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Motrona ZD Series Operating Instructions Manual

High speed position counters and differential counters with two encoder inputs
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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 outputs
• RS232 interface and high-speed analogue output available, RS485 (only ZR)
• Choice of 6-decade display (15 mm, 0.56'') or 8-decade display (10 mm, 0.36'')
ZD340_07d_e.doc / Apr-17
3046 Home Road. Powell, OH 43065
Operating Instructions
P: (740) 917-5781
F: (740) 917-5791
www.GenesisAutomationOnline.com
www.GenesisAutomationOnline.com
Page 1 / 50
Sales@GenesisAutomationOnline.com

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Summary of Contents for Motrona ZD Series

  • Page 1 www.GenesisAutomationOnline.com 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 •...
  • Page 2 Extended modes of operation ZD34003a/Aug06/hk Models ZA_xxx and models xx_330 included ZD34003c/May06/af/hk Analogue output assignment, Preset calculation, Serial appendix ZD34003d/Feb08/hk Motrona version with small corrections and modifications ZD34005a/Sept08/hk Dual counter mode (mode 10), small corrections ZD34005b/Dec08/hk Several amendments, additional clarifications ZD34007a/Dec10/kk/hk Parameter "Display Update Time", correction of default values, amendments,...

  • Page 3: Table Of Contents

    Table of Contents Available Models........................4 Introduction.........................6 Electrical Connections......................7 3.1. Power Supply ........................9 3.2. Auxiliary Outputs for Encoder Supply................9 3.3. Impulse Inputs for Incremental Encoders ................9 3.4. Control Inputs Cont.1 – Cont.4 ..................9 3.5. Switching Outputs K1 – K4....................10 3.6. Serial Interface ......................10 3.7.

  • Page 4: Available Models

    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.
  • Page 5 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 642, ZA 642, ZR 642 ZD 632, ZA 632, ZR 632 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...

  • Page 6: Introduction

    “OS32” operator software (free of charge, download from our homepage www.motrona.com • Where you like to have free serial access to the unit by PLC or IPC or by a remote operator terminal, please observe the serial protocol details described in our separate manual “Serpro”...

  • Page 7: Electrical Connections

    3. Electrical Connections 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21 22 23 24 25 26 27 28 29 30 31 32 Co m+ (K1 - K 4) K1 out Encoder1* Fast...
  • Page 8 Terminal Name Function Common Ground Potential (0V) +5,2V out Aux. output 5.2V/150 mA for encoder supply +24V out Aux. output 24V/120 mA for encoder supply Common Ground Potential (0V) Encoder 2, /B Encoder 2, channel /B (B inverted) Encoder 2, /A Encoder 2, channel /A (A inverted) Encoder 1, /B Encoder 1, channel /B (B inverted)

  • Page 9: Power Supply

    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;...

  • Page 10: Switching Outputs K1 - K4

    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.

  • Page 11: Operating Modes Of The Counter

    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.

  • Page 12: Single Mode" (Encoder 1 Only): F07.062 = 0

    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: Impulse Scaling Impulse Scaling Remainder Encoder1...

  • Page 13: Sum Mode" (Encoder 1 + Encoder 2): F07.062 = 1

    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.

  • Page 14: Differential Mode (Encoder 1 - Encoder 2): F07.062 = 2

    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.

  • Page 15: Master Counter And Integrated Batch Counter: F07.062 = 3

    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.*) Only the inputs of encoder 1 are active (master counter).

  • Page 16: Evaluation Of The Real Cutting Length: F07.062 = 4

    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.

  • Page 17: Diameter Calculation With Winding Rolls: F07.062 = 5

    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.

  • Page 18: Radius Calculation With Winding Rolls: F07.062 = 6

    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.

  • Page 19: Cut-To-Length Control Counter: F07.062 = 7 Or 8

    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 –...
  • Page 20 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.

  • Page 21: Monitor For Slip, Torsion, Skew Position, Shaft Fracture: F07.062 = 9

    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.

  • Page 22: Dual Counter, Two Independent Counters For Encoders 1 And 2: F07.062 = 10

    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".

  • Page 23: Keypad Operation

    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:    PROG DOWN ENTER Key functions depend on the actual operating state of the unit. Essentially we have to describe three basic states: •...

  • Page 24: Direct Fast Access To Presets

    Step State Key action Display Comment Normal operation Counting Display of the > 2 sec. Parameter group Level:  F02 … F06 Select group # F06 Parameter group Confirmation of F06.  F06.050 The first parameter of this group is F06.050 Level: ...

  • Page 25: Change Of Parameter Values On The Numeric Level

    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.

  • Page 26: Code Protection Against Unauthorized Keypad Access

    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.

