TI5000 EXManual

Model TI-5000EX
Serial/Incremental Encoder
User's Manual
Software Version 3.3
Mitchell Electronics, Inc.
180B Mill Street

P. O. Box 2626
Athens, OH 45701
September 1, 2006
L. Mitchell
Voice: 740-594-8532
FAX: 740-594-8533
Email: support@mitchell-electronics.com
URL: http://www.mitchell-electronics.com
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LIMITED WARRANTY: Seller warrants that the articles furnished hereunder shall be free from defects in
material and workmanship for a period of one year from date of shipment. In no event will the seller be liable
for incidental or consequential damages arising from the use of this equipment, software, or documentation.
The liability of the Seller shall be limited to repair or replacement of, at its option, any defective units returned
to the Seller. Equipment or parts subject to improper use or unauthorized repair are not covered by
warranty. Repaired or replaced parts shall be covered for the remainder of the original warranty period or an
additional ninety (90) days from shipment by the Seller, whichever is longer. No other warranty expressed
or implied is made.
Copyright 2006 Mitchell Electronics, Inc.

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Table of Contents
1 INTRODUCTION ........................................................................................................................................................ 1
1.1 OVERVIEW ........................................................................................................................................................... 1

1.2 HOW TO USE THIS MANUAL .................................................................................................................................. 1
1.3 SETUP AND SOFTWARE INSTALLATION................................................................................................................. 2
1.3.1 HARDWARE CONNECTIONS ............................................................................................................................... 2
1.3.2 SOFTWARE INSTALLATION ................................................................................................................................ 2
1.3.2.1 WINTI5000EX PC SOFTWARE INSTALLATION............................................................................................... 3
1.3.2.2 PC USB DRIVER INSTALLATION .................................................................................................................... 3
1.3.2.3 DOWNLOAD PROGRAMS TO THE TI-5000EX USING WINTI5000EX............................................................... 4
1.4 NEW IN THIS RELEASE ......................................................................................................................................... 5
1.5 OPTIONS .............................................................................................................................................................. 5
2 OPERATION ........................................................................................................................................................ 7
2.1 BASIC OPERATION ............................................................................................................................................... 9

2.1.1 HELP ................................................................................................................................................................ 9
2.1.2 MENUS ............................................................................................................................................................. 9
2.1.2.1 TEST AND MOTOR REPAIR MENU .................................................................................................................. 9
2.1.2.2 SYSTEM SETUP MENU ................................................................................................................................... 9
2.1.2.2.1 SYSTEM DATA TAB..................................................................................................................................... 9
2.1.2.2.2 USER OPTIONS TAB ................................................................................................................................. 10
2.1.2.2.3 DOWNLOAD TI-3000/TI-5000EX SOFTWARE TAB ................................................................................... 10
2.1.2.3 HELP MENU................................................................................................................................................. 10
2.1.3 TEST BUTTONS............................................................................................................................................... 10
2.1.3.1 DATA DISPLAY BUTTON............................................................................................................................... 11
2.1.3.2 LINE LEVELS BUTTON ................................................................................................................................. 11
2.1.3.3 COUNT TEST BUTTON ................................................................................................................................. 11
2.1.3.4 CONTINUOUS COUNT TEST BUTTON ............................................................................................................ 11
2.1.3.5 PHASE TEST BUTTON .................................................................................................................................. 11
2.1.3.6 MEMORY TEST BUTTON .............................................................................................................................. 11
2.1.4 MISCELLANEOUS BUTTONS ............................................................................................................................ 11
2.1.4.1 SELECT FEEDBACK BUTTON ....................................................................................................................... 12
2.1.4.1.1 ENCODER/RESOLVER RADIO BUTTONS .................................................................................................... 12
2.1.4.1.2 ENCODER MANUFACTURER MENU............................................................................................................ 12
2.1.4.1.3 ENCODER TYPE MENU ............................................................................................................................. 13
2.1.4.1.4 MOTOR MANUFACTURER (MEMORY) MENU.............................................................................................. 13
2.1.4.1.5 COUNTS PER REVOLUTION BUTTON......................................................................................................... 13
2.1.4.2 DISPLAY PINOUT BUTTON............................................................................................................................ 14
2.1.4.3 SAVE REPORT TO FILE BUTTON .................................................................................................................. 14
2.1.4.4 PRINT REPORT BUTTON .............................................................................................................................. 14
2.1.4.5 POLES MENU............................................................................................................................................... 14
2.2 SERIAL ENCODER GENERAL INFORMATION........................................................................................................ 15
2.2.1 DATA DISPLAY ................................................................................................................................................ 15
2.2.1.1 ENCODER SELECTION.................................................................................................................................. 15
2.2.1.2 COMMUTATION ............................................................................................................................................ 16
2.2.1.3 POSITION COUNT ......................................................................................................................................... 17
2.2.1.4 ENCODER STATUS ....................................................................................................................................... 17
2.2.2 COUNT TEST................................................................................................................................................... 18
2.2.2.1 REVOLUTION ............................................................................................................................................... 19
2.2.2.2 COUNT ........................................................................................................................................................ 19
2.2.2.3 TARGET ....................................................................................................................................................... 19
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2.2.2.4 ERROR ........................................................................................................................................................ 19

2.2.2.5 COUNT/REV................................................................................................................................................. 19
2.2.2.6 STUCK BITS................................................................................................................................................. 19
2.2.2.7 INTERNAL ERROR ........................................................................................................................................ 20
2.3 GENERIC INCREMENTAL QUADRATURE PULSE ENCODERS ................................................................................ 21
2.3.1 DESCRIPTION.................................................................................................................................................. 21
2.3.2 CONNECTION .................................................................................................................................................. 21
2.3.3 SETUP ............................................................................................................................................................ 22
2.3.4 TESTING ......................................................................................................................................................... 22
2.3.5 DATA DISPLAY ................................................................................................................................................ 22
2.3.5.1 COMMUTATION ............................................................................................................................................ 23
2.3.5.1.1 NORMAL COMMUTATION........................................................................................................................... 23
2.3.5.1.2 SINE COSINE COMMUTATION ENCODERS ................................................................................................. 25
2.3.5.2 COUNT ........................................................................................................................................................ 26
2.3.5.3 RATE ........................................................................................................................................................... 27
2.3.5.4 LINE STATES ............................................................................................................................................... 27
2.3.5.5 INDEX .......................................................................................................................................................... 27
2.3.6 LINE LEVELS................................................................................................................................................... 28
2.3.6.1 REALTIME LEVELS ....................................................................................................................................... 29
2.3.6.2 MIN LEVELS................................................................................................................................................. 29
2.3.6.3 MAX LEVELS ............................................................................................................................................... 29
2.3.7 COUNT TEST................................................................................................................................................... 30
2.3.7.1 REVOLUTION ............................................................................................................................................... 30
2.3.7.2 COUNT ........................................................................................................................................................ 30
2.3.7.3 TARGET ....................................................................................................................................................... 30
2.3.7.4 ERROR ........................................................................................................................................................ 30
2.3.7.5 COUNT/REV................................................................................................................................................. 30
2.3.7.6 STUCK BITS................................................................................................................................................. 31
2.3.7.7 INTERNAL ERROR ........................................................................................................................................ 31
2.3.8 CONTINUOUS COUNT TEST ............................................................................................................................. 32
2.3.9 PHASE ANGLE TEST ....................................................................................................................................... 33
2.3.9.1 REALTIME .................................................................................................................................................... 33
2.3.9.2 MAX VAL ..................................................................................................................................................... 34
2.3.9.3 MIN VAL ...................................................................................................................................................... 35
2.4 GENERIC PARALLEL ABSOLUTE ENCODERS ...................................................................................................... 36
2.4.1 DATA DISPLAY ................................................................................................................................................ 38
2.4.1.1 LINE STATES ............................................................................................................................................... 38
2.4.1.2 BINARY CODE.............................................................................................................................................. 38
2.4.1.3 GRAY CODE ................................................................................................................................................ 39
2.4.1.4 BCD CODE ................................................................................................................................................. 39
2.5 GENERIC RESOLVERS........................................................................................................................................ 40
2.5.1 GENERAL COMMENTS .................................................................................................................................... 40
2.5.2 TYPES SUPPORTED ........................................................................................................................................ 41
2.5.3 CONNECTION .................................................................................................................................................. 41
2.5.4 SETUP ............................................................................................................................................................ 42
2.5.5 TESTING ......................................................................................................................................................... 44
2.5.6 DATA DISPLAY ................................................................................................................................................ 44
2.5.6.1 RESOLVER ANGLE READINGS ..................................................................................................................... 45
2.5.6.2 RESOLVER OUTPUT..................................................................................................................................... 45
2.5.6.3 RESOLVER EXCITATION SET POINTS ........................................................................................................... 46
2.6 MANUFACTURER SPECIFIC ENCODER DETAILS .................................................................................................. 47
2.6.1 FANUC MOTORS ............................................................................................................................................. 48
2.6.1.1 GENERAL COMMENTS ................................................................................................................................. 48
2.6.1.2 TYPES SUPPORTED ..................................................................................................................................... 48
2.6.1.2.1 IDENTIFICATION......................................................................................................................................... 49
2.6.1.3 CONNECTION ............................................................................................................................................... 49
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2.6.1.4.1 INCREMENTAL AND ABS ENCODERS ........................................................................................................ 49
2.6.1.4.2 SERIAL ENCODERS ................................................................................................................................... 49
2.6.1.5 TESTING ...................................................................................................................................................... 50
2.6.1.5.1 DATA DISPLAY.......................................................................................................................................... 50
2.6.1.5.1.1 COMMUTATION ...................................................................................................................................... 50
2.6.1.5.1.2 COUNT .................................................................................................................................................. 52
2.6.1.5.1.3 LINE STATES ......................................................................................................................................... 52
2.6.1.5.1.4 ENCODER STATUS................................................................................................................................. 52
2.6.1.5.2 COUNT TEST ............................................................................................................................................ 53
2.6.2 HEIDENHAIN SERIAL ENCODERS ..................................................................................................................... 55
2.6.2.2 TYPES SUPPORTED ..................................................................................................................................... 55
2.6.2.2.1 IDENTIFICATION......................................................................................................................................... 56
2.6.2.3 CONNECTION ............................................................................................................................................... 56
2.6.2.5 TESTING ...................................................................................................................................................... 56
2.6.2.5.1 DATA DISPLAY.......................................................................................................................................... 57
2.6.2.5.1.1 COMMUTATION ...................................................................................................................................... 57
2.6.2.5.1.2 COUNT .................................................................................................................................................. 58
2.6.2.5.1.3 ENCODER STATUS................................................................................................................................. 58
2.6.2.5.2 COUNT TEST ............................................................................................................................................ 59
2.6.3 HENGSTLER (UNICO) SSI SERIAL ENCODERS ................................................................................................ 60
2.6.3.2 TYPES SUPPORTED ..................................................................................................................................... 60
2.6.3.2.1 IDENTIFICATION......................................................................................................................................... 60
2.6.3.3 CONNECTION ............................................................................................................................................... 60
2.6.3.5 TESTING ...................................................................................................................................................... 61
2.6.3.5.1 DATA DISPLAY.......................................................................................................................................... 61
2.6.3.5.1.1 COMMUTATION ...................................................................................................................................... 62
2.6.3.5.1.2 COUNT .................................................................................................................................................. 62
2.6.3.5.1.3 ENCODER STATUS................................................................................................................................. 62
2.6.3.5.2 COUNT TEST ............................................................................................................................................ 63
2.6.4 INDRAMAT SERIAL ENCODERS ........................................................................................................................ 64
2.6.4.2 TYPES SUPPORTED ..................................................................................................................................... 64
2.6.4.2.1 IDENTIFICATION......................................................................................................................................... 64
2.6.4.3 CONNECTION ............................................................................................................................................... 65
2.6.4.5 TESTING ...................................................................................................................................................... 65
2.6.4.5.1 DATA DISPLAY.......................................................................................................................................... 65
2.6.4.5.1.1 COMMUTATION ...................................................................................................................................... 66
2.6.4.5.1.2 POSITION CODE RINGS.......................................................................................................................... 67
2.6.4.5.1.3 COUNT .................................................................................................................................................. 68
2.6.4.5.1.4 REVOLUTIONS CODE RINGS AND REVOLUTIONS.................................................................................... 68
2.6.4.5.1.5 ENCODER STATUS................................................................................................................................. 69
2.6.4.5.2 COUNT TEST ............................................................................................................................................ 69
2.6.4.5.3 MEMORY TEST ......................................................................................................................................... 70
2.6.5 KAWASAKI SERIAL ENCODERS ....................................................................................................................... 72
2.6.5.2 TYPES SUPPORTED ..................................................................................................................................... 72
2.6.5.2.1 IDENTIFICATION......................................................................................................................................... 72
2.6.5.3 CONNECTION ............................................................................................................................................... 73
2.6.5.5 TESTING ...................................................................................................................................................... 73
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2.6.5.5.1 DATA DISPLAY.......................................................................................................................................... 73

2.6.5.5.1.1 COMMUTATION ...................................................................................................................................... 74
2.6.5.5.1.2 COUNT .................................................................................................................................................. 74
2.6.5.5.1.3 ENCODER STATUS................................................................................................................................. 75
2.6.5.5.2 COUNT TEST ............................................................................................................................................ 76
2.6.6 MITSUBISHI SERIAL ENCODERS ...................................................................................................................... 77
2.6.6.2 TYPES SUPPORTED ..................................................................................................................................... 77
2.6.6.2.1 IDENTIFICATION......................................................................................................................................... 77
2.6.6.3 CONNECTION ............................................................................................................................................... 78
2.6.6.5 TESTING ...................................................................................................................................................... 78
2.6.6.5.1 DATA DISPLAY.......................................................................................................................................... 78
2.6.6.5.1.1 COMMUTATION ...................................................................................................................................... 79
2.6.6.5.1.2 COUNT .................................................................................................................................................. 79
2.6.6.5.1.3 ENCODER STATUS................................................................................................................................. 80
2.6.6.5.2 COUNT TEST ............................................................................................................................................ 80
2.6.7 RENCO ENCODERS ......................................................................................................................................... 82
2.6.8 SANYO DENKI SERIAL ENCODERS .................................................................................................................. 83
2.6.8.2 TYPES SUPPORTED ..................................................................................................................................... 83
2.6.8.2.1.1 ABSOLUTE ENCODER RESET PROCEDURES.......................................................................................... 84
2.6.8.2.2 IDENTIFICATION......................................................................................................................................... 85
2.6.8.3 CONNECTION ............................................................................................................................................... 85
2.6.8.5 TESTING ...................................................................................................................................................... 87
2.6.8.5.1 DATA DISPLAY.......................................................................................................................................... 87
2.6.8.5.1.1 COMMUTATION ...................................................................................................................................... 87
2.6.8.5.1.2 COUNT .................................................................................................................................................. 88
2.6.8.5.1.3 ENCODER STATUS................................................................................................................................. 88
2.6.8.5.2 COUNT TEST ............................................................................................................................................ 89
2.6.9 STEGMANN SERIAL ENCODERS ...................................................................................................................... 90
2.6.9.2 TYPES SUPPORTED ..................................................................................................................................... 90
2.6.9.2.1 IDENTIFICATION......................................................................................................................................... 91
2.6.9.3 CONNECTION ............................................................................................................................................... 91
2.6.9.5 TESTING ...................................................................................................................................................... 92
2.6.9.5.1 DATA DISPLAY.......................................................................................................................................... 92
2.6.9.5.1.1 COMMUTATION ...................................................................................................................................... 92
2.6.9.5.1.2 COUNT .................................................................................................................................................. 93
2.6.9.5.1.3 ENCODER STATUS................................................................................................................................. 93
2.6.9.5.1.4 MEMORY STATUS .................................................................................................................................. 95
2.6.9.5.2 COUNT TEST ............................................................................................................................................ 95
2.6.9.5.3 MEMORY TEST ......................................................................................................................................... 96
2.6.9.5.3.1 ALLEN BRADLEY MEMORY TEST ........................................................................................................... 96
2.6.10 SUMTAK SERIAL ENCODERS......................................................................................................................... 98
2.6.10.1 GENERAL COMMENTS ............................................................................................................................... 98
2.6.10.2 TYPES SUPPORTED ................................................................................................................................... 98
2.6.11 YASKAWA ENCODERS (ALLEN BRADLEY) .................................................................................................... 99
2.6.11.1 GENERAL COMMENTS ............................................................................................................................... 99
2.6.11.2 TYPES SUPPORTED ................................................................................................................................... 99
2.6.11.2.1 QUADRATURE INCREMENTAL WITH 3 COMMUTATION CHANNELS ............................................................ 99
2.6.11.2.2 QUADRATURE INCREMENTAL WITH SINGLE C COMMUTATION CHANNEL................................................. 99
2.6.11.2.3 ABSOLUTE ENCODERS ......................................................................................................................... 100
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2.6.11.2.3.1 ABSOLUTE ENCODER UPDATE TEST ................................................................................................. 101

2.6.11.2.3.2 ABSOLUTE ENCODER RESET PROCEDURES...................................................................................... 101
2.6.11.2.4 IDENTIFICATION..................................................................................................................................... 103
2.6.11.3 CONNECTION ........................................................................................................................................... 104
2.6.11.4 SETUP ..................................................................................................................................................... 104
2.6.11.5 TESTING .................................................................................................................................................. 104
2.6.11.5.1 DATA DISPLAY ..................................................................................................................................... 104
2.6.11.5.1.1 COMMUTATION .................................................................................................................................. 104
2.7 RESERVED....................................................................................................................................................... 106
2.8 ACCESSORIES ................................................................................................................................................. 106
2.9 PIN CONFIGURATIONS AND REFERENCE INFORMATION .................................................................................... 108
2.10 CLEANING...................................................................................................................................................... 138
2.11 SOFTWARE INSTALLATION AND REPAIR ......................................................................................................... 139
3 TESTING AND ENCODER BACKGROUND INFORMATION ........................................................................................ 140
3.1 TERMINOLOGY ................................................................................................................................................. 140

3.1.1 INCREMENTAL VERSUS ABSOLUTE ............................................................................................................... 140
3.1.1.1 TRADITIONAL ABSOLUTE ........................................................................................................................... 140
3.1.1.2 TRADITIONAL INCREMENTAL ...................................................................................................................... 141
3.1.1.3 INCREMENTAL/ABSOLUTE GRAY AREAS ................................................................................................... 141
3.1.2 SERIAL VERSUS NON-SERIAL ....................................................................................................................... 141
3.2 TEST THEORY .................................................................................................................................................. 143
3.2.1 INCREMENTAL ENCODER PHASE ANGLE TESTING ........................................................................................ 143
3.2.2 CHECKING AND SETTING COMMUTATION ...................................................................................................... 144
4 SPECIFICATIONS ................................................................................................................................................. 149
4.1 ELECTRICAL SPECIFICATIONS .......................................................................................................................... 149

4.2 SYSTEM DESCRIPTION ..................................................................................................................................... 150
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List of Figures
Figure 2.1 TI-5000EX Pictorial ................................................................................................................................. 8
List of Tables
Table 2.1 Main I/O Terminal Block, J1 Pin Configuration ............................................................................... 108
Table 2.2 Auxiliary I/O Terminal Block, J2 Pin Configuration........................................................................ 108
Table 2.3 Power Supply Connector, J3 Pin Configuration............................................................................. 109
Table 2.4 RS232 DCE Ports 0 and 1, J6 Pin Configuration ............................................................................ 109
Table 2.5 USB Connector, J9 Pin Configuration.............................................................................................. 109
Table 2.6 Control Connector, J10 Pin Configuration ...................................................................................... 110
Table 2.7 Can Bus Connector, J11 Pin Configuration .................................................................................... 110
Table 2.8 Resolver, J12 Pin Configuration........................................................................................................ 110
Table 2.9 TI-5007 Fanuc ABS Pulsecoder Connections & J1/J2 Pin Configuration................................. 111
Table 2.10 TI-5004, TI-5005, TI-5005W, TI-5006 Fanuc Pulsecoder Connections & J1 Pin Configuration
.......................................................................................................................................................................... 111
Table 2.11 TI-5008 Mitsubishi OSA104/OSE104 Serial Encoder & J1 Pin Configuration........................ 112
Table 2.12 TI-5010 Heidenhain RON3350 & ERN1387 Encoder & J1 Pin Configuration.......................... 112
Table 2.13 TI-5011 Kawasaki H20/M21 4 Pin Encoder & J1 Pin Configuration.......................................... 112
Table 2.14 TI-5012 Mitsubishi OSA14 Encoder & J1 Pin Configuration (Discontinued).......................... 113
Table 2.15 TI-5013 Sumtak REC/REM2048 17 Pin Encoder & J1 Pin Configuration................................. 113
Table 2.16 Sanyo Denki Encoder & J1 Pin Configuration............................................................................. 113
Table 2.17 TI-5014 Yaskawa C Channel UTOPH 17 Pin Encoder & J1 Pin Configuration....................... 114
Table 2.18 TI-5015 Yaskawa UTOPI-600UA 17 Pin Encoder & J1 Pin Configuration ............................... 114
Table 2.19 TI-5016, TI-5016W Fanuc Incremental 17 Pin Encoder & J1 Pin Configuration ..................... 115
Table 2.20 TI-5017 Yaskawa Absolute 17 Pin Encoder & J1 Pin Configuration ........................................ 115
Table 2.21 TI-5018 Renco RHS21D-P1-2000-8MM-5-CS-LD-M1-0-P-S 8 Pin................................................ 116
Table 2.22 TI-5019 Renco RCH20D-2000/3-8MM-5/0-LD/VC-I-M6-S 17 Pin .................................................. 116
Table 2.23 TI-5020 Fanuc Pulsecoder Alpha A, 6 Pole Connections & J1 Pin Configuration................. 116
Table 2.24 TI-5021 Indramat 12 Pin Connections & J1/J2 Pin Configuration ............................................ 117
Table 2.25 TI-5022 Indramat ROD1424 ROD 1430 Connections & J1/J2 Pin Configuration ................... 117
Table 2.26 TI-5023 Kawasaki HE-02/Sanyo Denki E03007758 8192 Count DB15....................................... 118
Table 2.27 TI-5024 Yaskawa Absolute DB15 Encoder & J1 Pin Configuration ......................................... 118
Table 2.28 TI-5025 Yaskawa C Channel SGM 9 Pin Encoder & J1 Pin Configuration.............................. 119
Table 2.29 TI-5026 Kawasaki HE-02 8192 Count 17 pin Enc. Connections & J1 Pin Configuration ...... 119
Table 2.30 TI-5027 Mitsubishi OBE12 & OBA13 9 Pin Encoder & J1 Pin Configuration.......................... 119
Table 2.31 TI-5028 Mitsubishi OBA13/OHA14B 17 Pin Encoder & J1 Pin Configuration ........................ 120
Table 2.32 TI-5029 Fanuc Incr. & ABS Pulsecoder DB25 Connections & J1/J2 Pin Configuration ....... 120
Table 2.33 TI-5030 Siemens/Hiedenhain ROD320 Inc. 17 pin Connections & J1/J2 Pin Configuration 120
Table 2.34 TI-5031 Siemens Hiedenhain Endat 17 Pin Encoder & J1, J2 Pin Configuration................... 121
Table 2.35 TI-5032 Kawasaki H20/M21 17 Pin Connector & J1 Pin Configuration..................................... 121
Table 2.36 TI-5033 Sanyo Denki with Sumtak AEC2048 10 pin Molex Conn. & J1 Pin Configuration... 122
Table 2.37 TI-5034 Fanuc Alpha Position Code 17 pin Encoder & J1 Pin Configuration ........................ 122
Table 2.38 TI-5035 Tamagawa OAH74/OAM74 16 pin Encoder & J1 Pin Configuration.......................... 122
Table 2.39 TI-5036 Sanyo Denki R11G4113A 17 Pin Encoder & J1 Pin Configuration............................. 123
Table 2.40 TI-5037 Fanuc Alpha A8 12 Pin Hirose Encoder & J1 Pin Configuration ................................ 123
Table 2.41 TI-5038 Generic MS Pins J1 & J2 Pin Configuration.................................................................... 123
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Table 2.42 TI-5039 Yaskawa Absolute AMP Mini-MNL 12 Pin Encoder & J1 Pin Configuration ............ 124
Table 2.43 TI-5040 Indramat MKD Resolver Pin Connections & J1/J2 Pin Configuration....................... 124
Table 2.44 TI-5041 Yaskawa 12 Bit Absolute Enc. 15 Pin Amp Connector & J1 Pin Configuration ...... 125
Table 2.45 TI-5042 Indramat MAC 12 Pin Connections & J1/J2 Pin Configuration................................... 125
Table 2.46 TI-5043 Baldor Heidenhain Endat 17 Pin Encoder & J1, J2 Pin Configuration ...................... 126
Table 2.47 TI-5044 Yaskawa Absolute Two AMP Mini-MNL 6 Pin Encoder & J1 Pin Configuration...... 126
Table 2.48 TI-5045 Renco N2300, 3400, 4200 & 4600 Amphenol PT06E14-19S(SR) 19 Pin...................... 127
Table 2.49 TI-5046 Mitsubishi OBE12 & OBA13 JST 9 Pin Encoder & J1 Pin Configuration.................. 127
Table 2.50 TI-5047 Fanuc Alpha I Pulsecoder Connections & J1 Pin Configuration................................ 127
Table 2.51 TI-5048 Renco RCH20, HRS 16 Pin ................................................................................................. 128
Table 2.52 TI-5049 Stromag/Hiedenhain SSI ECN1313/EQN1325 17 Pin Enc. & J1, J2 Pin Config........ 128
Table 2.53 TI-5050 Tamagawa 482000, 18 Pin Bayonet ................................................................................. 129
Table 2.54 TI-5051 Control Techniques/Stegmann SCM60 12 Pin Enc. & J1, J2 Pin Configuration...... 129
Table 2.55 TI-5052 Baldor 14-19P F (Fadal), 19 Pin Bayonet & J1, J2 Pin Configuration........................ 130
Table 2.56 TI-5053 Panasonic Minas A Incr. 15 pin Mini M-N-L Connections & J1 Pin Configuration .. 130
Table 2.57 TI-5054 Siemens/Heidenhain ROD 320 17 pin Encoder & J1 Pin Configuration.................... 130
Table 2.58 TI-5055 Siemens Hall/Tach 12 pin Encoder & J1 Pin Configuration ........................................ 131
Table 2.59 TI-5056 Sanyo Denki ABOSYN ABS Super 17 pin Connections & J1 Pin Configuration..... 131
Table 2.60 TI-5057 Allen Bradley/Stegmann MPF-B/MPG-A5 17 Pin Encoder & J1 Pin Configuration. 132
Table 2.61 TI-5058 Allen Bradley/Stegmann MPF-A3/A4/A45 17 Pin Encoder & J1 Pin Configuration. 132
Table 2.62 TI-5059 B and R/Hiedenhain Endat 17 Pin Encoder & J1, J2 Pin Configuration.................... 133
Table 2.63 TI-5060 Control Techniques/Stegmann Dicoder 17 Pin Enc. & J1, J2 Pin Configuration .... 133
Table 2.64 TI-5061 Indramat MAC/Stegmann AG 100 MSI 12 Pin Encoder & J1, J2 Pin Configuration 134
Table 2.65 TI-5062 Fanuc ABS Pulsecoder DDK 19 pin Connections & J1/J2 Pin Configuration.......... 134
Table 2.66 TI-5063 Baumuller/Stegmann Hiperface 12 Pin Encoder & J1 Pin Configuration ................. 135
Table 2.67 TI-5064 Allen Bradley MPL, 1326AB 19 pin Connections & J1 Pin Configuration................. 135
Table 2.68 TI-5065 Sanyo Denki INC-E 17 pin Connections & J1 Pin Configuration................................ 135
Table 2.69 TI-5066 Matsushita/Tamagawa, 17 Pin Connections & J1 Pin Configuration ........................ 136
Table 2.70 TI-5067 Sanyo Denki R11 Encoder, 15 Pin Encoder & J1 Pin Configuration......................... 136
Table 2.71 TI-5068 Modicon/Stegmann Hiperface 17 pin Euro Connections & J1 Pin Configuration... 136
Table 2.72 TI-5069 Stegmann Hiperface 8 pin Connections & J1 Pin Configuration ................................ 137
Table 2.73 TI-5070 Fanuc Alpha and Beta Pulsecoder Connections & J1 Pin Configuration.................. 137
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1 INTRODUCTION
1.1 OVERVIEW
The TI-5000EX is a complete solution for testing and debugging feedback devices typically found on modern
brushless permanent magnet servomotors. It offers users the ability to:
1. Easily perform tests on pulse based devices such as incremental encoders.

