INSTALLATION SINUS K

INSTRUCTIONS

13.6. Encoder board ES836

Board for incremental, bidirectional encoder to be used as a speed feedback for inverters of the SINUS K series
with VTC control and LIFT control. Two versions are available: one fitting encoders with power supply ranging
from 5 to 15VDC with complementary outputs and allowing output voltage fine-tuning; the other version fits
encoders with 24VDC power supply with both complementary and single-ended outputs.

Fig. 62: Encoder Board ES836

COMPATIBLE ENCODERS
DESCRIPTION CODE
POWER SUPPLY OUTPUT
Encoder board ES836 5VDC, 12VDC, LINE DRIVER, PNP, complementary
ZZ0095831
( 5…15V encoders) 15VDC PUSH-PULL outputs
NPN, PNP, complementary PUSH-
Encoder board ES836
ZZ0095832 24VDC PULL outputs and NPN, PNP,
(24V encoders)
single-ended PUSH-PULL outputs

13.6.1. E NVIRONMENTAL R EQUIREMENTS

Operating temperature 0 to + 50° C ambient temperature (contact Elettronica Santerno for
higher ambient temperatures)
Relative humidity 5 to 95% (non condensing)
Max. operating altitude 4000 (a.s.l.)

130/160
SINUS K INSTALLATION
INSTRUCTIONS

13.6.2. E LECTRICAL F EATURES

Value
Features of 24VDC encoder board – ZZ0095832
Min. Type Max. Unit
Encoder supply current, + 24 V, protected with self-resetting fuse 200 mA
Input channels Three channels: A, B and zero
notch Z
Type of input signal
Complementary or single-ended
Voltage range for encoder input signals 4 24 V
Pulse max. frequency with noise filter setting on 77kHz (1024imp @ 4500rpm )
Pulse max. frequency with noise filter setting off 155kHz (1024imp @ 9000rpm)

Input impedance in NPN or PNP mode (pull-up or pull-down external 15k

resistors are required)
Input impedance in push-pull mode or PNP and NPN mode with 3600
connection to internal load resistors (at max. frequency)

Value
Features of 5…..15VDC encoder board – ZZ0095831
Min. Type Max. Unit
Electronically protected encoder supply current, +12V 350 mA
Electronically protected encoder supply current, +5V 900 mA
Adjustment range for encoder supply voltage (5V mode) 4.4 5.0 7.3 V
Adjustment range for encoder supply voltage (12V mode) 10.3 12.0 17.3 V
Input channels Three channels: A, B and zero
notch Z
Type of input signal Complementary
Voltage range for encoder input signals 4 15 V
Pulse max. frequency with noise filter setting on 77kHz (1024imp @ 4500rpm )

Pulse max. frequency with noise filter setting off 155kHz (1024imp @ 9000rpm)

Input impedance in complementary push-pull or line driver

780
mode (at max. frequency)

ISOLATION:

The encoder supply line and inputs are galvanically isolated from the inverter control board grounding for a
500 VAC test voltage for 1 minute. Encoder supply grounding is in common with control board digital inputs
available in the terminal board.

131/160
INSTALLATION SINUS K
INSTRUCTIONS

13.6.3. I NSTALLING THE E NCODER B OARD ON THE I NVERTER

1) Remove voltage from the inverter and wait at least 5 minutes.

1) Remove the cover allowing to gain access to the inverter control terminals. The mounting columns for
the encoder board and signal connector are located on the left.

Fig. 63: Position of the Slot for the Encoder Board Fitting

3) Fit the encoder board and make sure that all contacts enter the relevant housing in the signal connector.
Fasten the encoder board to the metal columns using the screws supplied.
4) Configure the dip-switch and the jumper located on the encoder board based on the type of encoder being
used. Check that supply voltage in terminal board output is correct.
5) Turn on the inverter and set the parameters relating to the encoder feedback (see Programming Manual).

Fig. 64: Encoder board fastened to its slot

132/160
SINUS K INSTALLATION
INSTRUCTIONS

13.6.4. E NCODER B OARD T ERMINALS

A 9-pole terminal board is located on the front side of the encoder board.

