examples of external wiring.
The S-ABS II Card can be installed to either one of Slots 1 to 5 of PSC5000 Back Plane.
3.1 Appearance of the Faceplate of the S-ABS II Card
Figure 3.1 shows the faceplate of the S-ABS II Card.
Figure 3.1 - Faceplate of the S-ABS II Card
S–ABS II
MONITOR
S—D4024 —
I
N
P
U
T
C
H
1
C
H
2
C
H
3ST1
ST2
ST3
ST4
ST5

3-2 PSC5000 Serial Absolute Encoder Input Card II S-D4024
On the faceplate, there are 15 Monitor LED's (Status Display LED's; five LED's for
each channel) and an Input Connector.
When any error is detected, the corresponding LED will be turned ON in red. For
more information on detecting conditions of errors, refer to Section 4.1.
There is an Input Connector of 40 pins on the faceplate, and up to three channels of
serial signal lines can be connected to the connector. The pin arrangement will be
shown in Appendix C. The following are the connector and connector covers that
can be used for this Input Connector.
- Connector
FCN-361J040-AU (Manufacturer: Fujitsu Limited): Soldered jacks
- Connector Covers
FCN-360C040-B (Manufacturer: Fujitsu Limited): B Type
FCN-360C040-E (Manufacturer: Fujitsu Limited): E Type
FCN-360C040-H/E (Manufacturer: Fujitsu Limited): H/E Type
FCN-360C040-J1 (Manufacturer: Fujitsu Limited): J1 Type
3.2 Input Circuits
The S-ABS II Card has three input circuits, each of which receives RS-422A signals
provided from an serial absolute encoder (5 V differential output type, maximum
frequency 200 MHz) and converts them to 5 V TTL signals by Manchester coding.
For more information, refer to Appendices D to F.
Each input circuit includes the following as shown in Figure 3.2.
- Terminating resistor (100 ohms)
- CR noise filter (cut off frequency: 8 MHz)
- Protection circuit (diode cramp)
These input circuits are isolated from internal circuits by photo couplers
Figure 3.2 - Input Circuit
3.3K
6 pF
3.3K
Terminating
Resistor
100 ohms
Diode
Cramp RS-422 Receiver
From 5 V Differential
Output Type Encoder
to TTL Signal
DS26C32A 392
Photo Coupler
TLP115A
To Gate
Array
To Gate
Array
To Gate
Array
ISOL5V 5V
Ch1
Ch2
Ch3

3-3 Hardware of the S-ABS II Card
3.3 External Wiring
Important: When the S-ABS II Card conforms to the requirements of CE Marking,
use a shielded cable for wiring and connect its shield to the ground over
a length of at least 10 millimeters before outlet of cabinet. Also,
external circuit to be connected to the S-ABS II Card shall be "SELV". *
* "SELV" is a circuit that is designed and protected to prevent voltage
between circuit components possibly touched by operators under
normal condition or under single fault condition and voltage between
the earth and touchable and possibly grounded metal component
from exceeding 42.4 V peak and also to prevent an overvoltage
exceeding 42.4 V peak from producing.
Install external wiring from the serial absolute encoders to the S-ABS II Card with
reference to the examples shown in Figures 3.3 through 3.5. In these figures, Model
MSW1-4096-13N11-12 encoder of IHI is used as an example.
Figure 3.3 - Example of External Wiring between the Serial Absolute Encoder and the S-ABS II Card
When main power supply to PSC5000 System is turned OFF, serial absolute
encoder will maintain its data by using internal battery built in encoder or external
battery installed outside of encoder. To use external battery, provide an external
battery box as shown in Figure 3.4 and install it as close to encoder as possible,
because voltage of external battery is as low as 3.6 VDC.
Serial Absolute
Encoder
MSW1-4096-
13N11-12
External
Battery Box
A
B
C
D
K
L
E
F
G
H
R
S
T
M
J
A
B
C
D
K
L
E
F
G
H
R
S
T
M
J
A
B
C
D
K
L
E
F
G
H
R
S
T
M
J
A
B
C
D
K
L
E
F
G
H
R
S
T
M
J
A
B
C
D
K
L
E
F
G
H
R
S
T
M
J
A
B
C
D
K
L
E
F
G
H
R
S
T
M
J
A (+)
A ( )
B (+)
B ( )
Z (+)
Z ( )
RX (+)
RX ( )
GND
VCC (+12V)
RST
GND
VB2
SHIELD
CASE GND
To Control
Panel
(see Figure
3.5)

3-4 PSC5000 Serial Absolute Encoder Input Card II S-D4024
Figure 3.5 - Example of Wiring on Control Panel Side
Figure 3.4 - Internal Wiring in the External Battery Box
The encoder will first consume power of the external battery. When the external
battery becomes empty, the encoder will generate external battery alarm (red LED
will be turned ON) and start to consume power of the internal battery. If you replace
the external battery at this moment, you can save consumption of the internal
battery.
Important: Because replacement of the internal battery by the user himself is very
difficult, replace the external battery with new one as soon as the
external battery alarm is raised in order to minimize consumption of the
internal battery. For the backup time, refer to Appendices D through F.
Figure 3.5 illustrates an example of wiring on control panel side.
A
B
C
D
K
L
E
F
G
H
R
S
T
M
J
A
B
C
D
K
L
E
F
G
H
R
S
T
M
J
BT1
+
A
B
C
D
K
L
E
F
G
H
R
S
T
M
J
A (+)
A ( )
B (+)
B ( )
Z (+)
Z ( )
RX (+)
RX ( )
GND
VCC (+12V)
RST
GND
VB2
CASE GND
A-1
A-2
0V
+12V
From External
Battery Box
(see Figure 3.3)
RST
Direct Current
S-ABS II Card
Input Connector
(A-1 and A-2 are
pin numbers.
For more detail,
see Appendix C.)
Control Panel (Example of
use of Channel 1)

