Siemens MICROMASTER User manual

MICROMASTER
Encoder Module
Operating Instructions Issue 04/04
User Documentation

Foreword Issue 04/04
2 MICROMASTER Encoder Module Operating Instructions
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1 Foreword
Qualified Personnel
For the purpose of this Instruction Manual and product labels, a “Qualified
person” is someone who is familiar with the installation, mounting, start-up
and operation of the equipment and the hazards involved.
He or she must have the following qualifications:
 Trained and authorized to energize, de-energize, clear, ground and tag
circuits and equipment in accordance with established safety
procedures.
 Trained in the proper care and use of protective equipment in
accordance with established safety procedures.
 Trained in rendering first aid.
Safety guidelines
This manual contains notices intended to ensure your personal safety, as
well as to protect products and connected equipment against damage.
Information relating to your personal safety is highlighted by a warning
triangle. Warnings about property damage are displayed without a warning
triangle. Depending on the degree of risk involved, safety-related
information is presented in the following Categories:
DANGER
For the purpose of this documentation and the product warning labels,
“Danger“ indicates that death; severe personal injury or substantial
damage to property will result if proper precautions are not taken.
WARNING
For the purpose of this documentation and the product warning labels,
“Warning“ indicates that death; severe personal injury or substantial
damage to property can result if proper precautions are not taken.
CAUTION
With a warning triangle, “Caution” indicates that minor personal injury can
result if proper precautions are not taken.
ATTENTION
Indicates that an undesirable effect or state can occur if attention is not
paid to the advice given.
NOTE
For the purpose of this document, “Note” indicates important information
relating to the product or highlights part of the documentation for special
attention.

Issue 04/04 Foreword
MICROMASTER Encoder Module Operating Instructions 3
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User Documentation
WARNING
Before installing and commissioning, please read these safety instructions
and warning carefully and all the warning labels attached to the equipment.
Make sure that the warning labels are kept in a legible condition and
replace missing or damaged labels.
Proper Use
WARNING
 This equipment contains dangerous voltages and controls potentially
dangerous rotating mechanical parts.
 Non-Compliance with Warnings or failure to follow the instructions
contained in this manual can result in loss of life, severe personal injury
or serious damage to property.
 Only suitably qualified personnel should work on this equipment, and
only after becoming familiar with all safety notices and maintenance
procedures contained in this manual.
 The user should be fully conversant with all warnings, cautions and
notices contained within the MICROMASTER 440 Operating
Instructions.
 The successful and safe operation of this equipment is dependent
upon its proper handling, storage, installation, operation and
maintenance.
 National safety regulations are also applicable.

Foreword Issue 04/04
4 MICROMASTER Encoder Module Operating Instructions
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Table of Contents
1Foreword................................................................ 2
2Overview ................................................................ 5
3Installation ............................................................. 6
3.1 Prerequisites ...........................................................6
3.1.1 Preparation of the Inverter .......................................6
3.1.2 Preparation of the Encoder Module..........................6
3.2 Examples of Connections ........................................9
4Commissioning...................................................... 12
4.1 TTL Encoder............................................................ 13
4.2 HTL Encoder ...........................................................13
4.3 External Power Supply ............................................14
4.4 Encoder Module Parameterization...........................15
5Troubleshooting .................................................... 18
5.1 LED Indicators.........................................................18
5.2 Fault Codes .............................................................19
6Technical Specifications ....................................... 20

Issue 04/04 Overview
MICROMASTER Encoder Module Operating Instructions 5
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2 Overview
Figure 2-1 View of Encoder Module
The MICROMASTER Encoder Module has been designed to allow the
MICROMASTER 440 inverter to interface with the most common types of
digital encoders.
The Encoder Module can use High-voltage Transistor Logic (HTL) and
Transistor Transistor Logic (TTL) digital encoders.
When the Encoder Module is fitted to the MICROMASTER 440 it allows
closed-loop encoder feedback with the following benefits in comparison to
Sensorless Vector Control (SLVC) and Variable Frequency (V/f) operation
respectively
 Zero speed with full load torque capability
 Accurate speed control
 Enhanced dynamic performance of speed and torque control.
The module is supplied with power directly from the MICROMASTER 440
via the 40-way connector on the front of the inverter.
Notes
1. An external power supply has to be provided (See Figure 3-7
on page 11) for the proper operation of the Encoder Module, if:
 The encoder consumes a current of 140 mA or more at 18 to 24 V DC.
 The encoder consumes a current of 330 mA or more at 5 V DC.
 Cable lengths greater than 50 m are used.
2. The voltage of this power supply must comply with the Encoder Module
requirements and not exceed 24 Volts DC.
3. The Encoder Module does not process any input from the encoder’s
Zero Pulse and the Inverted Zero Pulse. The terminals “Z” and “ZN” are
provided for additional functionality, currently under development.

