BAV AS-LP-00008-01 BAE PD-AV-006 User s Guide7.1.4 BiSS frame - example resolution = 131,072, fixed data length 24 ... Action instruction 1 2. Action instruction 2 Keys are shown in

BAV AS-LP-00008-01BAE PD-AV-006

User’s Guide

english

www.balluff.com

www.balluff.com 3english

BAV AS-LP-00008-01/BAE PD-AV-006Evaluation System

1 Notes to the user 51.1 Validity 51.2 Symbols and conventions 51.3 Scope of delivery 51.4 System requirements 51.5 Abbreviations 5

2 Safety 62.1 Intended use 62.2 General safety notes for the angle measuring system 62.3 Component safety and protection 62.4 Explanation of the warnings 62.5 Disposal 6

3 Construction and function 73.1 System component overview 73.2 Absolute Magnetically Coded Disk 73.3 Processing electronics 73.4 Function 7

4 Installation and connection 84.1 Angles, distances, and tolerances 84.2 Assembling the angle measuring system 94.3 Electrical connection 10

4.3.1 USB cable 114.3.2 Incremental cable 114.3.3 Serial cable 114.3.4 BiSS USB adapter 12

4.4 Magnetic fields and cable routing 12

5 Software 135.1 Software overview 135.2 Installation 135.3 Starting the program 135.4 User interface 145.5 Calibration and parameterization functions 15

5.5.1 Functional areas within the calibration and parameterization functions 15

5.5.2 Data integrity and performance 155.5.3 Calibration routine 165.5.4 Sequence of calibration and parameterization functions 165.5.5 Calibration routine display elements 175.5.6 Error during calibration 175.5.7 Expert parameterization 18

5.6 Position detection and display (measure) 195.7 Overview of functions 20

6 Startup 216.1 Starting up the system 216.2 Check system function 216.3 Operating notes 21

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7 Interfaces 227.1 BiSS C interface 22

7.1.1 Principle 227.1.2 Data format (BiSS frame) 237.1.3 BiSS frame (general) 247.1.4 BiSS frame - example resolution = 131,072, fixed data length 247.1.5 BiSS frame - example resolution = 32,768, flexible data length 247.1.6 Uni-directional BiSS C 257.1.7 Bi-directional BiSS C (status register) 25

7.2 Synchronous Serial Interface (SSI) 267.2.1 Principle 267.2.2 Data formats 267.2.3 Faulty SSI query 26

7.3 Incremental interface 277.3.1 Analog interface (1 VPP) 277.3.2 Digital interface (RS422) 277.3.3 Maximum rotational speed, resolution, and edge distance 28

8 Technical data 298.1 Absolute magnetically coded disk 298.2 Processing electronics 29


The Evaluation System was developed in collaboration with iC-Haus GmbH.

1.1 Validity

This guide describes the construction, function, fitting, and installation for the Evaluation System as a functional module, consisting of the BAV AS-LP-00008-01 absolute magnetically coded angle measuring system (with processing electronics, from software release 2.0.6.0) and the BAE PD-AV-006 BiSS USB adapter.

The guide is intended for qualified technical personnel. Readthis guide before installing and operating the Evaluation System.

1.2 Symbols and conventions

Instructions are indicated by a preceding triangle. The result of an action is indicated by an arrow.

► Action instruction 1 ⇒ Action result

Action sequences are numbered consecutively:1. Action instruction 12. Action instruction 2

Keys are shown in angle brackets, e.g. “Confirm with ”.

Key combinations are buttons which are pressed simultaneously. These are joined by a plus sign, e.g. + .

Buttons are written in small caps, e.g. Update transdUcer.

Menu commands are joined with a greater-than sign, e.g. “Settings > Options” stands for the menu command “Options” from the “Settings” menu.

Note, tipThis symbol indicates general notes.

1.3 Scope of delivery

BAV AS-LP-00008-01

– Absolute magnetically coded disk– Processing electronics (MU1C)– Cable set for electronics and controller

BAE PD-AV-006

– BiSS USB adapter– Cable set for adapter and computer

The corresponding software for installation must be downloaded online from www.ichaus.de/MU1C.

1.4 System requirements

Installation requires administrator rights on the PC.

– Approved for Win XP (SP3), Windows 7 (32 bit + 64 bit), and Windows 8 (32 bit + 64 bit)

– Min. 1 GB RAM– USB 2.0

1.5 Abbreviations

BiSS Bi-directional synchronous serial interface

ESD Electrostatic discharge

GUI Graphical user interface

SSI Synchronous serial interface

1 Notes to the user


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2.1 Intended use

The absolute magnetically coded angle measuring system is intended for communication with a machine controller (e.g. PLC), only for limited application in laboratory operation or as a development tool. It is intended to be installed into a machine or system. Flawless function in accordance with the specifications in the technical data is ensured only when using original BALLUFF accessories. Use of any other components will void the warranty.

Non-approved use is not permitted and will result in the loss of warranty and liability claims against the manufacturer.

2.2 General safety notes for the angle measuring system

Installation and startup may only be performed by trained specialists with basic electrical knowledge.

Qualified personnel are those who can recognize possible hazards and institute the appropriate safety measures due to their professional training, knowledge, and experience as well as their understanding of the relevant regulations pertaining to the work to be done.

The operator is responsible for ensuring that local safety regulations are observed.In particular, the operator must take steps to ensure that a defect in the angle measuring system will not result in hazards to persons or equipment.If defects and unresolvable faults occur in the transducer, it should be taken out of service and secured againstunauthorized use.

2.3 Component safety and protection

The GND path of the BiSS USB adapter is not insulated. Improper machine shielding can destroy the adapter.

The Evaluation System contains components that can be damaged or destroyed by electrical discharge currents. Thus, suitable ESD safety precautions must be taken during assembly and connection.

2.4 Explanation of the warnings

Always observe the warnings in these instructions and the measures described to avoid hazards.

The warnings used here are structured as follows:

SIGNAL WORDHazard type and sourceConsequences if not complied with

► Measures to avoid hazards

The individual signal words mean:

NOTICEIdentifies a hazard that could damage or destroy the product.