2. Easily read and display counts, speeds, and states of input pulse lines from many devices
(including encoders).
3. Easily perform tests on resolver feedback devices.
4. Run diagnostics on serial encoders.
1.2 HOW TO USE THIS MANUAL
This manual is shipped with new units as a bound print version. It is also shipped on the installation CD as a
PDF file. When the WinTI5000EX program is installed, the PDF file is accessible from the WinTI5000EX
Help menu providing Acrobat Readers is installed on the user’s PC. This PDF copy of the manual may be
copied an distributed freely among company personnel. It may be viewed on any PC equipped with Acrobat
reader. This manual contains a great deal of important information pertaining to the use of the TI-5000EX
and to certain topics in servo motor repair in general. We hope that it will be widely read.
Section 2 of this manual describes the TI-5000EX Operation. This section will be all that many users need
to effectively apply the unit in their applications. For users who need to know more specifics of how the TI-
5000EX makes measurements and how details on how various feedback devices work, Section 3, 'Testing
and Encoder Background Information', will be beneficial. It should not be necessary for the typical user to
read Section 3, but the additional information may be helpful. The first part of Section 3 covers terminology,
and that is recommended reading due to the confusing terminology in use with encoders today.
Always make certain that the software revision noted on the front of this manual agrees with the revision
shown on the sign-on message on the display when the unit is powered up.
TI-5000 2 INTRODUCTION
1.3 SETUP AND SOFTWARE INSTALLATION
The TI-5000EX utilizes a PC for operator interface. It uses an RS232 or USB cable connected to a PC for
both operator interface and downloading new software.
1.3.1 HARDWARE CONNECTIONS
The TI-5000EX unit is powered by a wall mount power supply which is supplied with the system.
1. Plug the power supply cable into the TI-5000 power jack, J3, and plug the power supply into a 110
VAC outlet.
2. Select the cable harness for the encoder to be tested. Plug the 14 pin terminal block into J1 of the
TI-5000EX (and in some cases J2 if the encoder includes commutation lines or J12 if it is a
resolver). Connect the encoder into the mating connector on the other end of the harness.
3. Move the TI-5000 power switch to the ON position to apply power to the TI-5000EX and the encoder
under test.
1.3.2 SOFTWARE INSTALLATION
A summary of the software installation is as follows:

1. The TI-5000EX includes 3 programs that are installed with the latest version at the time of purchase,
so you will not normally need to load any programs into the TI-5000EX tester when it is a new
purchased. A procedure is provided below for loading program upgrades and updates into your TI-
5000EX at a later date.
2. You must load the WinTI5000EX program and associated software onto your PC for a new purchase.
This software is contained on the CD Rom that comes with your new system. When you update or
upgrade your software, it will often only be necessary to copy the new WinTI5000EX program to your
PC.
The TI-5000EX tester must communicate with the PC (desktop or notebook) that is to be used as the operator
interface. WinTI5000EX.exe is the operator interface program that runs on the PC. Communications between
the tester unit and the PC are accomplished using a PC COM port. The COM port can be either a real RS232
COM port or a USB Virtual COM port.
If an RS232 COM port is used, the TI-5000EX must be connected to the female DB9 connector on the PC
using the blue RS232 ribbon cable supplied with the tester. In either case, when WinTI5000EX is started, you
must go to the System Setup menu and select the COM port that you have decided to use (COM1, COM2,
COM3, etc.). This should only be necessary one time, and the configuration file will remember the selection
when the program is started in the future.
If you communicate between the PC and the TI-5000EX tester using the USB port (rather than the RS232 port),
you will need to install the USB drivers onto your PC using the CD Rom. A procedure below describes that
installation.
USB to serial converter cables are available which will plug into the PC USB port and provide you with a COM
port with a female DB9 to which you can connect the blue ribbon cable. To use this device, you will need to
follow the instructions that come with it for installing drivers on your PC. When you start WinTI5000EX the first
time, you will need to go to the System Setup menu and select the COM port that has been assigned to the
USB to serial converter. Often you will be able to tell which COM port was assigned during the driver
installation. Otherwise you can find out from the Windows Device Manager.
1.3.2.1 WINTI5000EX PC SOFTWARE INSTALLATION
1. The software can be installed by double clicking on the install.bat file on the CD. It will install the TI-
5000EX files in a folder called TI5000EX. It will not affect your present TI-5000 installation at all. You
can have both systems installed and run either one, but you cannot run both at the same time.
2. WinTI5000EX may have issues when changing logged in users on PCs running Windows XP Pro. To
avoid problems with more than one user, copy the TI5000EX folder from the root directory (where it is
installed by install.bat) to the Shared Documents folder. This seems to allow access by all users.
1.3.2.2 PC USB DRIVER INSTALLATION
The TI-5000EX has its own USB port which can be set up as a USB Virtual COM port. This is probably the
simplest way to go other than a standard RS232 serial port. For this you can use the standard USB cable that
comes with your TI-5000EX, and plug one end into the PC USB port and the other end into the TI-5000EX USB
port. However, you should make this connection the first time while following the sequence below for installing
the USB drivers.
This is the sequence for Windows XP. Other versions of Windows may differ somewhat, but they should be
close to this.
1. Make sure that the latest distribution files are located on your PC in the folder:
C:\TI5000EX. If not, then perform the installation to put them there.
2. Plug the USB cable into the TI-5000EX and into the USB port that you wish to use on the PC, and
power up the TI-5000EX.
3. The Found New Hardware Wizard window should open up. “Can Windows connect to Windows
Update to search for software?”. Click “No, not this time” and then click the Next button.
4. The next window will say “What do you want the wizard to do?”. Click on “Install from a list or specific
location (Advanced).” And then click the Next button.
5. In the next window, click on “Search for best driver in these locations.” Then check the box beneath it
labeled “Include this location in the search:”. Then click on the Browse button beneath the check box,
and navigate to the C: C:\TI5000EX folder and click on the TI5000EX_USB_DriverInstaller within it.
This is the folder that contains the drivers to be installed. Click OK in the browse window and then click
the Next button.
6. A window will pop up that says “Please wait while the wizard installs the software…”. Then another
window will pop us that says:
“The software you are installing for this hardware:
TI5000EX USB Composite Device
has not passed Windows logo testing…”.
Click on the Continue Anway button.
Wait for the installation to complete, and another window will pop up saying:
The wizard has finished installing the software for:
TI5000EX USB Composite Device”.
This will indicate that this phase of the installation has completed.
Note: The Silabs drivers used for this USB device actually have passed the Windows Logo testing.
However, because the USB device in your TI-5000EX uses the Mitchell Electronics, Inc. product
identification number (PID), Windows does not recognize the drivers as Silabs.
7. Click the Finish button, and the wizard will disappear. However another new hardware wizard will
quickly appear. This is normal because there two sets of drivers to be installed. Simply repeat steps 3
through 6 again to install the next set of files. When it is finished, the last window will say:
“The wizard has finished installing the software for:
TI-5000EX USB to UART Bridge Controller”.
This will indicate that the installation is complete. Click the Finish button to terminate the wizard.
As described above for the USB to RS232 converter, you will need to select the correct COM port in the
System Setup menu. You can use the Windows Device Manager (as described above) to determine the correct
COM port. The Device Manager will identify the TI-5000EX device. Typical wording would be “TI-5000EX USB
to UART Bridge Controller (COM7)”. In this case, COM7 would be the selection you should make in the
WinTI5000EX System Setup menu.
The USB port will now be used to communicate with your TI-5000EX in the same way as a conventional
RS232 port. You will use it during testing, and you will use it when downloading new software to your TI-
5000EX unit.
The USB port in the TI-5000EX is powered by the USB rather than the TI-5000 power supply. This allows you
to power down the TI-5000EX without losing the USB connection. Often you will wish to power down the unit
when connecting encoders, etc. As long as you do not disconnect the USB cable, the USB port will remain
connected. If you need to disconnect the USB port, you should first exit the WinTI5000EX software and power
down the TI-5000EX.
1.3.2.3 DOWNLOAD PROGRAMS TO THE TI-5000EX USING WINTI5000EX
New purchases come with the TI-5000EX application program already installed, so this step is not normally
necessary. However this section describes how future updates and upgrades can easily be downloaded to
the TI-5000EX using the WinTI5000EX downloader function. WinTI5000EX is the Windows based interface
for the TI-5000EX encoder test system. It is the program that you run on your PC whenever you use your TI-
5000EX tester.
To download your program using the WinTI5000EX downloader, the following steps should be followed:
1. Connect the RS232 or USB cable from the TI-5000EX to the PC in the normal manner (it is probably
already connected as a result of your day to day use).
2. Insert the upgrade media in to the appropriate drive on the PC (diskette into floppy disk drive A: or CD
ROM into the CD ROM drive) so that you can locate the new file to download. If the new file came via
email or internet download, just insure that you can find it in whichever folder it is located on your PC.
An example of a filename would be: “TI-5000_010008_000F000000000000.s”. It will start with “TI-
5000” and end in “.s”
3. Start WinTI5000EX in the normal manner (using shortcut on desktop or double clicking on
WinTI5000EX.exe from Windows Explorer or MyComputer).
4. Click on System Setup on the Menu Bar, and then click on the Download TI-3000/TI-5000EX Software
tab. Follow the instructions in the Instructions/Comments box.
The first instruction will be to select the file to download. This is done by pressing the Select File button.
Select the floppy drive A:, CD Rom drive, or appropriate folder as discussed in 2. above, and continue
until you find the file that you wish to download. Click on the filename to highlight it and select it. Press
OK after the correct file is selected.
The program will next prompt you to click on the Start Download button.
After clicking the Start Download button, you will be prompted to make sure the RS232 cable is
connected, turn the TI-5000EX OFF (if it is not already OFF), and then to turn the TI-5000EX unit back
ON.
As the board powers up, the downloading begins, and a new prompt appears telling you to wait for the
code to download. A progress bar appears indicate the progress in the download operation. A
Download Completed Successfully box will appear when the download is complete. Press the OK
button on this message box.
5. Exit WinTI5000EX and power down the TI-5000EX. Power up the TI-5000EX and restart
WinTI5000EX. Go to the WinTI5000EX System Setup menu and check for the correct version number.
Check the Currently Licensed Options frame to make sure that any new encoder support appears in
the list. Also make sure that all of your previously licensed options still appear in the list. If the licensed
options are incorrect, contact the factory for support.
If the unit does not come up properly, repeat the download procedure. If the unit still does not come up
properly, call for factory support.
1.4 NEW IN THIS RELEASE
Please see the document accompanying this software release for a description of this and previous version
updates.
1.5 OPTIONS
Numerous cable and other options are available for the TI-5000EX. Please refer to the current price list for a
complete listing of these options.

TI-5000 7 OPERATION
2 OPERATION
This device has various modes of operation. The Main Menu is used to select the desired mode.
When connecting an encoder to the TI-5000EX, go to the Main Menu and switch off the power (using the
slide switch, SW1, on the side of the TI-5000EX). Make the connection to the encoder, and switch the
power back on.
Testing for various encoders follows 3 easy steps.
1. Using the Select Feedback button, select the correct encoder type from the various encoder
selections supported by the TI-5000EX.
2. Click on the Data Display test button to determine whether the encoder is providing any data output
at all, determine whether the count is changing by approximately the correct amount as indicated by
the feedback selection, and determine for serial encoders whether any error bits are in the alarm
state.
3. For serial encoders, proceed to the Serial Count Test to more accurately determine whether the
correct number of counts per revolution is occurring. For quadrature pulse encoders, the Line Level
Test, Incremental Count Test, and Phase Angle Test may be performed for further confirmation.
The following sections will provide more detailed information as to how to test various feedback types
including incremental encoders, serial encoders, and resolvers.
TI-5000 8 OPERATION
Figure 2.1 TI-5000EX Pictorial

TI-5000 9 OPERATION
2.1 BASIC OPERATION
The TI-5000EX operation is controlled by test and setup buttons on the WinTI5000EX windows operator
interface display. The tests are selected via the test buttons across the top of the display. The device to be
tested and various testing options are selected via the Select Feedback button. Setup options for
WinTI5000EX may be accessed via the System Setup Menu at the top of the screen. Various other buttons
are available for test control, reporting, information, etc. during the course of the various tests.
2.1.1 HELP
The Help Menu will provide general help for the particular test currently selected.
Tool Tip Text Help is available on any display by using the PC mouse to move the pointer over the button or
data box in question. After a short delay, the text will appear near the pointer describing the use of the
particular Windows control (button, text box, etc.) of interest. This is a very quick way to get help without
having to go to the main help or the manual.
2.1.2 MENUS
The menus are selectable at the very top of the screen. The currently available menus are Test and Motor
Repair, System Setup, and Help. These will be described below.
2.1.2.1 TEST AND MOTOR REPAIR MENU
This menu allows selection of the Data Display, Line Levels, Count Test, Continuous Count Test, Phase
Test, and Memory Test. Each of these functions is also accessible by the buttons of the same name. Since
the buttons will be the more common method of accessing these functions, they will be discussed below with
the appropriate buttons.
2.1.2.2 SYSTEM SETUP MENU
This menu shows you the current setup for your TI-5000EX system, and allows you to make certain system
selections. The window is organized in 3 tabs: System/Data, User Options, and Download TI-3000/TI-
5000EX software).
2.1.2.2.1 SYSTEM DATA TAB
The System Data Tab allows you to see the current software version numbers and dates in the Software
Versions frame, identify (and change if desired) the currently selected COM port in the Serial Ports frame,
and identify the currently licensed software options for your system in the Currently Licensed Options frame.
The Software Versions frame shows the serial number for your TI-5000EX unit. You will need to know this
number when purchasing software upgrades because the application software will run correctly only on the
correctly serial numbered unit. This serial number is read from the TI-5000EX unit, so you will need to have
the RS232/USB cable connected and the unit powered up in order for this data to display correctly. The
WinTI5000EX version number and date refer to the WinTI5000EX program that is currently installed on your
PC and that you are using at the time you read this data. The TI-5000EX Flash version number and date
refer to the application program that is running inside your TI-5000EX unit. You will need to download a new
program to your TI-5000EX when you receive a program update or when you purchase a program upgrade
TI-5000 10 OPERATION
to add new support options to your system. The Boot Flash and Resolver programs are system programs
running inside your TI-5000EX unit. If these programs need to be updated, you will need to return your unit
to the factory.
The PC COM port to be used to communicate with the TI-5000EX tester hardware is selectable from COM1
through COM16 via the Select COM dropdown menu. This selection includes real COM ports and virtual
COM ports supported via the USB port. Normally a real COM port will be mapped in as COM1 or COM2.
Virtual COM ports will often start at COM4. You will likely need to use the Windows Device Manager to see
which COM Ports are available to the WinTI5000EX program. You must select one of the COM ports that is
shown in the device manager, and that port cannot be in use by any other programs.
2.1.2.2.2 USER OPTIONS TAB
This allows a short text file to be created that will show up in reports.
2.1.2.2.3 DOWNLOAD TI-3000/TI-5000EX SOFTWARE TAB
This menu allows downloading a new TI-5000EX Flash application file. See Section 1.3 for details
2.1.2.3 HELP MENU
The Help Menu provides selections: Help and About. The About selection provides support information for
the program.
The View Manual selection allows you to view the PDF version of the TI-5000EX manual providing that a
copy is residing in your TI-5000 folder and Adobe Acrobat Reader is installed on your PC. If you do not have
Acrobat Reader, it can be downloaded via the internet from http://www.adobe.com .
The Help selections will display Help files to help you use the WinTI5000EX system.
Tool Tip Help Text is now available for most button and data box controls. Even though this is not part of the
Help Menu, it is a very good way to get help with the WinTI5000EX program. Just move the mouse pointer
over the button or data box of interest. After a .5 second delay, help text should appear on the screen near
the mouse pointer. After 5 or 6 seconds it will disappear. If you are not finished reading it, move the pointer
away from the button or text box and then back to it, and the help text will reappear.
2.1.3 TEST BUTTONS
The Test buttons are located just below the menus. These buttons allow execution of the various tests: Data
Display, Line Levels, Count Test, Continuous Count Test, Phase Test, and Memory Test. Depending on the
feedback selections only some of these buttons will be available. Buttons which are not applicable to a
particular selected feedback device will be disabled.
The Exit to Windows button is not a test but is included with this group. It allows you to shut down the
WinTI5000EX program and return to the Windows operating system.
2.1.3.1 DATA DISPLAY BUTTON
Data Display is selected to read an encoder signal and display the count, commutation states and other
information. The details for the Data Display vary with the particular encoder, so read the section that
applies to the particular encoder or family of encoders for details.
2.1.3.2 LINE LEVELS BUTTON
Line Level Check provides for measuring the proper incremental encoder output voltages over a 0 to 14.9
volt range.
Warning: Voltages above15.0 VDC may damage the TI-5000EX input circuitry.
Measurement of serial encoder outputs is not implemented at this time. See the section on incremental
encoders for further details.
2.1.3.3 COUNT TEST BUTTON
The Count Test will verify that the encoder is incrementing the correct number of counts per revolution while
turning the encoder slowly by hand. This test is the only count test implemented for serial encoders. Refer
to the section on a particular encoder or family of encoders for further details.
2.1.3.4 CONTINUOUS COUNT TEST BUTTON
The Continuous Count Test will verify that the incremental encoder is incrementing the correct number of
counts per revolution for a large number of turns and may be conducted at high speeds. The Continuous
Count Test is available only for incremental encoders. It lets the operator ensure that the correct number of
counts occur from one index pulse to the next. This test may be run continuously without operator interaction
to check for an accumulated error. Refer to the section on incremental encoders for more details.
2.1.3.5 PHASE TEST BUTTON
The Phase Test is only available for incremental encoders. This test will measure and display the phase
angle from the rising edge of A to the rising edge of B. It will also measure A and B symmetry angles from
the rising edge to falling edge of a particular pulse (A or B respectively). See Section 3.2.1 for more
discussion on this topic.
2.1.3.6 MEMORY TEST BUTTON
The Memory Test is only used with certain serial encoders which include memory in the encoder and which
are currently supported by the system. Memory Test software licensing will be required to conduct memory
tests on these encoders.
2.1.4 MISCELLANEOUS BUTTONS
The Setup Menu allows selection of feedback manufacturer and type along with setting up various
parameters that may apply to the various types of feedback that you will be testing. The Setup Menu can be
accessed by pressing the SETUP Key. The Setup Menu can always be reached from the Main Menu, and it
can be reached from View 1 of most test menus.
2.1.4.1 SELECT FEEDBACK BUTTON
The Select Feedback button allows selection of feedback manufacturer and type along with setting up
various parameters that may apply to the various types of feedback that you will be testing. The selection
window can be accessed by pressing the Select Feedback button. This button is available from within most
tests, and the various selections available on this window are discussed below.
2.1.4.1.1 ENCODER/RESOLVER RADIO BUTTONS
The Select Feedback Window includes a Select Encoder frame and a Select Resolver frame. Each of these
frames includes a radio button that determines whether an encoder or resolver is to be selected for testing.
Note that the radio buttons are shaded pale blue indicating that they are a Windows control that allows a
user selection entry.
If the Encoder Feedback radio button is selected, the various selections options for encoder feedback, such
as manufacturer and type, are enabled and available to the user.
If the Resolver Feedback radio button is selected, no further setup is done in this window. Additional setup
will be done in the Data Display test window, which is the only test available for resolvers.
2.1.4.1.2 ENCODER MANUFACTURER MENU
The first step in encoder feedback selection is to select the encoder manufacturer. This is done using the
Encoder Manufacturer dropdown menu. Note that this menu is shaded pale blue to indicate that it is a
control that allows user selection entry. Incremental and parallel absolute encoders are so similar regardless
of manufacturer, that it generally is not helpful to specify a manufacturer. Instead these types of encoders
are selected as a generic type: Generic Incremental Encoder or Generic Parallel Absolute Encoder in the
dropdown menu for the manufacturer.
The properties of serial encoders are very specific to different manufacturers, so it is necessary to select a
particular manufacturer when serial encoders are in use. The menu lists all manufacturers supported by the
current software revision so that the user can easily determine which manufacturers are currently supported.
However, even though a manufacturer appears in the list, that manufacturer is supported on a given unit
only if the unit is licensed for that manufacturer. That can be determined from the System Setup menu. If a
manufacturer is not licensed, a message box will pop up during the selection warning that the support
license must be purchased before the selection will be available.
2.1.4.1.3 ENCODER TYPE MENU
When the encoder manufacturer selection has been made, the encoder type can then be selected using the
Encoder Type dropdown menu. The contents of this menu are completely dependent upon the encoder
manufacturer that has been selected.
If the manufacturer selection is Generic Incremental Encoder, the type will default to AB Quadrature and the
Type control will be disabled since there is currently no other valid choice. If the selection is Generic Parallel
Absolute, the Encoder Type Menu defaults to the one and only selection of 10 Bits Various Formats.
For encoder manufacturer name selection (such as Fanuc, Mitsubishi, etc.), the Encoder Type menu will
contain the various types of serial encoders that are supported for the selected manufacturer. The user must
select the encoder type corresponding to the particular encoder that he wishes to test.
2.1.4.1.4 MOTOR MANUFACTURER (MEMORY) MENU
Modern serial encoders are increasingly making use of memory. The encoder memory is typically used to
store motor parameters and sometimes even commutation information. This information may be read from
the encoder by the drive when the drive powers up so that the drives knows exactly what kind of motor is
connected to it.
Since this information is essential to the drive, this information must be intact and readable for the motor to
function properly on the drive. The TI-5000EX support is being expanded to support checkout of this
memory data to the greatest extent possible. If motor alignment data is included in the memory, this data is
translated into static alignment lockup angles when possible.
The details of the memory storage vary greatly from one motor manufacturer to the next. Even though two
manufacturers may be using the same Stegmann Hiperface or Heidenhain Endat encoder, the way data is
stored in the memory will generally be completely different. Therefore the Memory selection is based on
Motor Manufacturer rather than encoder type. Manufacturers who use a particular brand of encoder will be
shown when that encoder has been selected. This selection will be disabled for encoders that do not include
memory.
2.1.4.1.5 COUNTS PER REVOLUTION BUTTON
The Counts Per Revolution button is disabled for all serial encoders. Serial encoders automatically select
the correct counts per revolution when the type is selected.
The button will be enabled for Generic Incremental Encoder selection. The user should enter the number of
counts per revolution expected from the encoder under test. This will be four times the number or pulse per
revolutions (PPR) or number of lines per revolution. If you do not know the correct number to enter, either
use your best guess or let it default to a selection. When you run a Count Test, the correct number will be
determined by the test and can be entered at that time. Any number below 10,000,000 will be accepted by
the software. However, the correct number will be evenly divisible by 4 since the counts per revolution value
is always 4 times the number of pulses per revolution.
The number of counts per revolution must be correct in order for the Mechanical Angle and Electrical Angle
in the Data Display test to display correctly.
2.1.4.2 DISPLAY PINOUT BUTTON
The Display Pinout button is available from all tests, and it will bring up a window containing the J1 and J2
terminal block pin designations for quick reference.
2.1.4.3 SAVE REPORT TO FILE BUTTON
The Save Report to File button is available from all tests, and it will allow saving a report of the current test
results to a disk file. It will bring up a window that allows a comment line to be specified for the report. If no
comment is desired, simply click the OK button on the window. After the comment window, a file selection
window will appear in which the filename and path may be specified for the report file. The report will then be
saved to the specified file.
2.1.4.4 PRINT REPORT BUTTON
The Print Report button is available from all tests, and it will allow a report for the current test to be sent
directly to a printer for printing rather than storing on a disk file.
2.1.4.5 POLES MENU
The Poles Menu is selectable in the Data Display test. This control allows you to change the number of
poles for the motor associated with the selected feedback. The number of poles (and counts per revolution)
must be correct in order for the electrical angle to display correctly in the Data Display test. This angle must
be correct if it is to be used for feedback alignment purposes.
Currently, 2, 4, 6, or 8 poles may be selected.

2.2 SERIAL ENCODER GENERAL INFORMATION
Serial encoders are encoders which provide the position count and/or other information (such as error
detection bits, overheat bits, etc.) as a serial data stream to the drive or other external electronics. This
serial data is somewhat similar to data from your PC RS232 port, your PC network, etc. The encoder
normally maintains the count and other information internally, and transmits the resulting data in a serial
format which is typically proprietary to the encoder manufacturer. Some encoders provide both serial data
output and quadrature pulse output. For thorough testing, these encoders should be tested as both serial
and quadrature pulse incremental encoders. Examples of this would be the Sumtak, Sanyo Denki, and
Heidenhain Endat encoders. Please refer Section to 2.6 Manufacturer Specific Encoder Details for more
information on this topic.
2.2.1 DATA DISPLAY
Data Display is selected to read an input pulse signal and display the count and other information. The Data
Display format will vary depending upon the encoder manufacturer. Some manufacturers include more data
in the serial data stream than do others. The display format for Fanuc Alpha I serial encoders is shown
below as an example.
2.2.1.1 ENCODER SELECTION
The Encoder Selection frame displays the current selection which is Fanuc Serial Pulsecoder Alpha I64 (8
pole), with 65,536 counts per revolution. Normally either a TI-5005 or TI-5006 cable would be used with this
encoder depending upon whether it used a 17 pin circular or DB15 connector respectively.
2.2.1.2 COMMUTATION
The commutation frame provides information that can be used to set and check encoder commutation
alignment for permanent magnet brushless servomotors. The C1, C2, C4 and C8 boxes show the
commutation gray code pulses that are commonly used to indicate commutation position for Fanuc
encoders. However the next two boxes indicate the position in terms of mechanical and electrical degrees,
and this is usually a more accurate measurement to apply to commutation.
To the right of the Electrical Angle box is the setting for Poles. It is disabled and set to 8 poles for this Fanuc
motor. Because this motor has 8 poles (4 pole pairs), the commutation pattern will repeat 4 times in one
revolution of the motor shaft. This means that the commutation gray code bits will go through the same
sequence 4 times per revolution. Likewise, the electrical angle reading will go through 360 degrees 4 times
in one revolution. Checking the commutation by static lockup of the rotor (applying a DC test voltage to
armature winding to lock the rotor in a specified position) will result in the same commutation gray code or
electrical angle reading at all 4 lockup positions (within a close tolerance). Notes are available from Mitchell
Electronics, Inc. with procedures that describe checking and setting commutation for many kinds of
brushless PM servomotors.
The information described above is shown in the Data Display for a Fanuc Alpha A64 which is
communicating properly as shown in the figure below.
2.2.1.3 POSITION COUNT
The Count frame shows the position count in Decimal and HEX (hexadecimal). An initial check to make is to
verify that the encoder count changes by approximately the correct number of counts per revolution when
the shaft is rotated approximately one revolution. This count display can be used for that purpose.
2.2.1.4 ENCODER STATUS
The Encoder Status frame shows information that helps determine whether the encoder is working properly.
The first box is labeled INDEX. It will show OK if the encoder has been turned to the position where it will
index the count to zero, and it will show ALARM it is has not. This Alpha A64 does need to be indexed, but
many other serial encoders do not need to be indexed. They produce the correct position count immediately
upon power up with no need to index. For these encoders, this box will be disabled.
The next box labeled DATA will indicate RECEIVING if the encoder is communicating properly with the TI-
5000EX, and it will indicate NONE if it is not (as seen in the first figure above). An encoder not
communicating may be the result of a bad cable or possibly a bad encoder. Nothing can be done with an
encoder until the problem has been corrected, if indeed it can be corrected.
The next column, labeled Internal Error should read OK indicating no internal error indication in the data. If it
reads ALARM, then the encoder is indicating that it has detected an internal error, and normally the resulting
data is not dependable. An internal error would cause a drive fault in most cases. This usually requires an
encoder repair or replacement to correct. This field may not be in effect for all serial encoders.
The next column, with the heading BATTERY ALARM, will show ALARM if there is a battery error alarm and
OK if there is not. It is often possible to alternately connect and disconnect a battery voltage to the encoder
to verify that this bit is working properly. This field may not be in effect for all serial encoders.
The box labeled OVERHEAT, will show ALARM if there is an overheat error alarm and OK if there is not. It is
often possible to alternately connect and disconnect thermal lines to the encoder to verify that this bit is
working properly This field may not be in effect for all serial encoders.
The box labeled ENCODER ID will show the type of encoder detected by the tester for brands of encoders
that provide encoder identification information in the serial data. For encoders that do not indicate
identification (or identification is not supported by the TI-5000EX software), this field will be disabled.
2.2.2 COUNT TEST
The count test will verify that the encoder is incrementing the correct number of counts per revolution. It
works basically the same way for incremental encoders as it does for serial encoders as described in a
previous section. The Count Test must be run by turning the encoder slowly by hand.
In addition to checking for the correct number of counts/rev, this test checks for “stuck bits”. For testing to be
as complete as possible, some of the fundamental differences in quadrature pulse incremental encoders
and serial absolute encoders require the testing to be done differently. Quadrature pulse encoders do not
actually count. They simply produce pulses, and external electronic circuitry does the counting correctly if
the encoder produces the pulses correctly. Testing for incremental encoders relies heavily on testing for the
correct number of pulse edges per revolution. Absolute encoders produce a bit pattern to represent the
angle. This bit pattern may be produced by internal counting, by absolute tracks on the code wheel, by
interpolation of those tracks, or some combination of these things. The possibility exists for an absolute
encoder to produce the correct count bit pattern at the end of each revolution but not show some
intermediate angles correctly due to bits not changing properly. One or more bits never changing during a
revolution would represent such a problem. The Stuck Bit test checks to make sure that each bit used to
represent the angle in one revolution does actually change states during the revolution.
The Count Test is performed by slowly rotating the encoder by hand through 4 or more revolutions until the
box at the bottoms indicates Test Completed. The data in the results boxes will indicate how close to the
exact number of counts per revolution were registered, whether any bits failed to change state during a
particular revolution (stuck bits), and whether any internal errors were detected during a particular revolution.
The data boxes are described in detail below.
2.2.2.1 REVOLUTION
Each row on the display contains the results of the test for one revolution. The revolution box shows which
revolution the test is on at any time during the test. After 4 revolutions, the test is complete.
It is a good practice to re-run the test turning the encoder in the opposite direction, but the encoder must be
turned in only one direction in each individual test. Changing directions during a test will cause the test to
fail. Running the test several times may uncover a problem if the problem is intermittent.
2.2.2.2 COUNT
The actual count at the end of each revolution is displayed in the Count box. Ideally this number should
increase each time by the number of counts per revolution for the encoder.
Due to time delays in receiving the data packet from the encoder, the error is seldom zero. The higher the
encoder resolution and the faster it is turned, the higher the error will be. Turning the encoder as slowly as
possible gives the best results. Serial encoders that are counting incorrectly normally show large errors, so
any error below 500 is considered good.
2.2.2.3 TARGET
The Target box provides the target count which would ideally be registered at the end of each revolution. It is
against this target that the actual count is compared.
2.2.2.4 ERROR
The Error box displays the difference in the data in the Count box minus the Data in the Target box. Since
the target count is what we expect and the actual count is what we got, the difference is going to be the
error.
Due to differences in how that Count Test is performed for incremental encoders and serial encoders, the
error is quite different. For incremental encoders, the error for a good encoder should not be more than ±2.
For serial encoders, there is a time lag for the data to be transmitted from the encoder and received an
interpreted by the tester. This time lag causes a measurement error for serial encoders. This error will be
larger for high resolution encoders that are turned quickly, and it will be smallest for low resolution encoders
that are turned very slowly. Normally serial encoders that have counting problems will have very large errors,
so the error limit to indicate faulty counting is set at 500 counts/rev.
2.2.2.5 COUNT/REV
The box called Counts/Rev is the difference between the count at the end of the current revolution and the
count at the end of the last revolution. Ideally this should be equal to the number of counts per revolution of
the encoder. For incremental encoders, it will usually be within ±2. For incremental encoders, it is useful in
determining the number of counts/rev of an encoder for which you have no specifications.
2.2.2.6 STUCK BITS
During the count test, the tester checks to make sure that all the bits that are active in one revolution (or at
least the first 16 bits for encoders with more than 16 bit resolution) change state at least once during the
revolution. If they do, the data in the box shows OK. If a bit does not change states, it is determined to be a
“stuck bit”. Stuck bits are identified by a ‘1’ in the position of the bit that was stuck, while bits which checked
out OK are designated by a ‘0’ in those positions. The bits are displayed in groups of 4 with bits 15 to 12 on
the left and 3 to 0 on the right. For instance, the following bit pattern would indicate bit 13 as a stuck bit:
0010 0000 0000 0000
This error was generated by selecting a Mitsubishi OSA14 (14 bit encoder) and actually using an OBA13 (13
bit encoder) during the test. The test expected bit13 to change, but only bits 0-12 change for an OBA13. This
means that you should check your setup to make sure you have selected the correct encoder if you
encounter stuck bits.
2.2.2.7 INTERNAL ERROR
As described in the section on Data Display, many serial encoders include an internal error bit in the serial
stream that they transmit to the receiving electronics. Typically a HI error bit will indicate that some self test
within the encoder has uncovered an error. The exact meaning of this event depends entirely on the specific
encoder and you would need to read information on that encoder to understand the significance.
In the Data Display window, the Internal Error box will show ALARM whenever the tester receives data with
the error bit HI, but it will go back to displaying OK if the error bit is received LO. It is not uncommon for this
bit to be HI only part of the time when there is a problem. This means that it may be difficult to actually catch
the bit HI in Data Display. For that reason, during the Count Test the internal error bit is latched HI for a
particular revolution if it ever appears HI during that revolution. That means that it will show up with ALARM
in the box if it ever went HI during that revolution even if it cleared itself during the revolution. This latching of
data keeps you from missing the fact that the internal error alarmed.
2.3 GENERIC INCREMENTAL QUADRATURE PULSE ENCODERS
Generic incremental quadrature pulse encoders are extremely common on servomotors, and this selection
supports their testing on the TI-5000EX. Hall effect devices were very commonly used on early brushless
permanent magnet servomotors, and this selection also supports looking at Hall effect line states for static
alignment and diagnostics.
2.3.1 DESCRIPTION
Quadrature pulse encoders generate an A and B pulse which are 90 degrees out of phase with each other.
These encoders are usually used with external counting circuitry which counts either the pulses or the
edges. The resulting count increments or decrements depending upon the direction of rotation since the
rotation direction determines whether the A pulse will lead or lag the B pulse. Quadrature pulse encoders
have traditionally been referred to as incremental encoders. However, since some manufacturers are now
using the terms incremental and absolute to mean something else entirely, in this manual we will call these
encoders "Quadrature Pulse" to reduce confusion. When testing these encoders, select “Generic
Incremental Encoder” from the Encoder Feedback menu of the Select Feedback window which appears
after pressing the Select Feedback button (see previous sections on Basic Operation).
Many encoders currently used with servo motors are quadrature pulse encoders. Furthermore, several
serial encoders also include a quadrature pulse section. Examples of this would be the Sumtak, Sanyo
Denki, and Heidenhain Endat encoders. Thoroughly testing these encoders generally requires testing the
serial section by choosing the correct serial model selection and testing the quadrature pulse section by
selecting an incremental encoder with the correct number of counts per revolution. Please refer to Section
2.6 Manufacturer Specific Encoder Details for more information on this topic.
Besides quadrature pulse, there are encoders that are single channel or single channel with an index (i.e.:
they provide only an A line or an A and Z line). These encoders are often used as tachometers to provide a
pulse rate proportional to RPM. Technically these encoders cannot be called quadrature pulse because
they do not have two pulses that are 90 degrees apart. This also means that they cannot indicate direction.
They will increment the count in either direction. In industrial counting systems, another type of pulse called
A Count B Direction may be encountered. With this type of pulse, each pulse on the A line will increment or
decrement the count by 1 depending upon whether the state of the B Direction line is HI or LO respectively.
Stepper motor indexers commonly utilize this type of pulse. The single channel and A count B direction
signals are not supported by the current software revision of the TI-5000EX.
2.3.2 CONNECTION
The generic incremental quadrature pulse encoder will have A, B, and Z lines (often both true and
complement lines for each) which must be connected to J1 as indicated by the J1 pin configuration in Table
2.1. It will have a 0V common power supply line that must be connected to J1 pin 2. If it operates from 5
VDC power, the 5V line must be connected to J1 pin 1. If it uses something other than 5 V, it may be
powered by a bench power supply (if no adapter module for the TI-5000EX is available for it). The + power
supply line from the encoder should be connected to the + output of the bench power supply. The – power
supply line should be connected to the 0V line from the encoder at J1 pin 2 of the TI-5000EX. J1 pin1 of the
TI-5000EX must not be connected when an external power supply is used.
Generic incremental quadrature pulse encoders often have commutation lines (often both true and
complement), U, V, and W (sometimes S1, S2, S3 and other designations) for providing startup
commutation information to the servomotor drive. These lines should be connected to J2 pins in accordance
with the J2 pin configuration.
When Hall effect devices are connected to the TI-5000EX, the U, V, and W lines should be connected to J2
pins 7, 8, and 9 respectively. The 0V common power supply line to the Hall devices should be connected to
J1 pin 2. If the Hall devices can be powered by 5 VDC (which they often can), the + Hall power line should
be connected to J1 pin 1. If a higher voltage is required, the + Hall power line should be connected to the +
output of an external bench supply. The – output of the external supply should be connected to the Hall 0V
line at J1 pin 2. J1 pin 1 must not be connected when an external supply is used or the TI-5000EX may be
damaged.
2.3.3 SETUP
Generic Incremental Encoders are used as the example for describing the Basic Operation earlier in this
manual. Please see Section 2.1.3 for a description of the setup for this type of encoder.
2.3.4 TESTING
Generic Incremental Encoders incorporate Data Display, Line Levels, Incremental Count Test, and Phase
Test for a complete test sequence.
2.3.5 DATA DISPLAY
Data Display is selected by clicking the Data Display button to read A, B, and Z line states and the count
accumulated by the transitioning of these lines in a quadrature pulse pattern. The following figure shows the
Data Display for Generic Incremental Encoders.
2.3.5.1 COMMUTATION
The commutation information usually appears in the commutation frame, but it really depends upon whether
the encoder utilizes sine/cosine commutation. Only a few encoders employ the sine cosine commutation
output. The two types of commutation currently displayed are discussed in the next two sections. Clicking on
the Sine/Cosine Commutation radio button will change to display to better show the sine/cosine
commutation. Clicking on the Normal Commutation radio button will change it back.
2.3.5.1.1 NORMAL COMMUTATION
The normal commutation display automatically appears as the default when first entering Data Display, and
it will display commutation in the Commutation frame.
The boxes with headings H1, H2, H3, H4, H5, and H6 display the states of the lines connected to J2 pins 7,
8, 9, 10, 11, and 12 respectively. This display is used to display the commutation states of both Hall effect
switches and encoder commutation lines. Any line that is not connected will show up as ‘H’ since the line is
pulled to a HI state by internal pull-up resistors. When using Hall effect outputs, the complement lines often
do not exist, so the last 3 outputs will be HI all the time. Just ignore any parts of the display that are not being
used.
When complement lines are in use, it is important to verify that the true and complement lines are in the
opposite states at all times. In any case, it is important that the encoder provide the commutation states in
the correct pattern. You should rotate the encoder in the forward direction of the motor to verify the correct
commutation pattern along with true and complement states. The Table below shows the standard manner
of connecting commutation signals to the J2 connector and indicates under which heading the line state
information appears. The table also indicates the standard commutation pattern that you should expect to
see. You are free to connect commutation lines in other ways if you prefer. This is the way test cables from
Mitchell Electronics, Inc. will be wired because this is compatible with the TI-3000 Run Test System.
This commutation pattern will repeat as many times in one motor revolution as there are pole pairs. In other
words, this pattern will repeat 4 times on an 8 pole motor.
Signal U V W U* V* W*
Heading 1 2 3 4 5 6
Pin 7 8 9 10 11 12
H L L L H H
H H L L L H
L H L H L H
L H H H L L
L L H H H L
H L H L H L
The practical use for the commutation line states is for “setting the commutation” or aligning the encoder so
that the commutation line pattern is synchronized with position of the rotor magnets relative to the stator
armature windings. This can usually be easily verified applying a small DC voltage to the armature leads to
lock the rotor and observing the commutation line pattern as the shaft is wiggled slightly from the lockup
position.
An example would be a Yaskawa motor with U, V, and W lines. If it is locked up with +U –V –W (sometimes
called +U to neutral), it should show (in View 1) V HI, W LO, and U ready to toggle with a small wiggle of the
rotor.
This pattern will repeat over and over. Notice that the Z pulse is independent of the A and B pulses. For
practically all encoders, the Z pulse will go HI once per revolution. The portion of the angle for which it is HI,
and the states of A and B during which it is HI is very dependent upon the particular encoder manufacturer.
The box labeled MECHANICAL ANGLE will display the correct mechanical angle providing the correct
number of counts/revolution has been entered. The box labeled ELECTRICAL ANGLE will display the
correct electrical angle providing that correct numbers have been entered for counts/revolution and number
of motor poles.
Currently the TI-5000EX will show a positive count when quadrature signals are received with phase A
leading phase B. Many American and European motors will use encoders which have this phase
relationship for CW (clockwise) rotation. For many of these same motors, the forward armature direction is
also CW. In these cases the displayed electrical angle provides a very convenient way to check and set
commutation.
On the other hand, the forward armature direction for many Japanese motors is CCW. When turned in the
CCW direction the encoder phase is often B leading A which results in a negative count. This means that the
displayed electrical angle will decrease instead of increasing when the motor is turned in the forward CCW
direction. While this does not rule out using the electrical angle display for commutation setting, it does make
the display confusing. The TI-7000 allows the user to set the positive direction of encoder rotation, and this
feature may eventually be incorporated into the TI-5000EX.
2.3.5.1.2 SINE COSINE COMMUTATION ENCODERS
The Normal Commutation display automatically appears as the default when first entering Data Display. If
you click the Sin/Cos Commutation radio button, the display will switch to the sine/cosine display shown
below. Clicking on the Normal Commutation radio button will switch the display back to the normal
commutation.
The C and D channel sinusoidal amplitudes are converted to an angle which is displayed in the
Commutation frame under the label MECHANICAL ANGLE. This angle should change smoothly from 0 to
359 degrees in one revolution. Each ¼ turn should cause a 90 degree change in the angle. It is very similar
to verifying a resolver.
If the number of poles is set correctly, the electrical angle will be displayed under the label ELECTRICAL
ANGLE. This is probably not too important since you will want to use the Normal Commutation display to
check and set commutation. Also, if you have an encoder in which the C and D channel signals go through
360 degrees more than once, the mechanical and electrical angle interpretation will no longer be correct.
This display will show the sine/cosine commutation outputs for encoders which use that type of output, such
as the Heidenhain ERN1387 and RON3350 encoders used on Siemens servomotors. The TI-5010 cable is
compatible with these encoders on Siemens motors. The TI-5101 1V P-P Adapter Module must be used
with sine/cosine encoders in order to multiplex the C and D commutation channels into the TI-5000EX A and
B channel inputs. Dipswitch #1 on the TI-5101 must be set to the closed position in order to multiplex the C
and D channels properly (note: dipswitch #2 does not matter, so you can set it closed too just to make sure
you have the right one). If this is not done, you will see the angle display moving through 360 degrees with a
slight encoder rotation instead of a complete revolution. It should require a full revolution to move through
360 degrees although there may be some which go through 360 as many times as the number of pole pairs
for the motor.
Signal levels, interpreted as the sine and cosine of the displayed angle, are displayed in the Encoder Status
frame in boxes labeled Cosine and Sine.
C and D channel signal levels are displayed as voltages in the boxes labeled C-C* and D – D*. These are
the differential voltages between the true and complement lines. The software takes into account the 3.48
gain through the TI-5101, so is the actual differential output voltage of the encoder. The Heidenhain
specification is for the peak differential voltage to range between 0.75V p-p and 1.2V p-p. This means that
you should see amplitudes in the ranges shown in the following table. The maximum, minimum and nominal
values are shown.
ANG C-C* Max C-C* Min C-C* Nom D-D* Max D-D* Min D-D* Nom
0 0.00 -0.37 -0.60 -0.50