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3 Installation
3.1 Prerequisites
3.1.1 Preparation of the Inverter
Caution
The Encoder Module will only function with the MICROMASTER 440
inverters and must have Version 2.0 or above software installed.
The version level of software install in the inverter can be confirmed by
using one of the following procedures:
1. By accessing parameter r0018 which displays the current
software version number.
2. By reading the Rating Label on the inverter as shown in Figure
3-1 below.
The hardware version is indicated by the first three characters
and the software version is indicated by the last three
characters.
Figure 3-1 Inverter Rating Label
3.1.2 Preparation of the Encoder Module
The Encoder Module is mounted directly onto the MICROMASTER 440
input and output (I/O) board.
Should more than one option be mounted on the inverter, the sequence
shown in Figure 3-2 should be followed.
Figure 3-2 Option Mounting Sequence

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Screening
To ensure the correct functioning of the encoder the guidelines listed
below should be followed:
 Only twisted-pair screened cable should be used to connect the
encoder to the Encoder Module.
 The cable screen must be terminated in the screen clamp of the
Encoder Module as shown in Figure 3-3 below.
 If the encoder cable has a screen/earth/ground conductor, this should
be terminated to the PE terminal of the Encoder Module.
 Signals cables must not be installed close to power cables.
Figure 3-3 Screen Clamp and PE Terminal
Connections
The MICROMASTER Encoder Module has 12 terminal connections, which
are described in Table 3-1 below.
Table 3-1 Encoder Module Terminals
Terminal Description
A Channel A
AN Channel A Inverted
B Channel B
BN Channel B Inverted
Z Zero Pulse (not available. See Notes on page 5)
ZN Zero Pulse Inverted (not available. See Notes on page 5)
18V HTL Link Terminal (terminals LK & 18V only)
LK Shaft Encoder Supply Voltage
5V TTL Link Terminal (terminals LK & 5V only)
VE Supply to Shaft Encoder
0V Supply to Shaft Encoder
PE Protective Earth

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Encoder Status LED’s
The MICROMASTER Encoder Module has three LED’s, which indicate
current operating status of the encoder module (see Figure 3-4 below).
Figure 3-4 Encoder Module LED’s
The LED’s have been designed to indicate a healthy or fault condition in
the following areas:
 Channel A
 Channel B
 Zero Pulse
If the Encoder Module is working correctly the LED’s will flash on and off
as the shaft encoder is rotated. If a fault condition exists the LED’s will
either stop flashing and remain on or remain off.
NOTE
At high motor speeds the LED’s appear permanently on – this is due to the
high pulse rates.
Encoder DIP Switches
The DIP switches on the Encoder Module are provided to allow the user to
select the correct settings for the encoder unit attached to the Encoder
Module. See Figure 3-5 below.
Figure 3-5 Encoder Module DIP Switches
The settings of the DIP switches are explained in Table 3-2 below.

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Table 3-2 DIP Switch Settings
DIP-Switch 1 2 3 4 5 6
Encoder Type
TTL 120Ω Single-Ended Input ON ON ON ON ON ON
TTL Differential Input OFF ON OFF ON OFF ON
HTL >5 kΩSingle-Ended Input ON OFF ON OFF ON OFF
HTL Differential Input OFF OFF OFF OFF OFF OFF
The default settings of the DIP switches allow the Encoder Module to be
used with a HTL differential input encoder.
3.2 Examples of Connections
Figures 3-7, 3-8 and 3-9 show the various configurations of connection for
the Encoder Module. A detailed description of the precise configurations of
the encoder Module is given in Section 4 – Commissioning.
NOTE
The color-coding of the connection in the following Figures are for
illustration purposes only and the actual colors will vary depending upon
the type of cables used by the commissioning engineer.
Figure 3-6 shows a typical pulse encoder cable and how the encoder
connections relate to the encoder terminals.
0 V
Ua0 Ua1 Ua2
ABCDEFGH K L M
Ua2
Schir m
Shield
blindag e
blindaje
schermo
skärm
UPUaS
Ua0 0 V
Ua1
B
D
E
F
H
K
AL
M
C
G
J
UP
Rotary Pulse Encoder
1XP8001-1 / Up = 10 ... 30 V (HTL)
1XP8001-2 / Up = 5 V ± 10% (TTL)
MM4 Encoder
Module Connections
1xP8001 Encoder
Designations
Encoder Connector
Pin Designation
Encoder Connector
BN +24 V
or
+5 V
Z ZN A AN - B 0 V - -
Figure 3-6 Typical Encoder Connections