DANGERThe general warning symbol in conjunction with the signal word DANGER identifies a hazard which, if not avoided, will certainly result in death or serious injury.

2.5 Disposal

► Observe the national regulations for disposal.

2 Safety



3.1 System component overview

Fig. 3-1: Component overview

3.2 Absolute Magnetically Coded Disk

The magnetically coded disk can be re-ordered separately (Type code breakdown: BML-M60-A32-A0-M030/010-R0, ordering code: BML04HN).

Fig. 3-2:

5 2

8.060

Ø 15

Ø 30

A-A

Ø 10 M6

Ø 18 r6

A A

Construction of the magnetically coded disk

Master track“Nonius” (vernier) track

3 Construction and function

3.3 Processing electronics

Fig. 3-3:

75°60°

12.5

34.8

B

A

Ø40±0.1

46

8.59

1.6

1±0.

1

60°75°

2×Ø2H7

3×Ø3.4Ø0.1 A B

Ø0.1 A B

Construction of the processing electronics

3.4 Function

The Evaluation System is a perpendicularly magnetized, absolute “off-axis” angle measuring system with high system accuracy. Available in a single version, it offers a range of serial (absolute) and incremental interfaces for connection to a wide variety of control systems.

The Evaluation System is an alternative to the standard magnetic solutions for optimal, precise control of small motors and drives.

Using the BiSS USB adapter and the provided evaluation software, the different interfaces of the Evaluation System can be parameterized and required system tests performed.

Motor shaft

Processing electronics

Serial cable

PCIncremental cable

Serial cableUSB cable

BiSS USB adapter

Absolute magnetically coded disk

Controller

D-Sub plug (male)

BAV AS-LP-00008-01BAE PD-AV-006


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4.1 Angles, distances, and tolerances

Fig. 4-1:

11.2

4

+Pitch

–Pitch

–Roll+Roll–Yaw+Yaw

5

5

+X

+Y

Z

–X

–Y

Angles, distances, and tolerances

Distances/angles

Z (gap between sensor/disk) +0.1…+0.5 mm

Y –0.5…+0.5 mm

X –0.5…+0.5 mm

Yaw


4.2 Assembling the angle measuring system

NOTICEInterference in functionImproper assembly of the magnetically coded disk and processing electronics can affect the functioning of the angle measuring system and lead to increased wear or damage to the system.

► All permissible distance and angle tolerances (see section 4.1) must be strictly complied with.

► Install the measuring system so that moving parts do not touch any static components:– The processing electronics must not touch the

disk or the motor shaft.– The disk must not make any contact whatsoever

when turning.External magnetic fields change the functional properties. Magnetic fields with ≥ 1 mT reduce the precision of the system, magnetic fields of ≥ 30 mT destroy the magnetic tracks of the disk. The functionality of the system is no longer ensured.

► Direct contact with magnetic clamps or other permanent magnets must be avoided.

► Contact with other magnetic tapes (magnetic sides) must be avoided.

No forces may be exerted on the cable. ► Provide the cable with a strain relief.

NOTICEDischarge currentsElectrostatic discharges can destroy components.

► Take ESD safety precautions!

When fitting the disk and processing electronics, the following distances and tolerances must be observed (for values, see sec. 4.1 on page 8):– Gap between processing electronics and disk– Radial offset between processing electronics and disk– Tangential offset between processing electronics and

disk– Permissible angular tolerances

The optimal shaft diameter for press-fitting the disk is 10m5.

1. Press the disk onto the shaft (see Fig. 4-2).2. Place processing electronics on the centering pins.3. Hold the spacers between the motor and processing

electronics and fix the processing electronics with M3 screws.

4. Check the positioning of the processing electronics (see page 8).

4 Installation and connection (continued)

Fig. 4-2: Angle measuring system assembly

Mounting screws Spacers

Centering pins

Motor shaft

Motor

Component-free area


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4.3 Electrical connection

NOTICEDischarge currentsVoltage-carrying pins on the USB adapter can damage the processing electronics.

► Before connecting the USB adapter, observe the safety precautions for the USB adapter (see section 4.3.4, BiSS USB adapter)!

Before the components are connected, the software drivers must be installed (see section 5.2).

Note the information on Magnetic fields and cable routing on page 12.

The electrical connection is made via connectors. The pin assignments can be found in Tab. 4-2 to Tab. 4-4.

Fig. 4-3:

Slot J2(serial port A)

Slot J1(incremental port B)

Processing electronics connections

Connection for configuration

► Connect the USB adapter to the configuration computer using the USB cable.

► Connect the USB adapter to the processing electronics (slot J2) using the serial cable.

Fig. 4-4:

PC


Serial cableProcessing electronicsUSB cable

BiSS USB adapter

Connecting the processing electronics for configuration

Connection for analog/digital operation ► Connect the processing electronics (slot J1) to the

controller using the incremental cable. ► Connect the processing electronics (slot J2) to the

supply voltage using the serial cable.

Fig. 4-5: Processing electronics in

Serial cable

Incremental cable



analog/digital operation

Connection for SSI/BiSS operation

► Connect the processing electronics (slot J2) to the controller using the serial cable.

Fig. 4-6:

Serial cable



Processing electronics in SSI/BiSS operation

Supply voltage

Controller

Controller




4.3.1 USB cable

– For connecting the adapter to the configuration computer

– Operating voltage and configuration data– Connections: USB type A/USB type mini-B– Standard pin assignment

4.3.2 Incremental cable

– For connecting the processing electronics to the controller

– Incremental signals– Connections: J1 plug/open ends

Fig. 4-7: Incremental cable

Fig. 4-8:

12

111

2

J1 plug pin assignment, as viewed from socket side

Pin Signal

1 VT +A (+Sin)

Analog2 BK −A (−Sin)

3 GY PK +B (+Cos)

4 RD BU −B (−Cos)

5 RD GND

6 BU GND

7 WH +A

Digital

8 BN –A

9 GN +B

10 YE –B

11 GY +Z

12 PK –Z

Tab. 4-2: J1 plug pin assignment

4.3.3 Serial cable

– For connecting the evaluation unit to the controller– Operating voltage and BiSS/SSI interface– Connections: J2 plug/Sub-D plug

Fig. 4-9: Serial cable

J2 plug

Fig. 4-10:

16

J2 plug pin assignment, as viewed from socket side

Pin Signal

1 RD +5 V DC

2 BU GND

3 PK +Data

4 GY –Data

5 GN +Clk

6 YE –Clk

Tab. 4-3: J2 plug pin assignment

Sub-D socket

Fig. 4-11:

1

6 7 8 9

5432

Sub-D socket pin assignment, as viewed from socket side

Pin Signal

1 n. c. Not used

2 GN +Clk

3 YE –Clk

4 RD +5 V DC

5 n. c. Not used

6 BU GND

7 PK +Data

8 GY –Data

9 n. c. Not used

Tab. 4-4: Sub-D plug pin assignment



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You can find additional information on the programming adapter online at www.ichaus.de.

