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 o
Safety Instructions This manual is an essential part of the unit and contains important hints about function, correct handling and commissioning.
Table of Contents 1. 2. 3. Available Models ................................................................................................................ 4 Introduction......................................................................................................................... 6 Electrical Connections ......................................................................................................... 7 3.1. Power Supply ...................................................................
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 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 ZD34007c_e.
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.
1 2 3 X1 Cont. 4 Cont. 3 PROG RxD (RS232) Interface 1*) Interface 2*) Encoder1 /B E ncoder1 /A K4 out K3 out GND Encoder2 /B Encoder2 /A 4 5 6 7 8 9 10 11 12 13 14 15 16 Encoder1* *) Example shows wiring f or encoders with 5 volts power supply and RS422 line driver output Encoder 2* Digital Control Inputs RS232 +24 +5 A /A B 19 18 24 8 23 /B 7 - 20 +24 3 +5 2 A 22 /A 6 B 21 29 Co m+ (K1 - K 4) 26 K1 out 25 K2 out 10 K3 out TxD GND 14 30 31 *) Interface 1: *) Interface 2: ZD34007c_e.
Terminal 01 02 03 04 05 06 07 08 09 10 11 12 13 14 15 16 17 18 19 20 21 22 23 24 25 26 27 28 29 30 31 32 Name GND +5,2V out +24V out GND Encoder 2, /B Encoder 2, /A Encoder 1, /B Encoder 1, /A K4 out K3 out Cont.4 Cont.3 (PROG) RxD Ana.out 20 mA Ana.out +/-10V +Vin +5,2V out +24V out GND Encoder 2, B Encoder 2, A Encoder 1, B Encoder 1, A K2 out K1 out Cont.2 Cont.1 Com+ (K1-K4) TxD GND GND Function Common Ground Potential (0V) Aux. output 5.2V/150 mA for encoder supply Aux.
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).
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.
4. Operating Modes of the Counter For best survey, all parameters of the unit are arranged in 13 expedient groups, named “F01” - “F13”. Depending on the application, only a few of these groups may be important, while all other groups may be irrelevant for your specific application. This section describes possible applications and operating modes of the counter. The operation mode can be set under parameter group F07, parameter # F07.062. The following counting functions are available: Operating Mode F07.
All operating modes provide separate impulse scaling factors for each of the two encoders. Please observe that the display of the counter will only show whole numbers (integers) whereas remainders will be carried in the background Example: Differential Counter: Encoder1 Impulse Scaling Factor1 1000 x 0,98765 Impulses 967,65000 Encoder2 minus - Impulse Scaling Factor2 2000 x 1,23456 Impulses 2469,12000 = Display Remainder (background) -1501 0,47000 4.1. “Single Mode” (Encoder 1 only): F07.
4.2. “Sum Mode” (Encoder 1 + Encoder 2): F07.062 = 1 Both inputs encoder 1 and encoder 2 are active. From both values the unit forms the sum, with consideration of the individual encoder scaling factors. Where the encoder signal also provides direction information, this information will be considered by a corresponding sign of the count. Without direction information (channel A only) both encoder values will be added up.
4.3. Differential Mode (Encoder 1 – Encoder 2): F07.062 = 2 Both inputs encoder 1 and encoder 2 are active. From both values the unit forms the difference, with consideration of the individual encoder scaling factors. Where the encoder signal also provides direction information, this information will be considered by a corresponding sign of the count. Without direction information (channel A only) encoder 1 will increment and encoder 2 will decrement the counter.
4.4. Master Counter and Integrated Batch Counter: F07.062 = 3 This counter mode can be used for cut-to lengths applications, cyclic production flows, packing procedures etc. While the master counter takes care of the correct number of impulses per product, the background batch counter counts the number of products produced. This mode assumes that the automatic reset function has been activated for the master counter, providing restart from zero every time the preset value has been reached.
4.5. Evaluation of the Real Cutting Length: F07.062 = 4 This mode uses encoder 1 as a length counter and encoder 2 is not active. All counting occurs in the background and is not visible in the display. The counter gets started and stopped by remote control signals, and the final counting result appears in the display (frozen) whilst the counter already executes the next cycle in the background. For remote start and stop signals the inputs Cont.1 and Cont.
