Netzer VLR-100 Hollow Shaft Rotary Encoder Encoder Kit User Guide

Netzer VLR-100 Hollow Shaft Rotary Encoder Encoder Kit

Product Information

Specifications

• Model: VLR-100
• Type: Absolute Rotary Encoder
• Shaft Type: Hollow Shaft

Product Usage Instructions

1. Installation
   Before installing the VLR-100 encoder, ensure that you have read and understood the mechanical drawings and interface control drawings provided in the user manual.

2. Mechanical Mounting
   To mount the encoder, follow the End-of-Shaft Installation procedure outlined in section 10.1 of the user manual. Ensure proper alignment and secure mounting to prevent any misalignment issues.

3. Operational Mode
   The VLR-100 encoder supports SSi/BiSS operational modes. Refer to section 9.1 of the user manual for detailed instructions on configuring and utilizing these modes.

FAQ (Frequently Asked Questions)

• Q: What are the key features of the VLR encoders?
  A: The VLR encoders are designed for demanding applications, characterized by their low profile and absolute rotary encoding capability.

• Q: How should I handle ESD protection for the VLR-100 encoder?
  A: Refer to section 7 of the user manual for guidelines on ESD protection to prevent damage to the encoder during handling and operation.

VLR-100 PRODUCT GUIDE

• Absolute Rotary Encoder
• Hollow Shaft Kit Encoder

VLR Encoders Introduction

• Designed to meet the requirements of the most demanding applications
• The VLR series of Electric Encoders™ are a line of encoders designed to meet the needs of various industries, especially in extreme environments from defense to heavy machinery.
• The VLR series is engineered for high durability, It is a non-contact, low-maintenance, and easy-to-install solution. The capacitive technology ensures dependable performance, which is crucial for industries that operate under tough conditions.
• These encoders are based on capacitive technology developed and improved for over 20 years by Netzer Precision Position Sensors.

The VLR encoders are characterized by the following features that sets them apart from other similar encoders:

• Low profile (<12.5 mm)
• Hollow shaft (Stator / Rotor)
• No bearings or other contact elements
• High resolution and excellent precision
• Immunity to magnetic fields
• High reliability in extreme environments
• Durability and ease of installation
• High tolerance to temperature extremes, shock, moisture, EMI, RFI
• Holistic signal generation and sensing
• Digital interfaces for absolute position

The holistic structure of the VLR Electric Encoder™ makes it unique. Its output reading is the averaged outcome of the entire circumference area of the rotor. This inherent design characteristic provides the VLR encoder with outstanding precision as well as a tolerant mechanical mounting.
The absence of components such as ball bearings, flexible couplers, glass discs, light sources & detectors, along with very low power consumption, enables the VLR encoders to deliver virtually failure-free performance.

Technical Specifications

General

Default same direction from bottom side of the encoder
Mechanical

Electrical

Environmental

11msec saw-tooth per MIL-810G
Vibration functional| 7.7grms @ 20 to 2000 Hz per MIL-810G Category 24
Protection| IP 40

Ordering Code

Mechanical Drawings

Notes

1. Due to PCB’s inherent manufacturing tolerances, Netzer recommends the use of shims in order to achieve air gap.

Cable options

OD: Ø 0.6 ± 0.05 mm

| 28 AWG 40/44 Tinned copper Insulation: PFA Ø 0.12

OD: Ø 0.64 ± 0.05 mm

Temp. Rating| -55°C to +150°C
Braided shield| Thinned copper braided 95% min. coverage
Jacket| 0.45 silicon rubber (NFA 11-A1)| 0.44 silicon rubber (NFA 11-A1)
Diameter| Ø 3.45 ± 0.16 mm| Ø 3.53 ± 0.16 mm

Mechanical Interface Control Drawing

Notes

1. Other than the mount, allow at least 1 mm gap under the rotor, free of any metal.

Storage and Handling

• Storage temperatur e: -55°C to +125°C
• Humidity : Up to 98% non-condensing

 ESD Protection

As usual for electronic circuits, during product handling do not touch electronic circuits, wires, connectors or sensors without suitable ESD protection. The integrator / operator shall use ESD equipment to avoid the risk of circuit damage.

ATTENTION
OBSERVE PRECAUTIONS FOR HANDLING ELECTROSTATIC SENSITIVE DEVICES

Product Overview

1. Overview
   • The VLR-100 absolute position Electric Encoder™ is a rotary position sensor developed for demanding applications. Currently it performs in a broad range of applications, including defense, homeland security, medical robotics and industrial automation.
   • The Electric Encoder™ non-contact technology provides accurate position measurement through the modulation of an electric field.
   • The VLR-100 Electric Encoder™ is a kit-encoder, i.e., its rotor and stator are separate.