90 0.60 0.37 0.50 0.00
180 0.00 0.60 0.37 0.50
270 -0.37 -0.60 -0.50 0.00
Remember you are checking the peak differential voltage, so you must move the encoder to the positions
shown in the table above.
The models ERN1387 and RON3350 provide 8,192 counts per revolution. If the counts/rev is set to 8192,
the Normal Commutation display will also show 360 per revolution in the MECHANICAL ANGLE box, and
that angle will agree with the C/D channel angle. However, please note that the original TI-5000 angle
reading for the C/D channels did not agree. This is due to the way the C and D channels were assigned as
sine/cosine for that unit. The current TI-5000EX uses different assignments so that the C/D channel angle
and the angle from the encoder count agree. The relationship between the original TI-5000 and current TI-
5000EX is shown in the following table.
Original TI-5000 Sin/Cos Angle TI-5000EX Sin/Cos Angle
0 90
90 180
180 270
270 0
The Siemens alignment is based on the Z pulse, so it is more accurate to use the Normal Commutation
display rather than the sine/cosine angle for alignment. Also the count angle in the Normal Commutation
display can be displayed as an electrical angle. The static alignment procedure is to apply lockup voltages
with the polarity –U +V +W, and the electrical angle should be very close to zero degrees at each lockup
position. Remember, to get the correct electrical angle, you must enter the correct number of poles.
2.3.5.2 COUNT
The display shows the count accumulated by the A and B line transitions in the Count frame in the boxes
labeled DECIMAL and HEX. Normally the user will be more interested in the decimal count than the
hexadecimal representation. You should see counting activity when you turn the encoder. If you do not, you
may have a problem with the A or B lines. Again, the Line Level Test or an oscilloscope may help in
diagnosing the problem. When you rotate the encoder one revolution, the count should change by the
number of counts per revolution specified for that encoder. If you do not have that information, it can be
determined by the Count Test described.
2.3.5.3 RATE
The Rate frame shows the encoder rate in counts/sec or RPM. The counts per second may be important
when back-driving an encoder with a drive motor for determining whether it is moving too fast to perform
certain tests. The RPM may be useful when back-driving a motor for checking magnet and winding integrity.
In order for the RPM to read correctly, the correct number of counts/rev must have been entered into the
setup.
2.3.5.4 LINE STATES
The Line States frame utilizes 3 boxes with headings A, B, and Z to display the states of the A, B, and Z
lines coming from the encoder. The A and B lines should change following the quadrature pulse pattern
shown below when moved in the direction in which the A pulse leads the B pulse.
Signal A B Z
Heading A B Z
J1 Pin 3 5 7
L L X
H L X
H H X
L H X
The A, B, and Z lines will often be available as both true and complements. In this case, it is important to
make sure that both lines are changing as required. The Line Level check (to be discussed later) provides
this information. The Incremental Count Test and Phase Angle Test further ensure that this pattern is correct
and producing the correct counts.
2.3.5.5 INDEX
The Encoder Status frame begins with a box labeled INDEX. This box will indicate ALARM if the encoder is
not yet indexed and OK after it has been indexed. When you first enter the test, it will indicate ALARM. After
you have rotated the encoder past the index pulse, it will change to OK and the count will zero out. If this
does not occur, you may have a problem with the Z pulse. You can further check it out using the Line Level
Test and/or an oscilloscope.
You may wish to force the tester to re-index the encoder on the next index pulse. Click on the “Zero count on
next index” button to accomplish this. The INDEX box will change to ALARM until the next index pulse
occurs. You may also click the Data Display button to re-index.
2.3.6 LINE LEVELS
The Line Levels function provides for measuring the proper incremental encoder (not used on serial) output
voltages over a 0 to 14.9 volt range.
WARNING - Input voltages above 15 VDC may damage the TI-5000EX input circuitry.
This voltage range covers many of the very common incremental encoders. If precise or high speed
readings are required, a digital voltmeter or an oscilloscope can be used. However, the Line Levels function
can provide a good, quick, convenient indication of the state of each output line. The Line Level Test is only
available for incremental encoders. The Line Level display is shown in the following figure.
As the encoder is slowly rotated, the following items can be checked:
1. Each A, B and Z line is changing states and not sticking in the same state constantly.
2. Each A*, B*, and Z* complement line (if the encoder employs them) is changing states and is not
sticking in the same state constantly.
3. Each A*, B*, and Z* complement line is always in the opposite state from its A, B, and Z counterpart.
The Z line would normally be difficult to catch in the HI state since it is high for a very short part of the entire
rotation. However, the Line Level function also provides the encoder count and will zero the count on the Z
pulse. The INDEXED column will show ALARM until the encoder is rotated past the Z pulse. When this
occurs, the INDEXED column shows OK. At this point, if the encoder is rotated back until the count is again
approximately zero, the point at which the Z line goes to the HI state can be found.
The realtime levels should be checked to make sure they are correct voltages. The Instruction box indicates
that TTL levels would be 0.8V or below for a LO level and 2.0 V or above for a HI level. If you have
specifications for your encoder that show different requirements, then those specifications are what you
should apply in evaluating the encoder.
2.3.6.1 REALTIME LEVELS
To help ensure that each line is reaching both states, the LO state minimum and HI state maximum values
are reported on the lines “LO state” and “HI state” respectively. The minimum and maximum displays are
described below.
As you turn it, it will pick up each state for the A, A*, B and B* lines very quickly. Again, the Z and Z* lines
may not be caught so easily since the Z pulse occurs only once per revolution. If the encoder is rotated in
such a way as to make the count pass through zero a number of times, you should be able to catch the Z
pulse HI.
View 1 is the realtime line level display. It shows the present voltage from each encoder line and the encoder
count relative to when it was first indexed. The voltages for the true lines are followed by the line designation
in upper case (A, B, Z) while the complement line voltages are followed by the line designation in lower case
(a, b, z).
The example display above shows how the real time line level display looks when the Z pulse is HI. The
count is at zero, and the HI Z pulse has been found. You can see how the Count display was used to get to
zero to find the Z pulse HI.
2.3.6.2 MIN LEVELS
The line below the realtime levels is the minimum line level display. It shows the lowest voltage recorded for
each encoder line. Every line has been shown to go to a LO state of 0.1 V. What we are looking for here is a
line which has not gone to the LO state. That would indicate a problem with the encoder or cable.
2.3.6.3 MAX LEVELS
The line below the minimum levels is the maximum line level display. It shows the highest voltage recorded
for each encoder line. All lines are 2.0 V or above which are valid HI states. This means that all lines have
gone HI during our test. Again, we would be looking for a line that has never gone HI as an indication of a
problem.
2.3.7 COUNT TEST
The count test will verify that the encoder is incrementing the correct number of counts per revolution. It
works basically the same way for incremental encoders as it does for serial encoders as described in a
previous section. The Count Test must be run by turning the encoder slowly by hand. The Continuous Count
Test may be used while motoring incremental encoders at higher speeds.
The Count Test is performed by slowing rotating the encoder by hand through 4 or more revolutions until the
box at the bottoms indicates Test Completed. The data in the results boxes will indicate how close to the
exact number of counts per revolution were registered, whether any bits failed to change state during a
particular revolution (stuck bits), and whether any internal errors were detected during a particular revolution.
The data boxes are described in detail below.
2.3.7.1 REVOLUTION
Each row on the display contains the results of the test for one revolution. The revolution box shows which
revolution the test is on at any time during the test. After 4 revolutions, the test is complete.
It is a good practice to re-run the test turning the encoder in the opposite direction, but the encoder must be
turned in only one direction in each individual test. Changing directions during a test will cause the test to
fail. Running the test several times may uncover a problem if the problem is intermittent. Click on the Restart
Test button to re-run the test.
2.3.7.2 COUNT
The actual count at the end of each revolution is displayed in the Count box. Ideally this number should
increase each time by the number of counts per revolution for the encoder.
2.3.7.3 TARGET
The Target box provides the target count which will be registered at the end of each revolution. It is against
this target that the actual count is compared.
2.3.7.4 ERROR
The Error box displays the difference in the data in the Count box minus the Data in the Target box. Since
the target count is what we expect and the actual count is what we got, the difference is going to be the
error.
Due to differences in how that Count Test is performed for incremental encoders and serial encoders, the
error is quite different. For incremental encoders, the error for a good encoder should not be more than ±2.
2.3.7.5 COUNT/REV
The box called Counts/Rev is the difference in the count at the end of the current revolution and the count at
the end of the last revolution. Ideally this should be equal to the number of counts per revolution of the
encoder. For incremental encoders, it will usually be within ±2. For incremental encoders, it is useful in
determining the number of counts/rev of an encoder for which you have no specifications.
2.3.7.6 STUCK BITS
The Stuck Bit test does not apply to incremental encoders.
2.3.7.7 INTERNAL ERROR
Error information is normally transmitted by serial encoders, so the internal error field does not apply to
incremental encoders.
2.3.8 CONTINUOUS COUNT TEST
The purpose of the Continuous Count Test, like the count test, is to ensure that the correct number of counts
occur from one index pulse to the next when the encoder is rotated. Unlike the Count Test during which the
encoder must turned slowly by hand for 4 turns, this test may be run at high speed for many revolutions. The
encoder may be rotated by hand, or it may be driven by the motor. Also unlike the Count Test, it is
unaffected by changes in direction, so it can be run while an incremental encoder is in use on a machine.
The Continuous Count Test is available only for the incremental encoder selection.
Like the Count Test, the Continuous Count Test compares the actual number of counts received at each
index pulse to the target number of counts. The Revolution box shows 10 revolutions, and since this
encoder is 32,768 counts per revolution, we know that the target number of counts after 10 revolutions
would be 327,680 which is the number showing in the target box. The Count box shows that 327,680 counts
have been received, and the Error box shows 0 which would be the number in the Count box minus the
number in the Target box. This would be a perfect result after 10 revolutions.
Due to the update rate of the display, you may not see every revolution reported as the RPM increases. This
is not a problem as the tester is keeping track of the revolutions even though there is not time to display
them all.
2.3.9 PHASE ANGLE TEST
This section describes performing the Phase Angle Test. For an explanation into why phase angle tests
should be performed and what the results tell you, please see Section 3.2.1. The Phase Angle Test is
available only for the incremental encoder selection.
2.3.9.1 REALTIME
The 93 in the Readings box indicates that 93 phase measurements have been made so far during the test.
That gives you some idea as to how representative the readings are. The longer the test is running, the
better representation you have of the phase angles in terms of the min/max readings. The Realtime line
reports the phase and symmetry angles in real-time as they happen. The realtime data will be constantly
updated as the test proceeds. However the speed at which it is updated is dependent upon the speed at
which the encoder turns. The data on the Realtime line will probably be changing constantly because the
phase angles tend to vary somewhat as the encoder is rotated. The better quality encoders will exhibit more
constant phase and symmetry angles. To get the most accurate readings, it is essential to rotate the
encoder at a constant speed (RPM).
High resolution encoders often use interpolation to divide their sine wave output into smaller pulses. The
interpolation process generally causes phase angles to be jumpier. If the TI-5000EX is reading phase angles
at a high rate (controlled in part by the encoder rotational speed), it can be hard for the operator to interpret
the readings from jumpy data. Clicking the Take Sample button will take a sample of the real-time data and
hold it on the display. This makes it much easer to read. This can be done as many times as desired. The
Sample line shows a sample that was saved from a realtime reading when the Take Sample button was
clicked. An initial sample of the first real-time reading is taken automatically when the Phase Test is first
started.
The Phase B-A box reports the phase angle between the rising edge of B and the rising edge of A with A
leading B. It would ideally be 90 degrees when the encoder is moving in the direction of A leading B, or 270
degrees in the direction of B leading A. See Section 3.2.1 for a description of these phase angles.
The A Symmetry box reports the A Symmetry angle, which is the angle from the rising edge of A to the
falling edge of A, and it would ideally be 180 degrees. Likewise, the B Symmetry box reports the B
Symmetry, which is the angle from the rising edge of B to the falling edge of B, and it too would ideally be
180 degrees. These readings provide a measure of the symmetry of the pulses. A perfectly symmetrical
pulse would be HI for the same amount of time that it is LO, and that would result in an angle of 180
degrees. Specifications for these angles vary with encoder manufacturer, but a tolerance of ±22 degrees
from the ideal is a fairly typical specification.
The lowest rate for phase angle measurements is 25 counts per second. For rates slower than 25 CPS, the
RT line will not be updated.
Similarly, for pulse rates above 440,000 CPS, there is not enough resolution in the internal timer to resolve
phase angles to 1 degree. Therefore, above about 400,000 CPS, a TOO FAST prompt appears on the RT
line in place of the phase data.
You may wish to calculate the maximum and minimum RPM values corresponding to the max and min count
rates. The encoder RPM may be calculated from the number of counts per second and the number of lines
per revolution as follows:
RPM = (60 * RATE) / (4 * LINE)
For example, using a 500 line per revolution encoder, 20 CPS and 400,000 CPS would convert to 0.6 RPM
and 12,000 RPM respectively. This gives you the allowable RPM range for reading the phase angle for this
particular encoder. You can see from this that as the encoder resolution goes up, the allowable RPM for
phase readings will come down.
Substituting in 400,000 CPS for the maximum rate and 25 CPS for the minimum rate gives us the following
two equations for the max and min RPM:
MAXRPM = 6,000,000 / LINE
MINRPM = 375 / LINE
Rotating the encoder while keeping the speed as constant as possible in the allowable RPM range, should
result in good phase angle measurements.
2.3.9.2 MAX VAL
The Max Val line shows the maximum values of the phase and symmetry angles since the test started or the
last max/min reset.
To further help in evaluating jumpy data, the maximum and minimum values are recorded and displayed in
the View 2. The max and min values may be reset by clicking the Reset Max/Min Values button. The reset
process will set the max and min values to the values in the current real-time data reading. The values are
automatically reset when the Phase test is first started. If the encoder is stopped during a test, it may cause
a wild max or min value to be recorded. This would be a situation in which you would definitely want to
perform a reset. Of course the test can be exited and restarted to reset the max/min values as well. The max
value readings are most useful when the encoder is turned at a constant speed with a motor. The max
values will normally show a lot of variation when the encoder is rotated by hand and therefore may not be
that useful. The speed differences caused by rotating by hand will cause variation in the readings, and it
usually does not tell you much about the quality of the encoder. Therefore, max values should be ignored if
the encoder rotational speed is not constant.
2.3.9.3 MIN VAL
The Min Val line records the minimum values in the same manner as described above for the maximum
values.
2.4 GENERIC PARALLEL ABSOLUTE ENCODERS
The TI-5000EX provides limited support for Parallel Absolute Encoders. Parallel Absolute encoders are
functionally similar to many serial encoders because they maintain an absolute position rather than a relative
position like the incremental encoders. As with the serial encoders, their resolution is usually stated as some
number of bits for representing the count for one revolution. The major difference is that parallel encoders
provide an output line for each data bit. This can add up to a lot of lines, and this is one reason that this type
of encoder is not typically used with servo motors. Generally parallel output encoders will be used where an
absolute position must be obtained on power-up such as with a tool changer or something of that nature.
Even though these encoders are not normally used with a brushless motor to provide commutation and
positioning information, they will be found in machine tool products which use servo motors. Therefore,
servo motor repair shops may get requests from customers to test this type of encoder.
In order to check out this type of encoder, the tester must be able to read each line. The TI-5000EX utilizes
all of its signal input capability to support up to 10 bits of parallel signals. There are encoders with more than
10 bits and it is possible to check out these encoders 10 bits at a time. If a demand for testing parallel
encoders with resolutions higher than 10 bits occurs, then an adapter module may be developed for the TI-
5000EX in the future to directly support high resolution parallel absolute encoders.
Parallel encoder data may be encoded in various ways. Three of the more common codes are Binary, Gray
Code, and Binary Coded Decimal (BCD). Ideally, the technician would tell the tester what kind of code the
encoder is using, and the tester would convert the data to a position count using that code. Often however,
the technician may not have documentation on the encoder and may not know what kind of code is used by
it. Because of this, the TI-5000EX approach is to present the bit pattern in each of these codes at the same
time. If the technician happens to know that the encoder produces a gray code, then he will look at the gray
code display and ignore the other information. If he does not know what kind of code is produced, he can
look at all of the codes and decide for himself which code makes sense and therefore is probably the code in
use.
As an example, let’s consider an 8 bit binary encoder. If we turn it through 10 counts, we would see the
following patterns:
Bit Pattern Binary Gray Code BCD

Decimal Decimal
LLLL LLLL 0 0 000

LLLL LLLH 1 1 001
LLLL LLHL 2 3 002
LLLL LLHH 3 2 003
LLLL LHLL 4 7 004
LLLL LHLH 5 6 005
LLLL LHHL 6 4 006
LLLL LHHH 7 5 007
LLLL HLLL 8 15 008
LLLL HLLH 9 14 009
LLLL HLHL 10 12 00A (invalid BCD number)
If we look at the 3 BCD digits generated, things look pretty good until we get to the last display. Then we see
00A. If this were truly binary coded decimal, we will get only decimal numbers (0-9) in this display, and that
last position should be 010 instead of 00A. Because of this we can rule out BCD. The Gray Code numbers
are out of order and jumping all over the place. This tells us that we are not decoding a gray code. The only
numbers then that are moving smoothly from 0 to 10 are in the binary column. We can conclude that this is
the correct code.
Some absolute encoders complement the bits when they apply them to the output lines. In other words,
when they want to produce a 0 bit they put the line HI and conversely put it LO for a 1 state. For a
complemented output example, the lowest two bits when counting from 0 to 3 would change as follows:
HH 0
HL 1
LH 2
LL 3
Again when the behavior of the count is observed, the technician can usually make a judgment on which
code makes sense. Normally with binary encoding, both the TRUE and COMPLEMENT representations will
make sense. One count goes up while the other count comes down. In this case, it is not really important to
decide whether it is actually TRUE or COMPLEMENT data. You will be able to check it out in either case.
Normally only the TRUE or the COMPLEMENT but not both will make sense for Gray codes and BCD
codes. A Tamagawa OAS66 Absolute Encoder is an example of a 10 bit BCD encoder with complement
outputs. This encoder will provide position counts from 0 to 359 which can be directly interpreted as degrees
rotation.
Some absolute encoders will provide fewer than 10 bits. In these cases, the lines should be connected
starting with BIT 0 and working up to the highest bit available. The inputs for the higher bits that are not used
should be tied LO (connected to J2 pin 2 ground) if the encoder provides TRUE outputs. If it provides
COMPLEMENT outputs, the inputs may be left open and they will pull HI on their own. If it is not known
which it is, some experimentation will be necessary. TRUE outputs are probably more common than
COMPLEMENT outputs, so TRUE outputs would be a good first guess. Of course if a data sheet is available
for the encoder, then no guesswork should be necessary.
2.4.1 DATA DISPLAY
For the parallel absolute encoders, the Data Display is the only selection at this time. As described above,
all codes are displayed at the same time in the various views. The encoder connected in this example is a
10 bit binary BEI encoder. On this reading alone, TRUE and COMPLEMENT BCD coding possibilities can
be eliminated because they include digits outside the 0-9 range. As the encoder is rotated and more codes
are observed, it would become obvious that the binary code readings make sense and the gray code
readings do not. You will be able to see the bit pattern expressed in the various codes by looking at the
various views in Data Display.
A problem that is often found with absolute encoders is that a single bit or sometimes several bits simply are
not changing (stuck bits) as the encoder is rotated. This is most easily observed in the Line States display.
This type of problem will also make the count jump rather than changing smoothly. However, the count may
also jump if you are looking at the wrong code, so the line states are the most reliable indicator of stuck bits.
The binary and BCD encoders may glitch when they are changing from one position count to the next. That
is, there may be a momentary incorrect reading as they change. This does not necessarily indicate a
problem with this type of encoder. It is caused by the fact that all the bits do not change at exactly the same
instant as the position is moved to a new code. Gray code encoders should not have this problem. In fact,
gray codes are used specifically to prevent this problem. Gray codes are designed so that only one bit
changes when it moves from one position count to the next. By never changing more than one bit, the
problem of several bits not changing simultaneously is defeated.
2.4.1.1 LINE STATES
The Line States frame displays the states of the 10 lines as a bit pattern for bit 0-9 as a decimal number
encoded as true or complement binary. It is this bit pattern that is decoded into the various types of
numbers. Even if you cannot make sense of any of the numbers generated by the encoder, you can watch
the bit pattern. At a minimum, you would want to see all the lines change state as the encoder is turned. A
test showing a line never changing state would probably indicate a faulty output for that line.
2.4.1.2 BINARY CODE
The True Binary Code and Complement Binary Code frames display the bit pattern as though it represents
binary data. The true data is interpreting a HI bit as being a binary 1, while the complement data is
interpreting a LO bit as being a binary 1. Absolute encoders are specified both as true and complement
data, so it is important to interpret the data both ways. View 2 displays the bit pattern as a decimal number
encoded as true or complement binary. Both the true and complement numbers in this case are reasonable
numbers, so we cannot eliminate either possibility.
In this case, we know that this encoder is binary encoded, and we would find that the binary numbers move
smoothly through the count as we go from 0 to 1023. This would tell us that the encoder is most likely binary
encoded and is working correctly. Both the true and complement numbers will look good, so we really
cannot say which it is. Since we can get a good evaluation on it either way, it does not matter in terms of
testing.
The data is shown represented both as a decimal number and a hexadecimal number. Usually you will be
interested in the decimal number, but if you are familiar with hexadecimal representation, that display may
be beneficial to you.
2.4.1.3 GRAY CODE
The True Gray Code and Complement Gray Code frames display data that has been interpreted as gray
code data. We look at both true and complement data for the reasons described above for the binary data.
In this case, both data representations look good. We cannot conclude that it is not gray code from this
single reading. However, as we turn the encoder and watch how the counts change, we would see the gray
code data jumping around, and we could conclude that it is not encoded as gray code.
2.4.1.4 BCD CODE
The True BCD Code and Complement BCD Code frames display the bit pattern as a binary coded decimal
number.
The True BCD box indicates the encoding as BCD code. In this case, the true coding works out to be a
reasonable number (265), and it is displayed as such and shows VALID in the Code box. However, the
Complement BCD box shows one or more illegal BCD digits, so it indicates an INVALID in the Code box. If
we are good with converting bit patterns to BCD digits, we would see that bits 0-3 would represent 10 which
is illegal since BCD digits can only range from 0-9. Bits 4-7 would translate to 9 which is legal. The 2 bits, 8
and 9 will always represent a legal digit from 0-3.
Note that, if we do not know which encoding is in use for this encoder, then the INVALID in the Code box will
tell us that it is probably not Complement BCD. However, if Complement BCD is the specified encoding for
this encoder, then the INVALID would definitely indicate a problem with this encoder.
2.5 GENERIC RESOLVERS
The TI-5000EX provides support for resolver check out with built-in resolver hardware (no external adapter
module required). The resolver may be connected directly to the TI-5000EX resolver connector, J12. For
viewing the resolver signals on an oscilloscope, the TI-3011 Resolver Breakout Board may be plugged into
the resolver connector and the resolver connector plugged into the breakout board.
The excitation amplitude is adjustable over a range of 0.0 - 8.0V peak, and the excitation frequency is
adjustable from 1,000 to 20,000 Hz. in 4 ranges. These settings are made using the Resolver Excitation
Setup window as described in a later section.
2.5.1 GENERAL COMMENTS
Since a resolver is basically a transformer in which a voltage input to the excitation winding produces a
voltage output to the sine and cosine windings, there is a transformation ratio involved due to the number of
turns in these windings. The ratio may be checked approximately during setup by comparing the excitation
voltage selected during setup, with the Vector Level in the Data Display View 1. This is approximate
because the voltages are only expressed to 0.1 V resolution, and the vector level will be reduced if the sine
and cosine signals are not either in phase or 180 degrees out of phase with the excitation. If the same
excitation frequency and voltage are routinely used on a particular type of resolver, a significant difference in
vector level reading would warrant further investigation since a change in transformation ratio would not be
expected.
When the angle read from a resolver goes through 360 degrees in a single revolution, that resolver is called
a single speed or 1 speed resolver. However, resolvers can have various numbers of poles just like motors.
While a 2 pole resolver is referred to as a single speed resolver, a 4 pole resolver is a 2 speed resolver and
so on with the speed being the same as the number of pole pairs. The resolver angle reading will go through
360 degrees as many times as the speed. Servo motors will commonly use 1, 2, 3 and 4 speed resolvers.
Single speed resolvers are commonly used with any number of pole motors. However, resolvers higher than
single speed will normally be used on a servomotor with the same number of pole pairs as the resolver
speed. For instance, a 4 speed resolver would normally be used with an 8 pole motor. While this is typical, at
least one example is known of an 8 pole motor using a 2 speed resolver. Other kinds of applications
(besides servomotors) may use resolvers as high as 36 or more speeds. Servomotors, however, are
normally limited to the number of pole pairs of the motor (which is seldom above 6).
The most common problems that cause incorrect results from a good resolver are incorrect connection to
the tester and incorrect excitation. Double check connections and follow the suggestions in the section on
connections to ensure that the resolver is connected properly. The most common problems with excitation
are excitation amplitude too high or the excitation frequency too low. Both of these situations can lead to
waveform distortion, and waveform distortion can result in angle readings that are inaccurate, jumpy, dead
spots in the rotation, etc. Follow the procedures in the section on setup to avoid waveform distortion.
The question often comes up as to the effect of reversing various resolver leads. The following table shows
the effect of lead reversal, and this makes it clear why simply reversing the sine leads is the least
complicated way to change the resolver direction.
In the following table, when we say “reverse sine” we mean to switch the SIN and SIN* resolver leads on the
terminal block. When we say “exchange sine and cosine” we mean to connect the resolver SIN and SIN*
leads to the terminal block COS and COS* terminals respectively and connect the resolver COS and COS*
leads to the terminal block SIN and SIN* terminals respectively.
Leads to Change Effect
Reverse Sine Reverses direction of increasing angle.