4.6. Diameter Calculation with Winding Rolls: F07.062 = 5 With this mode encoder 1 receives line impulses from a measuring wheel or a feed roll of a winder or unwinder application. Furthermore the counter needs one trigger impulse from the rotation of the winding roll. From both signals the counter can calculate and display the actual roll diameter. All counting occurs in the background and only updated diameter readings appear in the display. Encoder 2 is not in use with this application.
4.7. Radius Calculation with Winding Rolls: F07.062 = 6 With this mode encoder 1 receives line impulses from a measuring wheel or a feed roll of a winder or unwinder application. Furthermore the counter needs one trigger impulse from the rotation of the winding roll. From both signals the counter can calculate and display the actual radius of the roll. All counting occurs in the background and only updated diameter readings appear in the display. Encoder 2 is not in use with this application.
4.8. Cut-to-Length Control Counter: F07.062 = 7 or 8 The cut-to-length function described here requires the use of a counter model possessing at least two front thumbwheel switches. Modes 7 and 8 serve for control of cut-to-length applications with line drives providing a fast – slow – stop speed profile. The table below explains which functions are assigned to the thumbwheels and preset registers Preset Thumbwheel 1 Function Tool Width Thumbwheel 2 Preset register F01.
The Start command can be assigned to any of the front keys or to or to any of the Control Inputs, by attaching the RESET function to it (e.g. set parameter F06.052 to 1 to assign the Start function to the ENTER key etc.). Also an automatic reset function with a timed output signal can be used, in order to ensure automatic stepping of the cutting sequence without a remote start signal. The diagram below shows the switching states of outputs 2, 3 and 4 with respect to above parameters.
4.9. Monitor for Slip, Torsion, Skew Position, Shaft Fracture: F07.062 = 9 This counter mode is a special version of the Differential Counter described previously. As a major difference, in this mode all four presets and outputs (K1 – K4) refer exclusively to the differential count, and also a programmable slip function has been added. Before forming the difference, each of the two encoder inputs is scaled individually according to the setting of the impulse scaling factor.
4.10. Dual Counter, Two Independent Counters for Encoders 1 and 2: F07.062 = 10 Both encoder inputs operate fully independent one from the other, with individual scaling, evaluation and display. Also each counter can be set or reset individually. Both counters are treated equally, except with recording of minimum and maximum values. With regard to this function one of the two counters has to be declared as the "main counter".
5. Keypad Operation An overview of all parameters and explanations can be found under section 6. The menu of the unit uses four keys, hereinafter named as follows: P PROG UP DOWN ENTER Key functions depend on the actual operating state of the unit. Essentially we have to describe three basic states: Normal operation General setup procedure Direct fast access to presets and set values 5.1.
Step 00 State Key action Normal operation Level: Parameter group 03 04 Level: Parameter numbers 05 06 Level: Parameter values > 2 sec. F01 Display of the Parameter group 5x F02 … F06 Select group # F06 F06.050 2x Confirmation of F06. The first parameter of this group is F06.050 Select parameter 052 09 10 F06.051… F06.052 0 8x 1 …. 8 F06.
5.4. Change of Parameter Values on the Numeric Level The numeric range of the parameters is up to 6 digits with 6-decade models and up to 8 digits with 8 decade models. Some of the parameters may also include a sign. For fast and easy setting or these values the menu uses an algorithm as shown subsequently.
5.5. Code Protection against Unauthorized Keypad Access Parameter group F05 allows to define an own locking code for each of the parameter menus. This permits to limit access to certain parameter groups to specific persons only. When accessing a protected parameter group, the display will first show “CODE” and wait for your entry. To continue keypad operations you must now enter the code which you have stored before, otherwise the unit will return to normal operation again.
6. Menu Structure and Description of Parameters All parameters are arranged in a reasonable order of functional groups (F01 to F13) You must only set those parameters which are really relevant for your specific application. Unused parameters can remain as they actually are. 6.1. Summary of the Menu This section shows a summary of the parameter groups, with an assignment to the functional parts of the unit.