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Figure 3-7 TTL Encoder Connections (5V DC)
Figure 3-8 HTL Encoder Connections (18V DC)

Issue 04/04 Installation
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Figure 3-9 Encoder with External Power Supply

Commissioning Issue 04/04
12 MICROMASTER Encoder Module Operating Instructions
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4 Commissioning
WARNING
Before installing and commissioning, please read these safety instructions
and warning carefully and all the warning labels attached to the equipment.
Make sure that the warning labels are kept in a legible condition and
replace missing or damaged labels.
 The inverter MUST be powered down before fitting the Encoder
Module to the inverter.
 This equipment contains dangerous voltages and controls potentially
dangerous rotating mechanical parts.
 Non-Compliance with Warnings or failure to follow the instructions
contained in this manual can result in loss of life, severe personal injury
or serious damage to property.
 Only suitably qualified personnel should work on this equipment, and
only after becoming familiar with all safety notices and maintenance
procedures contained in this manual.
 The user should be fully conversant with all warnings, cautions and
notices contained within the MICROMASTER 440 Operating
Instructions.
 The successful and safe operation of this equipment is dependent
upon its proper handling, storage, installation, operation and
maintenance.
 National safety regulations are also applicable.
The actions required to commission the MICROMASTER Encoder Module
depend upon the type of encoder that is connected to the Encoder Module.
These instructions will deal with each type of encoder individually.
Figure 4-1 Fitting the Encoder Module

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4.1 TTL Encoder
To commission the Encoder Module with a TTL Encoder, the following
procedure should be performed:
1. Ensure the Inverter is switch off.
2. Ensure the DIP-Switches have been set for the correct type of
Encoder. See Table 3-2 on page 9.
3. Fit the Encoder Module to the inverter as shown in Figure 4-1
above.
4. Connect the Channel A wire from the encoder to the ‘A’
terminal on the Encoder Module. See Figure 3-6 on page 9 and
Figure 3-7 on page 10.
5. Connect the Channel A inverted wire from the encoder to the
‘AN’ terminal on the Encoder Module.
6. Connect the Channel B wire from the encoder to the ‘B’
terminal on the Encoder Module.
7. Connect the Channel B inverted wire from the encoder to the
‘BN’ terminal on the Encoder Module.
8. Connect terminals ‘LK’ and ‘5V’ (see note) of the Encoder
Module together (this terminal has short-circuit protection).
9. Connect terminals ‘VE’ and ‘0V’ of the Encoder Module to the
power supply terminals of the encoder.
10. Switch the Inverter ON.
11. Proceed to Section 4.4 on page 15 for the parameterization
procedure.
NOTES
 If the encoder type is a TTL differential and a long cable length is
required (greater than 50 meters), DIP switches 2, 4, and 6 may be set
to ON which enables the 120Ωterminating impedance.
 The 5 V terminal is a regulated supply to ±5%.
 The cable from the encoder to the Encoder Module should be one
complete length.
 If the encoder type is a TTL single-ended encoder, there will only be a
single wire for the ‘A’ Channel.
4.2 HTL Encoder
To commission the Encoder Module with a HTL Encoder, the following
procedure should be performed:
1. Ensure the Inverter is switch off.
2. Ensure the DIP-Switches have been set for the correct type of
Encoder. See Table 3-2 on page 9.
3. Fit the Encoder Module to the inverter as shown in Figure 4-1
above.
4. Connect the Channel A wire from the encoder to the ‘A’
terminal on the Encoder Module. See Figure 3-6 on page 9 and
Figure 3-8 on page 11.
5. Connect the Channel A inverted wire from the encoder to the
‘AN’ terminal on the Encoder Module.