Terminal board with 3.81 mm pitch - two separate sections (6-pole section and 3-pole section)
Terminal Signal Type and features
no.
1 CHA Channel A encoder input (true)
2 CHA Channel A encoder input (false)
3 CHB Channel B encoder input (true)
4 CHB Channel B encoder input (false)
5 CHZ Channel Z (zero notch) encoder input (true)
6 CHZ Channel Z (zero notch) encoder input (false)
7 +VE Output for encoder supply 5V….15V or 24V
8 GNDE Encoder supply ground
9 GNDE Encoder supply ground

For the encoder connection to the encoder board, see wiring diagrams (following pages).

13.6.5. D IP - SWITCH
Encoder board ES836 requires two dip-switch banks to be set depending on the type of encoder being used.
Dip-switches are located in the top left corner of encoder board ES836 (see figure below).

SW2 SW1

TERMINAL BOARD

Fig. 65: Dip-switch Position

133/160
INSTALLATION SINUS K
INSTRUCTIONS

Dip-switch functions:

Switch OFF - open ON - closed

SW2 – 1 Channel Z with no band limit Channel Z with band limit
SW2 – 2 Channel Z with complementary signals Channel Z with only one single-ended signal
SW2 – 3 Channel Z type NPN (24V only) or PNP Channel Z Line driver or Push Pull
SW2 – 4 Channel B with no band limit Channel B with band limit
SW2 – 5 Channel B with complementary signals Channel B with only one single-ended signal
SW2 – 6 Channel B type NPN (24V only) or PNP Channel B Line driver or Push Pull
SW1 – 1 Channel A with no band limit Channel A with band limit
SW1 – 2 Channel A with complementary signals Channel A with only one single-ended signal
SW1 – 3 Channel A type NPN (24V only) or PNP Channel A type Line driver or Push Pull
SW1 – 4 Not used Not used
SW1 – 5 Not used Not used
SW1 – 6 Supply voltage 12 V (J1 in pos. 2-3) Supply voltage 5 V (J1 in pos. 2-3)

13.6.6. J UMPER F OR E NCODER S UPPLY

Two-position jumper J1 installed on control board ES836 and allows to set the encoder supply voltage. It is
factory-set based on the encoder board version. Set jumper J1 to position 1-2 to select non-tuned, 24V encoder
supply voltage.
Set jumper J1 to position 2-3 to select tuned, 5/12V encoder supply voltage. Supply values of 5V or 12V are to
be set through dip-switch SW1-6 (see table above).

13.6.7. T RIMMER
Trimmer RV1 installed on board ES836 (5..15V version) allows to adjust the encoder supply voltage. This can be
useful for encoders with intermediate voltage values if compared with factory-set voltage and can compensate
voltage drops in case of long distance between the encoder and the encoder board.
Adjustment procedure:
! put a tester on the encoder supply connector (encoder side of the connecting cable); make sure the
encoder is on.
! rotate the trimmer clockwise to increase supply voltage. Trimmer is factory-reset to obtain 5V and 12V
voltage (depending on dip-switch setting) in supply terminals. 5V configuration: power supply can range
from 4.4V to 7.3V; 12V configuration: power supply can range from 10.3V to17.3V.

NOTE Output voltage cannot be adjusted by trimmer RV1 for 24V encoder board.

Power supply values exceeding the encoder ratings may damage the encoder.
CAUTION:
Always use a tester to check voltage delivered from board ES836 before wiring.
Do not use the encoder supply output to power other devices. Failure to do so
CAUTION: would increase the hazard of control interference and short-circuits with possible
uncontrolled motor operation due to the lack of feedback.
The encoder supply output is isolated from the common terminal of the analog
CAUTION: signals incoming to the terminals of the control board (CMA). Do not link the two
common terminals together.

134/160
SINUS K INSTALLATION
INSTRUCTIONS

13.6.8. E NCODER W IRING AND C ONFIGURATION E XAMPLES

The figures below illustrate the electrical schematics and the dip-switch setup for the most popular encoder
models.