Group Function Group Function F07 062 063 064 065 066 067 068 069 070 Basic settings Mode of operation Decimal point encoder 1 Decimal point encoder 2 Decimal point combined <1,2> Multiplication factor <1,2> Division factor <1,2> Display offset <1,2> Brightness of LED display % Display Update Time F08 074 075 076 077 078 079 Analogue output definitions (ZA only) Output current or voltage Start value of conversion End value of conversion Output swing Zero offset Assignment of the Analogue Output F09
F11 Mode of Linearisation F11.108 Linearisation mode counter 1 F11.109 Linearisation mode counter 2 F12 F12.114 F12.115 F12.144 F12.145 F13 F13.146 F13.147 F13.176 F13.177 Table of Linearisation Counter 1 First interpolation point (x1 value) First interpolation point (y1 value) etc. --------> Last interpolation point (x16 value) Last interpolation point (y16 value) Table of Linearisation Counter 2 First interpolation point (x1 value) First interpolation point (y1 value) etc.
6.2. Description of the Parameters 6.2.1. F01 000 001 002 003 004 005 Preselections and presets Preselection K1 Preselection K2 Preselection K3 Preselection K4 Preset value encoder 1 Upon internal or external command the encoder 1 counter will set to this value Preset value encoder 2 Upon internal or external command the encoder 2 counter will set to this value 6.2.2.
6.2.3.
6.2.5. F05 033 034 035 036 037 038 039 040 041 042 043 044 045 Keypad protection codes Range Protected group F01 Protected group F02 Protected group F03 Protected group F04 Protected group F05 Protected group F06 Protected group F07 Protected group F08 Protected group F09 Protected group F10 Protected group F11 Protected group F12 Protected group F13 6.2.6.
F06 053 (continued) Switching characteristics of input „Cont.1“ 0= 1= 2= 3= 4= 5= 6= 7= 054 2= 3= 4= 5= 6= 7= 8= 9= 10= 11= 12= 13= 14= 055 Default 0 Ser. E3 0 … 14 0 E4 0…7 0 E5 0 … 14 0 E6 0…7 0 E7 0 … 14 0 E8 0 ...
6.2.7. Basic settings F07 062 Operation mode of the counter 0= 1= 2= 3= 4= 5= 6= 7= 8= 9= 10= 063 064 065 066 067 068 069 070 6.2.8. Analogue output definitions (ZA models only) F08 074 Output format 075 076 077 078 079 Ser. F2 0…5 0…5 0…5 0.0001 – 9.9999 0.0000 – 9.9999 -199999 - 999999 0…4 0 0 0 1.0000 0 0 0 F3 F4 F5 F6 F7 F8 F9 0.005 - 9.999 0.005 G0 Range 0…3 Default 0 Ser.
6.2.9.
F10 097 098 099 100 101 102 103 104 105 106 Switching characteristics K1 0= active with display ≥ preselection 1= active with display ≤ preselection 2= active with display ≥ preselection, 0→counter. Remaining errors are cancelled 3= active with display ≤ preselection, Set→counter.
6.2.11.
6.2.12. Hints for using the linearization function The subsequent drawing explains the difference between the modes of linearization. y y (x0)= -1000 (y0)= 900 Linearisation Mode = 2 Linearisation Mode = 1 (x15)= 1000 (y15)= 800 x (x8)= 0 (y8)= 750 x (x0)= 0 (y0)= 0 *) (x15)= +1000 (y15)= - 600 x-registers are to set the numeric counter value that the unit would display without linearization y-registers are to set the numeric value that should be displayed instead (i.e.
6.3. Clarification of the Counter Setting Functions This section is only important if you intend to preset the counter to values different from zero. The menu provides several options to reset one or both of counters to zero, or to set the counters to programmable preset values. Whilst with a reset command the data loaded into the counter is always zero, the setting procedure may load data from different locations, depending on the operating mode and some parameter settings.
7. Appendix for models ZD/ ZA/ ZR 6xx 7.1. Relay Outputs All available models are shown in section 1. While models ZD 3xx, ZA 3xx and ZR 3xx provide high-speed transistor outputs only, all models ZD 6xx, ZA 6xx and ZR 6xx provide four additional relay outputs, operating in parallel to the high-speed transistor outputs K1 – K4.