4.4 Magnetic fields and cable routing

Magnetic fields

The angle measuring system is a magnetically coded system. It is important to maintain adequate distance between the angle measuring system and strong, external magnetic fields.

NOTICEInterference in function and damage due to strong magnetic fieldsExternal magnetic fields change the functional properties. Magnetic fields with ≥ 1 mT reduce the precision of the system, magnetic fields of ≥ 30 mT destroy the magnetic material. The functionality of the system is no longer ensured.

► Direct contact with magnetic clamps or other permanent magnets must be avoided.

Cable routing

Do not route the cable between the angle measuring system, controller, and power supply near high voltage cables (inductive stray noise is possible).The cable must be routed tension-free.

Bending radius for fixed cable

The bending radius for a fixed cable must be at least 7.5 times the cable diameter.

4.3.4 BiSS USB adapter

Fig. 4-12: BiSS USB adapter

NOTICEVoltage-carrying pinsPins 1, 5, and 9 are not required for the Evaluation System, but they carry voltage.

► Do not connect pins 1, 5, and 9!

Damage to the componentsThe GND path of the BiSS USB adapter is not insulated. In certain circumstances, the adapter can be damaged by increased discharge currents via the measuring system.

► Observe the discharge currents in the machine design. ► Do not loop the ground (housing ground, shield) for

the processing electronics to the laptop through the BiSS adapter, as this could destroy the interface modules of the adapter.

► If the processing electronics are also grounded, an isolator (available from specialist retailers) can be interconnected.

There is an increased risk of discharge currents with laptops on which the protective earth (PE) of the power supply unit is not connected to the device (2-pin charging cable).

► Use a stationary desktop computer.

The following pins are to be used to connect the USB adapter to the processing electronics:

Pin Signal Function

1 VB +12 V, not required1)

2 +MA +Clk

3 –MA –Clk

4 VDD Supply voltage (+5 V, max. 90 mA)

5 –MO Not required1)

6 GND GND

7 +SLO +Data

8 –SLO –Data

9 +MO Not required1)

1) Do not connect!

Tab. 4-5: USB adapter pin assignment




5.1 Software overview

The software (MU1C Evaluation GUI) is the graphical user interface for intuitive configuration of interface parameters and calibrating the Evaluation System.The software can be used to perform a system test and display the position or status of the processing electronics.

The most significant features are:

– Graphic display of the position/status bits– System test with display of the remaining safety of the

overall system (in percent)– Setting the incremental interface parameters

– Analog (Sin/Cos)– Digital (ABZ)

• Edge distances• Resolution

– Setting the serial interface parameters (absolute position):– BiSS– SSI (binary/Gray)Each with a variable resolution.

– Calibrating the overall system (adjusting the processing electronics to the disk subject to installation tolerances)

5.2 Installation

A USB 2.0 port is required for full functionality.The USB adapter should be connected directly to the computer (USB hubs can cause errors).Without permanent administrator rights or in case of a high Windows security level (on Windows 7), installation to a folder other than “C:\Program Files\” is recommended (e.g. “C:\Users\Public\Documents”).

While the software drivers are installing, no cables may be connected to the USB adapter.

1. Download the software free-of-charge online from: www.ichaus.de/MU1C

2. Start “Setup.exe”. ⇒ The following software is installed:

– MU1C Evaluation GUI– BiSS USB adapter driver (iC-Haus)

3. Once the installation is completed successfully, connect the USB adapter (see section 4.3).

⇒ Driver installation is finished.

5.3 Starting the program

► Call up MU1C_eval_gui.exe. ⇒ The program starts and displays the user interface

(see section 5.4).

5 Software


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5.4 User interface

Fig. 5-1: User interface

The user interface is divided into 2 functional blocks:

1. Programming and Calibration for parameterization and calibration functions Calling up the functions by clicking the new sensor/check In (power on) button activates the areas of the user interface relevant to parameterization and calibration functions (see section 5.5) and sets the processing electronics to configuration mode.

Do not interrupt the connection between the processing electronics and computer (including the USB adapter) between the Check In and Check Out function calls.

5 Software (continued)

1 2

Status text field

2. Open Measurement Window for position detection and display Calling up the function by clicking the MeasUre (power on) button opens the Measure window to display the parameters relevant to position detection (see section 5.6).

In addition, the user interface provides information about the targets and adapters used.



5.5 Calibration and parameterization functions

5.5.1 Functional areas within the calibration and parameterization functions

The user interface features two functional areas for the calibration function (see Fig. 5-2):

Fig. 5-2:

1 1A

2 2A

Overview of the control and display elements of the calibration function

Area No. Description

Calibration 1 Calibration routing control elements

1A Display of the calibration routine

Interface Configuration

2 Interface configuration

2A When setting the interfaces, the user interface supports the end user with the following supplementary information:– Bits per Revolution (number of

position bits required (= resolution))– Measurement Step (resolution in

angular degrees)– Sin/Cos per Revolution (interface

with 1 VPP : Sin/Cos periods per revolution)

– Max. RPM (maximum disk speed resulting from the system)

Tab. 5-1: Description of the control elements for the calibration function; for numbering see Fig. 5-2

The individual functional descriptions are contained in section 5.7.

The status text field displays important information on the functional sequence, especially in the case of an error.


