Manual Z-4-Fold Level Shifter PR0095 Last revision: 2007-10-11 FANUC Robotics Europe S.A. Zone Industrielle - L-6468 Echternach Grand-Duché de Luxembourg Tel.: +352-72-7777-0 Fax.: +352 72 7777 - 403 [email protected] www.fanucrobotics.lu Seite 1 von 16 Content Chapters: 1. Description of the module.............................................................................................4 1.1. Purpose of use ......................................................................................................4 1.2. Technical data .......................................................................................................5 1.3. Principal circuit diagram ........................................................................................6 1.4. Connecting layout..................................................................................................7 1.4.1. Encoder input plug BR 2 (16-pole) .................................................................8 1.4.2. Encoder outputs plug BR3, 4, 5, 6 (12-pole) ..................................................9 1.4.3. Power supply (4-pole) ....................................................................................9 1.5. Displays ...............................................................................................................10 1.6. Settings ...............................................................................................................11 2. Installation ..................................................................................................................12 3. Commissioning ...........................................................................................................13 3.1. 4. Check-up before the commissioning ...................................................................13 Maintenance ...............................................................................................................14 4.1. Maintenance........................................................................................................14 4.2. Maintenance safety .............................................................................................14 4.3. Maintenance works..............................................................................................14 5. Trouble shooting.........................................................................................................15 6. Safety instructions ......................................................................................................16 Figures: Figure 1: Principal circuit diagram........................................................................................6 Figure 2: Layout...................................................................................................................7 FANUC Robotics Europe S.A. Zone Industrielle - L-6468 Echternach Grand-Duché de Luxembourg Tel.: +352-72-7777-0 Fax.: +352 72 7777 - 403 [email protected] www.fanucrobotics.lu Seite 2 von 16 Tables: Table 1: Technical data .......................................................................................................5 Table 2: Pin-out of encoder input ........................................................................................8 Table 3: Setting of the DIP-switches..................................................................................11 Table 4: Check-up .............................................................................................................13 Table 5: Maintenance ........................................................................................................14 Table 6: Possible errors/causes and trouble shooting .......................................................15 FANUC Robotics Europe S.A. Zone Industrielle - L-6468 Echternach Grand-Duché de Luxembourg Tel.: +352-72-7777-0 Fax.: +352 72 7777 - 403 [email protected] www.fanucrobotics.lu Seite 3 von 16 1. Description of the module The Z-4-Fold Level Shifter PR0095 gives out the signal of an incremental encoder potential-free to 4 outputs. At this the input signal to the evaluation electronic and to the 4 outputs is separated. Due to an input level in