Tamagawa Serial Encoders – Mitchell Electronics Inc

Overview

The Tamagawa serial encoders listed in the next section are supported by this selection. Tamagawa incremental encoders with A, B, and Z lines should be tested as Generic Incremental encoders.

Types Supported

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

TS5643 and TS5645 –

The 2,048 count TS5643 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 TS5643N110 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. The TS5643N110 is essentially the same as the Sumtak AEC2048 and the Sanyo Denki E07B111335. It is often found on Nachi robot motors.

The TI-5643N164 (Matsushita motors) and TI-5643N151 (Denso motors) do not have a Z pulse.

The TS5645N122 appears to be the basically the same as the TS5645 electronically. Physically they are a different package. These are found on Meiden motors.

If disconnected from the +5V power and the battery for some length of time, these encoders will require a reset (connect the RES line to +5V for 5 seconds or so). See the Encoder Status section below.

TS5647, TS5667, TS5668 and TS5669 –

These are all new style SmartABS encoders and are very similar to each other. They vary from each other primarily in the number of counts and the encoder ID. These are totally serial encoders with no incremental lines. The SD and SD* lines handle communications for to and from the encoder. The +5V, 0v, BATT+ and BATT 0V lines are the only other lines required.

The 65,536 count TS5647 encoder provides 16 bit resolution for a single-turn, so 1 turn will change the count by 65,536 (10000 HEX). Another 16 bits above the single-turn count are used to count revolutions, so it can keep track of ± 32,768 revolutions. This means that the largest positive count will be 2,147,483,647 (7FFF FFFF HEX) while the largest negative count is -2,147,483,648 (8000 0000 HEX).

The 1,048,576 count TS5648 encoder provides 20 bit resolution for a single-turn, so 1 turn will change the count by 1,048,576 (100000 HEX). Another 16 bits above the single-turn count are used to count revolutions, so it can keep track of ± 32,768 revolutions. This would be 36 bits total, but the TI-5000JX can only carry a 32 bit count. This means that the largest positive count will be 2,147,483,647 (7FFF FFFF HEX) while the largest negative count is -2,147,483,648 (8000 0000 HEX).

The 131,072 count TS5667 encoder provides 17 bit resolution for a single-turn, so 1 turn will change the count by 131,072 (20000 HEX). Another 16 bits above the single-turn count are used to count revolutions, so it can keep track of ± 32,768 revolutions. This would be 33 bits total, but the TI-5000JX can only carry a 32 bit count. This means that the largest positive count will be 2,147,483,647 (7FFF FFFF HEX) while the largest negative count is -2,147,483,648 (8000 0000 HEX).

The TS5669N221 is apparently the same as the TS5667 electronically. It even has the same ID code. The different part number is probably because it is in a different physical package.

If disconnected from the +5V power and the battery for some length of time, these encoders will require a reset. For these encoders, use the Reset button on the Data Display. There is no RES line for these encoders. See the Encoder Status section below.

TS5778 –

The 2,048 count TS5778 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 TS5778 also provides an incremental output with A and B (but no Z) channels, and the incremental counts may be tested using the methods described in the incremental section. But, the Count Test and Continuous Count Test will not work without a Z pulse. The incremental signals will provide 4,096 pulses or 16,384 counts per revolution (a version with 2,048 pulses or 8,192 counts per revolution has been reported to us). 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 Tamagawa TS5778 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.

Shinko motors use a TS5778 encoder. Kobelco robots use a TS5778N85 encoder. The cables for the Shinko and Kobelco are slightly different with the RES line on a different pin.

TS5781 –

The 4,096 count TS5781N13 encoder provides 12 bit resolution for a single-turn, so 1 turn will change the count by 4,096 (1000 HEX). Another 14 bits above the single-turn count are used to count revolutions, so it can keep track of 14,400 revolutions. This means that the largest positive count will be 58,982,399 (0383 FFFF HEX) and the count will not go negative. The forward direction for the serial count is CW, which is unusual for a Tamagawa encoder.