  • Page 27: Menu Structure And Description Of Parameters

    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.
  • Page 28 Group Function Group Function Basic settings Analogue output definitions (ZA only) Mode of operation Output current or voltage Decimal point encoder 1 Start value of conversion Decimal point encoder 2 End value of conversion Decimal point combined <1,2> Output swing Multiplication factor <1,2>...
  • Page 29 Mode of Linearisation Table of Linearisation Counter 1 F11.108 Linearisation mode counter 1 F12.114 First interpolation point (x1 value) F11.109 Linearisation mode counter 2 F12.115 First interpolation point (y1 value) etc. --------> F12.144 Last interpolation point (x16 value) F12.145 Last interpolation point (y16 value) Table of Linearisation Counter 2 F13.146 First interpolation point (x1 value)

  • Page 30: Description Of The Parameters

    6.2. Description of the Parameters 6.2.1. Preselections and presets Range Default Ser. Preselection K1 -199 999 - 999 999 1 000 Preselection K2 -199 999 - 999 999 2 000 Preselection K3 -199 999 - 999 999 3 000 Preselection K4 -199 999 - 999 999 4 000 Preset value encoder 1...
  • Page 31 6.2.3. Definitions for encoder 2 Range Default Ser. Encoder properties 0 … 3 Differential signals A, /A, B, /B (2 x 90°) HTL signals A, B (2 x 90°) single-ended Differential signals A, /A for count Differential signals B, /B to indicate static direction (if available) HTL signal A (single-ended) for count HTL signal B (single-ended) to indicate static...
  • Page 32 6.2.5. Keypad protection codes Range Default Ser. Protected group F01 Protected group F02 Protected group F03 0 = no protection Protected group F04 6079 Protected group F05 1 – 999 999 = Protected group F06 Protection code Protected group F07 for the actual Protected group F08 group...
  • Page 33 (continued) Range Default Ser. Switching characteristics of input „Cont.1“ 0 … 7 NPN (switch to -) function active LOW NPN (switch to -) function active HIGH NPN (switch to -) rising edge NPN (switch to -) falling edge PNP (switch to +), function active LOW PNP (switch to +), function active HIGH PNP (switch to +), rising edge PNP (switch to +), falling edge...
  • Page 34 6.2.7. Basic settings Range Default Ser. Operation mode of the counter 0 … 10 „Single“, encoder 1 only „Sum“, encoder 1 + encoder 2 „Differential“, encoder 1 – encoder 2 Master counter and batch counter Measuring of real cutting length Calculation of roll diameters Calculation of roll radius Cut-to-length control...
  • Page 35 6.2.9. Serial communication parameters Range Default Ser. Serial device address (unit number) 11 … 99 Serial baud rate 0 … 6 9600 Baud 4800 Baud 2400 Baud 1200 Baud 600 Baud 19200 Baud 38400 Baud Serial data format 0 … 9 7 Data, Parity even, 1 Stop 7 Data, Parity even, 2 Stop 7 Data, Parity odd, 1 Stop...
  • Page 36 Range Default Ser. Switching characteristics K1 0 … 5 active with display ≥ preselection active with display ≤ preselection Remark: ≥ and ≤ refer to active with display ≥ preselection, 0→counter. positive values Remaining errors are cancelled and are inversely active with display ≤...
  • Page 37 6.2.11. Parameters for Linearisation Modes of Linearisation Range Default Ser. Mode of linearization for counter 1 (encoder 1) 0 – 2 0 = Linearisation off 1 = Linearisation is defined for the numeric range (see drawings on from 0 to +999 999 only and negative values next page) will appear as a mirror of the positive values 2 = Linearisation is defined over the full range from -...
  • Page 38 6.2.12. Hints for using the linearization function The subsequent drawing explains the difference between the modes of linearization. (x0)= -1000 (y0)= 900 Linearisation Mode = 2 Linearisation Mode = 1 (x15)= 1000 (x8)= 0 (y15)= 800 (y8)= 750 (x0)= 0 (y0)= 0 (x15)= +1000 (y15)= - 600...

  • Page 39: Clarification Of The Counter Setting Functions

    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.

  • Page 40: Appendix For Models Zd 6Xx And Za 6Xx

    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 –...

  • Page 41: Specific Parameters For Units With Thumbwheel Switches

    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.
  • Page 42 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 F10.104...

  • Page 43: Appendix: Serial Communication Details

    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 •...

  • Page 44: Automatic And Cyclic Data Transmission

    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 : Actual count value of counter 1 (encoder 1)
  • Page 45 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...

  • Page 46: Serial Register Codes

    8.4. Serial Register Codes 8.4.1. Communication Commands Function Code Activate Data Store EEProm 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.
  • Page 47 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. Name Code 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...

  • Page 48: Specifications

    9. Specifications AC power supply 24 V~ +/-10%, 15 VA DC power supply 24V- (17 – 40V), approx. 100 mA (+ encoders) Aux. encoder supply outputs: 2 x 5,2 VDC, 150 mA each 2 x 24V DC, 120 mA each Inputs 2 universal encoder inputs (internal pull-down resistor, Ri = 8.5 kΩ...

  • Page 49: Dimensions

    10. Dimensions Models ZD3xx and ZA3xx: 110,0 (4.331’’) 91,0 (3.583) 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’’) ZD340_07d_e.doc / Apr-17 Page 49 / 50...
  • Page 50 110,0 (4.331’’) 88,5 (3.484) 96,0 (3.780’’) 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) ZD340_07d_e.doc / Apr-17...

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