5.5.2 Data integrity and performance

The maximum length of the calibration routine depends on the amount of RAM and the processor.

To achieve maximum performance, the following requirements are recommended:– Not connecting USB hubs to the USB path– Avoiding or closing resource-hungry applications on

the “test computer” running in parallel.– Due to the limited buffer of the BiSS USB adapter, a

cyclic transfer to the computer is required. To optimize this transfer rate (if errors occur during the calibration routine), proceed as follows:– Ensure that the computer has enough free RAM.– Increase the process priority of the software:

while executing the tool, open the Windows Task Manager and select the Processes tab. Right-click on the tool process and switch the priority to HIGH.


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5.5.3 Calibration routine

Calling up the calibration routine

► Start parameterization via new sensor/check In (power on).

⇒ The processing electronics are initialized (set to configuration mode) and must not be removed until the Check Out functional call (see Completing the calibration routine). Supply voltage is applied.

Calibrating the system and setting the parameters

At this point, only a brief description of calibration is provided. Due to the wide variety of options, individual setup and display options are described in sections 5.5.4 and 5.5.5.

System start-up requires a calibration run to set the processing electronics to the installation position (yaw, pitch, roll, gap) of the disk. This results in increased installation tolerances (margin of safety).

The recommended rotational speed for optimized calibration is between 100 and 300 rpm.

If the rotary movement is too slow (or too fast), an error message is displayed after measurement. The error message for too slow rotary movement is displayed in the following:

After each completed calibration routine, a verification of the overall system, including the disk used, is performed.

A differentiation is made between automatic calibration (Autom./Both) and manual calibration (Manual/Analog und Manual/Track).

The system accuracy achieved through calibration is always better with automatic calibration than manual calibration.

Automatic calibration calibrates both the analog path and the static track offset of the disk. This requires a constant rotary movement of approx. 4–6 revolutions.

By contrast, manual configuration allows for the calibration of the analog path and then the track offset with separate revolutions.

If no correct track offset values are available during analog calibration, the system test (margin of safety) may fail despite successful calibration.

Completing the calibration routine

► Click the save and check oUt (power off) button ⇒ Configuration mode is ended and the parameters

are saved. The processing electronics can be removed.

or ► Click check oUt wIthoUt savIng (power off)

⇒ Configuration mode is ended without saving the parameters. The processing electronics can be removed.

5.5.4 Sequence of calibration and parameterization functions

In the user interface, the function call-ups are arranged from top to bottom in chronological order (see Fig. 5-3).

Check in

Check out

1

2 2A

3 3A

5 6

4

Fig. 5-3: Overview of the chronological order of the calibration function




5.5.5 Calibration routine display elements

System Conditions – Track Offset – Margin Of Safety

As the Evaluation System is a 2-track Nonius system, the phase between master and Nonius track is relevant for absolute position calculation. During calibration, this phase relation is measured and the distance to the synchronization limits is output in percent. The resulting figure is called the “Track-Offset Margin of Safety” and is calculated using the following formula:

Margin of safety = 100 % ×Tolerable phase error – max. phase error

Max. phase error

When the margin of safety = 1%, the disk is only just functional. Here, tolerable phase error represents the maximum permissible error and max phase error represents the largest measured phase error.

To be able to provide a sufficiently reliable system, values >15 % (typ. 22 %) are recommended during set-up.

Analog Master Phase

The Analog Master Phase describes the angle between the sine and cosine signals (orthogonal system) of the master track:

Phase = 90° – (cosine – sine)Ideally, the phase = 0°, then the evaluation unit is positioned ideally (X-Y plane) with respect to the disk.If the position is not ideal, the phase between sine and cosine can be corrected by a maximum of ± 6°.

The typical correction values are in the range of –3° to +3°.


Calibration OK LED

The calibration OK LED lights up as soon as the calibration of the analog path phases can be reproduced across multiple series of measurements (deviations

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5.5.7 Expert parameterization

Hysteresis/latency

Setting the hysteresis and latency. Different filters for position detection can be selected in the sensor.

Filter level A is the only filter level to cause an additional hysteresis of 0.175°.

Depending on the selected filter setting, the latency is 2.7 µs to 2.5 ms (see Fig. 5-4).

Fig. 5-4:

A - 0.175°/2.5ms (dynamic)

B - 0.0°/650µs (dynamic)

D - 0.0°/10µs (fixed)

E - 0.0°/2.7µs (fixed)

18800

1ms

10ms

0.1µs

1µs

10µs

100µs

1880

RPM

18818.81.880.188

Late

ncy

Latency of the different filter settings depending on RPM

The working space (see Tab. 4-1 auf Seite 8) was determined with filter level A.


BiSS pos. data length

Setting the position data length for the BiSS interface:– Fixed (19 bits, default): default setting, data length

defined as 19 bits (for an example, see Fig. 7-3).– Flexible (14 to 17 bits): adjusts the data length to the

resolution (Bits per Revolution) in the range of 14 to 17 bits (for examples, see Fig. 7-4). If a resolution smaller than 14 bits is selected, leading null bits are added.



5.6 Position detection and display (measure)

Starting position detection/display

► Click the MeasUre (power on) button.

⇒ A new window opens (see following image) and the processing electronics are switched to the BiSS interface (bi-directional) to receive status information.

After the next close (power off) functional call-up, the original configuration is once again present.

Button Function

start contInUoUs read

Starts cyclic parameter acquisition and displays the current position.The position is displayed as a number in increments, and on a dial instrument in angular degrees.The button now reads stop contInUoUs read.

stop contInUoUs read

Stops cyclic parameter acquisition.

read statUs regIster

Reads and displays the error register from the processing electronics.


Button Function

close (power off)

Closes the parameter acquisition window; voltage is off.

Tab. 5-2: Parameter acquisition window buttons

The parameter acquisition window is divided into 2 parts. In the top section, the position data for the serial interface is displayed (BiSS uni-directional parameters).

Element Function

Display:Position [Inc]

Binary display of the serially transmitted, absolute position (values in increments)

Display:Position [Deg]

Position [Deg] in angular degrees (computed)

LED:Error

LED lights up in red when an error occurs and the BiSS interface error bit is set.