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6. Connect the Channel B wire from the encoder to the ‘B’
terminal on the Encoder Module.
7. Connect the Channel B inverted wire from the encoder to the
‘BN’ terminal on the Encoder Module.
8. Connect terminals ‘LK’ and ‘18V’ (see note) of the Encoder
Module together (this terminal has short-circuit protection).
9. Connect terminals ‘VE’ and ‘0V’ of the Encoder Module to the
power supply terminals of the encoder.
10. Switch the inverter ON.
11. Proceed to Section 4.4 below for the parameterization
procedure.
NOTE
 The 120Ωterminating impedance via the DIP switch must not be used
in conjunction with an HTL encoder.
 The 18 V terminal is an unregulated supply to a maximum of 24 V.
 The cable from the encoder to the Encoder Module should be one
complete length.
 If the encoder type is a TTL single-ended encoder, there will only be a
single wire for the ‘A’ Channel.
4.3 External Power Supply
An external power supply has to be provided (See Figure 3-9 on page 11)
for the proper operation of the Encoder Module, if:
 The encoder consumes a current of 140 mA or more at 18 to
24 V DC.
 The encoder consumes a current of 330 mA or more at
5 V DC.
 Cable lengths greater than 50 m are used.
The voltage of this power supply must comply with the Encoder Module
requirements and not exceed 24 Volts DC.
The Encoder Module should be configured for the appropriate encoder
type, either TTL or HTL and the power connections configured as shown in
the Figures on pages 9, 10 and 11.

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4.4 Encoder Module Parameterization
To enable the Encoder Module to function correctly with the inverter, the
parameters in Table 4-1 below must be modified:
Table 4-1 Encoder Module Parameters
Param. Name Values
r0061 Rotor Speed Indicate the speed of the rotor. Used to
check that the system is working correctly.
r0090 Rotor Angle Indicates the current angle of the rotor. This
function is not available on single input
channel encoders.
P0400[3] Encoder Type 0 = No Encoder
1 = Single Input Channel (A)
2 = Quadrature encoder without zero pulse
(Channel A+B) - The term "Quadrature"
means two periodic functions separated
by a quarter cycle or 90 degrees.
r0403 Status word of encoder Displays status word of encoder in bit format:
Bit00 Encoder module active 0 No
1 Yes
Bit01 Encoder error 0 No
1 Yes
Bit02 Signal o.k. 0 No
1 Yes
Bit03 Encoder low speed loss 0 No
1 Yes
Bit04 HW timer used 0 No
1 Yes
Details: See description of seven-segment
display given in the "Introduction to
MICROMASTER System Parameters".
P0408[3] Encoder pulses per
revolution
Specifies the number of encoder pulses per
revolution.
P0491[3] Reaction on speed
signal loss
Selects reaction on loss of speed signal.
Settings:
0 = Do not change to SLVC
1 = Change to SLVC
P0492[3] Allowed speed
difference
Used for high speed encoder loss detection.
Selects the allowable difference in calculated
speed signals between samples before it is
considered to have lost the speed signal
feedback. (Default = Calculated from inertia,
range from 0 ... 100.00)
Dependency: This parameter is updated
when P345 Motor start-up time is changed or
when a speed loop optimization is performed
(P1960 = 1).
There is a fixed delay of 40 mS before acting
upon loss of encoder at high speeds.
Caution:
When Allowed speed difference is set to 0,
then both high speed and low speed encoder
loss detection is disabled, thus encoder loss
will not be detected.
If encoder loss detection is disabled and
encoder loss occurs, then operation of the
motor may become unstable.

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Param. Name Values
P0494[3] Delay speed loss
reaction
Used for low speed encoder loss detection.
If the motor shaft speed is less than the
value in P0492 then encoder loss is detected
using a low speed encoder loss detection
algorithm. This parameter selects the delay
between loss of encoder at low speed and
reaction to the encoder loss. (Default =
Calculated from inertia, Range from 0 ...
64.000s)
Dependency: This parameter is updated
when P0345 Motor start-up time is changed
or when a speed-loop optimization is
performed (P1960 = 1).
Caution:
When this delay is set to 0, then low speed
encoder loss detection is disabled and low
speed encoder loss cannot be detected (high
speed encoder loss detection will still operate
if P0492 > 0). If low speed encoder loss
detection is disabled and encoder should be
lost at low speed, then operation of motor
may become unstable.
P1300 Control Mode 21 = Closed loop speed control
23 = Closed loop torque control