Reverse Cosine Reverses direction of increasing angle and advances the angle by 180
degrees.
Reverse both Sine and Cosine Advances the angle by 180 degrees without changing the direction.
Reverse Excitation Same as reversing sine and cosine.
Reverse All leads No effect.
Exchange Sine and Cosine Reverses direction of increasing angle and advances the angle by 90
degrees.
You can see that the effect of making a combination of changes can be predicted by the individual changes.
For instance, reversing the sine leads will reverse the direction. If we then reverse the cosine leads, the
direction is reversed again, and the angle is advanced by 180 degrees. The double reversal of direction puts
us back to the original direction, and we are advanced by 180 degrees. That is the same thing the table tells
us for reversing both the sine and cosine leads.
As an example of applying these rules, we could predict that exchanging the sine and cosine leads and
reversing the excitation leads would advance the angle by 270 degrees and reverse the rotation.
2.5.2 TYPES SUPPORTED
The TI-5000EX works with resolvers that accept an excitation input and produce outputs whose amplitudes
are proportional to the sine and cosine of the mechanical shaft angle. Multi-speed resolvers are compatible.
Their angle indication will simply go through 360 degrees multiple times per revolution. The TI-5000EX is not
compatible with synchros that produce outputs whose amplitudes are 120 degrees apart.
It is not uncommon for resolvers to be wired to use the Phase Analog method of resolving the mechanical
angle. With the Phase Analog method, excitation voltages 90 degrees apart in phase are applied to the sine
and cosine windings while the resultant output signal is taken from the stator winding (that would normally be
used for excitation). This is more of a method of reading the angle than a different type of resolver, and
these resolvers are normally compatible with the TI-5000EX providing they are connected in the
conventional manner as described in the next section.
2.5.3 CONNECTION
Resolvers will have excitation input and sine and cosine output leads that must be connected to the TI-
5000EX. Insert the TI-3011 Breakout Board into the 7 pin terminal block connector, J12, on the right hand
side of the unit, and then insert the resolver connector into the breakout board. The resolver can be plugged
directly into J12, but using the breakout board will provide some advantages, especially for an initial
connection. The breakout board provides the pin numbers and signal names to make it easy to wire your
resolver into the 7 pin terminal block, and it provides a simple way to connect an oscilloscope to the observe
the excitation, sine and cosine signals to verify clean signals with no distortion.
Note:
1. The excitation voltage measured on the oscilloscope from the EXC testpoint will be half the
voltage that is actually applied to the resolver excitation windings. This is due to the fact that
the resolver leads are normally connected between EXC and EXC* instead of EXC and
GND.
2. The excitation voltage displayed on the TI-5000EX takes into account the factor of 2, and it
should be correct (twice the oscilloscope reading).
3. The COS* and SIN* are at GND potential, so they should read correctly on the oscilloscope
and that should agree with the readings on the TI-5000EX display.
The resolver should be connected as follows:
Pin Label Use

1 GND Not normally used, but can be connected to an excitation lead.
2 EXC Connect one of the excitation leads to this pin.
3 EXC* Connect the remaining excitation lead to this pin.
4 COS Connect one of the cosine output leads to this pin.
5 COS Connect the remaining cosine output lead to this pin.
6 SIN Connect one of the sine output leads to this pin.
7 SIN Connect the remaining sine output lead to this pin.
It is not as important which leads you select for each pin as it is important that you document how you did it.
If you have pin configurations from the manufacturer, then you can use their designations. If not, you can
make up your own. Either way, you should document how you do it. That will allow you to connect it the
same way each time you work on the same type of motor, and any commutation alignment data that you
take should be repeatable.
Typical resolver lead designations would be as follows:
Typical Designation Typical Color Signal
R1 RED/WHI Excitation +
R3 BLK/WHI Excitation -
S1 RED Cosine +
S3 BLK Cosine -
S2 YEL Sine +
S4 BLU Sine -
If you have no colors to go by or other documentation, you could take resistance readings on the various
windings. Normally the sine and cosine windings will be very close to the same resistance, and the
excitation winding will be different.
2.5.4 SETUP
Setup for the resolver involves setting the commutation amplitude and frequency. This is accomplished by
clicking the Resolver Setup button from the Data Display with resolver as the selected feedback.
To ensure proper amplitude and frequency settings, you should connect an oscilloscope to the TI-3011
Breakout Board so that you can observe the excitation, sine, and cosine signals to verify correct levels with
good clean sine waves and no distortion. If you have voltage and frequency settings available from previous
encounters with a particular resolver, you may not need to observe the waveforms on the oscilloscope and
can go right to the desired settings. However, if you get poor readings, you may need to use the
oscilloscope to help determine the problem with the resolver.
Resolvers require the following setup sequence with the resolver to be tested already connected:
1. To select resolver feedback, click on the Select Feedback button in Data Display, and then
click on the Resolver Feedback radio button in the Select Resolver frame of the Select
Feedback window. Click the OK button after the resolver selection has been made.
2. Click on the Resolver Setup button in the Data Display to bring up the Resolver Excitation
Setup window.
3. Use the Frequency Range dropdown menu to select the range (1, 2, 3 or 4) which
corresponds to the desired frequency. The frequency covered by each range is shown on
the Instructions/Comments box on the display. The ranges are as follows:
Range Frequencies
1 1,000-2,000 Hz.
2 2,000-5,000 Hz.
3 5,000-10,000 Hz.
4 10,000-20,000 Hz.
If you know the frequency specified for your specific resolver or motor, then that will be the
frequency that you are selecting. If you do not have that information, you will want to select
a frequency which puts the sine and cosine signals either in phase or 180 degrees out of
phase with the excitation signal. To look at this phase, you will need to connect an
oscilloscope to the TI-3011 Breakout Board as described in the preceding section. When
signals are in phase or 180 degrees out of phase, their zero crossings will line up with each
other.
4. When the desired range has been selected, use the Frequency Set Point dropdown menu
to select the desired frequency within the selected range. On the bottom line under Set, the
frequency setting (in Hz.) will be shown. In the Actual Frequency in Hz. and Actual
Frequency in KHz. boxes, the actual measured frequency will be show. The frequency set
point and actual frequency numbers will normally be fairly close together, but not exact. If
the specified frequency is not available from the menu, just select the closest available
frequency, which will be plenty close enough.
Note: If the level is set too low to get a good frequency measurement, you may need to
adjust the level as described in the next step and then come back to the frequency
adjustment.
5. Click the Level Set Point dropdown menu and select a voltage in the 2 to 3 V range. Note
whether the voltage shown in the Vector Level box is between 1.5V and 3V. If it is not,
adjust the Level Set Point up or down to get the vector level in that range. A 2.5 V vector
level is a good target.
6. If the frequency and level adjustments are not where you want them yet, then repeat those
adjustments until you have the desired results.
2.5.5 TESTING
Generic Resolvers incorporate only the Data Display Test for a complete test.
2.5.6 DATA DISPLAY
Data Display is selected by clicking the Data Display button to read the resolver angle and vector level. The
Data Display is the only test available for resolvers.
2.5.6.1 RESOLVER ANGLE READINGS
The Resolver Angle Readings frame shows the current resolver angle in degrees and Baldor HEX code
angle. Unless you have used a Baldor resolver tester in the past and have lockup data recorded in that
format, just ignore the Baldor data and use the angle in degrees.
The angle displayed should change in a reasonable manner as the resolver is rotated. For instance if a 1
speed resolver is rotated ¼ revolution, the angle should change by 90 degrees. The angle should change
smoothly during the entire rotation.
2.5.6.2 RESOLVER OUTPUT
The Resolver Output frame shows the resolver output signals described in different ways. The individual
sine and cosine voltage levels are shown in the Sine and Cosine boxes respectively. The cosine will reach a
positive peak at 0 degrees and negative peak at 180 degrees, while the sine will reach a positive peak at 90
degrees and a negative peak at 270 degrees. The main thing to watch for here is that the peak voltages
reached by the cosine and sine outputs are the same, the positive and negative peaks are the same, and
the peaks are the same as the vector level. Within 0.1 or 0.2 volts is close enough to consider it the same
voltage. If either the sine or cosine signal is zero all the time or never changes, there is a problem with that
resolver channel or possibly with the resolver connections to the tester. An ohmmeter check of that winding
may reveal a shorted or open winding. If both signals are zero, then there may be a problem in the excitation
windings. Again an ohmmeter check may help determine the problem. The ohmmeter will measure the
resistance of the excitation winding on the stator. However, this winding is transformer coupled to an
excitation winding on the rotor, and the ohmmeter reading will not tell you anything about the rotor winding.
The Vector Level box displays a calculated quantity that, for lack of a better name, we call the vector level.
Trigonometry tells us that the square root of the sum of the squares of the sine and cosine of any angle is
equal to 1. Since the sine and cosine voltages are proportional to the sine and cosine of the angle, the
square root of the sum of the squares of these voltages should equal a constant voltage for an ideal
resolver. By computing this vector level from the sine and cosine voltages, we have access to a number that
can easily point out problems in resolver signals. As the resolver is rotated, the vector level should not vary
by more than a couple tenths of a volt. If it does, then the sine and cosine signals are not consistently at the
correct amplitudes. This may mean that there is a problem with the resolver, perhaps the signals coming
back from the resolver are distorted, or the excitation level may be too high. Using the breakout board to
connect an oscilloscope to the excitation, sine and cosine signals will help determine the problem.
If the sin/cos signals coming back from the resolver are too low and the vector level is below 1.0 V peak,
then the Vector Level box background will change to red indicating a low signal problem. From 1.0 V to 1.4
V, the background will be yellow indicating marginal levels. From 1.5 V to 2.9 V, the background will be
green indicating a good range of levels. From 3.0 V to 3.1 V the background is again yellow to indicate a
marginally high level. Levels from 3.2 V and above will show a red background to indicate a high level. The
excitation level must be adjusted into the acceptable range using the setup procedure described in the setup
section. If a good range cannot be achieved, then there is likely a problem with the resolver, and an
oscilloscope may help in figuring out the problem.
2.5.6.3 RESOLVER EXCITATION SET POINTS
The Resolver Excitation Set Points frame shows the frequency and level set points, in the Frequency and
Amplitude boxes respectively, that were selected in the Setup Window.
2.6 MANUFACTURER SPECIFIC ENCODER DETAILS
The following sections provide details on testing various manufacturers’ serial encoders (and some special
quadrature pulse encoders). When you are testing a particular kind of encoder, check this section to see if
there are any important testing details listed for it.
2.6.1 FANUC MOTORS
Motors with Fanuc ABS, incremental, and serial encoders are supported by the TI-5000EX. The current
revision software supports 6 and 8 pole Fanuc motors on all encoders (that we know of) except the Alpha
16000i. Most Fanuc motors are 8 poles, so the number of poles defaults to 8 whenever a new type of Fanuc
encoder is selected.
2.6.1.1 GENERAL COMMENTS
Fanuc serial encoders are used only with Fanuc motors. There are significant differences in the various
Fanuc models, but the test software takes that into account when displaying the results. The test procedure
and commutation pulse patterns are basically the same for the various serial encoders.
2.6.1.2 TYPES SUPPORTED
The following list shows the Fanuc encoders that are currently supported by the TI-5000EX:
Type Counts/Rev Cables
Pulsecoder A 1,048,576 TI-5004, TI-5005, TI-5006

Pulsecoder B 262,144 TI-5004
Pulsecoder B2 32,768 TI-5004
Pulsecoder C 40,000 TI-5005, TI-5006
Pulsecoder Alpha I8 8,192
Pulsecoder Alpha A8 8,192
Pulsecoder Alpha I64 65,536 TI-5005
Pulsecoder Alpha A64 65,536 TI-5004, TI5005
Pulsecoder Alpha 1000A 1,048,576
Pulsecoder Alpha I64i 65,536 TI-5047
Pulsecoder Alpha A64i 65,536 TI-5047
Pulsecoder Alpha 1000iI 1,048,576 TI-5047
Pulsecoder Alpha 1000iA 1,048,576 TI-5047
Pulsecoder Beta I32B 32,768 TI-5006
Pulsecoder Beta A32B 32,768 TI-5006
Pulsecoder Beta I64B 65,536 TI-5047
Pulsecoder Beta A64B 65,536 TI-5047
Pulsecoder Beta A128i 131,072 TI-5047
Pulsecoder ABS * Various TI-5007, TI-5016, TI-5029

Pulsecoder Incremental* Various TI-5007, TI-5016, TI-5029
* These encoders are tested as Generic Incremental and do not show up in the menu.
They should be set up as B leading A to get a + count in the CCW direction.
The Pulsecoder A, B, B2, and C are some of the earlier style encoders. They generally use 17 and 19 pin
round MS type and DB15 type connectors.
The Alpha series motors use the Alpha series encoders. They generally use 17 and 19 pin round MS type
and the DB15 type connectors, but some of the built-in Alpha 8 encoders on smaller motors will use AMP
D3100 two row connectors.
Fanuc has converted the Alpha encoders to a new, more compact package. These encoders commonly
employ the 17 pin round MS connector, but it will be on a short cable that plugs into the encoder case via a
14 pin dual row header type connector.
A new series of Alpha i motors utilizes Alpha i encoders. These encoders look very similar to the Alpha
encoders in the new package, and the data is very similar. However, they use a small 10 pin circular JAE
connector.
The Beta series motors use built-in Beta encoders. The earlier motors employ the Beta I32B and A32B
encoders. These encoders use DB15 connectors but also AMP D3100 two row connectors.
BetaM motors use built-in Beta I64B and Beta A64B encoders. These encoders use the small 10 pin circular
JAE connector.
The ABS and incremental encoders are tested like any other Generic Incremental Encoder.
2.6.1.2.1 IDENTIFICATION
The serial pulsecoders will normally have identification such as Pulsecoder A, Pulsecoder C, Pulsecoder
Alpha A64, etc. on the label. Otherwise, the part number starting with A860 may have to be used to identify it
by a reference to a Fanuc manual or a call to Fanuc.
The incremental and ABS encoders are easily identified due to the fact that they will have a 2000P, 3000P,
etc. following the A860 part number. This is the number of pulses per revolution for the encoder, and it
identifies it as and ABS or incremental. These encoders should be tested as Generic Incremental encoders.
2.6.1.3 CONNECTION
Connection requires using the correct cable as shown in the chart in the Menu List section. The cable pin
configurations are documented in the appendix of this manual.
Click on the Select Encoder button to make the selection. Follow the instructions below for either
incremental and ABS or serial encoders.
2.6.1.4.1 INCREMENTAL AND ABS ENCODERS
1. Click the Encoder Feedback radio button.

2. Select Generic Incremental Encoder from the Encoder Manufacturer dropdown menu.
3. The encoder type will default to AB Quadrature Count.
4. Click on the Enter Counts Per Revolution button. Multiply the number of pulses per revolution by 4
to get the number of counts/revolution. Fanuc incremental and ABS encoders will have a number
such as 2000P, 3000P etc. after the A860 part number, and this is the number of pulses per
revolution.
2.6.1.4.2 SERIAL ENCODERS
The Fanuc serial encoders require the following setup sequence:

1. Click on the Encoder Feedback radio button.
2. Select Fanuc from the Encoder Manufacturer dropdown menu.
3. Select the encoder type that you have from the Encoder Type dropdown menu.
The encoder types listed in the current software revision are shown in the preceding section.
Most Fanuc motors are 8 pole motors, and most of the encoder types specify 8 poles. There is a 6 pole
selection available for the Pulsecoder A and the Pulsecoder Alpha A64. To determine the number of poles,
apply a small voltage to 2 of the armature leads to lock the rotor, and then count the number of lockup
positions to determine the number of pole pairs. For instance, if the rotor locks up in 4 different shaft
positions, the motor has 4 pole pairs or 8 poles.
2.6.1.5 TESTING
Fanuc Incremental and ABS encoders are tested as Generic Incremental Encoders using Data Display, Line
Levels, Incremental Count Test, and Phase Test for a complete test. The Fanuc serial encoders (like most
serial encoders) use only the Data Display and the Serial Count Test.
The forward armature direction for Fanuc motors is CCW looking at the drive shaft end.
2.6.1.5.1 DATA DISPLAY
Data Display is the initial test, and it is started by default when WinTI5000EX 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:
1. Turn the encoder to ensure that the encoder is counting approximately the right number of counts
per revolution.
2. Use the commutation display to check or set the feedback commutation alignment.
3. 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.
2.6.1.5.1.1 COMMUTATION
The Fanuc 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. 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. In the case of the Fanuc
motors, they will default to 8 unless one of the two 6 pole types is selected. The gray code and electrical
angle are derived from a 10 bit commutation count in all serial pulsecoders except the Pulsecoder A, B, and
B2 in which case they come from the position count. The mechanical angle comes from the position count
for all Fanuc serial pulsecoders. The position count is absolute immediately upon power up only for the
Pulsecoder A, B, and B2. On all others it is only absolute after the encoder is indexed, so dashes will appear
in the Mechanical Angle box until the encoder is indexed. The Pulsecoder C does not display a mechanical
angle.
The table below shows 4 different lockups that can be used to check or set commutation on motors with
Fanuc serial encoders. The first two are commonly used with the gray codes but can be used with the
electrical angle as well. The first procedure requires energizing all 3 armature lines. A slight wiggle of the
shaft should result in the C8 indication toggling between 1 and 0. Likewise the second procedure in which
only lines V and W are energized results in the C4 indication toggling when the shaft is wiggled.
The last two procedures can only be used with the electrical angle since they do not result in unique gray
code patterns. 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. 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.
Lockup Elect. Angle Comm Pulses

C1 C2 C4 C8
+U –V –W 0 0 0 0 1→0
+V –W 90 0 1 0→1 0
+U –V 330
+U –W 30
The incremental and ABS encoders will be tested as Generic Incremental encoders, but their alignment
would follow the table below:
Lockup Comm Pulses

H1 H2 H3 H4 H5 H6
+U –V –W H H H L→H H H
+V –W H L H→L H H H
The entire gray code pattern is as follows:
Serial A,B,Z
A, B, B2, Alpha & C 3000P & 2500P
C8 C4 C2 C1 C8 C4 C2 C1
H4 H3 H2 H1
0 0 0 0 H H H H
0 0 0 1 H H H L
0 0 1 1 H H L L
0 0 1 0 H H L H
0 1 1 0 H L L H
0 1 1 1 H L L L
0 1 0 1 H L H L
0 1 0 0 H L H H
1 1 0 0 L L H H
1 1 0 1 L L H L
1 1 1 1 L L L L
1 1 1 0 L L L H
1 0 1 0 L H L H
1 0 1 1 L H L L
1 0 0 1 L H H L
1 0 0 0 L H H H
It may be worth checking in some situations to verify that this pattern is taking place correctly.
2.6.1.5.1.2 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. On power up, this count will be zero for the Pulsecoder A and Alpha
series when the encoder shaft is at the 9:00 position (i.e.: looking at the end of the shaft with the stamped
model number under it, the arrow on the shaft will be pointing to the left). These encoders internally keep up
with the count with respect to these references. The Pulsecoder C works differently in that its data reports
the difference in the count from the previous reading to the present reading. Therefore, its zero reading will
be referenced to its position at power-up. The TI-5000EX software accumulates these difference readings
and maintains and reports a total count so that the result is a value similar to the total counts reported for the
Pulsecoder A and Alpha series.
As mentioned previously, the count represents an absolute position on power up only for the Pulsecoder A,
B, and B2. On other encoders, the count represents an absolute position only after the encoder is indexed. It
does not represent an absolute position for the Pulsecoder C.
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.
2.6.1.5.1.3 LINE STATES
The Pulsecoder C is the only supported serial pulsecoder for which a line state is indicated. The line state
indicated is the Z or index line. This is not really an index line, like an incremental encoder, but an index bit
that goes HI once per revolution. Even though it is not really a line state per se, the Z line state box is a
convenient place to show it. The Pulsecoder C sets this bit HI momentarily when moved past the index
position, so you will see the indicator flash HI momentarily. Unlike an incremental encoder, it will not stay HI
if you stop right on the index position. The index pulse occurs when C1, C3, and C4 are HI and C2 is
changing between LO and HI. This commutation indication will occur in as many different positions as there
are pole pairs, but the index pulse will only occur in one of these positions. Note that this index indication is
quite different from the Alpha and Beta series encoders. For the Alpha and Beta encoders, the count is
index on the initial revolution after power up, while the Pulsecoder C is reporting an index position on every
revolution.
2.6.1.5.1.4 ENCODER STATUS
INDEX – The INDEX box is disabled for the Pulsecoder A, B, and B2 because these encoders display the
correct count on power up without indexing. It is also disabled for the Pulsecoder C because the TI-5000EX
does not index for these encoders. All other serial pulsecoders must be indexed on power up unless they
are absolute encoders which have been battery backed up. The absolute encoders will have an ‘A’ in their
name while the incremental encoders will have an ‘I’. For instance the Fanuc Alpha I64 is an incremental
encoder (incremental is Fanuc’s way of saying ‘not battery backed’ for serial encoders), so it will need to
index on every power up. An Alpha A64 encoders is an absolute (absolute is Fanuc’s way of saying ‘battery
backed’) so it will need to be indexed on power up only if it had not been connected to a battery.
Always verify that the INDEX box changes from ALARM to OK within one revolution of the encoder.
DATA - If no data is being sent from the encoder, NONE will be displayed in the DATA box. If the TI-5000EX
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
Pulsecoder.
INTERNAL ERROR - The INTERNAL ERROR box will show ALARM if there is an internal error alarm and
OK if there is not. Several bits in the data stream for the various Pulsecoders respond to the loss of an LED
and the resulting counting problems. These bits are consolidated and reported under the INTERNAL box
with ALARM if any are HI. If none of these bits are HI, then OK is displayed. Causes for alarms could be a
malfunctioning LED, incorrect alignment of the optics, and other problems. Removal of the board in the
Pulsecoder is likely to cause some alignment problems.
BATTERY - The BATTERY box will show ALARM if there is a battery error alarm and OK if there is not. It is
often possible to alternately connect and disconnect battery voltages to the encoder to verify that this bit is
working properly. This field is disabled for Alpha and Beta Pulsecoder I (incremental) encoders and the
Pulsecoder C because they do not have battery backup capability. The remaining absolute pulsecoders will
use this. The Pulsecoders with battery capability should show ALARM in this column if the voltage on the
+6VA and 0VA lines is less than approximately 4.6 VDC. If the voltage is above approximately 4.6 VDC, the
display should show OK. Many Fanuc encoders use a separate battery cable that is not part of the encoder
signal harness. However, some encoders use lines that are part of the signal harness for the battery. The
Fanuc serial cables (TI-5004, TI-5006, and TI-5007) bring out the battery line for easy connection (see cable
pinouts in the appendix). Using a clip lead to jumper the battery wire to J1 pin 1 (+5V) on the TI-5000EX is a
good way to supply battery voltage. When this is done and the display changes to OK, sometimes it is
necessary to connect the clip lead to J1 pin 2 (GND) in order to make it display ALARM again.
OVERHEAT - The OVERHEAT box will show ALARM if there is an overheat error alarm and OK if there is
not. It is often possible to alternately connect and disconnect thermal lines to the encoder to verify that this
bit is working properly This field may not be in effect for all serial encoders. Thermal contacts inside the
Pulsecoder complete a circuit to ground when temperatures are within range. When temperatures become
excessive, the contacts open, and the overheat bit is transmitted with the data. The Pulsecoders with the
DB15 connectors indicate only their own temperature and do not loop through the motor. Pulsecoders with
the circular connectors however, bring this circuit out on the BRN and RED wires (which do not go to the
circular connector). In a normal installation these wires are connected through other contacts such as motor
overload contacts. These wires can be connected together during testing. When connected together, the
Pulsecoder should not indicate an overheat condition (providing it is not overheated) with an OK display. If
these wires are disconnected from each other, the OVERHEAT box should indicate ALARM.
The newer Alpha i and Beta i encoders connect to the motor using two round brass contacts on the face of
the encoder (near the shaft coupling). This of course means that the encoder must be mounted on the motor
so that the motor overheat contacts mate with these contacts on the encoder. Unlike previous model
pulsecoders, these newer style encoders are apparently not looking for a contact closure but are reading a
thermistor of some similar device in the motor. If these contacts are shorted, the ALARM indication will not
change to OK (and stay that way). However, if a resistor from around 5K to 50K ohms is connected to these
contacts, the display will change to OK. A 10K resistor is a commonly available value, and it is probably a
good value to use for testing these encoders.
ENCODER ID – There is no encoder ID support for Fanuc serial encoders.
2.6.1.5.2 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 it will verify that the encoder is incrementing the correct number of counts per
revolution. The Count Test for the Fanuc 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.
2.6.2 HEIDENHAIN SERIAL ENCODERS
The Heidenhain serial encoders listed in the next section are supported by this selection. Heidenhain
incremental encoders with A, B, and Z lines should be tested as Generic Incremental encoders. Heidenhain
encoders with sine/cosine commutation outputs (like the ERN 1387) are discussed in the section on
incremental encoders.
Heidenhain encoders commonly show up on Siemens, Bosch, Baldor and Indramat motors among others.
The encoders built for the Indramat MDD series motors are significantly different from the standard
Heidenhain encoders, and they are described in the Indramat section. Some Heidenhain encoders feature
serial outputs, but all Heidenhain encoders have quadrature incremental outputs as well. All encoders
appear to have A and B outputs, but not all include a Z index pulse. When a Z pulse is provided, the
incremental part of the encoder can be tested like any other incremental encoder (as described in the
incremental section). It is typically the serial encoders that do not include an index pulse, and tips are given
in this section for testing the incremental section on those encoders.
The incremental outputs come in several formats: TTL, HTL, 1V p-p sine, and 11 µA p-p sine. The less
common 11µA format is not supported by the TI-5000EX. The 1V p-p sine outputs should be used with the
TI-5101 1 V p-p interface module. This module amplifies the 1V p-p signals up to a range near 5 V which is
more acceptable to the TI-5000EX. Usually the A and B signals will work without the amplification, but the Z
pulse sometimes will not. The TTL signals will work directly just like any other 5 V incremental encoders.
The HTL signals should be limited to less than 15 V to avoid over-voltage to the TI-5000EX inputs. When
the incremental encoders include commutation, it comes in the form of a C and D, sine and cosine, outputs.
These outputs provide one period of a sine or cosine wave for each revolution of the encoder which can be
converted to an angle. This angle can be read using the Sin/Cos 1 Period/Rev function by selecting
Incremental Encoder, AB Quadrature Count and then selecting Sin/Cos Commutation in the Data Display
window. The RON3350 and ERN1387 are two such encoders, and the ones used on Siemens 1FT6 motors
can be connected to the TI-5000EX using the TI-5010 cable (see Section 2.1.2.3).
Heidenhain supports two serial data formats: SSI and Endat. The TI-5000EX software is compatible with
both formats at this time (as indicated in the next section). In addition to the serial lines, the Endat encoders
also include 1V p-p A and B lines (no index pulse is included). The SSI encoders have only serial lines.
The following list shows the Heidenhain serial encoders that are currently supported by the TI-5000EX:
Type Format Counts/Rev Cables
ECN 1313-2048 Endat 8,192 TI-5031 (Siemens), TI5043 (Baldor),

TI-5059 (Bosch/B+R)
EQN 1325-2048 Endat 8,192 TI-5031 (Siemens), TI5043 (Baldor),
TI-5059 (Bosch/B+R)
EQN 1325-2048 SSI 8,192 TI-5049 (Stromag)
ERN 1381* Inc 8,192 TI-5010 (Siemens)
ERN 1387* Inc 8,192 TI-5010 (Siemens)
* Not serial encoders – test as incremental. May have sine/cosine comm. lines.
The Heidenhain encoders are normally clearly marked, so identification is not a problem. Especially for the
serial encoders, check the following:
1. For ECN1313 and EQN1325 encoders, check the label to see whether they are SSI or Endat
format. You will probably see Endat most often, but it can be confusing if it is an SSI and you
assume it is an Endat.
2. For ECN413, ECN1313, EQN415 and EQN1325 encoders, check to see whether they are labeled
Indramat or have an additional part number that starts with DSF or HSF. These are probably
Indramat encoders, and they use a format different from both SSI and Endat. See the Indramat
section for more information on these.
The TI-5000EX does not currently report an encoder ID field for Endat serial encoders, but this feature is
planned for future revisions. The SSI encoders are not known to have ID capability.
2.6.2.3 CONNECTION
configurations are documented in the appendix of this manual. Cable configurations other than the cables
listed are known to exist. There may be cables that are made by OEM machine manufacturers using these
encoders.
If properly cabled, the serial Endat encoders can be used with the 1V p-p adapter so that it is easier to check
the incremental portion with the same connection. See the section on cables for more information.
Click on the Select Encoder button to make the selection. The Heidenhain serial encoders require the
following setup sequence:

2. Select Heidenhain from the Encoder Manufacturer dropdown menu.
Siemens motors are most often 6 or 8 pole motors. The number of poles may be selected from the POLES
dropdown menu. To determine the number of poles, apply a small voltage to 2 of the armature leads to lock
the rotor, and then count the number of lockup positions to determine the number of pole pairs. For instance,
if the rotor locks up in 4 different shaft positions, the motor has 4 pole pairs or 8 poles.
The number of poles must be entered correctly in order to display the electrical angle correctly. It is essential
for the electrical angle to be correct when checking or setting the encoder alignment for correct
commutation.
2.6.2.5 TESTING
Heidenhain Incremental encoders are tested as Generic Incremental Encoders using Data Display, Line
Levels, Incremental Count Test, and Phase Test for a complete test. Heidenhain serial encoder types listed
above (like most serial encoders) use only the Data Display and the Serial Count Test.
The forward armature direction for Siemens motors is CW looking at the drive shaft end.
per revolution.
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 Heidenhain
encoders. 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 Heidenhain serial encoders.
The table below shows 3 different lockups which can be used to check or set commutation on Siemens
motors with Heidenhain 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 (CW looking at the shaft for Siemens). Failure to move the correct number
of degrees or in the correct direction would be an indication of a significant problem. Setting these angles
Lockup Elect. Angle
-U +V +W 0
+U –V 150
+U –W 210
The use of Heidenhain serial encoders on Bosch motors is more complicated than Siemens motors. Bosch
motors use the memory provided by the Endat encoders, and they store a commutation offset in the
memory. By using the commutation offset, the encoders do not have to be set to a common alignment. Each
motor can be aligned differently, and in general they are. If you are familiar with the Indramat digital
encoders, you recognize this scheme. You can use the TI-5000EX to see how the encoder is aligned when
you receive the motor, and you can set it back to that alignment after repair, but you cannot verify that that
alignment is actually correct. It is planned that future revisions of the TI-5000EX software will provide for
determining the correct alignment for Bosch motors.
We do not currently have alignment information for the Baldor motors using the Endat encoders.
2.6.2.5.1.2 COUNT
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.
The ECN 1313 encoders are single turn encoders in that they do not keep track of revolutions. The
EQN1325 encoders are multi turn encoders, and they will keep track of 4,096 revolutions.
Typically serial encoders that include incremental lines are tested both as incremental encoders and serial
encoders. Since the Heidenhain serial encoders do not include an index pulse, an incremental encoder
count test cannot be performed. Reading the absolute count from EQN 1325 provides a possible method of
also checking the integrity of the incremental count. The procedure is as follows:
1. Read the absolute count from the Data display and write it down.
2. Click the Select Feedback button and select an incremental encoder with 8192 counts per turn.
3. 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.
4. Select the EQN1325 serial encoder again.
5. 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.
A similar procedure can be used for the ECN 1313, but it is complicated by the fact that the ECN 1313 does
not count revolutions. This can be overcome by modifying the above procedure slightly. In step 1, turn the
encoder until the absolute count is approximately 1,000. In step 3, turn the encoder 10 1/4 turns clockwise.
In step 4, of course, select ECN 1313. In step 5, add 81920 (the count for 10 complete turns) to the
absolute reading. This would be the final reading if the ECN 1313 was capable of keeping track of
revolutions. Subtracting the count in step 1 from this number should be very close to the count recorded in
step 3.
INDEX – The INDEX box is disabled for all Heidenhain serial encoders because these encoders display the
correct count on power up without indexing.
Pulsecoder.
OK if there is not. The internal alarm is the result of self tests that are done by the encoder electronics.
Heidenhain literature indicates that causes for alarms could be position error, illumination, signal amplitude,
etc.
BATTERY - The BATTERY box is disabled for Heidenhain serial encoder because they do not utilize battery
backup.
OVERHEAT - The OVERHEAT box is disabled for Heidenhain serial encoders because they do not report
overheat conditions.
ENCODER ID – The ENCODER ID box is disabled in the current revision software because this feature is
not implemented. It is planned to include this in future software revisions.
revolution. The Count Test for the Heidenhain 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 bit12 for activity for 8,192 count 13 bit Endat encoders.
2.6.3 HENGSTLER (UNICO) SSI SERIAL ENCODERS
The Unico 319-663 encoder appears to be the same as the Hengstler Type RA 58 SSI 24 bit serial encoder.
There are 12 bits for counting revolutions and 12 bits for the rotational angle. These bits are put together in one
24 bit gray code data word. There is an alarm bit that follows the 24 bit count. According to the Hengstler
catalog, the alarm bit responds to low voltage, high temperature, broken disk or faulty LED.
Information on this encoder is available from the Hengstler catalog “Shaft Encoders, Linear and Angular
Measuring Systems 2001”. Danaher Controls (Ph. 800-234-8731) can supply the catalog.
The encoder power supply is specified between 10V and 30V, so it should be powered from an external supply
rather than the TI-5000EX. Connect an external bench supply to the +V and 0V pins of the encoder. Be sure to
also connect the 0V line to J1 pin 2 of the TI-5000EX to ensure a common ground system. While the power
supply is greater than 5V, the serial signals are 5V levels.
The following list shows the Hengstler serial encoders that are currently supported by the TI-5000EX:
Hengstler/Unico SSI 4,096 User Fabricated
These encoders are clearly marked with the part numbers shown in the previous section, so identification
should be no problem. The Hengstler part number is Type RA 58. The Unico part number is 319-66
2.6.3.3 CONNECTION
A cable for this encoder is not currently offered. The connector is a 12 pin connector of the type used on the
Indramat encoders, except the pin rotation is reversed. Cabling for the Hengster/Unico encoders can be
accomplished as follows:
J1 TB Pin TI-5000EX Signal Signal Encoder Pin Color
2 GND 0V 1 BRN
9 SERIN DATA 2 PNK
10 SERIN* DATA* 10 GRY
J2 TB Pin
3 CLK CLOCK 3 YEL
4 CLK* CLOCK* 11 GRN
10-30V 8 WHI
0V Signal 12 BLK
Direction* 5 BLU
The TI-5000EX really only uses the 0V reference and the data and clock true and complement lines. If the
Direction* line is left disconnected, the count increases for CW rotation. To reverse the direction connect the
Direction* line to the 0V Signal line.
Click on the Select Encoder button to make the selection. The Hengstler serial encoders require the

2. Select Hengstler from the Encoder Manufacturer dropdown menu.
The number of poles may be selected from the POLES dropdown menu. To determine the number of poles,
positions, the motor has 4 pole pairs or 8 poles.
commutation.
2.6.3.5 TESTING
Hengstler/Unico serial encoder types listed above (like most serial encoders) use only the Data Display and
the Serial Count Test.
No information on the Unico motor (such as forward armature direction) is available at this time.
per revolution.