The TS5781 also provides an incremental output with A, B, and Z channels, and the incremental counts may be tested using the methods described in the incremental section. The incremental signals will provide 5,000 pulses or 20,000 counts per revolution.

This encoder is unique in that it requires a 15 VDC power supply. The SRQ line must be pulled up to +15 VDC in order for the encoder to output serial data from the RX and RX* lines. The RX and RX* signals are normal 5V logic signals. The A, B and Z lines produce a 4 V p-p sine wave type signal riding on a 6 VDC DC level. While the TI-5000JX normally expects 5V A, B, and Z signals, the differential input receiver is able to process these levels satisfactorily. The Count Test using the Generic Incremental selection works with this encoder.

Some pinouts for these encoders show a battery line to pin N, but the N13 seems to loop pin N back to pin P (it does not go to the encoder). The battery is mounted in a small compartment in the encoder housing in this encoder. Connecting the battery and disconnecting it will switch the EXT BATTERY alarm on and off.

If disconnected from the +15V power and the battery for some length of time, these encoders will require a reset (connect the RES line to +15V for 30 seconds or so). See the Encoder Status section below.

MFE0017 –

The MFE0017 is similar to the SmartABS encoders (TS5647, TS5667, TS5668 and TS5669). The SD and SD* lines handle communications for to and from the encoder. The +5V, 0v, BATT+ and BATT 0V lines are the only other lines required. See ENCODER ID and UPDATE ERROR STATUS BUTTON sections below for notes on how the MFE0017 differs from the TS5647, TS5667, TS5668 and TS5669 encoders.

The 131,072 count MFE0017 encoder provides 17 bit resolution for a single-turn, so 1 turn will change the count by 131,072 (20000 HEX). Another 16 bits above the single-turn count are used to count revolutions, so it can keep track of ± 32,768 revolutions. This would be 33 bits total, but the TI-5000JX can only carry a 32 bit count. This means that the largest positive count will be 2,147,483,647 (7FFF FFFF HEX) while the largest negative count is -2,147,483,648 (8000 0000 HEX).

MFE2500 –

The MFE2500 come in at least two very different varieties. The MFE2500P8NBT is basically a 10,000 count/rev incremental encoder with serial commutation lines (RX and RX*). The A, B, and Z channels are supported under the Generic Incremental Encoder selection, but there is no direct support for the commutation signals at this time.

The MFE2500P8NX apparently is a serial version and is currently unsupported.

It is unclear at this point exactly how to identify these encoders from the part number. Apparently the P8 designation means an 8 pole motor. Possibly the X indicates the serial version. The most reliable identifier is probably the number of lines. The serial version has a +5VDC, 0V, SD, SD* (serial data), and a shield. It appears that there are no battery lines. The incremental version requires 8 lines for the A, B, Z, and RX channels plus +5V and 0V, so there it will probably be obvious which encoder is in use from the number of lines.

Identification

The Tamagawa encoders are typically clearly marked, so identification is usually not a problem. The TI 5000JX does currently report an encoder ID field for certain SmartABS serial encoders (an ID cannot be read from the MFE0017 at this time), and this will help assure that the correct selection has been made. Other series Tamagawa encoders are not known to have ID capability.

Testing

Tamagawa incremental encoders are tested as Generic Incremental Encoders using Data Display, Line Levels, Incremental Count Test, and Phase Test for a complete test. Tamagawa serial encoder types listed above (like most serial encoders) use only the Data Display, Serial Count Test and Memory Test if they have memory. Some Tamagawa serial encoders, such as the TS5643 & TS5645 include A, B, and Z incremental channels, and the incremental channels should be tested using the Generic Incremental Encoder selection.

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 communicating properly with the tester, not reporting internal errors, and displaying the correct encoder ID.

The following sections describe information shown on the display

Commutation

The electrical angle is best for checking and setting commutation. For a particular lockup polarity, the rotor will lock up in as many different positions as there are pole pairs, but the 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 electrical angle and mechanical angle are derived from the position count.