LED:Warning

LED lights up in red when a warning occurs and the BiSS interface warning bit is set.

LED:Accumula-ted E/W

LED lights up in red as soon as anerror or warning bit occurred once. (Reset by pressing the start/stop contInUoUs read button again)

Tab. 5-3: Parameter acquisition window displays/LEDs

This is followed by the status information which is read out via bi-directional communication (BiSS bi-directional parameters).

Error LED Displayed errors

Start Up Error turning on the processing electronics

Master Track: Poor Level

Amplitude of the master track too weak (check installation position)

Nonius Track: Poor Level

Amplitude of the Nonius track too weak (check installation position)

Consist-ency

Absolute values are not consistent. Check installation position (distances and tolerances) and repeat calibration.If this error occurs, the system is not working in absolute mode. In this case, calibration must be repeated.

Tab. 5-4: Parameter acquisition window error LEDs

These errors are also displayed through the error bit (active low).


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5.7 Overview of functions

Function (no.)* Element Description

Programming and Calibration (1)

Button New sensor /Check In

Switches the supply voltage on and initializes the processing electronics (the processing electronics are set to configuration mode and may no longer be removed until the Check Out functional call)

Calibration (2)

Drop-down menu

Duration The Duration drop-down menu adapts the duration of a calibration measurement to the rotational speed of the disk. Recommended setting: 3.0 sec.

Button Set Default Values (Optional, usually not required) If the processing electronics was calibrated outside of the specified measuring ranges and valid calibration is not possible as a result, the set defaUlt valUes button resets the processing electronics to the default values for its internal signal processing.

Button Calibrate Starts the calibration routine based on the set parameters:(Both, Analog, Track). The processing electronics are calibrated to the respective installation situation. This results in increased mounting tolerances (margin of safety). Furthermore, a verification of the mounting situation, including the disk used, is performed.

Checkbox Autom.: Both(Standard)

Calibration of the analog path and system (track) offset, as well as subsequent verification of the overall system (functional test).This routine is recommended as soon as a constantly rotating system is available. The system accuracy achieved through calibration is always better with automatic calibration than manual calibration.

Checkbox Manual: Analog(Experts only)

Part 1 (of 2) of manual calibration – analog path:During calibration where the disk is rotated manually, it is not possible to move the disk constantly across several revolutions. As a result, the measured values required for calibration and verification are recorded in 2 steps, each for one revolution.(Since the system (track) offsets have not yet been calibrated under certain circumstances, the verification (of the overall system) may display an error.)

Checkbox Manual: Track(Experts only)

Part 2 (of 2) of manual calibration – track (offset) path:The second part of manual calibration calibrates the (static) track offsets required to determine the absolute position.

Button Check Calibration Checks the function of the overall system (processing electronics with disk).The result is shown via the corresponding display elements (2A*).

Interface Configuration (3)

Drop-down menu

Port A+BResolution

Sets the resolution in the range of 4 to 131,072 increments/revolution. (The resolution set here applies to both the ABZ and the BiSS/SSI interface)

Drop-down menu

Serial Port ASerial Interface

Sets the type of serial interface (BiSS/SSI).

Drop-down menu

Incremental Port BIncremental Interface/Min. Edge Separation

Sets the type of incremental interface (1 VPP, ABZ) and the minimum edge distance.

Button Set Incremental Port B (volatile)

Immediately applies all parameters of port B (incremental interfaces), including resolution, to the processing electronics until the next power down. (Does not affect the check-out functions (5.1 and 5.2.))

Drop-down menu

Expert Setting the hysteresis and latency. Different filters for position detection can be selected in the sensor.Setting the position data length for the BiSS interface to the default setting (data length specified as 19 bit) or flexible adjustment of data length to the resolution (Bits per Revolution) in the range 14 to 17 bits.

Other(4, 5, 6)

Button Set Preset Position Sets the current position of the sensor to the value “0”.

Button Save And Check Out(Power Off)

Permanently saves all parameters in the processing electronics and closes the configuration mode. The supply voltage is off and the processing electronics can be removed.

Button Check Out without Saving (Power Off)

Closes the configuration mode without saving changes in the processing electronics. The supply voltage is off and the processing electronics can be removed.

Tab. 5-5: Description of the control elements, * for numbering, see Fig. 5-3 on page 16




6.1 Starting up the system

DANGERUncontrolled system movementWhen starting up, if the angle measuring equipment is part of a closed loop system whose parameters have not yet been set, the system may perform uncontrolled movements. This could result in personal injury and equipment damage.

► Persons must keep away from the system’s hazardous zones.

► Startup must be performed only by trained technical personnel.

► Observe the safety instructions of the equipment or system manufacturer.

1. Check connections for tightness and correct polarity. Replace damaged connections or devices.

2. Turn on the system.3. Check measured values in the controller and reset if

necessary.

SSI-/BiSS C interface

Only send clock impulses if there is power in the angle measuring system.

6.2 Check system function

Check all functions as follows after assembling the angle measuring system or exchanging a component:1. Start Continuous Read (software function in the

parameter acquisition window) and travel over an entire revolution to be able to check the “Accumulated Error/Warning”.

2. Use different positions to check whether the measuring system outputs the same position after a restart (off/on) as before the restart.

After replacing a component, calibration should be performed.

6.3 Operating notes

– Check and record the function of the angle measuring system and all associated components on a regular basis.

– If there are malfunctions in the angle measuring system, take it out of service and secure it against unauthorized use.

– Secure the entire system against unauthorized use.

The Evaluation System is an absolute measuring system. When the supply voltage is switched on, the absolute position is immediately available without the need for a reference run.

6 Startup


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7.1 BiSS C interface

For further information, seewww.biss-interface.com.

7.1.1 Principle

With the BiSS C interface, both position data and register data can be transmitted bi-directionally. The register data is transmitted parallel to the position data and has no effect on the system's measuring behavior. The Balluff BiSS C measuring systems can be connected to the controller via a point-to-point connection. The BiSS interface is compatible to the SSI interface in terms of hardware.