the range of 4 to 24V DC it is possible to use 5V and 24V encoders. All 4 outputs are also potential-free among each other and provided by separately supplied voltage in the range of 4V to 6V. A voltage converter internally produces a 5V supply voltage for 5V incremental encoder (max. 0,9A). If the internal 5 volt supply or the feed-in of the module for supply of the incremental encoder is used there is no electrical insulation to the evaluation electronic. A micro controller assumes the separation, interlocking of jitter, recognition of direction as well as the generation of the output signals within the module. Additionally a plausibility check of the input signals is carried out. 1.1. Purpose of use The module transforms the encoder signals, which are inducted by a commercial encoder. These signals can reach a level from 5 up to 24V DC. A potential free transformation to an output level of app. 5V (depending on the supply voltage of the output and on the load) with a RS 422 trait takes place. Additionally, pulse frequency of the output levels can be given in partition ratios of 1/2/4/8/16/32/64/128 and 256, whereas the counting direction can be negated. This requires only turning a DIP-switch. Partition ratios refer only to the encoder’s counting signals (K1 und K2), the zero encoder signal is given undivided. The module’s input frequency is max. 100 kHz. The module is connected via lockable header strips and is destined for top hat rail mounting (35mm). The frequency division is inactive, the counting direction reversal is switched of and the partition ratio is set to “1” on delivery. FANUC Robotics Europe S.A. Zone Industrielle - L-6468 Echternach Grand-Duché de Luxembourg Tel.: +352-72-7777-0 Fax.: +352 72 7777 - 403 [email protected] www.fanucrobotics.lu Seite 4 von 16 1.2. Technical data Power supply 12 – 35V DC reverse-polarity protected Power consumption app. 30mA on 24V without encoder DIP switch settings for partition ratios and counting direction Module configuration Power supply encoder 5V +/- 3%, max. 0,9A not potential-free to the feed-in or the same voltage like the feed-in with max. 0,7A (the voltage is app. 0,7V lower than the feed-in) Input level encoder 4 to 24 V DC Maximum input rate of encoder signal 100 kHz Power supply outputs 4V-6V DC Output level app. 5V, depending on the supply voltage of the output and the load, RS 422 trait Status display 1 LED – Operating state; 3 LED´s – Encoder signals Fuse protection Internal, 0,75A – self resetting Operating temperature 10° to 50° Storage temperature -30° to 70° Operating humidity 35 – 85 % relative humidity (without condensation) Safety class IP 24 Material Housing: Metal coated (RAL 5013) Weight app. 400 g Dimensions app. 194 x 76 x 36 (LxWxH) (dimensions without plugs and socket of DIN rail) Table 1: Technical data FANUC Robotics Europe S.A. Zone Industrielle - L-6468 Echternach Grand-Duché de Luxembourg Tel.: +352-72-7777-0 Fax.: +352 72 7777 - 403 [email protected] www.fanucrobotics.lu Seite 5 von 16 1.3. Principal circuit diagram DIP Switch 5V 0V K1 3 3 K1 Encoder CPU K2 K2 RS422 K0 K1 K2 Encoder Output #1 K0 Shield K0 5V 0V 3 LED3 LED2 LED1 3 RS422 LED4 K1 K2 Encoder Output #2 K0 Shield Shield 5V Encoder Supply 5V 12-35V 0V 3 3 RS422 K1 K2 Encoder Output #3 K0 Shield 5V DC Supply 0V DC 3 3 RS422 K1 K2 K0 Shield Shield Figure 1: Principal circuit diagram FANUC Robotics Europe S.A. Zone Industrielle - L-6468 Echternach Grand-Duché de Luxembourg Tel.: +352-72-7777-0 Fax.: +352 72 7777 - 403 [email protected] www.fanucrobotics.lu Seite 6 von 16 Encoder Output #4 1.4. Connection Layout Figure 2: Layout FANUC Robotics Europe S.A. Zone Industrielle - L-6468 Echternach Grand-Duché de Luxembourg Tel.: +352-72-7777-0 Fax.: +352 72 7777 - 403 [email protected] www.fanucrobotics.lu Seite 7 von 16 1.4.1. Encoder input plug BR 2 (16-pole) Clamp Function 1 Port 1 (A) + 2 Port 1 (A) - 3 Port 2 (B) + 4 Port 2 (B) - 5 Port 0 (C) + zero-impuls 6 Port 0 (C) – zero-impuls 7 / 8 connected internally Encoder supply 24 V DC – connection encoder 9 / 10 / 11 / 12 connected with 0 V supply internally 0 V DC – connection encoder 13 / 14 connected internally +5 V DC output 15 / 16 internally connected with shield