The method of alignment for Tamagawa encoders will vary with motor manufacturer, and Tamagawa encoders are used by many different motor manufacturers. There is not general alignment information to provide at this time.

While the Tamagawa SmartABS encoders have memory, there is no evidence so far of any motor manufacturers storing the alignment information in the memory.

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 Tamagawa serial encoders because these encoders display the correct count on power up without indexing.
INTERNAL ERROR – The SmartABS encoders (TS5647, TS5648, TS5667, TS5669, MFE0017) show an INTERNAL ERROR box which indicates OK when no internal errors exist. When there is an internal error, an abbreviation for each type of error in alarm will be shown in the box. The following is a list these errors:
RESET ERRORS RESET MULTI-TURN BUTTON - When these errors occur, the Reset Errors, Reset Multi-turn button should be clicked to attempt to reset the errors. If errors cannot be cleared or seem to keep recurring, then there may be a problem with the encoder. Some errors may be due having the encoder disconnected from the battery backup voltage for an extended period of time.
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 names of these errors are not consistent, so refer to this table for the explanation.

This bit will show alarm when the battery voltage drops below about 2.5V. That battery voltage should be 3.6V. This alarm will clear on its own when the correct battery voltage is connected to the battery leads.
BATTERY ERROR – The names of these errors are not consistent, so refer to this table for the explanation.

This box will show ALARM if the battery voltage is disconnected for a long enough time that the backup capacitor cannot supply adequate voltage. It must be cleared by a reset.
OVERFLOW - The OVERFLOW box will show ALARM when count in the multi-turn counter overflows its range. This alarm must be cleared by a reset.
ENCODER ID – The encoder ID will be displayed for Tamagawa SmartABS encoders, but the box will be disabled for other Tamagawa types. If the ID read from the encoder agrees with the encoder you have selected, then an OK message will appear such as, “TS5648 OK”. If there is disagreement, then the message will show and error such as, “TS5648 Error”. This would be interpreted to mean that an ID for a TS5648 encoder has been detected, but you have selected some other kind of encoder. In this case, you should correct your selection. If you have made the correct selection, then you may have a faulty encoder. No ID can be displayed for the MFE0017 encoder at this time.
UPDATE ERROR STATUS BUTTON – While other SmartABS encoders update their error status on the fly, the MFE0017 cannot. You must click the Update Error Status button to manually update the status information. For instance, you may be getting a Battery Alarm because there is not battery connected. When you connect a battery voltage (3.6V) to the battery line and 0V ground, you expect to see the Battery Alarm information change from ALARM to OK. For the MFE0017 encoder, you must click the Update Error Status button in order to see this happen.

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. This will run a standard Count Test on the absolute position count. The incremental count must be tested as described previously. The Count Test will verify that the encoder is incrementing the correct number of counts per revolution. The Count Test for the Tamagawa 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 stuck bit test will test bit0 to bit13 for activity for 16,384 count encoders and bit0 to bit14 for activity for 32,768 count encoders. As with all serial encoders, there will be some error shown in the Count Test.

There may be a difference in the number revolutions counted for various Tamagawa Smart ABS encoders of the same type. For instance the literature indicates the TS5648N100 would count 65,536 revolutions, but the TS5648N102 appears to count only 14,399 revolutions. The N102 may be a special encoder for Panasonic MTMA motors while the N100 is a standard encoder.

This kind of difference could cause the Count Test to fail if the revolution count goes between the minimum and maximum count during a Count Test. A test failure of this type can be ignored if you know that’s what caused it. It is most likely that you will not cross this revolution count boundary during a Count Test.

Memory Test

The Tamagawa SmartABS encoders include memory. Some motor manufacturers are using the memory and others apparently are not. In the future Memory Test functions may be purchased for specific manufacturers. Different manufacturers always make use of the memory in different ways, so support must be developed for each manufacturer. No Memory Test options are available at this time for SmartABS encoders.