Transmission is CRC-secured, i.e. the controller can check if the data was received correctly. If the transmission has failed, the data can be discarded and requested again. The transmission runs as follows:– An error and a warning bit are also transmitted.– Secure bi-directional data transmission is always

available (register communication).– Runtime compensation of the clock and data line is

possible. This makes it possible to use larger cable lengths or higher data rates.

Fig. 7-1:

Frame

Data tm

tA

Signal sequence for the BiSS C interface

– With the first rising edge, the controller signals that it is requesting a value from the processing electronics. The position value valid at this point is included in the data transmission later on (latch).

– The processing electronics confirm the data request with the second rising edge of the clock by setting low on the data line.

– The time difference between the second rising edge of the clock and the first low of the processing electronics data line corresponds to the runtime of both signals. It appears with all further frame edges and can thus be compensated for in the controller. This makes it possible to use much longer cables or higher data rates than with uni-directional interfaces. Example: Data with a Clk rate of 1 MHz can be transmitted by e.g. up to 400 m. Only around 20 m would be possible without runtime compensation.

– All further bits that the processing electronics transfer are output in the processing electronics at the next rising edge.

– The processing electronics prepare the data during tbusy. Once this is completed, the processing electronics will set the high (start bit) data signal and then transfer the data. First the CDS bit, the response to the CDM bit that was sent by the controller in the last frame, is output.

– Afterwards the data is transmitted starting with the MSB and going to the LSB.

– An error bit and warning bit as well as the CRC follow.– Register communication:

One bit can be transmitted by the controller to the processing electronics with each frame. To do this, the controller’s clock signal is either set to high or low during tm (see Adaptive timeout in 7.1.2). The processing electronics recognize it as a high or low bit (CDM) and mirror it in the CDS bit in the next frame. As a result, the controller can detect if the bit was recognized correctly (secure transmission).

– By transmitting one bit per frame, various addresses in the processing electronics can be read and written using several frames. Further information on errors or warnings is also available and it is possible to make a configuration there.

Safety through CRC test

To ensure the integrity of the data, a cyclical redundancy check (abbreviated CRC) is used in the controller. Here, a check value is calculated for the transmitted data in both the processing electronics and controller and then compared. If both values are identical, the data has been transmitted correctly. If the values are different, the data has been transmitted incorrectly and the position value must be requested again.

For safeguarding the data, the number of bits of the CRC value and the CRC polynomial must be set in the controller in addition to the data length. The length of the CRC value can also be calculated from the CRC polynomial and thus does not need to be indicated in each controller.

The controller is parameterized as follows:– Position: Length of data 19 bits, max. resolution 17 bits– 1 error bit– 1 warning bit– CRC: 6 bits (transferred inverted)The counter polynomial for CRC determination is 0x43 (hex), 67 (dec) or 1000011 (bin).

7 Interfaces



7 Interfaces (continued)

7.1.2 Data format (BiSS frame)

Clock rate (T_CLK) 50 kHz < f_CLK < 10 MHz where fCLK = 1/TCLK

Timeout (T_M) Adaptive (typ. Tm=2 × t_CLK, but tm

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7.1.3 BiSS frame (general)

Fig. 7-2:

Latch Position

Clk

D16D17ACK ...Busy... Start =1

CDS =0

D18 =MSB

D0 =LSB

CRCMSB

CRCLSB

D4 D3 D2 D1 E W

t

ttm

91011122425262728 8 7 6 5 0

BiSSData

Position (right-aligned)

Data-Range n + 8 Bit (n × Data + Error + Warning + 6 × CRC)

CDM

BiSS frame

For each resolution, D0 contains the position LSB (least significant bit). Its resolution in angular degrees is calculated as follows:

Resolution_Degree = 360°/resolution

7.1.4 BiSS frame - example resolution = 131,072, fixed data length

– BiSS position data length fixed (19 bits)– Resolution 17 bits, length of data 19 bits

Fig. 7-3:

Latch Position

Clk

D16ACK ...Busy... Start =1

CDS =0

D18 =0

D17 =0

D0 =LSB

CRCMSB

CRCLSB

D4 D3 D2 D1 E Wt

tm

91011122425262728 8 7 6 5 0

BiSSData

Position (always 19 Bit, right-aligned)

Data-Range 27 Bit (19 × Data + nError + nWarning + 6× CRC)

CDM

BiSS frame - example resolution = 131,072

Angular resolution of D0 (LSB) is 360°/131,072 = approx. 0.003°. The resolution is 17 bits, so the bits D16 (MSB) to D0 (LSB) are used.

7.1.5 BiSS frame - example resolution = 32,768, flexible data length

– BiSS position data length flexible (14 to 17 bits)– Resolution 15 bits, length of data 15 bits

Fig. 7-4:

Latch Position

Clk

D14ACK ...Busy... Start =1

CDS =0

D0 =LSB

CRCMSB

CRCLSB

D4 D3 D2 D1 E W

t

ttm

9101112222324 8 7 6 5 0

BiSSData

Position (15 Bit, right-aligned)

Data-Range 23 Bit (15 × Data + nError + nWarning + 6× CRC)

CDM

BiSS frame – example resolution = 32,768

Angular resolution of D0 (LSB) is 360°/32,768 = approx. 0.011°. The resolution is 15 bits, which is why only 15 bits are transferred in the flexible setting: bits D14 (MSB) to D0 (LSB).

(n is dependent on the BiSS Pos. Data Length settings)

Example: When the resolution is set to 2000, this results in an angular resolution of 360°/2000 = 0.18° per LSB (D0).

With the BiSS position data length setting fixed, the data length (Data) is always 19 bits.

For resolutions smaller than 14 bits, the leading bits up to a data length of 14 bits are filled in with null bits.




7.1.6 Uni-directional BiSS C

The Evaluation System generally supports BiSS C in both directions, but is also capable of uni-directional BiSS C transmission thanks to its backwards compatibility.

Only the data is transmitted from the measuring system to the controller. No additional information can be or is transmitted (such as register communication with bi-directional BiSS C).

CDS is always low.After sensor data MSB to LSB, one error and one warning bit are transmitted. The error and warning bits in the data set are active low. If no error or warning is present, both bits are high.