1. Encoder stator
2. Encoder rotor

Unpacking – Standard order
The package of the standard VLR-100 contains the encoder Stator & Rotor.
Optional accessories:

1. CNV-00003 (Blue Box), RS-422 to USB converter (with USB internal 5V power supply path).
2. NanoMIC-KIT-01, RS-422 to USB converter. Setup & Operational modes via SSi /BiSS interface.
3. RJ-VLR-100 – rotary jig
4. DKIT-VLR-100-SG-S0, Mounted SSi encoder on rotary jig, RS-422 to USB converter and cables.
5. DKIT-VLR-100-IG-S0, Mounted BiSS encoder on rotary jig, RS-422 to USB converter and cables.

Installation flow chart

Electric Encoder Software Installation

The Electric Encoder Explorer (EEE) software:

• Verifies correct mounting for an adequate signal amplitude
• Calibration of offsets
• General set up and signal analysis

This section describes the steps associated with installing the EEE software application.

Minimum requirements

• Operating system: MS windows 7/ 10, (32 / 64 bit)
• Memory: 4MB minimum
• Communication ports: USB 2
• Windows .NET Framework, V4 minimum

Installing the software

• Run the Electric Encoder™ Explorer file found on Netzer website: Encoder Explorer Software Tools
• After the installation you will see Electric Encoder Explorer software icon on the computer desktop.
• Click on the Electric Encoder Explorer software icon to start.

Mechanical Mounting

Encoder mounting – End-of-Shaft Installation

Typical encoder installation uses

• The Mounting clamps EAPK005, 3 each per stator & rotor are included.
• There are 6 mounting slots in the rotor and stator, 3 upper slots and 3 lower slots.
  The user can define the type of installation direction while using the upper or lower slots.

Encoder stator / Rotor relative position
For proper performance, the stator and rotor mounting surfaces should be coplanar.

• In an optimal mounting, the signal amplitude values generated by the encoder, would be in the middle of the range of the signal plot shown in the Encoder Explorer software (see plot below). This may vary according to the encoder type.
• Verify proper rotor mounting with the Encoder Explorer tools “Signal analyzer” or “Signal verification process.”

Note: for more information please read section 7

Electrical Connection

This chapter reviews the steps required to electrically connect the encoder with digital interface (SSi or BiSS-C).
Connecting the encoder
The encoder has two operational modes:
Absolute position over SSi or BiSS-C
This is the power-up default mode

SSi / BiSS interface wires color code

SSi / BiSS output signal parameters

Digital SSi Interface

Synchronous Serial Interface (SSi) is a point to point serial interface standard between a master (e.g. controller) and a slave (e.g. sensor) for digital data transmission.

Built In Test option (BIT)

• The BIT indicates critical abnormality in the encoder internal signals.
• ‘0’ – the internal signals are within the normal limits, ‘1’ – Error
• The Part Number of the encoder indicates whether the encoder includes BIT. If no BIT is indicated in the PN, there is no additional error bit.

| Description| Recommendations
---|---|---
n| Position resolution| 12 – 20
T| Clock period|
f= 1/T| Clock frequency| 0.1 – 5.0 MHz
Tu| Bit update time| 90 nsec
Tp| Pause time| 26 – ∞ μsec
Tm| Monoflop time| 25 μsec
Tr| Time between 2 adjacent requests| Tr > n*T+26 μsec
fr=1/Tr| Data request frequency|

Digital BiSS-C Interface

• BiSS – C Interface is unidirectional serial synchronous protocol for digital data transmission where the Encoder acts as “slave” transmits data according to “Master” clock. The BiSS protocol is designed in B mode and C mode (continuous mode). The BiSS-C interface as the SSi is based on RS-422 standards.

Built In Test option (BIT)

• The BIT indicates critical abnormality in the encoder internal signals.
• ‘1’ – the internal signals are within the normal limits, ‘0’ – Error
• The Part Number of the encoder indicates whether the encoder includes BIT. If no BIT is indicated in the PN, the error bit is always 1.

• The CRC polynomial for position, error and warning data is: x6 + x1 + x0. It is transmitted MSB first and inverted.
• The start bit and “0” bit are omitted from the CRC calculation.

| | 6 bits
| Timeout| Elapse between the sequential “start” request cycle’s.| | 25 μs

Setup mode over NCP (Netzer Communication Protocol)

• This service mode provides access via USB to a PC running Netzer Encoder Explorer application (on MS Windows 7/10). Communication is via Netzer Communication Protocol (NCP) over RS-422 using the same set of wires.
• Use the following pin assignment to connect the encoder to a 9-pin D-type connector to the RS-422/USB converter CNV-0003 or the NanoMIC.