Shielding encoder connector of encoder outputs and shielding of power supply Table 2: Pin-out of encoder input FANUC Robotics Europe S.A. Zone Industrielle - L-6468 Echternach Grand-Duché de Luxembourg Tel.: +352-72-7777-0 Fax.: +352 72 7777 - 403 [email protected] www.fanucrobotics.lu Seite 8 von 16 1.4.2. Encoder outputs plug BR3, 4, 5, 6 (12-pole) Clamp Function 1 / 2 connected internally 4 – 6 V DC supply output driver 3 / 4 connected internally 0 V DC supply output driver 5 Port 1 (A) + 6 Port 1 (A) - 7 Port 2 (B) + 8 Port 2 (B) - 9 Port 0 (C) + zero-impuls 10 Port 0 (C) – zero-impuls 11 / 12 internally connected with shield Shielding encoder connector of encoder input and shielding of power supply Table 3: Pin-out of encoder outputs 1.4.3. Power supply (4-pole) Clamp Function 1 + 12 – 35 V DC supply 2 0 V DC supply 3 / 4 internally connected with shield connector of encoder input and encoder outputs Table 4: Pin-out of power supply FANUC Robotics Europe S.A. Zone Industrielle - L-6468 Echternach Grand-Duché de Luxembourg Tel.: +352-72-7777-0 Fax.: +352 72 7777 - 403 Shield connection [email protected] www.fanucrobotics.lu Seite 9 von 16 1.5. Displays The module is equipped with 4 LED´s for display and control functions. Following the respective functions: LED4 – red (top) – unit ready-to-operate LED1 – red (second from the top) – encoder signal Port 1 LED2 – red (third from the top) – encoder signal Port 2 LED3 – red (fourth from the top) – encoder signal port 0 FANUC Robotics Europe S.A. Zone Industrielle - L-6468 Echternach Grand-Duché de Luxembourg Tel.: +352-72-7777-0 Fax.: +352 72 7777 - 403 [email protected] www.fanucrobotics.lu Seite 10 von 16 1.6. Settings The partition ratio of the encoder signals and the counting direction can be set by means of the DIP-switches, which are accessible from outside of the housing. The partition is only active if the DIP-switch 4 is set to OFF, in that case the partition is defined by the combination of DIP-switch 1 to 3. DIP switch 5 negates the counting direction independent from the setting of the other switches. Advice: The states of the Dip-switches are only read in at switch-on of the power supply, thus changes do not have any effect until the module is restarted. DIP 1 DIP 2 DIP 3 DIP 4 DIP 5 Partition Counting direction x x x On Off 1 Not negated Off Off Off Off Off 2 Not negated On Off Off Off Off 4 Not negated Off On Off Off Off 8 Not negated On On Off Off Off 16 Not negated Off Off On Off Off 32 Not negated On Off On Off Off 64 Not negated Off On On Off Off 128 Not negated On On On Off Off 256 Not negated x x x On On 1 Negated Off Off Off Off On 2 Negated On Off Off Off On 4 Negated Off On Off Off On 8 Negated On On Off Off On 16 Negated Off Off On Off On 32 Negated On Off On Off On 64 Negated Off On On Off On 128 Negated On On On Off On Table 3: Setting of the DIP-switches 256 Negated FANUC Robotics Europe S.A. Zone Industrielle - L-6468 Echternach Grand-Duché de Luxembourg Tel.: +352-72-7777-0 Fax.: +352 72 7777 - 403 [email protected] www.fanucrobotics.lu Seite 11 von 16 2. Installation Provided plans and sketches have to be observed. The default-connected values for electric energy have to be kept. Use only appropriate tools for installation as injury can occur otherwise. The laying of the electric connecting bends has to be carried out safely and sufficiently dimensioned. FANUC Robotics Europe S.A. Zone Industrielle - L-6468 Echternach Grand-Duché de Luxembourg Tel.: +352-72-7777-0 Fax.: +352 72 7777 - 403 [email protected] www.fanucrobotics.lu Seite 12 von 16 3. Commissioning 3.1. Check-up before the commissioning Damage may occur due to wrong connections and settings. Operate the module only with tested, correct connections and settings. The following conditions and set parameters have to be checked: • at the beginning of each working shift at disconnected operation • once a week during operation • after each maintenance or repair Pos. To be checked Where? 