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WARNING
 The “Flying Start” function of the MICROMASTER 440 inverter
should only be used with a Quadrature Encoder.
 To perform a “Flying Start” the direction of the motor must be
known to the encoder attached to the motor. A Single-Channel
encoder cannot determine the direction of rotation of the motor;
therefore it is NOT recommended that a “Flying Start” be
performed when using a Single-channel encoder.
Caution
1. Once the correct parameters values have been entered, it is
recommended to operate the inverter in V/f mode (P1300=0)
before speed/torque control with the encoder feedback is used
and check that it functions correctly.
2. The user must observe the motor shaft to check the direction of
rotation.
3. The direction of rotation must be checked against the value
displayed in r0061.
4. If the direction of rotation does not match, then the output
phases of the inverter or the encoder channels have to
transposed to prevent unstable operation of the inverter in
closed-loop control mode.
Setting P1820 to 1 can be used to reverse the motor rotation
without transposing the output phases.
NOTES
The encoder resolution (pulses per revolution) which may be entered will
be limited by the maximum pulse frequency of the encoder option board
(fmax = 300 kHz ).
The following equation calculates the encoder frequency depending on the
encoder resolution and the rotational speed (rpm). The encoder frequency
has to be less than the maximum pulse frequency:
f
=Pulses per revolution x r.p.m.[ ]
60
1
min
f
max >
Example: An Encoder may have 1024 pulses per revolution. It rotates at
Nn= 2850 min -1. This delivers f = 48,64 kHz < fmax = 300kHz, therefore
the Encoder can be used with the Encoder Module.
P0492 is measured in Hz per milliseconds. If the inverter output frequency
varies faster than the maximum allowable change in output frequency, it
will trip with a fault condition F0090.

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5 Troubleshooting
There are two types of fault indication on the MICROMASTER Encoder
Module:
 Three status LED’s on the front panel for indicating the operational
status of Channels A, B and Z (See Figure 5-1 below).
 Fault code display specific to the Encoder Module on the AOP, BOP.
Figure 5-1 Encoder Module LED’s
5.1 LED Indicators
The LED’s monitor the continuity of the connections between the Encoder
Module and the attached encoder.
Table 5-1 lists the possible conditions of the LED’s and the remedial action
required to resolve the fault condition.
NOTE
At high motor speeds the LED’s appear permanently on – this is due to the
high pulse rates.
Table 5-1 Encoder LED Display
LED LED Condition Meaning
Flashing Normal operating condition.
Permanently ON
Fault condition has occurred or the Channel is
not connected.
Check the connections of the cables from the
Encoder Module to the attached encoder.
All
Channels
Permanently OFF
Fault condition has occurred.
Check the connections of the cables from the
Encoder Module to the attached encoder.

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5.2 Fault Codes
The Encoder Module has only one fault code, which is – F0090. This
condition occurs when the allowed frequency rate of change, set in
P0492[3] is exceeded or when low speed encoder loss is detected.
NOTE
The reason for the encoder loss will be given in the level 3 parameter
P0949:
 P0949 = 1 means encoder loss of channel A or channel B or
channel A and channel B at high speed (shaft speed > P0492)
 P0949 = 2 means encoder loss of channel A or channel A and
channel B at low speed (shaft speed < P0492)
 P0949 = 3 means encoder loss of channel B at low speed
(shaft speed < P0492).
Should the encoder give a fault message F0090 the following remedial
action should be performed:
1. Check that an encoder is fitted. If the encoder is not fitted, set
P0400=0 and select SLVC mode (P1300 = 20 or 22).
2. Check the connections between the encoder and the inverter.
3. Check the encoder is not faulty (select P1300 = 0 and run at a
fixed speed then check the encoder feedback signal using
r0061). Check for correct magnitude and direction of speed.
4. Increase the encoder loss threshold in P0492.
5. Increase encoder low speed loss detection delay in P0494.

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6 Technical Specifications
Table 6-1 Technical Specifications
Operating Temperature -10 ºC to +50 ºC
Storage Temperature -40 ºC to +70 ºC
Humidity 95% relative humidity non-condensing
Maximum Pulse Frequency 300 kHz
Pulses per Revolution Up to 5000
TTL and HTL selection Via Link Wire
Degree of Protection IP20
Encoder Power Supply 5 V (±5%) @ 330 mA
or
18 V Unregulated @ 140mA short circuit proof
Dimensions 164 mm (h) x 73 mm (w) x 42 mm (d)