7.1.7 Bi-directional BiSS C (status register)

With the BiSS C interface, errors and warnings (E/W events) are transmitted in the serial data set. Additionally, the type of the error or warning can also be queried via register communication (status register).

The error and warning bits are, as with uni-directional interfaces, transferred in the serial data stream after the position data and before the CRC. The error and warning bits in the data set are transferred as active low. If no error or warning is present, both bits are high.

The reading of a register data byte requires approx. 50 data frames, i.e. it takes a finite time until the byte has been read. During this time, further E/W events may occur. They are signalized instantly in the data set. After the corresponding byte has been transmitted successfully, the byte can be reread and the information from the second event be evaluated.

Status register:

Using the register data, the controller can read the exact error or warning causes. The status registers can be found at the addresses 0x76 to 0x77. There, different error and warning causes are coded bit by bit.

Address 0x76:Bit 2: “Nonius” (vernier) track sensor signals too low

► Reduce gap

Bit 0: Master track sensor signals too low ► Reduce gap

Address 0x77:Bit 6: Configuration error in the EEPROM

► Replace electronics

Bit 3: Inconsistency error (error in redundancy check) ► Check installation position ► Perform calibration

Bit 2: Velocity too high when switching on ► Lower speed

Bit 1: Velocity too high ► Lower speed



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7.2 Synchronous Serial Interface (SSI)

7.2.1 Principle

SSI stands for Synchronous Serial Interface and describes a digital synchronous interface with a differential clock line and a differential data line.With the first falling clock edge (trigger time), the data word to be output is buffered in the processing electronics. Data output takes place with the first rising clock edge, i.e. the processing electronics supply one bit to the data line for each rising clock edge. In doing so, the line capacities and delays of drivers tv when querying the data bits must be taken into account in the controller.The maximum clock frequency fClk is dependent on the cable length (see Technical data on page 23). The tm time, also called monoflop time, is started with the last falling edge and is output as the low level with the last rising edge. The data line remains at low until the tm time has elapsed. Afterwards, the processing electronics are again ready to receive the next clock package.

7.2.2 Data formats

Clk

Data

TClk

tv tv

Clk

DataMSB LSB

TClk1 2 3 4 5 n n+1

tm

SSI

Clk

Data

TA

TClk = 1/fClk SSI clock period, SSI clock frequency

TA = 1/fA Sampling period, sampling raten Number of bits to be transmitted

(requires n+1 clock impulses)tm = 20 μs Time until the SSI interface is ready

againtv = 150 ns Transmission delay times

(measured with a 1 m cable)

(Position query)

At the factory, the Evaluation System has the following settings for data transfer that cannot be changed later:

Clock frequency 50 kHz < f_CLK < 4 MHz

Timeout 20 μs

Min. repeat rate TA ≥ (n + 2) T + tm with tm = 20 μs

Position data length Always 19 bits

E (low active error) 1 bit

Position values may not become negative. If the value falls below null, it will jump to the maximum value, which corresponds to the set resolution –1.

The resolution is set via the graphical user interface (GUI) of the processing electronics.

Example:

At a resolution of 2000 (11 bits), the position is transmitted right-adjusted, meaning in the bits D10 (MSB) to D0 (LSB). The redundant higher position bits (D11 to D18) remain low.

Fig. 7-5:

LatchPosition

Clk

Position (always 19 Bit, right-aligned)Data-Range 20 Bit (19 × Data + nError)

19 18

D18 =MSB

D0 =LSB

17

D17 D16 D15 D14 D1 E

16 15 2 1 0 t

t

tm

SSI Data

SSI signal sequence

7.2.3 Faulty SSI query

Underclocking

If there are too few clock edges, the current data level will be maintained for the time tm after the last negative edge from Clk. If, however, further positive edges occur within the tm time, the next bit will then be output. If the tm time has elapsed, the data output goes to high. The high level is maintained until the next clock pulse.

Overclocking

If there are too many clock edges, the data output will switch to low after the correct number of cycles has been completed. The tm timer is started again for every additional negative edge from Clk and the Tm event is set internally. Data switches back to high after the time tm has elapsed.




7.3 Incremental interface

7.3.1 Analog interface (1 VPP)

With the analog sine and cosine signals +A (+sin), −A (−sin), +B (+cos) and −B (−cos), the controller evaluates the difference in signal amplitudes and, from the signals, interpolates the precise position within a period (Fig. 7-6). For a movement over several periods, the controller also counts the number of periods.

For correct function, the sine signal and the cosine signal must be evaluated depending on the direction.

Fig. 7-6:

0 5.625 11.25 α [°]

Output voltage

+B (+cos) − (−B (−cos))

App

rox.

1 V

+A (+sin) − (−A (−sin))

Signals for the sine and cosine sensor (1.28 mm pole width) in forward direction (with rotational angle α (see Fig. 4-1 on page 8) = 11.25° = one sine period with magnetically coded disk BML-M60-A32-A0-M30/010-R0)

The processing electronics transmit the measurement as an analog sine/cosine differential signal with an amplitude of approx. 1 Vpp (peak/peak value) in the nominal range to the controller. With the magnetically coded disk (BML-M60-A32-A0-M30/010-R0), the period is 11.25°.

Fig. 7-7:

+A (+Sin)

−A (−Sin)

Circuitry example of subsequent electronics with analog output

7.3.2 Digital interface (RS422)

Digital incremental measuring system

The processing electronics transmit the measurement as a differential voltage signal (RS422) to the controller.The edge distance A/B corresponds to 360°/resolution of the sensor.

Fig. 7-8:

A

B

Z

Digital output signals

Fig. 7-9:

+A

–A

+B

–B

+Z

–Z

Circuitry of subsequent electronics (RS422)

Signal periods el.

Edge distance

Reference impulse

A channel

B channel

Z channel

PLCProcessing electronics

E.g. IC 26C32

E.g. IC 26C32

E.g. IC 26C32



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7.3.3 Maximum rotational speed, resolution, and edge distance

The selection of the resolution and edge distance determines the maximum rotational speed that the sensor can detect. This results in a maximum speed in accordance with the following formula:

Speedmax. [rpm] =60,000

Edge_distancemin. [ms] × resolution

The maximum rotational speed is limited to speeds under 12,000 rpm depending on the setting (see Tab. 7-1).