7.3. Specific Parameters for Units with Thumbwheel Switches The following parameter settings apply for units with thumbwheel switches only and are not relevant for all other models: 7.3.1. Read and update thumbwheel switch settings All actual thumbwheel settings are automatically considered when the unit is powered up. However, changes during normal operation will not be considered, unless upon special remote command.
From this follows that, if you use a counter model with two sets of thumbwheels only (thumbwheel set 1 and thumbwheel set 2), you would only have preselections referring to encoder1, but no thumbwheel access to the sum. To avoid such kind of limitations, parameter F10.104 allows free assignments between any of the thumbwheel switch sets (switch1 to switch4, see previous figure) and any of the four outputs (K1 to K4) Setting of parameter F10.
8. Appendix: Serial Communication Details Serial communication with the counter can be used for the following purposes: PC setup of the counter, using the OS32 Operator software Automatic and cyclic transmission of counter data to remote devices like PC, PLC or Data Logger Communication via PC or PLC, using the communication protocol This section describes the essential and basic communication features only. Full details are available from the special SERPRO manual. 8.1.
8.2. Automatic and Cyclic Data Transmission Set any cycle time unequal to zero to parameter F09.085. Set the serial access code of the register you would like to transmit to parameter F09.086. In theory you could transmit any of the internal registers by serial link, however only the following registers make really sense: F09.086 = 6 F09.086 = 7 F09.086 = 8 F09.086 = 9 F09.086 = 10 F09.
Upon correct request, the counter will respond: STX C1 C2 x x x x x x x ETX BCC STX = Control character (Hex 02) C1 = Register code to read, High Byte C2 = Register code to read, Low Byte xxxxx = Counter data *) ETX = Control character (Hex 03) BCC = Block check character *) Leading zeros will not be transmitted The Block-Check-Character represents the EXCLUSIVE-OR function of all characters from C1 to ETX (both comprised).
8.4. Serial Register Codes 8.4.1. Communication Commands Function Activate Data Store EEProm Code 67 68 These commands have to be sent to the unit every time after one or several new parameters have been transmitted, in order to activate or to store the new values. Both commands are "dynamic", i.e. it is sufficient to just send the data value "1" to the corresponding code position. Example: send the command "Activate Date" to the counter with Unit No.
Function code "10" (Start Serial Transmission) is incompatible with the serial handling of control commands and will cause communication conflicts 8.4.3. Actual counter data Nr. 6 7 8 9 10 14 Name Actual count value of counter 1 (encoder 1) Actual count value of counter 2 (encoder 2) Actual analogue output voltage (models ZA) Latest minimum value from the minimum record register Latest maximum value from the maximum record register Actual display value as shown on the LED display ZD34007c_e.
9. Specifications AC power supply DC power supply Aux. encoder supply outputs: : : Inputs : 24 V~ +/-10%, 15 VA 24V- (17 – 40V), approx. 100 mA (+ encoders) 2 x 5,2 VDC, 150 mA each 2 x 24V DC, 120 mA each 2 universal encoder inputs (internal pull-down resistor, Ri = 8.5 kΩ each channel) 4 digital control inputs HTL (Ri = 3.3 kΩ) Low < 2.5 V, High > 10 V, min. pulse width 50 µsec. Counting frequency (per encoder) : RS422 and TTL differential: 1 MHz (min.
10. Dimensions Models ZD3xx and ZA3xx: 110,0 (4.331’’) 91,0 (3.583) 48,0 (1.890) 10,0 (.394) 44,0 (1.732) 8,0 (.315) 96,0 (3.780’’) 9,0 (.345) 129,0 (5.079) 140,5 (5.531) Panel cut out: 91 x 44 mm (3.583 x 1.732’’) ZD34007c_e.
Models ZD6xx and ZA6xx: 110,0 (4.331’’) 88,5 (3.484) 8,0 (.315) 10,0 (.394) 90,5 (3.563) 96,0 (3.780’’) 12,0 (.472) 111,5 (4.39) 96,0 ( 3.78 ) With optional plexi glass cover for protection class IP65 motrona part # 64026) 9,0 (.345) 129,0 (5.079) 140,5 (5.531) 18,5 (.728) Panel cut out (w x h): 89 x 91 mm (3.504’’ wide x 3.583’’ high) ZD34007c_e.