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. The number of poles must be entered correctly for the electrical
angle to be correct.
We do not currently have alignment information for the Unico motors using the Hengstler/Unico encoders.
2.6.3.5.1.2 COUNT
the hexadecimal representation useful. This is an absolute encoder, and it will remember the count on power
up.
The Hengstler/Unico serial encoder produces a count of 4,096 (12 bits) per revolution. In addition, they
count up to 4,096 full revolutions, so the count can range -8,388,608 (800000 HEX) to +8,388,607 (7FFFFF
HEX). (24 bits - 12 bits for count per revolution and 12 bits of revolution count). The data is in gray code, but
the TI-5000EX automatically decodes it and displays it as a binary count.
As mentioned previously, the count increases when rotated in the CW direction when the Direction* line is
disconnected. Connecting the Direction* line to the 0V Signal line reverses the direction.
INDEX – The INDEX box is disabled for Hengstler/Unico serial encoders because these encoders display
the correct count on power up without indexing.
encoder.
INTERNAL ERROR - The currently supported Hengstler/Unico encoders provide one error bit which is
reported in the Error field. This bit is reported under the Error column with an "ALARM" message if it is HI. If
this bit is LO, an "OK" message results. Hengstler/Unico literature indicates that causes for alarms could be
low voltage, high temperature, broken disk or faulty LED.
BATTERY - The BATTERY box is disabled for Hengstler/Unico serial encoder because they do not utilize
battery backup.
OVERHEAT - The OVERHEAT box is disabled for Hengstler/Unico serial encoders because they do not
report overheat conditions.
ENCODER ID – The ENCODER ID box for the Hengstler/Unico serial encoders because they do not
provide ID information.
display. The Count Test will verify that the encoder is incrementing the correct number of counts per
revolution. The Count Test for the Hengstler/Unico encoders is not significantly different from that for other
The stuck bit test will test bit0 to bit11 for activity for 4,096 count 12 bit encoders. The stuck bit test is run on
the gray code data read from the encoder rather than after conversion to the binary data.
2.6.4 INDRAMAT SERIAL ENCODERS
This section covers the so called digital Indramat motors and feedback. The part numbers begins with MDD,
MHD, MKD, and MKE. These motors use complicated serial encoder and resolver feedback systems which
include memory data to identify the motor to the drive.
The older motors, whose part numbers begin with MAC, are much simpler. They use Hall effect feedback for
commutation, and use incremental encoders for position feedback. They also include a tachometer for speed
feedback. Refer to previous sections on Generic Incremental Encoders whenever MAC motors are involved.
Accessories available for the MAC motors include the TI-5042 cable and the TI-5005 Adapter Module which
allow connection to the encoder, Halls, and tach at the same time.
This section covers the serial digital feedback devices, and does not cover MAC motors.
The following list shows the Indramat serial encoders that are currently supported by the TI-5000EX:
Type Type Counts/Rev Cables
DSF02SN-H ECN 212 Single Turn - Heidenhain 1024 TI-5021

DSF02MN-H EQN 224 Multi Turn - Heidenhain 1024 TI-5021
DSF04SN-H ECN 413 Single Turn - Heidenhain 2048 TI-5021
DSF04MN-H EQN 425 Multi Turn - Heidenhain 2048 TI-5021
HSF04SN-H ECN 1313 Single Turn - Heidenhain 2048 TI-5021
HSF04MN-H EQN 1325 Multi Turn - Heidenhain 2048 TI-5021
DSF02SN-S EQN 425 Single Turn - Stegmann 2048 TI-5021
MDD, MKD, MKE Resolver memory board TI-5040
The Indramat encoders are identified by the Heidenhain ECN/EQN part number as well as the Indramat
DSF number. The older MDD motors can have the ECN212, EQN224, ECN413 and EQN425 encoders (the
newer ones will have the 400 series encoders). According to the manual, the MDD motors can also use
resolver feedback, but it does not appear to be very common.
The MHD motors will use the ECN413, EQN425, ECN1313 and EQN1325 encoders.
The MKD motors typically use resolver feedback, but according to the manual, they can come with encoder
feedback. The MKE motors seem to be environmentally sealed versions of the MKD motors.
To avoid confusion, please note that Heidenhain has encoders using these same part numbers in their
standard catalog, and they are completely different. The Heidenhain ECN1313 and EQN1325 ENDAT
encoders were discussed in a previous section, and they are not the same as the Indramat encoders. The
Endat encoders are used in Siemens, Bosch, Heidenhain, and Baldor motors, and they will not have the DSF
part number on them.
2.6.4.3 CONNECTION
Click on the Select Encoder button to make the selection. The Indramat serial encoders require the following
setup sequence:

2. Select Indramat from the Encoder Manufacturer dropdown menu.
Indramat motors are 6 and 8 pole motors. Other numbers of poles would be rare if they exist at all. The
number of poles may be selected from the POLES dropdown menu. To determine the number of poles,
positions, the motor has 4 pole pairs or 8 poles. The parameters in the encoder memory also will show the
number of pole pairs.
commutation.
2.6.4.5 TESTING
As mentioned previously, Indramat MAC motors with Heidenhain Incremental encoders are tested as
Generic Incremental Encoders using Data Display, Line Levels, Incremental Count Test, and Phase Test for
a complete test. Indramat serial encoder types listed above (like most serial encoders) use only the Data
Display and the Serial Count Test.
The forward armature direction for Indramat motors is CW looking at the drive shaft end.
per revolution.
When Data Display first starts for the Indramat encoders, a support message box appears to display
important support information relevant to the Indramat encoders since they are quite unique. The message
content is as follows:
1. Read the Indramat Alignment Note From Mitchell Electronics, Inc.

2. Power down the TI-5000EX before connecting or disconnecting Indramat feedback devices.
3. Disconnect the resolver from the resolver board before reading the resolver board memory.
The alignment notes provide a detailed procedure for alignment when dealing with both encoders and
resolvers, and it is very informative to read. The Data Display continuously reads position data from the
encoder, and it is best not to connect or disconnect the encoder while this data transfer is occurring.
Entering Data Display without the feedback device connected could result in missing important data, so it is
best to have the feedback connected before starting. Disconnecting the resolver board while the TI-5000EX
is powered could cause transient voltages to develop on the resolver board. This is especially a problem is if
the resolver is connected to the resolver board during the memory read operation. Always disconnect the
resolver from the memory board and power down the TI-5000EX before connecting to the resolver board to
avoid the possibility of generating high voltage transients.
Data Display should be used as the initial check to see whether the encoder is doing anything at all. The
following sections describe information shown on the display.
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. 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 absolute position information in the serial data. The mechanical and
electrical angle data is absolute immediately on power up for Indramat serial encoders.
The table below shows 2 different lockups that can be used to check or set commutation on Indramat digital
motors with serial encoders.
The 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 (CW looking at the shaft for Indramat). Failure to move the correct number
of degrees or in the correct direction would be an indication of a significant problem. Setting these angles
Lockup Elect. Angle
+U –V +U –V lockup angle read from the memory test
+U –W +U –W lockup angle read from the memory test
Unlike most feedback alignment discussed in this manual, Indramat digital motors do not have a common
lockup angle, and in general, they will all lock up at different angles. Indramat motors store a commutation
offset in the encoder memory. By using the commutation offset, the encoders do not have to be set to a
common alignment. In order to correctly check or set the alignment, you have to run the Memory Test on the
encoder, and write down the +U –V and +U –W lockup angles provided by the memory test.
The MKD motors utilize a memory board along with the resolver. Again, you must perform a Memory Test to
get the lockup angle for that particular motor. When you have the correct lockup angle, you can then lock up
the motor and check for that resolver angle in the conventional manner.
A document is available from Mitchell Electronics, Inc. with more detail on Indramat alignment procedures.
2.6.4.5.1.2 POSITION CODE RINGS
There are significant differences between the Indramat encoders and other serial encoders described in this
manual. The serial data returns sine and cosine amplitudes rather than position counts. In this regard, the
data is similar to resolver data, and it can be converted to an angle. Furthermore, sine/cosine data is
returned for the 1 period/revolution code ring and the 16 periods/revolution code ring for the 200 series
encoders and for the 1 period/revolution code ring, 8 periods/revolution code ring and the 64
periods/revolution code ring for the 400 and 1300 series encoders. An absolute position angle can be
calculated from the 1 period/rev data. However, this angle can be determined more accurately if it is
interpolated using the finer resolution 8, 16, and 64 period/rev data. The TI-5000EX displays the data both
ways as will be further explained.
As described above, the absolute position angle information is available as both mechanical and electrical
angles. To display the electrical angle correctly, the number of poles must be set correctly. The mechanical
angle always changes 360 degrees for a full rotation of the encoder. The mechanical angle should roughly
agree with the angle in the 1R box. In fact, the 1R box provides the approximate angle, and that angle is
further refined by interpolation with the angles in the 1/8R, 1/16R, and 1/64R boxes. While the 200 series
encoders produce a 1R and 1/16R position, the 400 and 1300 series encoders produce 1R, 1/8R and 1/64R
position data. This allows for even more precise interpolation.
It is not necessary to completely understand the interpolation. Rather, it is important to understand that the
final angle is made up from the contributions of these various angles, and that even when working correctly,
the mechanical angle will typically not agree exactly with the 1R angle. If we are not looking for perfect
agreement, then why are the various angles displayed and how should we evaluate them? The following
guidelines should help in evaluating the data for the ECN212 and EQN224 encoders:
1. Data in the Mechanical Angle, INCREMENTAL, 1/16R and 1R boxes should all be changing as the
encoder is rotated.
2. The Mechanical Angle and 1R boxes should be approximately equal (within a few degrees).
3. As the data in the 1/16R box goes through 360 degrees, the 1R box data should change about 22
degrees (22.5 ideally).
4. As the data in the Mechanical Angle box changes by 360 degrees, the data in the INCREMENTAL
box should change by about 1024 counts.
Use following guidelines should help in evaluating the data for the ECN413, ECN1313, EQN425, and
EQN1325 encoders:
1. Data in the Mechanical Angle, INCREMENTAL, 1/64R, 1/8R and 1R boxes should all be changing
as the encoder is rotated.
2. The Mechanical Angle and 1R boxes should be approximately equal (within a few degrees).
3. As the data in the 1/64R box goes through 360 degrees, the 1/8R box data should change about 45
degrees. Likewise for 360 degrees in the 1/8R column and the 1R data should change by 45
degrees.
4. As the data in the Mechanical Angle box changes by 360 degrees, the data in the INCREMENTAL
box should change by about 2048 counts.
2.6.4.5.1.3 COUNT
The data in the INCREMENTAL box is captured as quadrature pulses on the A and B channel inputs. Since
there is no index pulse to which it may be referenced, it must be compared with the absolute data to verify
that the correct number of counts per revolution is occurring.
As usual, the encoder device selected is identified. In this case, it is the ECN212C which provides 1024 (2 to
the 10th) counts per revolution. Data Display should be used as the initial check to see whether the encoder
is doing anything at all. There are no alarm bits produced by these encoders. If no data is being sent from
the encoder, that problem will be detected and reported in Data Display. An encoder may be connected to
the TI-5000EX and rotated by hand through one revolution to see whether the count is changing by
approximately the correct amount. The count and all angles increase when the encoder is turned in the
clockwise (CW) direction. .
2.6.4.5.1.4 REVOLUTIONS CODE RINGS AND REVOLUTIONS
While the ECN212, ECN413 and ECN1313 are single turn encoders, the EQN224, EQN425, and EQN1325
are multi turn encoders. The multi turn encoders include revolution count information in the Revolutions
Code Rings frame. The multi turn encoders are capable of keeping track of 4096 revolutions (0 – 4095). The
angle data from the revolution code rings is used to produce a revolutions count which is displayed in the
REVOLUTIONS box. For single turn encoders, the Revolutions Code Rings frame and REVOLUTIONS box
will be disabled.
The revolutions are measure by 3 code wheels for 200 series encoders and 4 code wheels for 400 and
1300 series encoders. The wheels are driven by a gear train that provides ratios of 16:1, 256:1, and 4096:1
for 200 series and 8:1, 64:1, 512:1, and 4096:1 with reference to the main encoder shaft. The angles from
these code wheels are displayed in the 16R, 256R, and 4096R boxes for the 200 series encoders and 8R,
64R, 512R, and 4096R boxes for the other encoders. Again, by mathematically interpolating these code ring
angles, the exact number of turns can be determined. This is the number that appears in the
REVOLUTIONS box. The following procedure will help determine that the revolution counting sections are
working properly:
1. Rotate the encoder 128 revolutions. During the motion verify the following:
a. The 1R angle should go through 360 128 times.
b. The 16R angle should go through 360 very approximately 8 times.
c. The 256R angle should change by approximately 180 degrees.
d. The 4096Rev angle should change by approximately 11 degrees (ideally 11.25).
2. At the end of 128 revolutions, verify that the revolution count has changed by 128.
This procedure will help determine that the EQN425 and EQN1325 revolution counting sections are working
properly:
1. Rotate the encoder 128 revolutions. During the motion verify the following:
a. The 1R angle should go through 360 128 times.
b. The 8R angle should go through 360 very approximately 16 times.
c. The 64R angle should go through 360 very approximately 2 times.
d. The 512R angle should change by approximately 90 degrees.
e. The 4096R angle should change by approximately 11 degrees (ideally 11.25).
2. At the end of 128 revolutions, verify that the revolution count has changed by 128.
Of course there are many possible variations on this procedure. In general, if you turn it more that 128
revolutions, you will have a better feel for whether all parts are working properly. Conversely, if you turn it
fewer times, the test will be less accurate. It is somewhat of a judgment call as to how much time you decide
to spend turning the encoder to convince yourself that it is working properly.
Each of these angles is scanned at various times, and the information for each may not be current when the
encoder is moving. In that regard, do not be alarmed if a wild revolution count is seen from time to time while
the encoder is moving. However, the revolution count should be correct whenever the encoder is stopped.
When the Indramat motor is equipped with resolver feedback, use the resolver display. At this time, the TI-
5000EX does not support reading revolution counts for multi-turn resolver feedback. See the Generic
Resovlers section for more on motors with resolver feedback.
INDEX – The INDEX box is disabled for all Indramat serial encoders because there is no indexing with these
encoders. The displayed angles are absolute on power up.
encoder.
Indramat encoders do not need to be indexed, they provide no internal errors bits, they do not need a
battery, and they do not provide overheat information, so there are no fields on the Data Display for any of
that information.
ENCODER ID – The ENCODER will be implemented for the Indramat encoder in future software revisions.
Currently there is no Count Test for the Indramat encoders. The procedure described in the preceding
section can be used to verify correct counting.
2.6.4.5.3 MEMORY TEST
As explained previously, the feedback for Indramat digital motors use a memory device containing motor
parameters. This data is programmed in at the factory and cannot be changed by the drive. Some of the
default tuning constants may be overridden by the drive, but the data in the encoder is fixed. This device is
read by the drive system on power-up prior to moving the motor. If the drive system cannot read the memory
or if it gets incorrect data from it, the motor will not run. It is therefore very important to verify that the memory
can be read and appears to be correct. The memory also contains information that allows checking the
commutation alignment.
In verifying correct memory data and memory operation, we are looking at two things:
1. Is the data correct and not corrupted?
2. Is it the correct data for this motor?
The first item is done automatically. The data in the encoder is encoded with the ability to check data
integrity. The TI-5000EX does this automatically as it reads and displays the various motor parameters. Any
parameter that fails this check is not displayed, and “BAD DATA” is displayed in its place. We do not know
what the drive requirements are, but the logical guess is that if there is even one bad parameter, the drive
will not run the motor. Experience so far indicates that it is somewhat rare for the encoder memory to
actually have a problem. Many things such as a bad encoder cable, incorrect connection of the TI-5000EX,
etc. could cause a bad data read. Especially if you are unfamiliar with testing Indramat motors, you might
check with Mitchell Electronics, Inc. if you have an encoder (or especially, several encoders) that do not read
the data correctly.
The second item amounts to making sure that the encoder that is on the motor is the correct one.
Sometimes in trouble-shooting, encoders get swapped in an attempt to isolate a problem, and the encoder
on the motor you have could be the wrong one entirely. In general the data from the encoder should match
the data from the motor nameplate. In this regard, we are looking for gross errors. Minor differences in the
encoder data and nameplate data are normal.
The display shown below is a memory test from an ECN212 encoder. The motor type number and motor
parameters are fairly self explanatory. These numbers should match reasonably well with the nameplate
data. Toward the end of the right column is some information that is useful to the repairman. The number of
pole pairs is 3, which indicates a 6 pole motor. This may not be universal, but it appears that the MDD
motors are 6 poles, while the MHD, MKD, and MKE can be either 6 or 8 pole. The feedback type of 3
indicates the ECN212 encoder (as described above). The encoder count of 256 pulses/rev corresponds to
1024 counts/rev as read by the TI-5000EX. The commutation offset number of 238 is what tells the drive
how to provide correctly timed armature currents to the motor. The TI-5000EX uses the commutation offset
to calculate what the +U –V and +U –W lockup angles should be in electrical degrees for proper feedback
alignment, and these angles are reported in the Derived Data frame.
Name Plate data: MDD112D-N-020-N2L-130PB0
Natural Convection Natural Convection Surface Cooled Surface Cooled

Nominal Torque Nominal Current Nominal Torque Nominal Current
MdN 38.00 Nm IdN 43.80 A MdN 57.00 Nm IdN 65.80 A
RPM Torque Constant Mass

n 2000 min-1 Km 0.87 Nm/A m 59 kg.
Comparing the above nameplate data to the encoder data below, we see a typical situation. The nameplate
does not include all of the encoder data. Most of the data is very close, but the RPM data is further off than
you might expect.
2.6.5 KAWASAKI SERIAL ENCODERS
There are several models of Kawasaki serial encoders, and two are currently supported by the TI-5000EX.
The H20/M21 8,192 count/rev encoders are used with relatively large robot motors. Connection to these
encoders requires only 4 lines: 5 V power, ground, and a pair of RS485 data lines. The cables available are the
TI-5011 (4 pin direct connection to the encoder) and the TI-5032 (17 pin circular MS type connector).
HE-02 8,192 count/rev encoders are used on somewhat smaller robot motors. They are supported by the TI-
5023 (DB25 connector) and TI-5026 (17 pin circular MS type connector) cables. This encoder is the same as
the 8192 count Sanyo Denki E03007758.
The following list shows the Kawasaki serial encoders that are currently supported by the TI-5000EX:
H20/M21 8,192 TI-5011 or TI-5032
HE-02 8,192 TI-5023 or TI-5026
The following motor models use H20M21 encoders:
Model Description
P20B10200LCL62 4 poles
P60B13150HCX23 8 poles
P80B22450RCX2A 8 poles
P80B22450RCX2R 8 poles
Sanyo Denki uses the P series part numbers for their motors too, and they show the bold character as the
encoder identifier. The last two, L and X, are not in the Sanyo Denki literature but appear in the part
numbers for Kawasaki motors using H20M21 encoders. There is some inconsistency in some of the
descriptions in the manuals, but this should provide some useful guidance. The assignments are as follows:
Letter Encoder
S00 Wire saving incremental, 2000 or 6000 PPR
S07 Wire saving incremental, 2048 PPR
SA0 Wire saving incremental, 2000 or 6000 PPR, rigid shaft
J Absolute encoder with motor flange of 60 mm or less
A00 ABS-E encoder with motor flange of 76 mm or more
AA0 ABS-E encoder with motor flange of 76 mm or more, rigid shaft
M ABS-RIII, 8192 PPR super capacitor unavailable
N ABS-RII, 8192 PPR super capacitor unavailable
V ABS-RII super capacitor built-in
L H20M21
X H20M21
HE-02 encoder part numbers are not as well known. The two part numbers that we have seen so far are
listed below:
Part# Description
BS11SEN20SB
MRM21201H 8 poles
2.6.5.3 CONNECTION
Click on the Select Encoder button to make the selection. The Kawasaki serial encoders require the

2. Select Kawasaki from the Encoder Manufacturer dropdown menu.
The Kawasaki motors using H20/M21 encoders are known to come in both 4 and 8 pole versions. Motors
using HE-02 encoders are known to come in 4, 6, and 8 pole versions. The number of poles may be
selected from the POLES dropdown menu.
To determine the number of poles, apply a small voltage to 2 of the armature leads to lock the rotor, and
then count the number of lockup positions to determine the number of pole pairs. For instance, if the rotor
locks up in 4 different shaft positions, the motor has 4 pole pairs or 8 poles.
commutation.
2.6.5.5 TESTING
The model H20M21 is a serial encoder and (like most serial encoders) uses only the Data Display and the
Count Test.
The model HE-02 encoder has both a quadrature pulse section, and a serial section. To completely test these
encoders, the quadrature pulse section should be tested like any standard quadrature pulse incremental
encoder (8,192 counts/rev). Selecting this encoder from the Kawasaki menu allows testing the serial section
using the Data Display and Count Test.
The forward armature direction for Kawasaki motors (like most Japanese motors) is CCW looking at the
drive shaft end.
display.
Use it for the following:

per revolution.
The Fanuc style commutation gray code shown as C1 – C8 (HE-02 only) 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
Kawasaki encoders. 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.
immediately on power up for Kawasaki serial encoders.
The table below shows 3 different lockups which can be used to check or set commutation on motors using
Kawasaki 4 pole and 8 pole motors with H20M21 and HE-02 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.
degrees in the forward direction (CCW looking at the shaft). 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.
Lockup Elect. Angle
-U +V +W 0
+U –V 150
+U –W 210
2.6.5.5.1.2 COUNT
The H20M21 encoders are multi turn encoders in that they keep track of revolutions. The position count is 0
to 8,191 (13 bits) and the revolution count is from -32,768 to 32,767 (16 bits). Since the position count and
revolution count are not synchronized well with each other, they are displayed separated. The position count
is displayed in the COUNT frame, and it will go to 8,191 and then back to 0 to start over (in the decimal
representation).
The HE-02 uses a 0 to 8,191 (13 bit) position count and keeps track of revolutions from -128 to +127 (256
revolutions). This is displayed in the Count frame as 8 more bits of data (above the 13 position bits) as are
most serial encoders.
Serial encoders that include incremental lines, like the HE-02, are tested both as incremental encoders and
serial encoders.
INDEX – The INDEX box is disabled for all Kawasaki serial encoders because these encoders display the
encoder.
INTERNAL ERROR - The information in this box reports on the error bits. The encoder literature for the
H20/M21 describes 3 error bits:
Error Code & Msg Description
BUSY -1553 Encoder initialize Error Unable to determine absolute data on power on.
ABSALM -1556 ABS-track Error Incremental counter data and absolute data do not match.
INPALM -1557 INC-pulse error Incremental A and B pulses are abnormal.
At this time we cannot be sure that the bit locations and identities have been determined correctly, but we
believe that they have. We can force one of the error bits by interrupting the light source in the encoder. We
believe that it is the ABSALM error that is produced in that case. Once the error has been produced in this
manner, cycling powering to the encoder will restore proper operation. It will probably require testing known
bad encoders to verify the error bits absolutely. In any case the Internal bit will display ALARM instead of
OK, if any of the 3 bits monitored go HI.
No error bits have been positively identified for the HE-02 encoder.
BATTERY - The BATTERY box is disabled for Kawasaki serial encoder because they do not utilize battery
backup.
OVERHEAT - The OVERHEAT box is disabled for Kawasaki serial encoders because they do not report
overheat conditions.
ENCODER ID – The ENCODER ID box is disabled as there is no known identification data with the
Kawasaki encoders.
revolution. The Count Test for the Kawasaki encoders is not significantly different from that for other
The stuck bit test will test bit0 to bit12 for activity for 8,192 count 13 bit Kawasaki encoders.
2.6.6 MITSUBISHI SERIAL ENCODERS
The Mitsubishi serial encoders listed in the next section are supported by this selection. Mitsubishi incremental
encoders with A, B, and Z lines should be tested as Generic Incremental encoders.
The following list shows the Mitsubishi encoders that are currently supported by the TI-5000EX:
OBE12 4,096 TI-5027, TI5028

OBA13 8,192 TI-5027, TI5028, TI-5046
OSA14 16,384 TI-5027, TI5028
OBA/OSA17 131,072 TI-5027, TI5028
OSA/OSE104 1,048,576 TI-5012
OSA105 1,048,576 TI-5012
OSA253 1,048,576 TI-5012
The OSA253, OSA105, OSA104 and OSE104 encoders appear to use 20 bits to represent one revolution for
1,048,576 counts per revolution. It could even be inferred that the 104 in the model number could indicate 1.04
million counts. However, some customers have reported that the Mitsubishi literature does not indicate this
many counts per revolution. It may be that all available bits are not used by Mitsubishi equipment. However,
since there seem to be 20 bits in use, the TI-5000EX will report them until a more appropriate way to present
the count is understood. All of these encoders seem to use the same circuit board, so they work virtually
identically. The OSA253 and OSA105 do not seem to have the external overheat lines coming into the
encoders. In this situation, the overheat inputs are jumpered together on the PCB so that the overheat
indication does not go into alarm. Data Display for these encoders displays overheat, battery, and internal error
bits.
The OAH14B and OSA14 are both 16,484 counts/rev, the OBA13 is 8,192 counts/rev, and the OBE12 is 4,096
counts/rev. The numerical part of the model number is apparently the number of bits in the count for one
revolution. There is a battery bit for the OAH14B, OSA14, and OBA13, but there is not even a battery line for
the OBE12. It may be that OBA indicates an absolute encoder where battery backup is used, and OBE does
not use it. Internal error bits are displayed for all of these except the OAH14B for which an error bit is yet to be
identified. None of these encoders show an overheat bit.
The encoders whose part numbers begin with OSA or OSE apparently are the removable type encoders.
They can be removed in one piece from the motor by removing 4 mounting screws. There is a coupling that
connects the encoder shaft to the motor shaft. On most of these encoders, the part number can be seen on
a bar code sticker after the encoder is removed. These stickers are often not visible when the encoder is
mounted on the motor.
The encoders whose part numbers begin with OBA or OBE apparently are the built-in type encoders. These
encoders cannot be removed in one piece from the motor. They must be disassembled from the motor shaft.
Usually these encoders can be identified by markings on the large, square IC (integrated circuit) on the
encoder PCB which can be seen when the encoder cover is removed. An OBA13 encoder will normally
have OBA13 stamped on this IC.
Apparently the OSA17 and OBA17 encoders have the ability to be programmed as other types of encoders.
Currently, when a replacement for an OSA14 encoder is purchased, it will be identified as an OSA17 instead
of OSA14. In most cases it seems to be identified as OSA17-020. In this situation, the OSA14 selection
should be use to read the encoder. In a similar manner, some encoders labeled OBA17 have been found to
respond better to the OBA13 selection. The TI-5000EX now reports an encoder ID field for Mitsubishi serial
encoders. This field provides further support in identifying the correct selection to use for various encoders -
even ones that may be programmed to work like a different part number. Use this encoder ID field to help
verify that you have selected the correct encoder.
2.6.6.3 CONNECTION
listed are known to exist. These may be cables that are made by OEM machine manufacturers using these
encoders.
Click on the Select Encoder button to make the selection. The Mitsubishi serial encoders require the

