Sanyo Denki Motors and Serial Encoders – Mitchell Electronics Inc

Overview

The Sanyo Denki serial encoders listed in the next section are supported by this selection. Sanyo Denki incremental encoders with A, B, and Z lines should be tested as Generic Incremental encoders. This would include the so called Wire-saving Incremental types.

Types Supported

The following list shows the Sanyo Denki encoders that are currently supported by the TI-5000JX:

INC-E -

The INC-E type is the incremental wire saving encoder, and it can be tested as an AB quadrature incremental encoder. These encoders are known to come in 2,000 pulse (8,000 counts/rev) and 6,000 pulse (24,000 counts/rev) versions, and there are likely other resolutions as well. The wire-saving incremental encoders basically provide A, B, and Z quadrature pulse and index signals with complement lines. When the encoder powers up, these same lines provide U, V, and W signals respectively. The initial U, V, and W signals provide the drive an absolute reference that can be used for startup commutation before the encoder count is indexed by the Z pulse. Once the encoder is indexed, of course the A and B quadrature count provides an absolute position referenced to the Z pulse position.

E03007758 –

The 8,192 count Sanyo Denki E03007758 encoder provides 13 bit resolution for a single-turn, so 1 turn will change the count by 8,192 (2000 HEX). Another 8 bits above the single-turn count are used to count revolutions, so it can keep track of ± 128 revolutions. This means that the largest positive count will be 1,048,575 (000F FFFF HEX) while the largest negative count is -1,048,576 (FFF0 0000 HEX). It also provides an incremental output with A, B, and Z channels, and these functions of the encoder may be tested using the methods described in the incremental section. The incremental signals will provide 2,048 pulses or 8,192 counts per revolution. This encoder is the same as the Kawasaki HE-02 encoder.

E07B111335 –

The 2,048 count Sanyo Denki E07B111335 encoder provides 11 bit resolution for a single-turn, so 1 turn will change the count by 2,048 (800 HEX). Another 13 bits above the single-turn count are used to count revolutions, so it can keep track of ± 4,096 revolutions. This means that the largest positive count will be 8,388,607 (007F FFFF HEX) while the largest negative count is -8,388,608 (FF80 0000 HEX). The Sumtak also provides an incremental output with A, B, and Z channels, and these functions of the encoder may be tested using the methods described in the incremental section. The incremental signals will provide 2,048 pulses or 8,192 counts per revolution. This encoder is essentially the same as the Sumtak AEC2048 and the Tamagawa TS5643.

E07B151103 –

The Sanyo Denki E07B151103 encoder provides 15 bit resolution for a single-turn, so 1 turn will change the count by 32,768 (7FFF HEX). Another 11 bits above the single-turn count are used to count revolutions, but the revolution count is limited to 0 to 1,799 revolutions. This means that the largest positive count will be 58,982,399 (0383 FFFF HEX) and the count will not go negative. This Sanyo Denki also provides an incremental output with A and B, channels but no Z channel, and these functions of the encoder may be tested using the methods described in the incremental section. The incremental signals will provide 32,768 counts per revolution. Without a Z pulse the incremental count test will not work, so the serial count must be used as a reference. The following procedure may be used:

Read the absolute count from the Data display and record it.
Click the Select Feedback button and select an incremental encoder with 32,768 counts per turn.
Click OK to go back to the data display, and it should show a count of zero. Turn the encoder approximately 10 revolutions, and record the count.
Select Sanyo Denki E07B151103 serial encoder again.
Go back to data display and read the absolute count from the display. Subtract the count recorded in step 1 from this count. It should compare very closely to the count recorded in step 3.

E07B151306 –

The Sanyo Denki E07B151306 encoder provides 15 bit resolution for a single-turn, so 1 turn will change the count by 32,768 (7FFF HEX). Another 13 bits above the single-turn count are used to count revolutions, so it can keep track of ± 4,096 revolutions. This means that the largest positive count will be 134,217,727 (07FF FFFF HEX) while the largest negative count is -134,217,728 (F800 0000 HEX). This Sanyo Denki also provides an incremental output with A, B, and Z channels, and these functions of the encoder may be tested using the methods described in the incremental section. The incremental signals will provide 32,768 counts per revolution. No encoder connector has been identified for motors using this encoder, but the wire colors and connection to the TI-5000JX are shown in Section 2.9 Table 2.16.