Electric encoder interface, D Type 9 pin Female

SSi Clock / NCP RX

| Gray| Clock / RX +| 2
Blue| Clock / RX –| 1

SSi Data / NCP TX

| Yellow| Data / TX –| 4
Green| Data / TX +| 3
Ground| Black| GND| 5
Power supply| Red| +5V| 8

Connect Netzer encoder to the converter, connect the converter to the computer and run the Electric Encoder Explorer Software Tool
Electrical connection and grounding
Observe the following grounding consideration:

1. The cable shield electrically floating (unconnected) by default.
2. It’s highly recommended to keep the motor PWM wires electrically shielded and/or kept away from the encoder.
3. Ground the host shaft to avoid interference from the host system, which could result in encoder internal noise.
   Note: 4.75 to 5.25 VDC power supply required

 Signal Verification

1. Starting the Encoder Explorer
   Make sure to complete the following tasks successfully:

   • Mechanical Mounting
   • Electrical Connection to the encoder
   • Encoder Explore Software Installation

Run the Encoder Explorer tool (EE)

• Ensure proper communication with the encoder: (Setup mode by default).
• The Encoder position-dial is colored blue when in Setup Mode, either through the NanoMic or the BlueBox (a). Note that the operational mode is not available through the BlueBox (b).
• The Signal amplitude bar indicates whether the signal is within the acceptable tolerance (c) . Note that prior to performing the Signal Verification process the bar could indicate an out of tolerance signal (d).
• Encoder data is displayed in the encoder data area (CAT No., Serial No.) (e).
• The position dial display responds to shaft rotation (f).
• It is important to perform the Signal Verification process prior to the calibration of the encoder to ensure optimal performance.

Signal verification process

• The Signal Verification process ensures that the encoder is mounted correctly and provides good signal amplitudes. This is performed by collecting raw data of the fine and coarse channels during rotation.
• Select on the main screen (a).
• Select to initiate the process (b).
• Rotate the shaft in order to collect the fine and coarse channels data (c).
• If the process is successful, the status “Signal verification successful” would appear (d).
• The ‘amplitude circle’ would be centered between the two green circles, preferably in the middle of the tolerance (e).
• Note however, that mounting the encoder towards the extreme mechanical tolerances might cause the amplitude circle to be offset from the exact middle of the nominal position.
• If the signal is out of tolerance the Error notification “Amplitude is lower/higher than the min/max limit of XXX” would appear (g).
• In Addition, the status “Signal verification failed – perform calibration amplitude” would appear at the top (h).
• Stop the process and re-mount the encoder, making sure that the mechanical installation tolerances are not exceeded, removing or adding shims as required.
• Repeat the Signal Verification process after the remount.
• Once the signal verification process is successfully completed, proceed to the encoder calibration phase, Section 13

Calibration

• It is important that upon every new installation of the encoder, the Signal Verification process is completed prior to attempting calibration of the encoder.
• For encoders with FW 4 version 4.1.3 or higher, it is possible to select either a fully automated calibration process, or a manual phase-by-phase calibration process.

Auto-calibration

• Auto Calibration is supported by encoders with FW 4 version 4.1.3 or higher.

• For these encoders an additional “Auto-calibration” button is displayed.

• Auto-calibration process
  The Auto-calibration process consists of three stages:

  1. Jitter test – evaluates the electric noise for the Fine, Medium, and Coarse encoder channels. During the jitter test, the shaft must be stationary.
     Attention! The Pass/Fail criteria of the Jitter test is according to very strict factory criteria and failing it would abort the Auto Calibration process.
     However, the manual Jitter test as part of the Manual Calibration process in section 13.4, would enable the user to decide whether the jitter is acceptable to its needs.

  2. Offset calibration – performs the offset calibration, the shaft must rotate continuously.

  3. Absolute Position (AP) calibration – performs Coarse Amplitude Alignment (CAA) and Medium Amplitude Alignment (MAA) are calculated.
     During Auto-Calibration process the encoder’s Zero-Position remain in the factory default zero position for new encoders. It is possible to set the Zero Point through the top menu bar, by selecting “Calibration” tab, and clicking “Set UZP” as defined in section 13.3.

• Performing Auto-calibration
  Press the button.
  The main auto-calibration window opens.

  • Select the appropriate measurement range applicable to your application (a).

• Make sure to keep the shaft still and press the

  • The Noise test would be performed and upon successful completion the “Noise test” label will be marked with a green check mark.
  • The Offset calibration would automatically start upon completion of the Noise test. This calibration requires that the shaft be rotated continuously.
  • The AP calibration would automatically start upon completion of the Accuracy Calibration. Continue rotating the shaft in this phase until the AP calibration is completed, and the encoder is reset.
  • Once the reset is over, the Auto-calibration process is successfully finished.