A wrong encoder-board connection may damage both the encoder and the
CAUTION
board.

In all figures, dip-switches SW2-1, SW2-4 and SW1-1 are ON (77kHz band limit
NOTE is on). Set dip-switches to OFF if encoders generating greater output frequency
are used.

NOTE The maximum length of the encoder cable depends on the encoder output control
capacity, not on encoder board ES836. See technical features of the component.

Dip-switch SW1-6 is not shown in the figures because its setting depends on the
NOTE supply voltage required by the encoder. Dip-switch SW1-6 is to be used only for
5..12V encoder board. Refer to the dip-switch setting table to set SW1-6.
Zero notch connection is optional and is required for particular software
applications only. However, zero notch connection does not affect software
NOTE
applications that do not require this type of connection. See SINUS K’s
Programming Manual.

Fig. 66: LINE DRIVER or PUSH-PULL Encoder with Complementary Outputs

135/160
INSTALLATION SINUS K
INSTRUCTIONS

Fig. 67: PUSH-PULL Encoder with Single-ended Outputs (with 24VDC board only)

Because settings required for a single-ended encoder—which is made possible

with a 24V board only (dip-switches SW2-1, SW2-5, SW1-2 closed)—deliver a
CAUTION reference voltage to terminals 2, 4, 6, the latter are not to be connected. Failures
will occur if terminals 2, 4, 6 are connected to encoder conductors or to other
conductors.

Only push-pull, single-ended encoders may be used, with an output voltage equal
NOTE to the supply voltage. Only differential encoders may be connected if their output
voltage is lower than the supply voltage
Some manufacturers use the acronym HTL for push-pull outputs with a power
supply ranging from 18 VDC to 30VDC. For the acquisition of this type of
NOTE
encoder, the same configuration used for push-pull inverters shall be used for the
encoder board.

136/160
SINUS K INSTALLATION
INSTRUCTIONS

Fig. 68: PNP or NPN encoder with single-ended outputs and load resistors with external wiring (only for 24VDC
encoder board)

137/160
INSTALLATION SINUS K
INSTRUCTIONS

Fig. 69: PNP or NPN encoder with single-ended outputs and load resistors with internal wiring (only for 24VDC
encoder board)

The connection of NPN encoders is possible only with 24VDC encoder board;
CAUTION 5..15VDC encoder board is not capable of acquiring NPN encoders. Encoders with
standard, 5V TTL outputs cannot be acquired.
NPN encoders or PNP encoders are provided with special outputs requiring a resistive
pull-up load or pull-down load to the mains or to the common. The load resistor rating
is determined by the manufacturer of the encoder; load resistors are to be externally
NOTE wired as shown in the figure. The resistor common is to be connected to the mains
(NPN encoder) or to the common (PNP encoder).Incorporated resistors can be used
only if the encoder can operate with 4700 load resistors (see connection in Figure
13.20).
Using an NPN encoder or a PNP encoder implies pulse distortion because the duration
of the rising edge is different from the duration of the dropping edge. Pulse distortion
depends on the load resistor ratings and the cable parasite capacity. Do not use PNP
NOTE
encoders or NPN encoders for applications where the encoder output frequency is
higher than a few kHz dozens. Use Push-Pull encoders or better encoders with a
differential line-driver output instead.

138/160
SINUS K INSTALLATION
INSTRUCTIONS

13.6.9. W IRING
Use a screened cable to connect the encoder to the board. Screening should be grounded to both ends of the
cable. Use the special clamp to fasten the encoder wire and ground the cable screening to the inverter.

Fig. 70: Wiring the Encoder

Do not stretch the encoder wire along with the motor supply cable.
Connect the encoder directly to the inverter using a cable with no intermediate devices, such as terminals or
connectors.
Use a model of encoder suitable for your application (as for connection length and max. rev number).
Preferably use encoder models with complementary LINE-DRIVER or PUSH-PULL outputs. Non-complementary
PUSH-PULL, PNP or NPN open collector outputs offer a lower immunity to noise.
The encoder electrical noise occurs as the difficult speed adjustment or irregular operation of the inverter; in the
worst cases, it can lead to the inverter stop due to overcurrent conditions.