E07B171103 –

The Sanyo Denki E07B171103 encoder provides 17 bit resolution for a single-turn, so 1 turn will change the count by 131,072 (0001 FFFF HEX). Another 11 bits above the single-turn count are used to count revolutions, but the revolution count is limited to 0 to 1,799 revolutions. This means that the largest positive count will be 235,929,599 (0E0F FFFF HEX) and the count will not go negative. This Sanyo Denki also provides an incremental output with A, B, channels but no Z channel, and these functions of the encoder may be tested using the methods described in the incremental section. The incremental signals will provide 32,768 counts per revolution. Without a Z pulse the incremental count test will not work, so the serial count must be used as a reference. The following procedure may be used:

Read the absolute count from the Data display and write it down.
Click the Select Feedback button and select an incremental encoder with 32,768 counts per turn.
Click OK to go back to the data display, and it should show a count of zero. Turn the encoder approximately 10 revolutions, and write down the count.
Select Sanyo Denki E07B171103 serial encoder again.
Go back to data display and read the absolute count from the display. Subtract the count recorded in step 1 from this count. It should compare very closely to the count recorded in step 3.

R11G4113A –

The Sanyo Denki R11G4113A encoder is very similar to the E07B151306 described above. It differs in the fact that it does not provide A, B, and Z quadrature pulses, it provides 14 bit resolution for a single-turn instead of 15 bits, and it requires a -5VDC supply in addition to the normal +5VDC. Because it is 14 bits, 1 turn will change the count by 16,384 (3FFF HEX). Another 13 bits above the single-turn count are used to count revolutions, so it can keep track of ± 4,096 revolutions. This means that the largest positive count will be 67,108,863 (03FF FFFF HEX) while the largest negative count is -67,108,864 (FC00 0000 HEX). An external power supply must be connected to provide -5VDC to pin M. Connect the positive power supply terminal to J1-2 (0V or GND), and connect the – terminal to the GRN wire that is loose at the terminal block end (see the TI-5036 cable description). Make certain that this wire does not inadvertently come into contact with any other wires. The power supply used must have a floating ground. There must be no connection between its negative terminal and ground.

R11ABS –

The R11ABS is a name we have given to this encoder for lack of official identification. It appears to be the same as the Sanyo Denki R11G4113A except that it is 8,192 counts/rev (13 bits) for a single-turn. Like the R11G4113A, it keeps track of ± 4,096 revolutions.

Absolute Encoder Reset Procedures

If the Sanyo Denki serial encoders have not been connected to a 5V power supply or battery backup for a period of time, they will need a reset operation. Before the reset operation, the backup mode bit will be in alarm and will stay in alarm even when battery backup is connected. To accomplish a reset operation, must be performed on the encoder.

There are several different types of encoders, and the names of the signals and details of the procedure may differ somewhat. The following paragraph will describe resetting the E07B151103 encoder. You may have to experiment somewhat if your encoder does not have the same lines or behave exactly the same as this one. Email support@mitchell-electronics.com if you have further questions.

When it has been powered down for a long time, the E07B151103 encoder will typically show ALARM for BATTERY WARN and OK for BATTERY ALARM. The CLEAR SIGNAL line can be connected to 5VDC for 5 seconds to clear the multi-turn count, but it does not clear the alarms. Connecting 5VDC to the RESET line for 5 seconds should reset the encoder and clear the alarms. Typically the BATTERY WARN will change to OK, and the BATTERY ALARM WILL change to ALARM. It is in alarm because there is not battery voltage connected. If the Bat+ line is then connected to 5V, both BATTERY WARN and BATTERY ALARM should show OK. Check the pin designations in Section 2.9 for the various Sanyo Denki cable descriptions (listed in Types Supported) for identifying the CLEAR, RESET and BAT lines.

Identification

P Series –

Sanyo Denki uses the P series part numbers for some of their motors for which a part number breakdown is provided in their manuals. They show the bold character as the encoder identifier. There is some inconsistency in some of the descriptions in the manuals, but this should provide some useful guidance. The assignments are as follows:

Some example P series models are shown below:

6?BM Series –

Another series (probably older than the P Series) of Sanyo Denki motors uses part numbers that begin with a 2 digit number followed by ‘BM’, such as 61BM, 62BM, etc. It is unclear how these part numbers breakdown, but the following part numbers are presented with the encoder use with them. The letters in the part numbers that may have to do with the encoder are in bold. While this is not a clear part number breakdown, it may be useful in identifying the feedback device used on these models.

Connection

Connection requires using the correct cable as shown in the chart in the Type Supported section. Also the Athena ‘Feedback Selection’ frame has a cable dropdown menu from which you can select the cable that you need. After making the cable selection, that selection will appear on the Data Display report which is helpful in documenting the cable used. Download cable sheets from the Customer Page at http://www.mitchell-electronics.com for cable pinouts and wiring details.

Apparently some Sanyo Denki feedback devices do not come with a connector, and wire colors are used to indicate the various signals. Some are listed below:

INC-E Wire-saving Incremental

E07B15130

ABS-E (Request Signal Unavailable)

ABS-RII (Request Signal Available)

Testing

Sanyo Denki incremental encoders and incremental lines on Sanyo Denki serial encoders are tested as Generic Incremental Encoders using Data Display, Line Levels, Incremental Count Test, and Phase Test for a complete test. Sanyo Denki serial encoder types listed above (like most serial encoders) use only the Data Display and the Serial Count Test. The forward armature direction for Sanyo Denki motors is CCW looking at the drive shaft end.