• The user can review the calibration results by clicking the button (b).

• It is always possible to abort the Auto Calibration process by clicking the button (c).

• Auto-calibration failures

  • If a test fails (for example the Noise test) – the result will be marked with in red X.
  • If the calibration process failed, corrective recommendations will be displayed, corresponding to the element which had failed the test.
  • It is possible to review detailed information regarding the failure, by clicking the button (d).

• Manual calibration
  The Manual calibration process consists of the following stages:

  1. Offset calibration – performs the offset calibration, the shaft must rotate continuously.
  2. CAA / MAA Calibration – performs Coarse Amplitude Alignment (CAA) and Medium Amplitude Alignment (MAA) are calculated
  3. Zero Position Set – Used to determine a Zero Position other than the factory default.
  4. Jitter Test – Used to determine the amount of jitter and allow the user to decide if acceptable.

• Select on the main screen (a).

• Offset calibration
  In this process, the DC offset of the sine and cosine signals are compensated over the operational sector (offset calibration).

  • Click (b).
  •  Rotate the shaft continuously during data collection, covering the whole working sector of the application from end to end. The progress bar (c) indicates the progress of the  data collection.
  • Rotation speed is not a parameter during data collection. By default, the procedure collects 500 points. The collected data for the fine / coarse channels, should be a clear “thin” circle which appears in the center of the plots (d) (e) with a possible slight offset.
  • When offset calibration is completed, click on <Continue to CAA/MAA Calibration> button (f).

• Calibration of Coarse Amplitude Alignment (CAA) & Medium Amplitude Alignment (MAA)

  • The following calibration aligns the coarse channel, and medium channel in certain encoders, with the fine channel by collecting data from each point in both channels. This is performed to make sure that every time the encoder is turned on, it would provide an accurate absolute position.
  • Select the relevant option from the Measurement Range options (a):
  • Full mechanical rotation – shaft movement is over a full 360 degrees rotation – (that is the recommended calibration).
  • Limited section – shaft has a limited rotation angle which is less than 360 degrees. In this mode you need to input the rotation range by degrees.
  • Free sampling mode – sets the number of calibration points in accordance with the total number of points in the text box. The system displays the recommended number of points by default. The minimum points over the working sector is nine.
  • Note that the Total number of points would change to the optimal default according to the selected measurement range above.
  • Click the button (b).

• The Calibration process control (c) indicates the current position, and the next target position to which the shaft should be rotated.

  • Rotate the shaft to the next position, stop and click the button to sample the position (d). The shaft should be at STAND STILL when clicking the button.

• The Shaft movement status (e) indicates the shaft movement status.

  • Complete the sampling process using the following routine: positioning the shaft –> stand still –> clicking (d) to sample the position.
  • When the process is completed click the button (f).

• Setting the zero-position of the encoder

  • Select one of the options for setting the zero point and click .
  • It is possible to set either current position or rotate the shaft to any other position to be set as the zero point.
  • It is also possible to set the Zero Point through the top menu bar, by selecting “Calibration” tab, and clicking “Set UZP”.

• Jitter test

  • The jitter test is used evaluate the level of electric noise.
  • Common jitter should be up +/- 3 counts; higher jitter may indicate system noise and would require better grounding or shielding of the electric noise source.
  • Select “Calibration” tab, and click “Jitter Test”
  • Select the Jitter test mode (a).
  • Set the Timing and Sampling parameters (b).
  • Click button (c) and check if the results (d) are within acceptable tolerances for the intended application.
  • Another indication of excessive jitter/noise when the blue dots in signal amplitude circle are not evenly distributed on a thin circle as appears below.

Operational Mode

• SSi / BiSS
  • Operational Mode indication of the SSi / BiSS encoder interface is available by using the NanoMIC to connect with the encoder. When in Operational Mode the color of the position dial is orange.
  • For more information read about NanoMIC on Netzer website
  • The operational mode is using SSi / BiSS interface with 1MHz clock rate.
  • The encoder position-dial is colored orange when in Operational Mode. The bar below the dial, is the corresponding binary word output for the current shaft position (a).

Corporate Headquarters ISRAEL

• Netzer Precision Position Sensors A.C.S. Ltd. Misgav Industrial Park, P.O. Box 1359
• D.N. Misgav, 2017400 Tel: +972 4 999 0420
• USA
• Netzer Precision Position Sensors Inc. 200 Main Street, Salem
• NH 03079
• Tel: +1 617 901 0820
• www.netzerprecision.com

References

• Rotary Encoders : Absolute Position Sensors by Netzer

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