The resulting resolution in angular degrees, as well as the maximum rotational speed (depending on the resolution) is displayed by the software (see Tab. 7-2).


Resolution (increments per revolution)

Angular resolution in angular degrees (per

increment (LSB))

512 Approx. 0.703

1000 Approx. 0.36

1024 Approx. 0.351

2000 Approx. 0.18

2048 Approx. 0.175

3600 Approx. 0.10

4096 Approx. 0.087

5000 Approx. 0.072

8192 Approx. 0.044

16384 Approx. 0.022

32768 Approx. 0.011

36000 Approx. 0.010

65636 Approx. 0.005

131072 Approx. 0.003

Tab. 7-2: Angular resolution = 360°/resolution

Resolution (increments per revolution)

Minimum edge distance

40 ns 80 ns 160 ns 320 ns 640 ns 1.28 µs 5.12 µs 20.48 µs

Maximum physical frequency in MHz

6.3 MHz 3.2 MHz 1.6 MHz 800 kHz 400 kHz 200 kHz 50 kHz 15 kHz

Maximum rotational speed (revolutions/min)

512 12,000 12,000 12,000 12,000 12,000 12,000 12,000 5,722

1,000 12,000 12,000 12,000 12,000 12,000 12,000 11,718 2,929

1,024 12,000 12,000 12,000 12,000 12,000 12,000 11,444 2,861

2,000 12,000 12,000 12,000 12,000 12,000 12,000 5,859 1,464

2,048 12,000 12,000 12,000 12,000 12,000 12,000 5,722 1,430

3,600 12,000 12,000 12,000 12,000 12,000 12,000 3,255 813

4,096 12,000 12,000 12,000 12,000 12,000 11,444 2,861 715

5,000 12,000 12,000 12,000 12,000 12,000 9,375 2,343 585

8,192 12,000 12,000 12,000 12,000 11,444 5,722 1,430 357

16,384 12,000 12,000 12,000 11,444 5,722 2,861 715 178

32,768 12,000 12,000 11,444 5,722 2,861 1,430 357 89

36,000 12,000 12,000 10,461 5,208 2,604 1,302 325 81

65,536 12,000 11,444 5,722 2,861 1,430 715 178 44

131,072 11,444 5,722 2,861 1,430 715 357 89 22

Tab. 7-1: Correlation: Maximum rotational speed, resolution, and edge distance



8.1 Absolute magnetically coded disk

Coding Magnetic 2-track Nonius

Gap 0.1 to 0.5 mm

System accuracy with IC-MU

< ±0.2° absolute(error per revolution)

Rotational speed ≤12,000 revolutions/minute

Operating temperature −40 to +85°C

Pole width (Master/Nonius track)

1.28 mm/0.96 mm

Number of pole pairs (Master/Nonius track)

32/31

Outer diameter 30 mm

Inner diameter 10M6

Height 8.06 mm

Material

Support material Aluminum

Magnetic material Rubber ferrite

8.2 Processing electronics

Dimensions 46 × 23 × 10 mm

Mounting holes 3 × Ø 3.4 mm

Centering holes 2 × Ø 2 mm

Interfaces

Absolute – SSI (50 kHz to f_CLK to 4 MHz, 20 μs timeout)

– BiSS (50 kHz to f_CLK to 10 MHz, adaptive timeout)

Incremental Digital or analog interface

Load > 120 ohms

Revolution speed ≤ 12,000 revolutions per minute (see Tab. 7-1 on page 28)

System accuracy (See section 8.1)

Operating temperature –40 to +80 °C

Supply voltage 5 V ±5%

Max. current draw (without load)

90 mA

Resolutions ≤ 131,072 (17 bits) increments per revolution (corresponding to angular resolutions up to 0.0027°)

Rotational speed ≤ 12,000 revolutions per minute (see Tab. 7-1 on page 28)

8 Technical data


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www.balluff.com

Headquarters GermanyBalluff GmbHSchurwaldstrasse 973765 Neuhausen a.d.F.Phone + 49 7158 173-0Fax +49 7158 [email protected]

Global Service Center

GermanyBalluff GmbHSchurwaldstrasse 973765 Neuhausen a.d.F.Phone +49 7158 173-370Fax +49 7158 [email protected]

US Service Center

USABalluff Inc.8125 Holton DriveFlorence, KY 41042Phone (859) 727-2200Toll-free 1-800-543-8390Fax (859) 727-4823 [email protected]

CN Service Center

ChinaBalluff (Shanghai) trading Co., ltd.Room 1006, Pujian Rd. 145. Shanghai, 200127, P.R. China Phone +86 (21) 5089 9970Fax +86 (21) 5089 [email protected]

Notes to the userValiditySymbols and conventionsScope of deliverySystem requirementsAbbreviations

SafetyIntended useGeneral safety notes for the angle measuring systemComponent safety and protectionExplanation of the warningsDisposal

Construction and functionSystem component overviewAbsolute Magnetically Coded DiskProcessing electronicsFunction

Installation and connectionAngles, distances, and tolerancesAssembling the angle measuring systemElectrical connectionUSB cableIncremental cableSerial cableBiSS USB adapter

Magnetic fields and cable routing

SoftwareSoftware overviewInstallationStarting the programUser interfaceCalibration and parameterization functionsFunctional areas within the calibration and parameterization functionsData integrity and performanceCalibration routineSequence of calibration and parameterization functionsCalibration routine display elementsError during calibrationExpert parameterization

Position detection and display (measure)Overview of functions

StartupStarting up the systemCheck system functionOperating notes

InterfacesBiSS C interfacePrincipleData format (BiSS frame)BiSS frame (general)BiSS frame - example resolution = 131,072, fixed data lengthBiSS frame - example resolution = 32,768, flexible data lengthUni-directional BiSS CBi-directional BiSS C (status register)

Synchronous Serial Interface (SSI)PrincipleData formatsFaulty SSI query

Incremental interfaceAnalog interface (1 VPP)Digital interface (RS422)Maximum rotational speed, resolution, and edge distance

Technical dataAbsolute magnetically coded diskProcessing electronics