Data Display

Data Display is the initial test, and it is started by default when Athena is started. When already in another test, it can be started by clicking on the Data Display button among the test buttons at the top of the display. Use it for the following:

Turn the encoder to ensure that the encoder is counting approximately the right number of counts per revolution.
Use the commutation display to check or set the feedback commutation alignment.
Check the encoder status for the following: ensure that the encoder is indexed, communicating properly with the tester, not reporting internal errors, correctly displaying overheat and battery alarms, and displaying the correct encoder ID (if ID is implemented).

The following sections describe information shown on the display.

Commutation

The Fanuc style commutation gray code shown as C1 – C8 and the electrical angle can be used to check and set commutation using a static rotor lockup by applying a small lockup voltage to the stator windings. We strongly recommend using the electrical angle as the superior method of alignment for Sanyo Denki encoders. For a particular lockup polarity, the rotor will lock up in as many different positions as there are pole pairs, but the gray code and electrical angle indications will be the same at each lockup position. The mechanical angle will be different at each lockup position (except for 2 pole motors where there is only one lockup position), so it is not as convenient to use for feedback alignment. See section 3.2 for a more detailed description of commutation alignment procedures.

The number of poles must be entered correctly for the electrical angle to be correct. The gray code, electrical angle and mechanical angle are derived from the position count. The position count is absolute immediately on power up for Mitsubishi serial encoders.

The table below shows 3 different lockups that can be used to check or set commutation on motors with Sanyo Denki serial encoders. The first one puts the feedback on a zero electrical angle which some users favor. It requires applying power to all 3 armature lines.

The last two procedures require applying power to only two armature leads at a time. It is easy to go from +U –V to +U –W just by moving the minus lead from V to W. This should cause the motor to jog 60 electrical degrees in the forward direction (CCW looking at the shaft for Sanyo Denki). Failure to move the correct number of degrees or in the correct direction would be an indication of a significant problem. Setting these angles within ±3 electrical degrees is normally quite sufficient.

Here are typical Sanyo Denki lockups for serial encoders.

Count

The Count frame displays the encoder count both as a decimal and hexadecimal number. Users will typically be interested in only the decimal count, but encoder repairmen and other advanced users may find the hexadecimal representation useful. In general this count will not be zero on power up. This is an absolute encoder, and it will remember the count on power up. The number of counts/rev for the various models is shown in the table in an earlier section on types of encoders supported.

Always verify that the encoder count appears to change by the correct number of counts/rev while turning the encoder. If the count is not changing, then there is an encoder problem. As described in a later section, the Count Test may be performed to more accurately determine whether the correct number of counts per revolution is occurring, but this is an important initial evaluation.

Encoder Status

INDEX – The INDEX box is disabled for all Sanyo Denki serial encoders because these encoders display the correct count on power up without indexing.
DATA - If no data is being sent from the encoder, NONE will be displayed in the DATA box. If the TI 5000JX and the encoder are communicating correctly, RECEIVING will be displayed in the DATA box. The cabling is the first thing to check if the encoder is not communicating, but it can also mean a component failure in the encoder.
BATTERY ALARM - The BATTERY ALARM bit is not completely understood, but it seems to indicate a situation in which the internal capacitors of the encoder have discharged such that the encoder is in need of a reset (see earlier section for reset). It serves somewhat the function that the INTERNAL ERROR serves for other encoders. While BATTERY ALARM is in ALARM, the revolution count and the position count (within a single-turn) may not be synchronized. When the revolution count goes through zero, the position count may not go though zero. Generally a reset will take care of this problem.
BATTERY WARN - The BATTERY WARN box will show ALARM if there is a battery error alarm and OK if there is not. It seems to work similarly to the battery alarm for most other encoders. It only seems to work as expected as long as the encoder is not in need of a reset. The battery voltage range appears to be from about 3.6V to 5.0V.
OVERHEAT - The OVERHEAT box will be disabled for Sanyo Denki encoders because no overheat condition is detected.
ENCODER ID – There is no encoder ID support for Sanyo Denki serial encoders.

Count Test

The Count Test can be started by clicking on the Count Test button among the test buttons at the top of the display. The Count Test will verify that the encoder is incrementing the correct number of counts per revolution. The Count Test for the Sanyo Denki encoders is not significantly different from that for other encoders, so please refer to the general information on the count test in Section 2.2.2 for further details. The number of bits tested by the Stuck Bit Test varies depending upon the particular model. Encoders with greater than a 16 bit count per revolution will test bit0 to bit15 for activity. Others will test as many bits as are used in the count for one revolution.