2. Select Mitsubishi from the Encoder Manufacturer dropdown menu.
Most Mitsubishi motors are 8 pole motors. The number of poles may be selected from the POLES dropdown
menu. To determine the number of poles, apply a small voltage to 2 of the armature leads to lock the rotor,
and then count the number of lockup positions to determine the number of pole pairs. For instance, if the
rotor locks up in 4 different shaft positions, the motor has 4 pole pairs or 8 poles.
commutation.
2.6.6.5 TESTING
Mitsubishi Incremental encoders are tested as Generic Incremental Encoders using Data Display, Line
Levels, Incremental Count Test, and Phase Test for a complete test. Mitsubishi serial encoder types listed
above (like most serial encoders) use only the Data Display and the Serial Count Test.
The forward armature direction for Mitsubishi motors is CCW looking at the drive shaft end.
per revolution.
We strongly recommend using the electrical angle as the superior method of alignment for Mitsubishi
immediately on power up for Mitsubishi serial encoders.
Mitsubishi 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.
degrees in the forward direction (CCW looking at the shaft for Mitsubishi). 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.
Lockup Elect. Angle
-U +V +W 0
+U –V 150
+U –W 210
2.6.6.5.1.2 COUNT
INDEX – The INDEX box is disabled for all Mitsubishi serial encoders because these encoders display the
encoder.
BATTERY - The BATTERY box will show ALARM if there is a battery error alarm and OK if there is not. The
battery alarm will show when the encoder detects a battery voltage of 2.8VDC or less for some encoders
and 3.2VDC or less for others. It is often possible to alternately connect and disconnect battery lines to the
encoder to verify that this bit is working properly. Drive literature indicates that 3.6VDC lithium batteries are
used. The battery line is brought out near the terminal block on the test cable (see test cable charts in
section 2.9 for more info). Connecting a 3.6V source between the line and 0V ground (J1 pin2) should make
the display change from ALARM to OK. There is a time constant associated with the battery bit, and the
battery voltage may need to be applied for a minute or so before the indication changes. Likewise the battery
voltage may need to be removed and the battery input connected to 0V ground for a period of time for the
ALARM indication to return.
OVERHEAT - The OVERHEAT box will show ALARM if there is an overheat error alarm and OK if there is
not. This box will be disabled for encoders for which no overheat is detected, such as the OBA13.
It is often possible to alternately connect and disconnect thermal lines to the encoder to verify that this bit is
working properly This field may not be in effect for all serial encoders. Thermal contacts inside the encoder
complete a circuit to ground when temperatures are within range. When temperatures become excessive,
the contacts open, and the overheat bit is transmitted with the data. Encoders with the circular connectors,
such as the OSA104, bring this circuit out on the RED wires (which do not go to the circular connector). In a
normal installation these wires are connected through other contacts such as motor overload contacts.
These wires can be connected together during testing, and the encoder should not indicate an overheat
condition (providing it is not overheated) with OK. If these wires are disconnected from each other, the
OVERHEAT box column should indicate ALARM.
ENCODER ID – Data from encoders OBE12, OBA13, OSA14, OAH14B, and OBA/OSA17 contains
information that identifies the encoder. For these encoders, ENCODER ID field is enabled but it is disabled
for other encoder types. When the encoder type detected agrees with the encoder type selected, the
ENCODER ID box will show the type detected followed by OK. If they disagree, it will show the type
detected followed by Error. In that case, you should change your selection to match the type that is
indicated. This is especially helpful when you are testing an OSA17-020 encoder that has been programmed
to replace an OSA14. A similar case is an OBA17-052 encoder that has been programmed to look like an
OBA13. It can be difficult to make the correct selection without using the ID information.
revolution. The Count Test for the Mitsubishi encoders is not significantly different from that for other
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.
2.6.7 RENCO ENCODERS
The Renco encoders supported by the TI-5000EX are tested as Generic Incremental Encoders and do not
have a separate test. A section for them is included in this manual because, in the implementation used on
Electrocraft motors, they have an important difference from standard quadrature pulse incremental
encoders.
Renco encoders encountered in servo motor repair are generally quadrature pulse incremental encoders. It is
not uncommon for the Renco encoders to include U, V, and W commutation pulses as well. One such encoder,
the RCH20D-2000/3-8MM-5/0-LD/VC-I-M6-S P/N 79994-004, is used with Electrocraft motors. This encoder is
supported by the TI-5019 cable which will allow it to be tested as a quadrature pulse 8,000 count/rev encoder.
This cable also provides a display of the U, V, and W (also designated S1, S2, and S3 or A, B, and C)
commutation pulses as signals 1, 2, and 3 (4, 5, and 6 unused) in the Data Display function. In addition there is
an analog output line (pin H) which produces distinct voltages for the 6 commutation steps. The commutation
states and corresponding nominal analog voltages should be as follows:
U V W Analog Voltage
(1) (2) (3) (VDC)
H L H 3.30
H L L 2.63
H H L 4.15
L H L 1.40
L H H 2.08
L L H 0.80
When the motor is back driven and the analog voltage is viewed on an oscilloscope, it generates a stair step
pattern. Each change in the stair step corresponds to a change in the commutation lines.
Another Renco encoder used with servo motors is the RHS21D-P1-2000-8MM-5-CS-LD-M1-0-P-S P/N 79994-
023. It may be used with Electrocraft or Giddings and Lewis motors. It produces A, B, and Z pulses but does
not provide commutation pulses. It is supported by the TI-5018 cable which will allow it to be tested as a
quadrature pulse 8,000 count/rev encoder. Note that the pin configuration for the 8 pin Amp connector is
different than the configuration published by Renco for standard RHS series encoders. Standard Renco
encoders use pin 2 for ground. The configuration used for this encoder is apparently proprietary to the motor
manufacturer.
The pin configurations for these Renco encoders are shown in Section 2.5 and may be helpful if you encounter
these encoders.
2.6.8 SANYO DENKI SERIAL ENCODERS
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. The Wire-
saving Incremental types should be tested as incremental encoders.
The following list shows the Sanyo Denki encoders that are currently supported by the TI-5000EX:
Number Type Counts/Rev AB Lines Z Line Cables

INC-E TI-5065
E03007758 8,192 Yes Yes TI-5023, TI5026
E07B111335 ABS-E 2048 2,048 Yes Yes TI-5013
E07B151103 ABS-E 32768 32,768 Yes No TI-5056
E07B151306 32,768 Yes Yes User Fabricated
E10B171103 ABS-E 131072 131,072 Yes No TI-5056
R11G4113A ABS-RII 16,384 No No TI-5036
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.
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.
The 2,048 count Sanyo Denki E07B1113335 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.
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, 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:
2. Click the Select Feedback button and select an incremental encoder with 32,768 counts per turn.
3. 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.
4. Select Sanyo Denki E07B151103 serial encoder again.
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.
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:
2. Click the Select Feedback button and select an incremental encoder with 32,768 counts per turn.
3. 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.
4. Select Sanyo Denki E07B151103 serial encoder again.
The Sanyo Denki R11G4113A encoder is very similar to the E07B151309 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.
2.6.8.2.1.1 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, the
CLEAR SIGNAL line must be connected to 5VDC for 5 seconds to clear the Backup Mode bit. See the
various cable descriptions for identifying the CLEAR SIGNAL line.
Sanyo Denki uses the P series part numbers for 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:
Letter Encoder
S00 Wire saving incremental, 2,000 or 6,000 PPR
S07 Wire saving incremental, 2,048 PPR
SA0 Wire saving incremental, 2,000 or 6,000 PPR, rigid shaft
J Absolute encoder with motor flange of 60 mm or less
A00 ABS-E encoder with motor flange of 76 mm or more
AA0 ABS-E encoder with motor flange of 76 mm or more, rigid shaft
M ABS-RIII, 8,192 PPR super capacitor unavailable
N ABS-RII, 8,192 PPR super capacitor unavailable
V ABS-RII super capacitor built-in
.
2.6.8.3 CONNECTION
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
J1 TB Pin Signal Sanyo Color
1 +5 VDC RED
2 GND BLK
3 A BLU
4 A* BRN
5 B GRN
6 B* VIO
7 Z (or C) WHI
8 Z* (or C*) YEL
9 RX GRN/BLK
10 RX* PUR/BLK
E07B15130
1 +5 VDC RED
2 GND BLK
3 A BLU
4 A* BRN
5 B GRN
6 B* PUR
7 Z WHT
8 Z* YEL
9 RX GRN/BLK
10 RX* PUR/BLK
FREE CLEAR RED/BLK
ABS-E (Request Signal Unavailable)
1 +5 VDC RED
2 GND, BATT GND BLK
3 A WHI/BLU
4 A* BLU
5 B WHI/YEL
6 B* YEL
7 Z (C) WHI/ORG
8 Z* (C*) ORG
9 S WHI/BRN
10 S* BRN
FREE Frame GND WHI/GRN
FREE RES GRN
FREE BATT + WHI/BLK
FREE BATT 0V BLK
ABS-RII (Request Signal Available)
J1 TB Pin Signal Cable Color
1 +5 VDC RED
2 GND BLK, YEL
2 BAT- (0V) PUR
9 ES+ BRN
10 ES- BLU
11 ENCREQH ORG
12 ENCREQL GRN
FREE -5 VDC GRY
FREE BAT+ PNK
FREE ECLR WHI
Click on the Select Encoder button to make the selection. The Sanyo Denki serial encoders require the

2. Select Sanyo Denki from the Encoder Manufacturer dropdown menu.
Sanyo Denki motors come with various number of poles. The number of poles may be selected from the
POLES dropdown menu. To determine the number of poles, apply a small voltage to 2 of the armature leads
to lock the rotor, and then count the number of lockup positions to determine the number of pole pairs. For
instance, if the rotor locks up in 4 different shaft positions, the motor has 4 pole pairs or 8 poles.
commutation.
2.6.8.5 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.
per revolution.
We strongly recommend using the electrical angle as the superior method of alignment for Sanyo Denki
immediately on power up for Mitsubishi serial encoders.
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.
degrees in the forward direction (CCW looking at the shaft for Sanyo Denki). Failure to move the correct
Lockup Elect. Angle
-U +V +W 0
+U –V 150
+U –W 210
2.6.8.5.1.2 COUNT
INDEX – The INDEX box is disabled for all Sanyo Denki serial encoders because these encoders display
the correct count on power up without indexing.
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 bits counts per turn bits may
not be synchronized. When the revolution count goes through zero, the counts per turn may not.
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.
revolution. The Count Test for the Sanyo Denki encoders is not significantly different from that for other
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.
2.6.9 STEGMANN SERIAL ENCODERS
The Stegmann serial encoders listed in the next section are supported by this selection. Stegmann incremental
encoders with A, B, and Z lines should be tested as Generic Incremental encoders. Stegmann encoders used
on Indramat digital motors are discussed in the Indramat section. This section deals with Stegmann
Hiperface and SSI encoders.
The Stegmann AG100 SSI encoder is used on Indramat MAC motors. The AG661 SSI encoder is used on
Siemens 1FT5 series motors. The Stegmann SSI encoders are similar to SSI format encoders from other
manufacturers such as Heidenhain and Hengstler. They use clock and data lines, and there are no
incremental lines.
The newer Stegmann Hiperface encoders are showing up on many brands of motors including Allen
Bradley, Baumuller, Berger Lahr (Telemechanique), Control Techniques, Elau, Modicon, Octacom, Rexroth,
and Sew Eurodrive to name a few. While the details are different, the Hiperface encoders are similar in
function to the Heidenhain Endat encoders. There are serial lines for accessing absolute position data and
memory data, and they use analog 1V p-p sine and cosine signals that can be counted like A and B
quadrature lines. Also like the Endat encoders, there is no index pulse. Without an index pulse, in order to
obtain absolute position information from the incremental count (from the 1V p-p lines), the incremental
count must first be referenced to absolute position data read from the serial lines. Tips are given in later
sections for testing the incremental section on these encoders.
Some Hiperface encoders are specified to operate from 5 VDC, but others are specified in the 7VDC to 12
VDC range. Since even the 5VDC versions will accept up to 12 VDC, it is recommended that the TI-5104
Adapter Module, which provides 8 VDC, be used with the Stegmann Hiperface encoders (Caution: Always
check the rating listed on the encoder label to verify the range!). The 8VDC output is within the correct
range for all Hiperface encoders that we have encountered. The TI-5104 also provides the additional
advantage of amplifying the 1V p-p sine outputs from the incremental lines.
The following list shows the Stegmann serial encoders that are currently supported by the TI-5000EX:

Inc / Pos / Rev
SCS60/70 Hiperface 2,048 / 16,384 / NONE TI-5069 (Generic), TI-5068 (Modicon)

SCM60/70 Hiperface 2,048 / 16,384 / 4096 TI-5069 (Generic), TI-5068 (Modicon)
SRS50/60 Hiperface 4,096 / 32,768 / NONE TI-5069 (Generic), TI-5057 (AB MPF)
TI-5058 (AB MPF),
TI-5064 (AB MPL, 1326)
SRM50/60 Hiperface 4,096 / 32,768 / 4096 TI-5069 (Generic), TI-5057 (AB MPF)
TI-5058 (AB MPF),
TI-5064 (AB MPL, 1326)
AGI100 SSI NONE / 4,096 / 4,096 TI-5061 (Indramat MAC)
AGI661 SSI NONE / 4,096 / 4,096 TI-5061 (Siemens 1FT5)
Note: The first count is the number of counts/rev for the incremental signals, the second is the number of
counts/rev for the absolute serial position count, and the last count is the number of revolutions that can be
counted (for multi turn encoders only).
The Stegmann encoders are normally clearly marked, so identification is not a problem. The TI-5000EX
does currently report an encoder ID field for Hiperface serial encoders, and this will help assure that the
correct selection has been made. The SSI encoders are not known to have ID capability.
2.6.9.3 CONNECTION
Connection requires using the correct cable as shown in the chart in the Menu List section. The TI-5069
generic cable connects directly to the 8 pin connector on the encoder, so it should work with all Hiperface
encoders. The cable pin configurations are documented in the appendix of this manual. Cable configurations
other than the cables listed are known to exist. There may be cables that are made by OEM machine
manufacturers using these encoders.
If properly cabled, the Stegmann Hiperface encoders can be used with the TI-5104 Adapter Module so that it
is easier to check the incremental portion with the same connection. See the section on cables for more
information.
Click on the Select Encoder button to make the selection. The Stegmann serial encoders require the

2. Select Stegmann from the Encoder Manufacturer dropdown menu.
4. Select a Motor Manufacturer name if Memory support exists and you have purchased it.
The encoder types listed in the current software revision are shown in a preceding section.
The number of poles may be selected from the POLES dropdown menu. To determine the number of poles,
positions in one revolution to determine the number of pole pairs. For instance, if the rotor locks up in 4
different shaft positions, the motor has 4 pole pairs or 8 poles.
commutation.
2.6.9.5 TESTING
Stegmann incremental encoders are tested as Generic Incremental Encoders using Data Display, Line
Levels, Incremental Count Test, and Phase Test for a complete test. Stegmann serial encoder types listed
above (like most serial encoders) use only the Data Display, Serial Count Test and Memory Test if they
have memory.
per revolution.
3. 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 electrical angle is best for checking and setting commutation. 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 position count is absolute immediately on power
up for Stegmann Hiperface and SSI serial encoders. The Indramat MAC and Siemens motors, that use the
Stegmann SSI encoders, use Hall effects for motor commutation, so the encoder does not need to be
aligned for commutation purposes.
The method of alignment for Hiperface encoders will vary with motor manufacturer. The table below shows 2
different lockups that can be used to check or set commutation on Allen Bradley motors with Hiperface serial
encoders.
The 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 (CW looking at the shaft for Allen Bradley). Failure to move the correct
Lockup Elect. Angle
+U –V 110 (lockup angle read from the memory test – see memory section)
+U –W 170 (lockup angle read from the memory test – see memory section)
Unlike most feedback alignment discussed in this manual, Allen Bradley MPL, MPF and 1326 motors using
Hiperface encoders do not have a common lockup angle, and in general, they will all lock up at different
angles. These motors store a commutation offset in the encoder memory. By using the commutation offset,
the encoders do not have to be set to a common alignment. In order to correctly check or set the alignment,
you have to run the Memory Test on the encoder, and write down the +U –V and +U –W lockup angles
provided by the memory test.
2.6.9.5.1.2 COUNT
As mentioned previously, the Hiperface encoder provides an incremental count using the 1V p-p analog
signals. This count is shown in the Incremental Count frame. This count may be zeroed at any time by
pressing the Zero Count button. The SSI encoders do not provide an incremental count
The Revolution and Position Count frame displays the absolute position count as a decimal number in the
POS COUNT box. This count will range from 0 to counts/rev -1. Multi turn encoders will provide a
revolutions count as a decimal number in the REV COUNT box. This box is disabled for single turn
encoders. The HEX COUNT box will display, in hexadecimal format, the position count (for single turn
encoders) and a composite position and revolutions count (where the revolution LSB is the next bit above
the MSB of the position count for multi turn encoders). Most users will be interested only in the decimal
count, but encoder repairmen and other advanced users may find the hexadecimal representation useful. In
general the absolute count numbers will not be zero on power up. Because it is an absolute encoder, 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.
As an example of single and multi turn model numbers, the SRS50/60 encoders are single turn encoders in
that they do not keep track of revolutions. The SRM50/60 encoders are multi turn encoders, and they will
keep track of 4,096 revolutions. The “S” and “M” in the names designate single and multi turn respectively.
Typically serial encoders that include incremental lines are tested both as incremental encoders and serial
encoders. Since the Stegmann Hiperface serial encoders do not include an index pulse, an incremental
encoder count test cannot be performed. Comparing the incremental count with the absolute count provides
a possible method of also checking the integrity of the incremental count. The procedure is as follows:
1. Move the shaft until the absolute position count in the POS COUNT box reads 0.
2. Click the Zero Count button to force the incremental count to 0.
3. Turn the encoder 10 revolutions. With multi turn encoders, you can use the data in the REV
COUNT box to keep track, but you will just have to count revolutions for single turn encoders.
4. Adjust the shaft to get as close as possible to 0 in the POS COUNT box.
5. Write down the incremental count in the INCREMENTAL box. It should be very close to 10 times
the number of incremental counts/rev.
encoder. There is no good way to determine whether data is being received from the Stegmann SSI
encoders, so the DATA box is not implemented for those selections.
Stegmann literature lists the causes for alarms which are detailed in the following discussion of error type.
ERROR TYPE – When the Hiperface encoder produces an internal alarm, a code indicating the cause of the
alarm may be read from the encoder. This code is displayed for Hiperface encoder alarms. For other types
of encoders, the error type is displayed if it is known. The following list of errors applies to the Hiperface
encoders:
Code Type Description

00H No error
01H Initialization Analog signals outside specification
02H Initialization Internal angle offset erroneous
03H Initialization Data field partition table destroyed
04H Initialization Analog limit not available
05H Initialization Internal I2C bus not serviceable
06H Initialization Internal checksum error
07H Protocol Encoder reset has occurred as a result of program monitoring
09H Protocol Parity error
0AH Protocol Checksum of the transmitted data is wrong
0BH Protocol Unknown command
0CH Protocol Number of data transmitted wrong
0DH Protocol Command argument transmitted is impermissible
0EH Data Data may not be written to the data field selected
0FH Data Wrong access code
10H Data The size of the specified data field cannot be changed
11H Data Specified word address outside data field
12H Data Access to non-existent data field
01H Position Analog signals outside specification
1FH Position Speed too high, position formation not possible
20H Position Position of single-turn impermissible
21H Position Position error, multi turn
28H Position Error absolute valued formation linear measurement system
1CH Other Monitoring the magnitude of the analog signals (process data)
1DH Other Critical encoder current (contamination, transmitter breakdown)
1EH Other Critical encoder temperature
08H Other Counter overflow
ENCODER ID – The ENCODER ID will indicate the type of Hiperface encoder in use based on the ID
code read from the encoder. This box will be disabled for other types of encoders that do not provide ID
data.
2.6.9.5.1.4 MEMORY STATUS
The Read Memory Status button on the Data Display allows the user to check whether memory is currently
in use for a particular encoder. Clicking the button when connected to an SRM50 encoder on an Allen
Bradley MPL motor would produce the following display:
Memory Status
Field WE AC# CE Bytes
0 YES 0 NO 32
1 YES 0 NO 32
2 YES 0 NO 32
3 YES 0 NO 32
4 Undefined field 0
5 Undefined field 0
6 Undefined field 0
7 Undefined field 0
Total bytes used 128
Total bytes unused 0
Total used + unused 128
This tells us that there are 4 memory fields of 32 bytes each defined in this encoder. All 4 fields are write
enabled (WE). The access code is set to 0 (could be 0, 1, 2, or 3). The code enable bit (CE) is not set for the
4 defined fields, so the access code does not have to be used. The total bytes number of memory bytes
used is 128. The total bytes unused is 0, and this means that all of the available memory is in use. No more
data fields could be defined for this memory because it is used up.
This data formatting is done by the motor manufacturer and is of little concern to the TI-5000EX user.
However, it is useful to look at it to verify that the memory looks normal. For instance if you see that no fields
have been defined for an encoder on an Allen Bradley MPL motor, it is very likely that the encoder has been
replaced and the correct data has not been programmed into the memory. This would be very important to
know because the motor would not run correctly on the Allen Bradley drive. It is also useful to check on
unfamiliar motors to determine whether the motor manufacturer is using the memory.
This Memory Status data is automatically included on the Data Display report when a Stegmann Hiperface
encoder has been selected.
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 Stegmann 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. The slow data rate from the Hiperface encoders will make the errors somewhat larger than
typical serial encoders. Turning the encoders very slowly will help reduce the errors.
2.6.9.5.3 MEMORY TEST
As explained previously, the Stegmann Hiperface encoders include a memory device like Heidenhain Endat,
Indramat, and some other encoders. Various models of Hiperface encoders are used on many different
brands and models of motors. Some motor manufacturers make use of the encoder memory, and others do
not. For instance, the encoder memory does not appear to be used on fLI-M100 and L1070 model Baumuller
motors. However, it is used on Allen Bradley MPL, MPF, and 1326 type motors. As explained previously, the
Read Memory Status button on the Data Display can be used to determine whether the memory is in use.
When the memory is used, it will normally be programmed with the motor model number and sometimes
motor parameters. The drive can read this memory data on power up and determine what kind of a motor is
connected to it. Some manufacturers, such as Allen Bradley and Indramat, are now programming a
commutation offset value into the memory. This offset tells the drive the difference in the present feedback
alignment from the ideal feedback alignment so that the drive can adjust its timing to compensate for an
imperfectly aligned feedback device. This relieves the manufacturer of performing a precise alignment
during manufacturing. They simply program in the offset for the drive to read. This means that each motor
may be aligned somewhat differently, but the repair shop must still align the feedback the way the drive is
expecting it to be. The TI-5000EX memory support will display the proper alignment angles based on this
memory data so that the repair technician can properly align the feedback.
Because the way in which the memory is used differs with the various motor manufacturers, software
support must be developed for each brand (and sometimes models) of motors. Therefore TI-5000EX
memory support must be purchased for each motor type in addition to the basic Stegmann encoder support.
2.6.9.5.3.1 ALLEN BRADLEY MEMORY TEST
Allen Bradley MPL, MPF and 1326 motors use the Hiperface encoder memory to store motor parameters.
This data is programmed at the factory and cannot be changed by the drive. This data is read by the drive
system on power-up prior to moving the motor. If the drive system cannot read the memory or if it gets
incorrect data from it, the motor will not run. It is therefore very important to verify that the memory can be
read and appears to be correct. The memory also contains information that allows checking the
commutation alignment.
In verifying correct memory data and memory operation, we are looking at two things:
1. Is the data correct and not corrupted?
2. Is it the correct data for this motor?
The first item is done automatically. The data in the encoder is encoded with the ability to check data
integrity. The TI-5000EX does this automatically as it reads and displays the various motor parameters. Any
incorrect data in one of the data blocks will result in an incorrect checksum calculated for that block. This will
be reported with the text “Error” followed by the calculated checksum and then the data from the checksum
field. The word “Error” is all you need to see to know that the information is correct. If the data is correct, the
checksum field will show the text “OK”. We do not know what the drive requirements are, but the logical
guess is that if a checksum error occurs, the drive will not run the motor. Experience so far indicates that it is
somewhat rare for the encoder memory to actually have a problem. Many things such as a bad encoder
cable, incorrect connection of the TI-5000EX, etc. could cause a bad data read. Especially if you are
unfamiliar with testing Allen Bradley motors, you might check with Mitchell Electronics, Inc. if you have an
encoder (or several encoders) that do not read the data correctly.
The second item amounts to making sure that the encoder that is on the motor is the correct one.
Sometimes in trouble-shooting, encoders get swapped in an attempt to isolate a problem, and the encoder
on the motor you have could be the wrong one entirely. In general the data from the encoder should match
the data from the motor nameplate. In this regard, we are looking for gross errors. Minor differences in the
encoder data and nameplate data are normal.
The display shown below is a memory test from an SRM50 encoder. The motor type number and motor
parameters are fairly self explanatory. These numbers should match reasonably well with the nameplate
data. At the end of the right column is some information that is useful to the repairman. The number of pole
pairs is 4, which indicates a, 8 pole motor. This may not be universal, but it appears that the MPL and MPF
motors are 8 poles, while the 1326 motors are 4 poles.
The TI-5000EX uses the commutation offset (not shown) to calculate what the +U –V and +U –W lockup
angles should be in electrical degrees for proper feedback alignment, and these angles are reported in the
Derived Data frame.
Name Plate data:

CAT NO. MPL-A310P-MK22AA
SERIAL NO. H000659
STALL TORQUE 1.58 Nm
MAX SPEED 5000 RPM
RATED OUTPUT 0.73 KW
Comparing the above nameplate data to the encoder data below, we see that the data agrees quite well.
The data from this screen may be saved or printed as a report either in the usual manner with the Save
Report to File or Print Report buttons.
The Diagnostic File button may be used to save a copy of the data to a disk file as Intel hexcode. You may
wish to do this to send to Mitchell Electronics, Inc. in the event that there might be a question about the data.
You may also wish to have a copy in case you would need to program it into a new encoder.
2.6.10 SUMTAK SERIAL ENCODERS
The Sumtak serial encoders listed in the next section are supported by this selection. Sumtak incremental
encoders with A, B, and Z lines should be tested as Generic Incremental encoders.
The following list shows the Sumtak encoders that are currently supported by the TI-5000EX:
AEC/AEM 2048 2,048 TI-5013
The Sumtak AEC/AEM 2048 serial encoder is essentially the same as the Sanyo Denki E07B111335.
Please refer to that section of the manual for further information at this time.
2.6.11 YASKAWA ENCODERS (ALLEN BRADLEY)
The Yaskawa encoders supported by the TI-5000EX are tested as Generic Incremental Encoders and do
not have a separate test. A section for them is included in this manual because they have a number of
important differences from standard quadrature pulse incremental encoders.
There are 3 major types of Yaskawa quadrature type incremental encoders (A, B, and Z lines), and there are
serial encoders used on the newer Sigma II motors. The quadrature type encoders are supported by the TI-
5000EX, but support for the serial encoders is not yet available. The TI-5000EX does include a Yaskawa
selection, but some of the encoders should be tested using the Generic Incremental Encoder selection.
The 3 major types of Yaskawa encoders currently supported are fundamentally quadrature type, but they
have some differences from the typical and require some special treatment. Part numbers often are not
clearly marked on the encoder boards, so identification is not always easy. Often there will be an encoder
part number on the encoder cover. This section will include part numbers associated with the encoders and
motors, and signal lines shown in the cable documentation can be used as an aid in identifying the
encoders.
Yaskawa encoders are used on Allen Bradley 8500 Series Digital Servo Motors. See the following section
on absolute encoders when working with Allen Bradley motors.
ABZ & UVW various TI-5015

ABC C Channel 16,384, 32,768 TI-5014, TI-5025
ABC Absolute 4,096, 32,768 TI-5017, TI-5024, TI-5039, TI-5041,
TI-5044
2.6.11.2.1 QUADRATURE INCREMENTAL WITH 3 COMMUTATION CHANNELS
One Yaskawa incremental style includes 3 commutation true lines and 3 commutation complement lines (U,
U*, V, V*, W, W*). A typical part number for this type of encoder would be UTOPI-600VA. As per the chart in
the identification section, these are 24,000 counts per revolution. This is the simplest, most straight-forward
type of Yaskawa encoder. Many other encoder brands on the market work in a similar manner, and this type
can be tested simply as a quadrature pulse incremental encoder. By connecting the commutation lines to
the their respective inputs on J2, the commutation line states can be displayed while setting commutation.
This encoder is supported by the TI-5015 Cable which is documented in Section 2.5. Part numbers for this
type of encoder will start with UTOP whereas part numbers starting with UTOMA would be absolute
encoders. If a count test can be performed satisfactorily using the TI-5015 cable and the commutation lines
are being displayed properly, then this encoder has most likely been properly identified.
2.6.11.2.2 QUADRATURE INCREMENTAL WITH SINGLE C COMMUTATION CHANNEL
The second Yaskawa incremental encoder type multiplexes the 3 commutation signals onto one pair of lines
-C and C*. Some typical part numbers for this type encoder are: UTOPH-81AWF, UTOPH-40AWM,
UTOPH-81AUS, and UTOPI-81AUS. Part numbers for this type of encoder will start with UTOP whereas
part numbers starting with UTOMA would be absolute encoders. The state of the single pair of C channel
lines represents Z, U, V, or W depending upon the states of the A and B lines. As the encoder is rotated and
the A and B line states change, the information represented by the C and C* lines changes as well. It is very
difficult to visually decode this information with an oscilloscope, but the TI-5000EX equipped with a TI-5103
Yaskawa Adapter Module, can convert the C channel information to U, V, W, and Z signals so you can test
this encoder as a standard incremental encoder. The TI-5103 decodes the information from the C and C*
lines in hardware, and routes the U, V, W, and Z signals out on separate lines which can be connected to
the TI-5000EX and/or viewed with an oscilloscope (such as with the TI-5250 Signal Breakout Box).
Some of these encoders utilize a 17 pin circular connectors and bring out an index pulse on the K and L
lines. In such cases where the index pulse is provided, the encoder can be tested as an incremental
encoder without the TI-5103, but the commutation information cannot be tested without the TI-5103. Some
motors, such as an SGM-08U3B4L, bring the encoder signals out on a 9 pin AMP connector. The 9 pins are
only enough to provide +5 V, GND, A, B, C, and their complements. Since there is no separate index pulse
provided, and the index pulse must come from the C and C* lines, the TI-5103 Yaskawa Adapter Module is
absolutely necessary for these encoders. For the 17 pin connectors, you must use the TI-5014 Cable which
is documented in Section 2.5. If the encoder is using the 9 pin AMP connector, use the TI-5025. There may
be other types of connectors in use, and a user fabricated cable must be used in those cases.
You may encounter some C Channel encoders made by Sony Magnescale, and these have some
peculiarities. For other Yaskawa encoders, there is a definite relationship between the commutation pulses
and the index (Z) pulse. The position where the index pulse occurs will be very close to one of the positions
where the U commutation pulse changes state, the V commutation pulse is LO and the W commutation
pulse is HI. For a correctly aligned encoder, this would occur near the –U +V +W lockup position. This
relationship between the index pulse and the commutation signals apparently does not exist for the Sony
Magnescale encoders. In fact, in several different motors of this type that we have investigated, no
relationship was found. The positioning of the index pulse relative to the commutation pulses appeared to be
random. Normally, you can use the index pulse to align Yaskawa motors, but we believe that using the
commutation pulses is the correct method for motors using the Magnescale encoders. Motors using these
encoders tend to be very small. A representative part number is SGM-A5A3TF11X.
2.6.11.2.3 ABSOLUTE ENCODERS
The third type of Yaskawa encoder is commonly referred to as an absolute encoder. Some of these
encoders are used on Allen Bradley 8500 Digital Servo Motors. Typical part numbers for absolute encoders
are UTMAH-B15ASB, UTMAH-B15BSB and UTMAH-B15A5B1. The part number always starts with UTMA
instead of UTOP, so they are more easily identified than the first two types discussed. The absolute
encoders are available in at least 4 different numbers of counts/revolution: 4,096 (2 to the 12th), 32,768 (2 to
the 15th), 65,536 (2 to the 16th), and 131,072 (2 to the 17th). The motor model SGM-04VW14B is an
example of a 4,096 count/rev encoder. The 32,768 count/rev. encoders are often called 15 bit absolutes.
The 16 and 17 bit ABS encoders are serial encoders and are not currently supported by the TI-5000EX.
These encoders are called absolute encoders because they are capable of long term backup by an external
battery and short term backup by internal capacitors. Like any quadrature encoder, the A and B quadrature
pulses are used by external equipment to maintain a position count. However this count is also maintained
in an internal counter and retained via battery backup when the normal power supply to the encoder is
turned off. Two counts are maintained internally – a position count and a revolutions count.
The basic encoder tests may be run on Absolute encoders by either selecting them from the Yaskawa types
if you have the TI-5000Y Yaskawa Option or from Generic Incremental Encoders if you do not. If you have
the TI-5000Y Yaskawa Option, the U, V and W states which are derived from the count will be shown on the
Data Display and can be used for feedback alignment. If you do not have the Yaskawa Option you can use
the electrical angle display available in the Data Display for commutation alignment. The forward armature
direction for Yaskawa motors is CCW facing the shaft. The Data Display will show the encoder angle
increasing in the same direction when a Yaskawa ABS encoder has been selected (TI-5000Y option), but
the encoder angle will increase in the opposite direction if the Generic Incremental Encoder selection has
been made. This could be a source of confusion. Using the –U +V +W lockup for the zero angle will help
because the zero angle will be in the same position for both the Yaskawa selection and the Generic
Incremental Encoder selection.
The TI-5000EX cannot provide correct commutation information until the encoder has been indexed. If
during the course of working with an absolute encoder, you have any reason to believe the index has been
disturbed (such as powering down the encoder and moving it), you should force a new index by pressing the
“Zero count on next index” button, verifying that the prompt in the INDEX box changes to ALARM, and
moving the encoder until the ALARM prompt in the INDEX box changes back to OK.
Even though 32,768 count/rev encoders are fairly high resolution the high speed processing of the TI-
5000EX allows Incremental Count Tests to be performed accurately to 3,000 RPM for these encoders.
2.6.11.2.3.1 ABSOLUTE ENCODER UPDATE TEST
As mentioned previously, the absolute encoders will send a position count and a revolution count to the
drive to update it to the proper absolute position on power-up. The revolution count is sent as serially
encoded data on the A line. Testing of the revolution count update is not supported on the TI-5000 at this
time. A position count of up to 32,768 is also sent at power-up as quadrature A and B edges. This updates
the drive as to the correct angular encoder position on power-up so that the drive can properly commutate
the armature lines and provide startup torque to the motor. This is important because normally an
incremental encoder cannot provide absolute position information to the drive until the motor has moved the
encoder past the index pulse. Since there are no commutation pulses, this is the only way the drive can
figure out how to commutate the motor.
Using the TI-5103 Yaskawa Adapter Module and the TI-5000Y Yaskawa upgrade option, it is now possible
for the TI-5000 to check for a correct position count update. The procedure is very straightforward:
1. Using the TI-5017 (or other absolute encoder cable), connect the absolute encoder into the
TI-5103, and connect the TI-5103 to the TI-5000. Make sure that the TI-5103 JS1 jumper is
removed.
2. Power up the TI-5000, and select the correct absolute encoder from the Yaskawa menu.
3. Select Data Display from the Encoder Test Menu, and rotate the encoder until it indexes.
4. Turn the encoder manually approximately ¼ revolution in the direction to produce a positive
count, stop turning, and click on the Cycle Power button to cycle the power to the encoder.
5. After a few seconds when the data appears in the Before Cycle and Cycle Update columns,
make sure that the two numbers do not differ by more than about 8 counts.
You may wish to re-index the encoder and repeat the test by turning the encoder ¾ revolution in step 4 just
to make sure everything looks good. We believe that a difference of 8 counts in these two numbers is a
good tolerance, but there is not a lot of experience at this time. This tolerance may be updated as
experience is gained with this test.
The encoder will no longer be properly indexed after executing this test, and the ALARM prompt will appear
in the Indexed column. Rotate the encoder until the ALARM prompt changes to OK before proceeding with
other operations.
2.6.11.2.3.2 ABSOLUTE ENCODER RESET PROCEDURES
You may encounter an absolute encoder, try to test it as an incremental encoder, and find that it is not
producing any quadrature pulses. Assuming it is a good encoder, this probably means the encoder is in
need of a reset. It may be due to not having a battery connected for so long that it loses its retained count,
but in any case, absolute encoders can get into a condition in which they will not produce quadrature pulses
(and therefore cannot be tested) until a reset procedure is performed. The reset procedure is different for a
12 bit versus a 15 bit ABS encoder. The procedure for the 15 bit encoder usually goes smoothly. The 12 bit
encoders seem to be harder to reset for some reason.
15 BIT:
On the sample 15 bit encoders we have used, there are two LED indicators on the top and bottom of the 2nd
encoder printed circuit board. The top LED (1LED) seems to come on and go off during power up when the
encoder is working normally. The bottom LED (2LED) seems to flash twice while the 1LED is ON. This
probably corresponds with the 2 bursts of data coming from the encoder to update the drive and computer.
When the encoder is in need of a reset, 1LED will turn ON when the power comes on, but it will not turn right
back OFF like normal. Also in this condition, no quadrature pulses will be generated as the encoder is
rotated. In this case, the encoder must be given a RESET and be supplied with a battery backup. The reset
procedure is as follows:
1. Disconnect all power from the encoder. Connect a shorting jumper from pin R to pin S, and leave it
connected for a minimum of 4 minutes.
2. Disconnect the jumper from pin R to pin S after 4 minutes, and connect a battery (or 5 V supply)
with + to pin T and ground to pin S.
3. Proceed to power up the encoder in the normal manner.
When the encoder powers up, the LED indicators should behave in the normal manner, and the encoder
should produce quadrature pulses when it is rotated. On the first power-up after RESET, it seems to be very
important that a voltage be connected to the battery pins before voltage is applied to the normal 5 volt pin.
The encoder seems to have some built-in logic that will not allow it to work without this voltage. However, it
appears to be required only on the first power-up, and subsequent power-ups apparently work fine without
the battery voltage as long as the internal capacitors have not lost their charge. This procedure should
cause the encoder to produce quadrature pulses and allow you to perform all the normal tests with the TI-
5000EX tester. The TI-5017 Cable is designed for the 15 Bit ABS encoder and brings out the lines required
to perform this procedure.
12 BIT:
There is a second reset procedure which is required for 12 Bit Absolute encoders. The pin configuration is
identical to the 15 Bit Absolute except for the addition of S and S* lines on pins K and L respectively. This
encoder is also supported by the TI-5017 Cable. These encoders can be tested as 4,096 count/rev
quadrature pulse encoders. Like the 15 bit, they may require a reset before they produce pulses for testing.
The procedure that seems to work is similar to but a little more complex than the 15 Bit Absolute. The
procedure that has worked for us is as follows:
1. With the encoder powered down, connect a battery (or 5 V supply) with + to pin T and ground to pin
S.
2. Connect a shorting jumper from pin R to pin S, and leave it connected for a minimum of 4 minutes.
3. Disconnect the jumper from R to S and connect a shorting jumper from pin R to pin T (that is to the
battery or 5 V supply) for 4 or 5 minutes.
4. With the jumper still connected from pin R to pin T, power up the encoder in the normal manner.
5. Disconnect the jumper from pin R to pin T. Cycle the power, and the encoder should power up with
the LED flashing green then off. The encoder should produce A, B, and Z pulses. If the Red LED
does not go off, try cycling the power again.
Notes:
1. Make sure that you leave the battery voltage connected after the reset. If you remove that battery
voltage, you will have to repeat the reset procedure.
2. It seems to be common for this procedure not to work the first time. You may have to repeat the
procedure. I think you can probably repeat steps 3 – 5 rather than going all the way back to step 1.
Going back to step 1 is fine, but it does take longer.
3. The R, S and T pins refer to the 17 pin circular connector. If you have a 12 or 15 pin rectangular
AMP connector (other something else), you will need to use the same functional lines. The following
table should help with that:
17 Pin connector Pin Function Yaskawa Color
R Reset WHI/GRY
T 3.6V Batt ORG
S 0V Batt ORG/WHI
These are the colors that seem to be used in most cases by Yaskawa.
Some further description of the part numbers may be helpful. The following description will not cover all
encoders, but hopefully it will help identify many of them. We can work from an example – the UTOPH-
600UBXXX. The UT indicates a special detector which is an encoder for AC servo motors or AC spindle
motors. The OP designation indicates incremental encoder (optical encoder) types as opposed to the MA
designation for the absolute encoder (multi-turn). The H means coupled with a plate spring for the motor,
whereas E means coupled with couplings for the motor and I means built-in. The 600 indicates the number
of pulses per revolution. The number of pulses per revolution and the corresponding number of counts per
revolution (which is 4 times the pulses per revolution) is indicated in the following chart:
Incremental Encoders
Code Pulses/Rev Counts/Rev Code Pulses/Rev Counts/Rev