3-5 Hardware of the S-ABS II Card
In case of Model MSW1-4096-13N11-12 encoder of IHI, all the circuits in the
encoder will be cleared to the initial state if reset signal (RST) is connected to power
supply (+12V) for longer than four seconds, and all status flags and revolution
number counter will be reset, except position data for less than one revolution which
will be kept. Also, connecting the shield terminal (M) of encoder cable to the
grounding terminal (J) or the 0V terminal (G) of the control panel may have effect to
increase resistance against noise. Depending on the situation, connect the shield
terminal to either one of the terminals.
Be careful that power supply voltage, operation of clearing signals, and shield
terminal pin of other models of encoders are different from those of the encoder of
IHI. Refer to Appendices E and F for the specifications of other encoders.
ATTENTION: When connecting the battery, be sure to confirm the
polarity of its terminals (i.e., positive (plus) terminal and negative
(minus) terminal). Connecting incorrect polarities of the battery could
result in destruction of this equipment.
ATTENTION: Confirm the power to this equipment is disconnected
before starting wiring work. Failure to observe this precaution could
result in electrical shock and destruction.
!

3-6 PSC5000 Serial Absolute Encoder Input Card II S-D4024

4-1 Programming
CHAPTER 4
Programming
This chapter describes organization of registers of the PSC5000 Serial Absolute
Encoder Input Card (S-ABS II) and the methods to define the registers.
4.1 Organization of Registers
The S-ABS II Card has five registers, consisting of one absolute position data
register for each channel (total three registers), one error status register, and one
register to set forcibly turning off LED. Table 4.1 shows these registers.
Table 4.1 - Registers in the S-ABS II Card
Register
Number
0
2
4
6
7
Contents of Register
Absolute position data of
Channel 1 (32-bit data)
Absolute position data of
Channel 2 (32-bit data)
Absolute position data of
Channel 3 (32-bit data)
Error Status
Setting to forcibly turn off
LED
Read/Write
of Register
Read only
Read only
Read only
Read only
Write only
Method to Define Register
Define by the IODEF statement as a double integer number
(!) or by the HIODEF statement as a real number.
Define by the IODEF statement as a double integer number
(!) or by the HIODEF statement as a real number.
Define by the IODEF statement as a double integer number
(!) or by the HIODEF statement as a real number.
Define by the IODEF statement as a single integer number
(%) or a boolean number (@).
Define by the IODEF statement as a single integer number
(%)
The following sections describe the bit organization of these registers.
4.1.1 Registers 0, 2 and 4 Containing Absolute Position Data
The data contained in the registers 0, 2 and 4 consists of data for less than one
revolution and data for revolution number of one revolution or more. The data for
less than one revolution exists in the lower 11 bits (Bit 0 to Bit 10), and is an angle
data expressed by equally dividing one revolution of the encoder shaft to 2048 parts.
The upper 12 bits higher than Bit 10 (Bit 11 to Bit 22) show the data for revolution
number of one revolution or more and count revolution number of the encoder shaft.
Bits 23 to 31 show the same value, and express the polarity (positive or negative) of
the output data.
The range of the absolute position data is from -223 to +223 - 1 (from
-8388608 to 8388607). This range corresponds to -212 to +212 - 1 (-4096 to 4095)
revolutions, based on the reset (initialized) status.

4-2 PSC5000 Serial Absolute Encoder Input Card II S-D4024
4.1.2 Register 6 to Show Error Status
Five bits of this register are used for showing error status of each channel as shown
in the following figure. When normal, the corresponding bit is "0" (low), and when an
error occurred, the corresponding bit is set to "1" (high). The most significant bit (bit
15) is always "0" (low).
Based on the conditions of register 6, the Status Display LEDs on the faceplate of
the S-ABS II Card are turned ON or OFF.
2
11
2
10
2
9
2
8
2
7
2
6
2
5
2
4
2
3
2
2
2
1
2
0
2
10
2
9
2
8
2
7
2
6
2
5
2
4
2
3
2
2
2
1
2
0
2
12
2
12
2
12
2
12
2
12
2
12
2
12
2
12
2
12
22
31 30 29 28 27 26 25 24 23
2120191817161514131211109876543210
bit
bit
Polarity (0: Positive, 1: Negative)
Data for Revolution Number
of One Revolution or More Data for Less Than One Revolution
The bit organization of these registers is as follows.
L ST5ST4ST3 ST2ST1ST5ST4 ST3 ST2ST1ST5ST4 ST3ST2ST1
1514131211109876543210
bit
Channel 3
Error Status Channel 2
Error Status Channel 1 Error Status
Register 6
Contents of Error
Status 1 (ST1): When using Model MSW1-4096-13N11-12 of IHI, Status 1
shows "LED wire broken".
When using Model AEF-013-2048 of Sumtak, Status 1 shows
"external battery alarm".
When using Model NAR-H11M-AD of Nemicon, Status 1
shows "external battery alarm".
When using Model NAR-H13M-AD of Nemicon, Status 1
shows "overflow".
Status 2 (ST2): Status 2 shows "communication error" (in case of any models
of encoders).
Status 3 (ST3): When using Model MSW1-4096-13N11-12 of IHI, Status 3
shows "system down".
When using Model AEF-013-2048 of Sumtak, Status 3 shows
"system down".
When using Model NAR-H11M-AD of Nemicon, Status 3
shows "system down".
When using Model NAR-H13M-AD of Nemicon, Status 3
corresponds position bit 224 (this is not error).
Status 4 (ST4): Status 4 shows "CRC error" (in case of any models of
encoders).