139/160
INSTALLATION SINUS K
INSTRUCTIONS

13.7. SERIAL ISOLATED BOARD ES822

Serial isolated board RS232/485 controlling SINUS K and SINUS PENTA inverters. It permits to connect a
computer via interface RS232 or permits the multidrop connection of modbus devices via interface RS485.
Interface signals are galvanically isolated with respect to the control board ground and the common of the
control board terminals.

Fig. 71: Isolated Board ES822

DESCRIPTION CODE
Serial isolated board RS 232/485 ZZ0095850

140/160
SINUS K INSTALLATION
INSTRUCTIONS

13.7.1. E NVIRONMENTAL R EQUIREMENTS

Operating temperatures: 0 to + 50 °C ambient temperature (for higher temperatures, please contact
Elettronica Santerno)
Relative humidity: 5 to 95% (non-condensing)
Max. operating altitude 4000 (a.s.l.)

13.7.2. E LECTRICAL F EATURES

CONNECTION:
When board ES822 is fitted, RS-485 connector automatically disables; 9-pole D connectors (male D connectors
for RS-485, or female D connectors for RS-232-DTE located on board ES822) activate depending on the
position of J1.

Contacts of 9-pole, male D connector CN3 (RS-485):

PIN FUNCTION
1–3 (TX/RX A) Differential input/output A (bidirectional) according to standard RS485. Positive polarity with
respect to pins 2 – 4 for one MARK.
2–4 (TX/RX B) Differential input/output B (bidirectional) according to standard RS485. Negative polarity
with respect to pins 1 – 3 for one MARK.
5 (GND) control board zero volt
6-7 Not connected
8 (GND) control board zero volt
9 +5 V, max 100mA for power supply of optional, external converter RS-485/RS-232

Contacts of 9-pole, female D connector CN2 (RS-232-DCE):

PIN FUNCTION
1, 9 Not connected
2 (TX A) Output according to standard RS232
3 (RX A) Input according to standard RS232
5 (GND) zero volt
4-6 Connected together for loopback DTR-DSR
7-8 Connected together for loopback RTS-CTS

141/160
INSTALLATION SINUS K
INSTRUCTIONS

13.7.3. I NSTALLING I SOLATED B OARD ES822

1) Remove voltage from the inverter and wait at least 5 minutes.

2) Remove the cover allowing to gain access to the inverter control terminals. The mounting columns for the
encoder board and signal connector are located on the right.

Fig. 72: Position of the slot for the installation of the serial isolated board

3) Fit the encoder board and make sure that all contacts enter the relevant housing in the signal connector.
Fasten the encoder board to the metal columns using the screws supplied.

4) Configure the dip-switch and the jumper located on the board choosing the type of connection required.

142/160
SINUS K INSTALLATION
INSTRUCTIONS

13.7.4. C ONFIGURING I SOLATED B OARD ES822

13.7.4.1. J U M P E R S E L E C T I N G RS232/RS485

Jumper J1 configures board ES822 as interface RS485 or RS232. Positions are silk-screened on board ES822.
Jumper between pin 1-2: CN3 is enabled (RS485)
Jumper between pin 2-3: CN2 is enabled (RS-232)

Fig. 73: Jumper Configuration for RS232/RS485.

143/160
INSTALLATION SINUS K
INSTRUCTIONS

13.7.4.2. D I P -S W IT C H E N A B L IN G T E R M IN A T O R RS-485

(See section 11.2 relating to serial communications):

For serial link RS-485 in board ES822, terminator is selected with dip-switch SW1 as shown in the figure below.
The line terminator of the farthest inverter from the master computer (or the only inverter in case of direct
connection to the master computer) shall be enabled: dip switch SW1, selector switches 1 and 2 in position ON
(default setting).
The line terminator of the other inverters in intermediate positions shall be disabled: dip switch SW1, selector
switches 1 and 2 in position OFF (default setting).
Serial link RS-232-DTE does not require any particular setup of dip switch SW1.

Fig. 74: Configuring Line Terminator RS485 Dip-switch

144/160