01 Are the module’s supply connections connected correctly and undamaged? Module 02 Are the mechanical covers of the module assembled correctly and undamaged? Module 03 Do the module’s operating displays show the correct functions? Module Table 4: Check-up FANUC Robotics Europe S.A. Zone Industrielle - L-6468 Echternach Grand-Duché de Luxembourg Tel.: +352-72-7777-0 Fax.: +352 72 7777 - 403 [email protected] www.fanucrobotics.lu Seite 13 von 16 4. Maintenance 4.1. Maintenance The maintenance personal has to be skilled and qualified sufficiently for the respective works. 4.2. Maintenance safety Please inform the operating personal in time about maintenance works. Coordinate these works with further, spreading procedures. All safety relevant changing in machine operation behavior has to be reported immediately. Switch off the machine and protect it against unauthorized reactivation. All changes have to be documented and the operating personal has to be instructed. 4.3. Maintenance works The following table states all necessary maintenance works and frequency: Description Where Measures Frequency Cleaning; Module Cleaning of the module; Annually; if necessary every 6 month Detachable connections Checking all detachable connections Indicator lamps Module Functional checking of the relevant indicator lamps weekly Electric connections Module Visual check for damage, bruise and abrasion monthly Table 5: Maintenance FANUC Robotics Europe S.A. Zone Industrielle - L-6468 Echternach Grand-Duché de Luxembourg Tel.: +352-72-7777-0 Fax.: +352 72 7777 - 403 [email protected] www.fanucrobotics.lu Seite 14 von 16 5. Trouble shooting As an optical indicator the module features 4 LED’s which allow for error detections on malfunctions. Note: During operation the brightness of LED 1-3 depends on the incoming frequency of encoder signals (flickering). Especially LED 3 might possibly not glow properly if the incoming frequency is quite low. Kind of error Signal on the module Trouble shooting Signal receiver does not receive any signals LED 4 does not glow Supply voltage is not available or reverse-poled, check wiring and power supply Signal receiver receives signals but reports encoder error LED 3 glows very bright Encoder zero-impuls is reversepoled, change wiring to correct polarity Signal receiver does not receive any signals LED 1 or 2 glow very bright, independently from the encoder incoming frequency Port 1 or 2 is not assigned with encoder counting signals but e.g. with supply voltage; make up correct wiring Signal receiver does not receive any signal LED 1- 4 glow Power supply for the respective output is not available; check wiring of the output on the module as well as the power supply Table 6: Possible errors/causes and trouble shooting Please check all mentioned sources of error first before returning the tool! FANUC Robotics Europe S.A. Zone Industrielle - L-6468 Echternach Grand-Duché de Luxembourg Tel.: +352-72-7777-0 Fax.: +352 72 7777 - 403 [email protected] www.fanucrobotics.lu Seite 15 von 16 6. Safety instructions The module is not specified and designed to use as a safety critical component in the medical sector. The use of the module in this sector is inadmissible. - Please contact a specialist if there are any doubts concerning the mode of operation, safety or tool connections. - If any item or liquid gets into the tool, disconnect power supply and ask qualified personal to check the tool before further use. - Avoid strong mechanical load of the tool. - Do not expose the tool to high temperatures, strong vibrations or high humidity. - Never put the tool on an unstable surface. Persons can be injured if the tool falls down. - Also consider the safety instructions and manuals of the other units to which the tool gets connected. - In industrial facilities the regulations for the prevention of industrial accidents of the employers’ liability insurance association for electric plants and equipment are to be considered. - In schools, training facilities or any other workshops the use of electronic products has to be observed by skilled personal. - If there are any questions concerning the correct connection or if there is anything which is not fully explained in the manual, please contact our technical information desk. FANUC Robotics Europe S.A. Zone Industrielle - L-6468 Echternach Grand-Duché de Luxembourg Tel.: +352-72-7777-0 Fax.: +352 72 7777 - 403 [email protected] www.fanucrobotics.lu Seite 16 von 16