100 25,000 100,000 B50 25,000 100,000
150 1,500 6,000 05A 500 2,000
200 2,000 8,000 10A 1,024 4,096
250 2,500 10,000 20A 2,048 8,192
300 3,000 12,000 40A 4,096 16,348
400 4,000 16,000 81A 8,192 32,768
500 5,000 20,000
600 6,000 24,000
Absolute Encoders
Code Bits/Rev Counts/Rev

B12 12 4,096
B15 15 32,768
B16 16 65,536 (serial – not supported)
B17 17 131,072 (serial – not supported)
The UB is the name of the encoder series. The last 3 numbers (indicated by XXX in the example) have to do
with the cable length, connector type, customer spec., version, etc.).
The 16 and 17 bit absolute encoders are serial encoders, and are not supported by the TI-5000EX at this
time.
2.6.11.3 CONNECTION
Connection requires using the correct cable as described in preceding sections. The cable pin
listed may exist. These are likely cables that are made by OEM machine manufacturers using these
encoders.
2.6.11.4 SETUP
Except for differences noted in preceding sections, the Yaskawa encoders are tested like any other Generic
Incremental Encoder. Please refer to the sections pertaining to Setup for Generic Incremental Encoders for
further details.
2.6.11.5 TESTING
Except for differences noted in preceding sections, the Yaskawa encoders are tested like any other Generic
Incremental Encoder. Please refer to the sections on Generic Incremental Encoders for further details on
testing.
The forward armature direction for Yaskawa motors is CCW looking at the drive shaft end.
per revolution.
The following sections describe information shown on the display. Refer to the section on Generic
Incremental Encoders for more information on the Data Display.
The Yaskawa encoders all can be aligned using either the commutation pulse display or the electrical angle.
For the current software revision, the number of poles on the ABS motors must be 8, and the selection is
forced to 8. Also keep in mind that the forward direction of the encoder (direction of increasing count), CCW,
is opposite the forward armature direction, CW, for the Yaskawa motors. This can be a little confusing, but it
should not be a problem if the alignment is performed where the angle is zero as shown below.
The U, V, W and the C Channel encoders (using the TI-5103 Yaskawa Adapter Module) will use the Generic
Incremental Encoder selection where the U, V, W comm. pulses and their complements will be displayed as
H1 through H6. Since the ABS encoders do not produce commutation pulses, the TI-5000EX software
creates them for display purposes from the encoder count. Since it uses the count, it is very important that
the selection with the correct number of counts per revolution be selected.
The following table shows several alignment possibilities.
Lockup Electrical Angle H1(U) H2(V) H3(W)
-U +V +W 0
+U -V -W 180 H→L H L
2.7 RESERVED
2.8 ACCESSORIES
Please consult the latest price sheet or call for ordering information concerning options and accessories for the
TI-5000EX.

2.9 PIN CONFIGURATIONS AND REFERENCE INFORMATION
See Figure 2.1 for the connector locations on the enclosure.
Table 2.1 Main I/O Terminal Block, J1 Pin Configuration
TI-5000EX TB Header J1 Signal Parallel Absolute Signal
1 VCC VCC
2 GND GND
3 AIN+ BIT9
4 AIN-
5 BIN+ BIT8
6 BIN-
7 ZIN+ BIT6
8 ZIN-
9 SERIN+ BIT7
10 SERIN-
11 SEROUT+
12 SEROUT-
13 NC
14 NC
Note: Pin 1 is at the end of the terminal block closest to the power supply connector.
Table 2.2 Auxiliary I/O Terminal Block, J2 Pin Configuration
TI-5000EX TB Header J2 Inc/Ser Parallel Absolute Signal Output
1 AOUT+
2 AOUT-
3 BOUT+
4 BOUT-
5 ZOUT+
6 ZOUT-
7 COMM1 BIT0
8 COMM2 BIT1
9 COMM3 BIT2
10 COMM4 BIT3
11 COMM5 BIT4
12 COMM6 BIT5
Note: Pin 1 is at the end of the terminal block closest to the end of the case and adjacent to J1.
Table 2.3 Power Supply Connector, J3 Pin Configuration
Connection Signal
Inner conductor GND

Outer conductor +9 VDC
Table 2.4 RS232 DCE Ports 0 and 1, J6 Pin Configuration
Serial Header DB9 Signal
1 1 CD0 (Out handshake)

2 6 DSR0 (Out handshake)
3 2 RD0 (Data output)
4 7 RTS0 (In handshake)
5 3 TD0 (Data input)
6 8 CTS0 (Out handshake)
7 4 DTR0 (Opt In handshake)
8 9 RI0 (Out handshake)
9 5 GND0
10 NC
11 1 CD1 (Out handshake)
12 6 DSR1 (Out handshake)
13 2 RD1 (Data output)
14 7 RTS1 (In handshake)
15 3 TD1 (Data input)
16 8 CTS1 (Out handshake)
17 4 DTR1 (Opt In handshake)
18 9 RI1 (Out handshake)
19 5 GND1
20 NC
Notes: 1. Signals are referred to the DTE end, as is the normal convention. The TI-5000EX is a DCE
device.
Table 2.5 USB Connector, J9 Pin Configuration
USB Connector Pin Signal
1 VCC
2 DATA-
3 DATA+
4 GND
Table 2.6 Control Connector, J10 Pin Configuration
Connector J10 Signal
1 U
2 V
3 W
4 ENABLE
5 ENABLE*
6 5V/9V
7 BRAKE
8 GND
Table 2.7 Can Bus Connector, J11 Pin Configuration
Can Bus Connector Pin Signal
1 CAN LO
2 CAN HI
3 GND
Table 2.8 Resolver, J12 Pin Configuration
TI-5000EX Terminal Block J12 Signal
1 GND
2 EXC
3 EXC*
4 COS
5 COS*
6 SIN
7 SIN*
Table 2.9 TI-5007 Fanuc ABS Pulsecoder Connections & J1/J2 Pin Configuration
J1 TB Pin J2 TB Pin Signal MS3106A22-14S
1 +5 VDC L
2 GND M
3 A A
4 A* B
5 B C
6 B* D
7 Z E
8 Z* F
7 C1 G
8 C2 H
9 C4 J
10 C8 K
Notes: 1. Used with Fanuc ABS Pulsecoders such as A860-0320-T112-2500P, A860-0326-

T103 3000P, etc.
Table 2.10 TI-5004, TI-5005, TI-5005W, TI-5006 Fanuc Pulsecoder Connections & J1 Pin Configuration
TI-5004 TI-5005 TI-5006

J1 TB Pin Signal MS3106A22-14S MS3106A20-29S(W) DB15
1 +5 VDC L J, K 8, 15
2 GND M N, T 1, 2, 3
9 SD A A 12
10 SD* B D 13
11 REQ E F 5
12 REQ* F G 6
FREE BATT+ T R 14
Notes: 1. TI-5004 – 19 pin Pulsecoder A uses MS3102A22-14P connectors.

2. TI-5005 – 17 pin Pulsecoder C and Pulsecoder A use MS3102A20-29PW
connectors.
3. TI-5005 – 17 pin Alpha series Pulsecoders uses MS3102A20-29P connectors.
4. The "W" indicates the polarization of the MS3102A20-29P.
5. TI-5006 – 15 pin Pulsecoder Alpha, A & C use DB15 connectors.
Table 2.11 TI-5008 Mitsubishi OSA104/OSE104 Serial Encoder & J1 Pin Configuration
J1 TB Pin Signal MS3106A22-14S
1 +5 VDC S
2 GND R
9 SD H
10 SD* J
11 REQ K
12 REQ* L
BATT E
Table 2.12 TI-5010 Heidenhain RON3350 & ERN1387 Encoder & J1 Pin Configuration
J1 TB Pin Signal 29169726
1 +5 VDC 10
2 GND 7
3 A 1
4 A* 2
5 B 11
6 B* 12
7 Z 3
8 Z* 13
9 C 5
10 C* 6
11 D 14
12 D* 4
Note: Must be used with the TI-5101 1 V p-p Adapter Module to read C and D channels.
Table 2.13 TI-5011 Kawasaki H20/M21 4 Pin Encoder & J1 Pin Configuration
J1 TB Pin Signal 4 Pin Connector
1 +5 VDC 2
2 GND 1
9 SD 4
10 SD* 3
11 REQ 4
12 REQ* 3
Table 2.14 TI-5012 Mitsubishi OSA14 Encoder & J1 Pin Configuration (Discontinued)
J1 TB Pin Signal MS3106A20-29S Cable Color
1 +5 VDC S RED
2 GND G, R WHI,WHI/BLK
9 MR C BLK
10 MRR D GRN
+BAT F RED,BLK
Note: This harness also includes a 220 ohm resistor from J1-1 to J1-10 and another 220 resistor
from J1-10 to J1-12.
Table 2.15 TI-5013 Sumtak REC/REM2048 17 Pin Encoder & J1 Pin Configuration
1 +5 VDC H RED
2 GND G WHI
3 A A PNK
4 A* B BLU
5 B C VIO
6 B* D YEL
7 Z K GRY
8 Z* L ORG
9 RX E TAN
10 RX* F BRN
FREE CLEAR R GRN
FREE BATT T BLK
Table 2.16 Sanyo Denki Encoder & J1 Pin Configuration
1 +5 VDC RED
2 GND BLK
3 A BLU
4 A* BRN
5 B GRN
6 B* PUR
7 Z WHT
8 Z* YEL
9 RX GRN/BLK
10 RX* PUR/BLK
FREE CLEAR RED/BLK
Table 2.17 TI-5014 Yaskawa C Channel UTOPH 17 Pin Encoder & J1 Pin Configuration
1 +5 VDC H RED
2 GND G WHI
3 A A BLU
4 A* B BRN
5 B C YEL
6 B* D ORG
7 Z K GRN
8 Z* L BLK
9 C E VIO
10 C* F PNK
Table 2.18 TI-5015 Yaskawa UTOPI-600UA 17 Pin Encoder & J1 Pin Configuration
J1 TB Pin J2 TB Pin Signal MS3106A20-29S Cable Color
1 +5 VDC H RED
2 GND G BLK
3 A A BLU
4 A* B BLU/WHI
5 B C WHI
6 B* D WHI/BLK
7 Z E GRN
8 Z* F GRN/WHI
7 U K ORG
8 V M RED/BLK
9 W P BLU/BLK
10 U* L ORG/BLK
11 V* N RED/WHI
12 W* R GRN/BLK
Table 2.19 TI-5016, TI-5016W Fanuc Incremental 17 Pin Encoder & J1 Pin Configuration
J1 TB Pin J2 TB Pin Signal MS3106A20-29S
1 +5 VDC J,K
2 GND N,T
3 A A
4 A* D
5 B B
6 B* E
7 Z F
8 Z* G
7 C1 C
8 C2 P
9 C4 L
10 C8 M
Notes: 1. Used with Fanuc Incremental Pulsecoders.

2. The "W" indicates the polarization of the MS3102A20-29P.
Table 2.20 TI-5017 Yaskawa Absolute 17 Pin Encoder & J1 Pin Configuration
1 +5 VDC H RED
2 GND G WHI
3 A A ORG
4 A* B ORG/BLK
5 B C GRN
6 B* D GRN/BLK
7 Z E BLU
8 Z* F BLU/BLK
9 S K GRN/WHI
10 S* L BLU/WHI
FREE RES R BLK
FREE 0V BAT S WHI/BLK
FREE +BAT T RED/BLK
Table 2.21 TI-5018 Renco RHS21D-P1-2000-8MM-5-CS-LD-M1-0-P-S 8 Pin
J1 TB Pin Signal AMP MTE8 Cable Color
1 +5 VDC 1 RED
2 GND 8 BLK
3 A 2 WHI
4 A* 3 RED/BLK
5 B 4 GRN
6 B* 5 BLU
7 Z 6 ORG
8 Z* 7 WHI/BLK
Table 2.22 TI-5019 Renco RCH20D-2000/3-8MM-5/0-LD/VC-I-M6-S 17 Pin
1 +5 VDC J,K RED

2 GND L,M BLK
3 A A YEL
4 A* B GRY
5 B C BLU
6 B* D PNK
7 Z E ORG
8 Z* F TAN
7 S1 T GRN
8 S2 N BRN
9 S3 P WHI
FREE ANALOG H VIO
Table 2.23 TI-5020 Fanuc Pulsecoder Alpha A, 6 Pole Connections & J1 Pin Configuration
J1 TB Pin Signal P1 DF1B-5EP-2.5RC P2 DF1B-6EP-2.5RC

1 +5 VDC 1,2
2 GND 3,4,6
9 SD 1
10 SD* 2
11 REQ 3
12 REQ* 4
FREE +6 V (Batt) 5
Notes: 1. +6 V lead may be connected to 5 or 6 volts to simulate a battery if desired.

Table 2.24 TI-5021 Indramat 12 Pin Connections & J1/J2 Pin Configuration
J1 TB Pin J2 TB Pin Signal 29169705 Cable Color Cable Color
1 +8 VDC 12 RED
2 GND 10 WHI
3 C+ 8 WHI
4 C- 1 RED
5 S+ 5 GRN
6 S- 6 BLK
7 NC
8 NC
9 SDI 4 GRN
10 NC
11 SDO 7 BLK
12 NC
3 SCL 2 ORG
5 FS 3 BLU
Table 2.25 TI-5022 Indramat ROD1424 ROD 1430 Connections & J1/J2 Pin Configuration
J1 TB Pin J2 TB Pin Signal 29169705 Cable Color
1 +5 VDC 2,12 RED

2 GND 10,11 WHI
3 A 5 BLU
4 A* 6 GRN
5 B 8 ORG
6 B* 1 BLK
7 Z 3 RED/BLK
8 Z* 4 WHI/BLK
Notes:
1. Keyed at pin 9
2. Remove pin 7 to allow for a .078” dia. polarizing pin.
Table 2.26 TI-5023 Kawasaki HE-02/Sanyo Denki E03007758 8192 Count DB15
J1 TB Pin Signal DB15 Cable Color
1 +5 VDC 11 RED
2 GND 10 WHI
3 A 1 ORGI
4 A* 2 ORG/BLK
5 B 3 GRN
6 B* 4 GRN/BLK
7 Z 5 BLU
8 Z* 6 BLU/BLK
9 SD 7 GRN/WHI
10 SD* 8 BLU/WHI
11 SYNC 9 BLK/WHI
2 GND 12 WHI/BLK
FREE B+ 13 RED/BLK
FREE SET 14 BLK
Table 2.27 TI-5024 Yaskawa Absolute DB15 Encoder & J1 Pin Configuration
J1 TB Pin Signal DB15 Cable Color
1 +5 VDC 8 RED
2 GND 7 WHI
3 A 1 ORG
4 A* 2 ORG/BLK
5 B 3 GRN
6 B* 4 GRN/BLK
7 Z 5 BLU
8 Z* 6 BLU/BLK
9 S 10 GRN/WHI
10 S* 11 BLU/WHI
FREE RES 13 BLK
FREE 0V BAT 14 WHI/BLK
FREE +BAT 15 RED/BLK
Table 2.28 TI-5025 Yaskawa C Channel SGM 9 Pin Encoder & J1 Pin Configuration
1 +5 VDC 8 RED
2 GND 7 WHI
3 A 1 BLU
4 A* 2 GRN
5 B 3 BLK
6 B* 4 ORG
9 C 5 RED/BLK
10 C* 6 WHI/BLK
NC FG 9 DRAIN
Table 2.29 TI-5026 Kawasaki HE-02 8192 Count 17 pin Enc. Connections & J1 Pin Configuration
1 +5 VDC E RED
2 GND F WHI
3 A J ORGI
4 A* K ORG/BLK
5 B L GRN
6 B* M GRN/BLK
7 Z H BLU
8 Z* G BLU/BLK
9 ABS D GRN/WHI
10 ABS* C BLU/WHI
11 SYNC A BLK/WHI
FREE BT- R WHI/BLK
FREE BT+ P RED/BLK
FREE SET S BLK
Table 2.30 TI-5027 Mitsubishi OBE12 & OBA13 9 Pin Encoder & J1 Pin Configuration
J1 TB Pin Signal AMP 9 Pin Cable Color
1 +5 VDC 7 RED
2 GND 8 WHI
9 SD 4 BLU
10 SD* 5 GRN
11 REQ 1 BLK
12 REQ* 2 ORG
FREE BAT 3 RED/BLK
FREE FG 9 SHLD
Table 2.31 TI-5028 Mitsubishi OBA13/OHA14B 17 Pin Encoder & J1 Pin Configuration
1 +5 VDC S RED
2 GND R WHI
9 SD A BLU
10 SD* B GRN
11 REQ C BLK
12 REQ* D ORG
FREE BAT F RED/BLK
NC FG N SHLD
Table 2.32 TI-5029 Fanuc Incr. & ABS Pulsecoder DB25 Connections & J1/J2 Pin Configuration
J1 TB Pin J2 TB Pin Signal DB25
1 +5 VDC 12,13,25
2 GND 1,2,14
3 A 23
4 A* 22
5 B 21
6 B* 20
7 Z 9
8 Z* 8
7 C1 19
8 C2 18
9 C4 17
10 C8 16
Notes: 1. Used with Fanuc Incremental such as 10000P and ABS Pulsecoders such as 2000P,
2500P, 3000P, etc.
Table 2.33 TI-5030 Siemens/Hiedenhain ROD320 Inc. 17 pin Connections & J1/J2 Pin Configuration
J1 TB Pin Signal MS3106A20-29S
1 +5 VDC C, J,K
2 GND N,P,T
3 A A
4 A* D
5 B B
6 B* E
7 Z F
8 Z* G
Table 2.34 TI-5031 Siemens Hiedenhain Endat 17 Pin Encoder & J1, J2 Pin Configuration
1 +5 VDC 10 RED
2 GND 7 WHI
3 A 1 BLK
4 A* 2 BRN
5 B 11 ORG
6 B* 12 YEL
7 NC
8 NC
9,11,13 DATA 3 GRN
10,12,14 DATA* 13 BLU
3 CLOCK 5 VIO
4 CLOCK* 14 GRY
Table 2.35 TI-5032 Kawasaki H20/M21 17 Pin Connector & J1 Pin Configuration
1 +5 VDC E RED
2 GND F BLK
9 SD C GRN
10 SD* D WHI
11 REQ C GRN
12 REQ* D WHI
Table 2.36 TI-5033 Sanyo Denki with Sumtak AEC2048 10 pin Molex Conn. & J1 Pin Configuration
J1 TB Pin Signal 03-0601152 Cable Color
1 +5 VDC 10 RED
2 GND 9 WHI
3 A 1 PNK
4 A* 2 BLU
5 B 3 VIO
6 B* 4 YEL
7 Z 5 GRY
8 Z* 6 ORG
9 RX 7 TAN
10 RX* 8 BRN
FREE CLEAR 12 GRN
FREE BATT 14 BLK
Table 2.37 TI-5034 Fanuc Alpha Position Code 17 pin Encoder & J1 Pin Configuration
1 +5 VDC H RED
2 GND K WHI
3 PAE A GRN
4 PAE* N BLK
5 PBE C ORG
6 PBE* P BLU
7 PSE B RED/BLK
8 PSE* R WHI/BLK
Table 2.38 TI-5035 Tamagawa OAH74/OAM74 16 pin Encoder & J1 Pin Configuration
J1 TB Pin Signal 39-01-2160 Cable Color
1 +5 VDC 4 RED
2 GND 12,14 BLK, WHI/BLK
3 A 1 BLU
4 A* 9 BLU/BLK
5 B 2 ORG
6 B* 10 ORG/BLK
9 RX 5 GRN
10 RX* 13 GRN/BLK
FREE RESET 3 RED/BLK
FREE BATT 6 WHT
Table 2.39 TI-5036 Sanyo Denki R11G4113A 17 Pin Encoder & J1 Pin Configuration
1 +5 VDC H RED
2 GND G,K BLK,VIO
2 BAT- S WHI
9 ES+ E YEL
10 ES- F ORG
11 ENCREQH N BLU
12 ENCREQL P BRN
FREE -5 VDC M GRN
FREE BAT+ T GRY
FREE ERES R PNK
FREE SHLD J TAN
Table 2.40 TI-5037 Fanuc Alpha A8 12 Pin Hirose Encoder & J1 Pin Configuration
J1 TB Pin Signal RM-15TRD-12S Cable Color
1 +5 VDC 4 RED
2 GND 11 WHI
9 SD 7 GRN
10 SD* 8 BLK
11 REQ 5 ORG
12 REQ* 6 BLU
FREE 6 VA (BATT) 9 RED/ BLK
Table 2.41 TI-5038 Generic MS Pins J1 & J2 Pin Configuration
J1 TB Pin J2 TB Pin Signal MS Connector Cable Color
1 +5 VDC ANY PIN RED

2 GND ANY PIN BLK
3 A ANY PIN BLU
4 A* ANY PIN BLU/WHI
5 B ANY PIN WHI
6 B* ANY PIN WHI/BLK
7 Z ANY PIN GRN
8 Z* ANY PIN GRN/WHI
7 U ANY PIN ORG
8 V ANY PIN RED/BLK
9 W ANY PIN BLU/BLK
10 U* ANY PIN ORG/BLK
11 V* ANY PIN RED/WHI
12 W* ANY PIN GRN/BLK
Table 2.42 TI-5039 Yaskawa Absolute AMP Mini-MNL 12 Pin Encoder & J1 Pin Configuration
J1 TB Pin Signal MNL Connector Cable Color
1 +5 VDC 9 RED
2 GND 10 WHI
3 A 1 ORG
4 A* 2 ORG/BLK
5 B 3 GRN
6 B* 4 GRN/BLK
7 Z 5 BLU
8 Z* 6 BLU/BLK
9 S FREE GRN/WHI
10 S* FREE BLU/WHI
FREE RES 12 BLK
FREE +BAT 7 RED/BLK
Table 2.43 TI-5040 Indramat MKD Resolver Pin Connections & J1/J2 Pin Configuration
TI-5000EX TI-5102 Signal 10 Pin Header Cable Color Cable Color

J1 Pin J2 Pin J2 Pin
1 2 +8 VDC(EXC) 10 RED/BLK
2 3 GND(EXC*) 1 WHI/BLK
3 5 COS* 7 WHI
4 4 COS 9 RED
5 7 SIN* 3 GRN
6 6 SIN 5 BLK
7 NC
8 NC
9 SDI 6 GRN
10 NC
11 SDO 8 BLK
12 NC
3 SCL 4 ORG
5 FS 2 BLU
Table 2.44 TI-5041 Yaskawa 12 Bit Absolute Enc. 15 Pin Amp Connector & J1 Pin Configuration
1 +5 VDC 8 RED
2 GND 7 WHI
3 A 1 ORG
4 A* 2 ORG/BLK
5 B 3 GRN
6 B* 4 GRN/BLK
7 Z 5 BLU
8 Z* 6 BLU/BLK
9 S 10 GRN/WHI
10 S* 11 BLU/WHI
FREE RES 13 BLK
FREE +BAT 15 RED/BLK
FREE FG DRAIN
Table 2.45 TI-5042 Indramat MAC 12 Pin Connections & J1/J2 Pin Configuration
J1 TB Pin J2 TB Pin Signal 29169705 Encoder Cable Color
1 +8 VDC 2,12 (C1) RED

2 GND 10,11 (C1) WHI
3 A 5 (C1) BLU
4 A* 6 (C1) GRN
5 B 8 (C1) ORG
6 B* 1 (C1) BLK
7 Z 3 (C1) RED/BLK
8 Z* 4 (C1) WHI/BLK
J1 TB Pin J2 TB Pin Signal 29169705 Hall/Tach Cable Color
9 Tach V 4 (C2) ORG

2 GND 2,11 (C2) WHI
13 +15 V 10 (C2) RED
14 -15 V 12 (C2) RED/BLK
7 H1 7 (C2) BLU
8 H2 8 (C2) GRN
9 H3 9 (C2) BLK
J1 TB Pin J2 TB Pin Signal 2 Pin M-N-L Cable Color
2 OH2 1 (C3) WHI

12 OH1 2 (C3) GRN
Notes: 1. C1, C2, and C3 represent 3 different cables making up this test cable.
Table 2.46 TI-5043 Baldor Heidenhain Endat 17 Pin Encoder & J1, J2 Pin Configuration
1 +5 VDC 9 RED
2 GND 10 WHI
3 A 2 BLK
4 A* 11 BRN
5 B 4 ORG
6 B* 8 YEL
7 NC
8 NC
9,11,13 DATA 12 GRN
10,12,14 DATA* 1 BLU
3 CLOCK 7 VIO
4 CLOCK* 5 GRY
Table 2.47 TI-5044 Yaskawa Absolute Two AMP Mini-MNL 6 Pin Encoder & J1 Pin Configuration
J1 TB Pin Signal MNL Connector Cable Color
1 +5 VDC 3(RED) RED

2 GND 4(RED) WHI
3 A 1(WHI) ORG
4 A* 2(WHI) ORG/BLK
5 B 3(WHI) GRN
6 B* 4(WHI) GRN/BLK
7 Z 5(WHI) BLU
8 Z* 6(WHI) BLU/BLK
FREE RES 6(RED) BLK
FREE 0V BAT 2(RED) WHI/BLK
FREE +BAT 1(RED) RED/BLK
FREE FG 5(RED) DRAIN
Note: Colors on the MNL pins refer to the colors of the two housings.
Table 2.48 TI-5045 Renco N2300, 3400, 4200 & 4600 Amphenol PT06E14-19S(SR) 19 Pin
1 +5 VDC J,K RED

2 GND L,M WHI
3 A A ORG
4 A* B ORG/BLK
5 B C GRN
6 B* D GRN/BLK
7 Z E BLU
8 Z* F BLU/BLK
7 HALL A T BLU/WHI
8 HALL B U GRN/WHI
9 HALL C V BLK/WHI
FREE ANALOG H BLK
FREE THERM+ R RED/WHI
FREE THERM- S WHI/BLK
FREE FG G DRAIN
Table 2.49 TI-5046 Mitsubishi OBE12 & OBA13 JST 9 Pin Encoder & J1 Pin Configuration
J1 TB Pin Signal JST SMP-09V-BC Pin Cable Color
1 +5 VDC 7 RED
2 GND 8 WHI
9 SD 3 BLU
10 SD* 4 GRN
11 REQ 1 BLK
12 REQ* 2 ORG
FREE BAT 6 RED/BLK
FREE FG 9 SHLD
Table 2.50 TI-5047 Fanuc Alpha I Pulsecoder Connections & J1 Pin Configuration
J1 TB Pin Signal JAE 10 pin round Cable Color
1 +5 VDC 8,9 RED/YEL

2 GND 7,10 WHI/GRY
9 SD 2 GRN
10 SD* 1 BLK
11 REQ 6 ORG
12 REQ* 5 BLU
FREE BATT+ 4 VIO
Table 2.51 TI-5048 Renco RCH20, HRS 16 Pin
J1 TB Pin J2 TB Pin Signal DF11-16DS-2C Cable Color
1 +5 VDC 1 RED
2 GND 3 BLK
3 A 5 BLU
4 A* 7 BLU/WHI
5 B 9 WHI
6 B* 11 WHI/BLK
7 Z 13 GRN
8 Z* 15 GRN/WHI
7 S1 2 ORG
8 S2 4 RED/BLK
9 S3 6 BLU/BLK
10 S1* 10 ORG/BLK
11 S2* 12 RED/WHI
12 S3* 14 GRN/BLK
Table 2.52 TI-5049 Stromag/Hiedenhain SSI ECN1313/EQN1325 17 Pin Enc. & J1, J2 Pin Config.
1 +5 VDC 8 RED
2 GND 7 WHI
3 A 1 BLK
4 A* 2 BRN
5 B 3 ORG
6 B* 4 YEL
7 NC
8 NC
9,11,13 DATA 10 GRN
10,12,14 DATA* 11 BLU
3 CLOCK 12 VIO
4 CLOCK* 13 GRY
Table 2.53 TI-5050 Tamagawa 482000, 18 Pin Bayonet
J1 TB Pin J2 TB Pin Signal PT02E-14-18P Cable Color
1 +5 VDC K RED
2 GND T,K BLK, BLK/RED
3 A B BLU
4 A* C BLU/WHI
5 B N WHI
6 B* P WHI/BLK
7 Z M GRN
8 Z* U GRN/WHI
7 U E ORG
8 V F RED/BLK
9 W G BLU/BLK
10 U* R ORG/BLK
11 V* S RED/WHI
12 W* H GRN/BLK
Shield D Drain
FREE Thermal A ORG/RED
FREE Thermal L BLU/RED
Table 2.54 TI-5051 Control Techniques/Stegmann SCM60 12 Pin Enc. & J1, J2 Pin Configuration
1 +V 12 RED
2 GND 10 BLU
3 COS+ 4 VIO
4 REF COS 1 BLK
5 SIN+ 5 WHI
6 REF SIN 6 BRN
7 NC
8 NC
9,11 DATA+ 2 GRY
10,12 DATA- 3 GRN
FREE TEMP 7 YEL
FREE TEMP 8 ORG
FREE DRAIN 9 DRAIN
Table 2.55 TI-5052 Baldor 14-19P F (Fadal), 19 Pin Bayonet & J1, J2 Pin Configuration
J1 TB Pin J2 TB Pin Signal PT02E-14-19 Cable Color
1 +5 VDC S RED
2 GND E BLK
3 A H BLU
4 A* J BLU/WHI
5 B F WHI
6 B* G WHI/BLK
7 Z K GRN
8 Z* U GRN/WHI
7 U M ORG
8 V B RED/BLK
9 W A BLU/BLK
10 TSTAT L ORG/BLK
11 TSTAT P RED/WHI
12 ENC ERROR T GRN/BLK
Shield D Drain
Table 2.56 TI-5053 Panasonic Minas A Incr. 15 pin Mini M-N-L Connections & J1 Pin Configuration
J1 TB Pin Signal Mini Univ M-N-L Cable Color
1 +5 VDC H RED
2 GND G WHI
3 A A PNK
4 A* B BLU
5 B C VIO
6 B* D YEL
7 Z K GRY
8 Z* L ORG
9 RX E TAN
10 RX* F BRN
FREE BATT T BLK
Table 2.57 TI-5054 Siemens/Heidenhain ROD 320 17 pin Encoder & J1 Pin Configuration
1 +5 VDC C,J,K RED

2 GND N,P,T WHI
3 A A GRN
4 A* D BLK
5 B B ORG
6 B* E BLU
7 Z F RED/BLK
8 Z* G WHI/BLK
FREE Shield H Drain
Jumpered R,S
Table 2.58 TI-5055 Siemens Hall/Tach 12 pin Encoder & J1 Pin Configuration
J1 TB Pin J2 TB Pin Tach TB Signal 29169705 Cable Color
1 +5 VDC 4 RED
2 GND 5 BRN
4 Tach neutral 6 GRN
1 Tach (T) 7 BLK
7 Shield 8 TAN
6 Thermal 9 YEL
5 Thermal 10 BLU
3 Tach (R) 11 ORG
2 Tach (S) 12 WHI
7 RLGS (H1) 1 VIO
8 RLGT (H2) 2 GRY
9 RLGR (H3) 3 PNK
Table 2.59 TI-5056 Sanyo Denki ABOSYN ABS Super 17 pin Connections & J1 Pin Configuration
1 +5 VDC H RED
2 GND, BATT GND G,S WHI,WHI
3 A A GRN
4 A* B GRN/BLK
5 B C GRN/WHI
6 B* D BLU/WHI
9 S E ORG
10 S* F ORG/BLK
11 RQ N BLU
12 RQ* P BLU/BLK
FREE Frame GND J Drain
FREE EM CLEAR K BLK
FREE Temp L BLK/WHI
FREE Temp M WHI/BLK
FREE RES R RED/WHI
FREE BATT + T RED/BLK
Table 2.60 TI-5057 Allen Bradley/Stegmann MPF-B/MPG-A5 17 Pin Encoder & J1 Pin Configuration
1 +V 11 RED
2 GND 12 BLU
3 COS+ 3 VIO
4 REF COS 4 BLK
5 SIN+ 1 WHI
6 REF SIN 2 BRN
7 NC
8 NC
9,11 DATA+ 5 GRY
10,12 DATA- 6 GRN
FREE TEMP 13 YEL
FREE TEMP 14 ORG
Table 2.61 TI-5058 Allen Bradley/Stegmann MPF-A3/A4/A45 17 Pin Encoder & J1 Pin Configuration
1 +V 9 RED
2 GND 10 BLU
3 COS+ 3 VIO
4 REF COS 4 BLK
5 SIN+ 1 WHI
6 REF SIN 2 BRN
7 NC
8 NC
9,11 DATA+ 5 GRY
10,12 DATA- 6 GRN
FREE TEMP 13 YEL
FREE TEMP 14 ORG
Table 2.62 TI-5059 B and R/Hiedenhain Endat 17 Pin Encoder & J1, J2 Pin Configuration
1 +5 VDC 7 RED
2 GND 10 WHI
3 A 15 BLK
4 A* 16 BRN
5 B 12 ORG
6 B* 13 YEL
7 NC
8 NC
9,11,13 DATA 14 GRN
10,12,14 DATA* 17 BLU
3 CLOCK 8 VIO
4 CLOCK* 9 GRY
Table 2.63 TI-5060 Control Techniques/Stegmann Dicoder 17 Pin Enc. & J1, J2 Pin Configuration
1 +5 VDC 16 RED
2 GND 17 BLK
3 A 10 BLU
4 A* 13 BLU/WHI
5 B 14 WHI
6 B* 15 WHI/BLK
7 I 11 GRN
8 I* 12 GRN/WHI
7 S2 6 RED/BLK
8 S3 8 BLU/BLK
9 S1 4 ORG
10 S2* 7 RED/WHI
11 S3* 9 GRN/BLK
12 S1* 5 ORG/BLK
FREE SCREEN 3 DRAIN
FREE THERM, PTC 1 RED/BLK (individual wire)
FREE THERM, PTC* 2 WHI/BLK (individual wire)
Table 2.64 TI-5061 Indramat MAC/Stegmann AG 100 MSI 12 Pin Encoder & J1, J2 Pin Configuration
1 +10-32 VDC 8 RED

2 GND 1 WHI
FREE 4 BLK
FREE 5 BRN
FREE 7 ORG
FREE 9 YEL
9 DATA 2 GRN
10 DATA* 10 BLU
3 PULSE 3 VIO
4 PULSE* 11 GRY
FREE SHIELD 6 DRAIN
Table 2.65 TI-5062 Fanuc ABS Pulsecoder DDK 19 pin Connections & J1/J2 Pin Configuration
J1 TB Pin J2 TB Pin Signal JMCR2119F
1 +5 VDC 11
2 GND 12
3 A 3
4 A* 4
5 B 5
6 B* 6
7 Z 1
8 Z* 2
7 C1 7
8 C2 8
9 C4 9
10 C8 10
Notes: 1. Used with Fanuc ABS Pulsecoders often found on robots.

Table 2.66 TI-5063 Baumuller/Stegmann Hiperface 12 Pin Encoder & J1 Pin Configuration
J1 TB Pin Signal 29169726 Cable Color
1 +V 12 RED
2 GND 10 WHI
3 COS+ 8 GRN
4 REF COS 1 BLK
5 SIN+ 5 ORG
6 REF SIN 6 BLU
7 NC
8 NC
9,11 DATA+ 2 RED/BLK
10,12 DATA- 7 WHI/BLK
FREE SHIELD 9 DRAIN
Table 2.67 TI-5064 Allen Bradley MPL, 1326AB 19 pin Connections & J1 Pin Configuration
J1 TB Pin Signal TNM 16-19 Cable Color
1 +V K,N RED
2 GND L,P BLU
3 COS+ C VIO
4 REF COS D BLK
5 SIN+ A WHI
6 REF SIN B BRN
7 NC
8 NC
9,11 DATA+ E GRY
10,12 DATA- F GRN
FREE TEMP R YEL
FREE TEMP S ORG
Table 2.68 TI-5065 Sanyo Denki INC-E 17 pin Connections & J1 Pin Configuration
1 +V J RED
2 GND N WHI
3 A A BLU
4 A* D GRN
5 B B BLK
6 B* E ORG
7 Z F RED/BLK
8 Z* G WHI/BLK
FREE SHLD H DRAIN
Table 2.69 TI-5066 Matsushita/Tamagawa, 17 Pin Connections & J1 Pin Configuration

1 +5 VDC A,C RED
2 GND B,D,R WHI,WHI/BLK
9,11 SD E GRN
10,12 SD* F BLK
11 REQ 3
FREE FG DRAIN
FREE Batt+ RED/BLK
Notes: 1. +Batt V lead may be connected to 3.2 volts to simulate a battery if desired.
Table 2.70 TI-5067 Sanyo Denki R11 Encoder, 15 Pin Encoder & J1 Pin Configuration
J1 TB Pin Signal 15 Pin Molex Cable Color
1 +5 VDC 5 RED
2 GND 6,8 BLK
2 BAT- 10 WHI
9 ES+ 1 YEL
10 ES- 2 ORG
11 ENCREQH 3 BLU
12 ENCREQL 4 BRN
FREE -5 VDC 7 GRN
FREE BAT+ 9 GRY
FREE ERES 11 PNK
FREE SHLD J TAN
FREE GND 12 VIO
Table 2.71 TI-5068 Modicon/Stegmann Hiperface 17 pin Euro Connections & J1 Pin Configuration
J1 TB Pin Signal 29169726 Cable Color
1 +V 1 RED
2 GND 2 WHI
3 COS+ 6 GRN
4 REF COS 5 BLK
5 SIN+ 7 ORG
6 REF SIN 8 BLU
7 NC
8 NC
9,11 DATA+ 10 YEL
10,12 DATA- 9 BRN
FREE TEMP 12 VIO
FREE TEMP 13 GRY
FREE DRAIN SHLD
Table 2.72 TI-5069 Stegmann Hiperface 8 pin Connections & J1 Pin Configuration
J1 TB Pin Signal 8 Pin Berg Cable Color
1 +V 1 RED
2 GND 2 BLU
3 COS+ 8 VIO
4 REF COS 4 BLK
5 SIN+ 7 WHI
6 REF SIN 3 BRN
9,11 DATA+ 5 GRY
10,12 DATA- F GRN
Table 2.73 TI-5070 Fanuc Alpha and Beta Pulsecoder Connections & J1 Pin Configuration
J1 TB Pin Signal JAE 10 pin round Cable Color
1 +5 VDC A2,B2 RED/YEL

2 GND A1,B1,A6 WHI/GRY
9 SD 2 GRN
10 SD* 1 BLK
11 REQ 6 ORG
12 REQ* 5 BLU
FREE BATT+ 4 VIO
2.10 CLEANING
The instrument case is made of ABS plastic. The following guidelines are based on information supplied by
the plastic resin manufacturer. The resin manufacturer tested and rated the environmental stress cracking
effects of many basic chemicals and commercial products. The ratings reflect the effects of continuous
exposure (7 days at 73oF) to each chemical substance. This is an extreme case relative to the process of
cleaning the instrument case. The following information, therefore, should be viewed as a guideline.
Compatible cleaning agents:

Mild detergent solutions (3-5%); Ivory, Tide, Top Job,
Impact dishwasher liquid, Windex(dilute or rinse quickly).
Higher concentrations can be used with prompt rinsing.
Incompatible Cleaning Agents:

Acetone, Benzene, Isopropyl Alcohol, Methanol, Kerosene, Ethyl Alcohol(100%), Ethylene Chloride.
2.11 SOFTWARE INSTALLATION AND REPAIR
Software upgrades and updates will be sent to the customer as a file (typically a file on a diskette or email),
which will be user installable. Section 1.3.2 discusses downloading a file to the TI-5000EX. Documentation
accompanying the upgrade will discuss the changes made, and provide useful notes. If the revision is very
extensive, a new manual may accompany the software.
If problems are encountered in using this equipment, please call for assistance. Do not return equipment
without first calling for a return authorization number. The RA number should be included on the address
label as shown below. In the event equipment is returned, it must be well packed for safe shipping.
Address the package as follows:
Mitchell Electronics, Inc.

180B Mill St.
Athens, OH 45701
Attn: Customer Service

RA XXXX
Service Phone:
(740)594-8532
Support Contacts:
Voice: (740)594-8532
FAX: (740)594-8533
Email: support@mitchell-electronics.com
URL: http://www.mitchell-electronics.com
TI-5000 140 Theory of Operation
3 TESTING AND ENCODER BACKGROUND INFORMATION
The Theory of Operation section will provide technical details concerning system hardware and software.
The information in this section is designed to provide detail beyond operating instructions to help the user
obtain the maximum benefit from the system.
3.1 TERMINOLOGY
This section will attempt to explain various terminologies such as serial, absolute, incremental and so forth.
Unfortunately, often the same terms will be used in a different context by different manufacturers, but this
section will at least describe what is meant by these terms in reading this manual.
3.1.1 INCREMENTAL VERSUS ABSOLUTE
There is considerable confusion over the use of the incremental and absolute terminology. This is
understandable considering the evolution of encoder technology. Hopefully this section will clarify rather
than further muddy the waters. At least it will provide a basis for understanding the use of the terms
incremental and absolute in this manual.
3.1.1.1 TRADITIONAL ABSOLUTE
A traditional absolute encoder will have numerous code rings with different binary weightings which will
provide a digital data word representing the absolute position of the encoder within one revolution down to
the precision of the least significant bit. This is the type of encoder that we call “Parallel Absolute” in the
encoder selection. A simple example would be 3 code rings in which the most significant bit is HI during 1/2
the turn and LO during the other 1/2 turn. The next code ring goes from LO to HI two times during a turn
while the least significant bit switches from LO to HI 4 times as shown in the following table:
COUNT BIT2 (MSB) BIT1 BIT0 (LSB) A B Z
0 0 0 0 0 0 1
1 0 0 1 1 0 0
2 0 1 0 1 1 0
3 0 1 1 0 1 0
4 1 0 0 0 0 0
5 1 0 1 1 0 0
6 1 1 0 1 1 0
7 1 1 1 0 1 0
There are 8 unique data words to represent the 8 positions which can be reported by this encoder. Adding
more bits will divide one revolution into smaller segments, and the encoder will therefore provide higher
resolution. It will resolve one rotation into finer segments, but at the expense of adding more output lines to
represent the additional bits. Typically this type of absolute encoder will be offered with a gray code output
rather than the straight binary code shown above. Gray codes are designed to give the same information,
but only one bit changes at a time when moved from one segment to the next. In the above example, all bits
change state when moving from segment 7 to segment 0. Due to electronic delays, all bits do not change at
the same instant in time, so there may be a short time in which the bits do no correctly represent the
position. The gray code eliminates this problem.
The distinguishing feature of the absolute encoder is that the encoder reports the absolute position of the
encoder to the electronics. It can do this immediately upon power-up with no need for indexing.
3.1.1.2 TRADITIONAL INCREMENTAL
A traditional incremental encoder works differently. It provides an A and a B pulse output as shown in the
table above. These pulse outputs really provide no usable count information in their own right. Technically
they provide a 2 bit gray code which can count from 0 to 3, but this is not how it is used. With the
incremental encoder, the counting is done in the external electronics. The beauty of the A/B quadrature
pulse pattern shown above is that the change in state can be counted by the electronics, and the direction of
the count can be determined by which changes first: A or B. One of the advantages to incremental encoders
is that there are always only two lines, A and B (and sometimes their complement lines A* and B*) for any
number of counts per turn resolution. The disadvantage is that the point where the counting begins depends
on the counter in the external electronics and not on the position of the encoder. Usually the counter is
zeroed on power up, and it begins counting from there as the encoder is turned. The encoder could be at
any position when power-up occurs. The motion of the encoder simply causes the external counter to
increment the count up or down as it moves, and the count is not referenced to its absolute position.
In most cases, the incremental encoder must be referenced to the absolute position to be useful. One way
this is done is to include an index pulse on an additional line, Z, which will go HI at one point during the
encoder revolution. On power-up the encoder can be turned during a "homing" sequence until the index
pulse is found by the external electronics. If the external electronics zeros the counter (or sets it to some
other known count), the encoder now becomes referenced to the encoder's absolute position. Homing can
also be accomplished with reference to proximity switches and other signals that indicate a reference
position.
The distinguishing feature of the incremental encoder is that the encoder reports an incremental change in
position of the encoder to the electronics. The electronics must add this change in position to the absolute
position determined by the electronics upon power-up by indexing.
3.1.1.3 INCREMENTAL/ABSOLUTE GRAY AREAS
As noted above, the absolute encoder presents the absolute position to the electronics, while the
incremental reports to the electronics that it has moved through some increment. The downside to the
incremental is the requirement for initial homing to provide absolute position information. What if we worked
on our incremental encoder system so that we could remember the homing information through a power
cycling, and homing during power-up was not required? Could we be justified in calling our incremental
encoder an absolute encoder? Fanuc apparently takes this point of view because they use “absolute” as
their terminology for A,B, and Z pulse encoders with battery backup. If the encoder and external counter is
powered by a battery so that it truly can provide absolute position information on power up, it is functionally
very similar to an absolute encoder. Of course if you want to make connections to this type of encoder and
test or otherwise evaluate it, you find that for all practical purposes you have to consider it an incremental
encoder because it looks nothing like the traditional absolute encoder described above.
3.1.2 SERIAL VERSUS NON-SERIAL
Serial encoders are encoders that transfer their information to the electronics in a serial data stream. Any of
the counting schemes discussed above could transfer their count to the electronics using serial data. The
traditional absolute encoder described above would have 16 data lines if it provided 16 bit resolution (counts
up to 65535). If each data bit used a true and complement line for noise immunity, this would be 32 lines.
The term normally used for this kind of data is "parallel". The printer on most PC computers transfers data in
a parallel manner, 8 bits at a time. It is fast at the expense of a lot of wires. Serial data provides for the
transmission of the data one bit after the other rather than all at once. All 16 bits mentioned above could be
sent on one data line, but it could take 16 times as long (all other things equal). Many serial encoders have a
request line to interrogate the encoder for data, and a data line for receiving the data from the encoder. If
true and complement lines are used in each case, only 4 wires plus power and ground are needed for any
resolution.
From the standpoint of trouble-shooting, serial encoders present several problems. Often the encoder does
not send any data unless it is properly interrogated by the request line. The bit pattern that appears on the
data line after interrogation is not simple to interpret and is constantly changing as the encoder moves. It is a
complex problem to correctly read and evaluate this information, and it is beyond the capabilities of standard
universal test equipment. The TI-5000EX provides this information in an easily interpreted format which
makes evaluating serial encoders practical.
The term serial encoder is, of course, combined with incremental, absolute, etc. depending upon other
details of its design and construction. Just remember that the serial terminology refers to the fact that the
information is sent from the encoder to the electronics in a serial fashion, and that is independent of other
terminologies applied to it. For instance, the Fanuc Alpha encoders are serial. The Alpha I model is called
incremental because it has no battery, but the Alpha A model is called absolute because it has battery
backup capability.
3.2 TEST THEORY
This section will describe why tests are performed the way they are, and what information is gained by the
test. In some cases this is obvious, but in other cases the reasons may not be clear.
3.2.1 INCREMENTAL ENCODER PHASE ANGLE TESTING
The question is often asked as to how important it is to perform the phase angle test. The standard answer
is that it is more or less an auxiliary test ranking below the Count Test in importance. The Count Test verifies
that the encoder is producing the correct number of counts per revolution. Accurate counting is essential,
and it must be verified above all else. However, the phase angle measurement can expose problems with
the encoder such as improper assembly, etc. Out of tolerance phase angles may even provide clues to
counting problems. Large phase angle errors reduce the rotational speeds at which the encoder can
produce acceptable signals for the electronics with which it is used. We can discuss the phase angles with
the help of picture of the A and B pulses like you would see on an oscilloscope.
┌───────┐ ┌───────┐ ┌───────┐ ┌─

CH A+ │ │ │ │ │ │ │
──┘ └───────┘ └───────┘ └──────┘
STATE L │ H H │ L L │ H H │ L L │ H H L │
│ ┌───┼───┐ │ ┌───┼───┐ │ ┌───────┐ │
CH B+ │ │ │ │ │ │ │ │ │ │ │ │
──┼───┘ │ └───┼───┘ │ └───┼───┘ └──┼─
STATE L │ L │ H │ H │ L │ L │ H │ H L │ L H H L│
COUNT 0 │ 1 │ 2 │ 3 │ 4 │ 5 │ 6 │ 7 8 │ 9 10 11 12│
│ │ │ │ │ │ │ │ │
│ │ │ │ │ │ │ │ │
│ │ │ │ │ │ │ │ │
0 90 180 270 0 90 180 0 0
A/B Quadrature Lines
As with an oscilloscope, the first events are on the left, and the last events are on the right of the picture.
We will give the first rising edge of A an angle of 0, and measure everything else relative to it. The falling
edge of A is halfway between the two rising edges of A, so it must be at the 180 degree point. With this
information we can determine the A symmetry angle. This measurement tells whether the A pulse is
symmetrical. In simple terms, this just means is it HI for the same amount of time that it is LO? We
determine this by subtracting the angle for the rising edge from the angle for the falling edge (180 - 0 = 180).
In this case, it is 180 degrees which is perfect. The A symmetry angle is simply how many degrees the A
pulse is HI.
We can apply a similar analysis to the B pulse which has a rising edge at 90 degrees and a falling edge at
270 degrees. Again, we determine this by subtracting the angle for the rising edge from the angle for the
falling edge (270 - 90 = 180). We get another perfect 180 degree symmetry angle.
This tells us that these two signals are perfect by themselves, but we are not quite done. We need to see
how they relate to each other, and we do that by measuring the phase angle. This angle is the angle from
the rising edge of A to the rising edge of B, and we determine it by subtracting the angle for the rising edge
of a from the angle for the rising edge of B (90 - 0 = 90). We have found that the phase angle is also perfect
for our perfect encoder. If the encoder is rotated in the opposite direction, we would see that the rising edge
of B occurs at 270 degrees, and our phase angle would be 270 degrees. This is also a perfect answer.
Now that we have determined these angles, let's step back a minute and see what they mean. We also
need to understand why 180 degrees is a perfect symmetry angle, and 90 or 270 is a perfect phase angle.
Looking back at the picture, we see that there are 4 edges for each period (each complete 360 degrees) of
encoder rotation. Our ideal encoder will evenly space these edges apart in the period. Any other angles will
space some of the edges further apart and at the same time crowd others closer together. Spreading apart
is fine, but crowding together is a problem. The electronics connected to the encoder will count these edges,
and it will have a maximum rate at which it can receive the edges. This maximum rate really amounts to a
minimum time separation between edges. As you know, when the encoder rotational speed is increased, the
edges will move closer together. Simply put, if incorrect phase angles cause the edges to move closer
together, it has the same effect as speeding up the encoder. Incorrect phase angles can cause minimum
edge separation times to be reached at significantly lower rotational speeds that for the ideal phase angles.
When the time separation between edges reaches the minimum, then the counting circuitry in the receiving
electronics will begin missing counts. Of course, the flip side to this situation is that, if the rotational speed is
slow enough, the phase angles matter very little because there is still adequate time spacing between
edges.
Typical phase angle specifications for phase angles are ± 22 degrees. This means that the 90 degree phase
angle could range between 68 and 112 degrees, and it would meet that manufacturer's specifications.
The last topic to consider is how to make good phase angle measurements. The primary requirement is to
rotate the encoder at a constant rotational speed. The TI-5000EX tester times the intervals shown in the
picture and converts those times to angles. If the encoder speed is accelerating (speed ramping up), then
the edges on the right hand end of the picture will be closer together than the edges on the left side, due
simply to the increase in speed. This speed increase would cause phase angles and symmetry angles to
look incorrect even with our ideal encoder. Since the tolerance on the phase angles is fairly broad, normally
it is possible to get a constant enough speed rotating an encoder by hand. However, the best situation would
be to rotate it with a constant speed motor.
3.2.2 CHECKING AND SETTING COMMUTATION
Checking and setting commutation is one of the most important tasks you will perform with the TI-5000EX.
In most cases, the Commutation frame will display a mechanical and an electrical angle. Often it will also
display commutation pulses. In the case of incremental encoders and Hall effect switches, the display will
represent the states of actual lines from the feedback coming into J2 pins 7 through 12. The most common
line configurations are 3 lines showing U, V, and W; 6 lines showing U, V, W, U*, V*, and W*; and 4 line gray
codes.
Some feedback devices can be aligned dynamically by back driving the motor and viewing the generated
voltage and feedback output on an oscilloscope. Since many feedback devices (such as serial encoders)
have no signal to observe during dynamic alignment, the method of static lockup is the remaining option.
Because it is more universal and generally a simpler procedure, alignment using static lockup is
recommended in this manual. Static lockup is accomplished by applying a small lockup voltage (normally
keeping the lockup current below ½ rated current) to 2 or 3 of the armature leads. This will move the rotor to
a position for which the feedback display is known. If the feedback display is incorrect, it can be repositioned
until it is correct, and this procedure will align the feedback correctly to the rotor. The information on the Data
Display will differ for various types of feedback, and the procedure may differ as well. Some of the more
common variations are shown below.
When Hall effect switches are used, the alignment is almost surely line to line. This will also be the case for
some incremental encoders with commutation pulses replacing Hall effect switches in earlier models.
Reliance motors with Renco encoders would be an example. The alignment for these feedback devices are
best done with the commutation pulse display.
The following statement is very important in using commutation states for alignment. It must be understood
in order to get the desire result.
A particular pattern of HI and LO commutation states will occur over a range of rotor position angles
and will not define a single position angle. In order to define a single position angle, one of the
commutation line states must be at a transition point changing between HI and LO. Correct data for
alignment using commutation lines will always include a transition point for one of the lines.
Below is a typical line to line alignment showing a transition from HI to LO on H1 and HI and LO line states
on H2 and H3 respectively. This example is presented as general guidance, but you must verify the correct
alignment for your particular motor. Line to line alignment using comm. pulses is shown below::
+U –V H→L H L
Some servo motors with incremental encoder feedback will use line to neutral alignment. These motors are
often referred to as “AC servo motors”. It is often easiest to align them using the pulse display as well. In
some cases the position relationship between the index pulse and the commutation pulses is known, and
the electrical angle can also be used for alignment. The example below shows that relationship for certain
Yaskawa motors. If you understand that relationship, you can use the electrical angle, but otherwise the safe
method is to use the commutation pulse states.
This is presented as general guidance, but you must verify the correct alignment for a particular motor. Line
to neutral alignment using commutation pulses is shown below:
+U -V -W 180 H→L H L
The Commutation frame when serial encoders are selection will show mechanical and electrical angles and
often a 4 bit gray code. The 4 bit gray code is a carryover from the Fanuc encoders. It works well for aligning
Fanuc encoders, but the electrical angle is a superior choice for other serial encoders. An example is the
Mitsubishi serial encoder alignment shown below.
Lockup Elect. Angle
-U +V +W 0
+U –V 150
+U –W 210
Several things are worth pointing out in the above example. The first lockup results in a zero angle. Some
servo technicians like to find a lockup that will provide a zero angle, and this is fine. However, there is
nothing magic about a zero angle lockup. For some motors such as Indramat digital, you do not want to
think in those terms because it is likely that there is no zero angle lockup. In fact, for these motors the lockup
angles are not the same from one motor to the next. The alignment is always dependent upon the motor and
drive design, so a zero angle lockup for a motor will only exist if it was designed to have one. Motor and
drive designers often do design systems to have common lockups (like zero) so that it simplifies alignment
procedures during manufacturing.
In this manual, we are suggesting checking both the +U –V and +U –W lockups, and there are several
reasons why it is helpful:
1. Using the same two lockups each time standardizes the procedure.
2. Locking up with +U –W after locking up with +U –V, causes the motor to jog in the direction of its
forward armature phase rotation. This allows the technician to check rotation at the same time he
checks alignment.
3. The difference in electrical angle from the +U –V to +U –W lockup is always 60 degrees. Checking
for that difference allows the technician to make sure that the correct number of poles and counts
per rev has been selected.
For a busy technician, getting the correct results is often a matter of sticking to a procedure that is familiar
and that provides for catching common mistakes. Some mistakes are listed above, but this procedure will
also help catch such mistakes as simply connecting to the wrong armature lead. The lockups shown above
will repeat as many times as there are pole pairs. For instance you would see the above lockup in 4 different
positions for an 8 pole motor. Checking the lockup for at least 2 positions is another good way of double
checking.
The Fanuc commutation gray code is shown as C1 – C8, and it can be used to check and set commutation
using a static rotor lockup by applying a small lockup voltage (normally keeping the lockup current below ½
rated current) as can the mechanical and electrical angle.
The rotor will lock up in as many different positions as there are pole pairs. The gray code electrical angle
indications will be the same at each lockup position while the mechanical angle will be different.
Lockup Elect. Mech. C1 C2 C4 C8

Angle Angle
+U –V –W 0 0, 90, 180, 270 (8 pole) 0 0 0 1→0
0, 120, 240 (6 pole)
+V –W 90 22.5, 112.5, 202.5, 292.5 (8 pole) 0 1 0→1 0
30, 150, 270 (6 pole)
+U –V 330 82.5, 172.5, 262.5, 352.5 (8 pole)

110, 230, 350 (6 pole)
+U –W 30 7.5, 97.5, 1872.5, 277.5 (8 pole)

10, 130, 250 (6 pole)
Alignment by static lockup can be applied to resolvers as well as to encoders and Hall effect pickups. Since
there are differences between resolvers and other types of feedback, the techniques are slightly different as
well. A major difference is that resolver of different speeds will be used with different numbers of poles of
motors. Most of the time a resolver will either be a single speed or the same number of speeds as the
number of motor pole pairs. In other words, 8 pole motors will normally use either a single speed resolver or
a 4 speed resolver. There is at least one known instance of a 2 speed resolver being used on an 8 pole
Modicon motor, but this seems to be a rare practice. For the typical situation, you can think of the 1 speed
resolver as showing the mechanical angle, and a resolver the same number of speeds as motor pole pairs
as showing the electrical angle.
For the case of the single speed resolver with multiple numbers of pole pairs, there will be a different angle
reading at each lockup position very much as shown above for the mechanical angle with the Fanuc
encoders. An example is show below for a 4 pole Parker motor with a single speed resolver:
Lockup Angle Resolver Angle
–V +W 0, 180,
+U –V 30, 210
+U –W 60, 240
Three different lockups are shown with 6 different angles. You may wonder when you lock it up for instance
with +U –V, which angle (30 or 210) should be used for your setting. It does not matter, because you will end
up with the same 2 lockup angles either way.

TI-5000 149 Specifications
4 SPECIFICATIONS
4.1 ELECTRICAL SPECIFICATIONS
QUADRATURE PULSE ENCODERS
INPUT -
Rate Up to 1,000,000 CPS (quad)

Max count ± 2,147,483,647 (quad)
INCREMENTAL COUNT TEST -

Rate Up to 1,000,000 CPS (quad)
PHASE -
Rate 25 CPS to 400,000 CPS

Resolution 1 degree
SERIAL ENCODERS
Rate Varies with encoder type.
RESOLVERS
Excitation 1,000 - 20,000 Hz.

Speed Up to 3,600 RPM
Angle resol. To .1 degree
ELECTRICAL INTERFACE
Input/Output -
0 - +15 VDC maximum
RS232 Serial Interface -
Compatible with standard EIA RS232C levels (+3 to +15 and -3 to -15).
USB –
Standard USB.
POWER
Supply 110 VAC 100 mA input, 9VDC 1000 mA output (wall mount supply)
TI-5000 150 Specifications
4.2 SYSTEM DESCRIPTION
SYSTEM SPECIFICATIONS
Computer: PC Compatible
Operating System: Windows95, Windows98, WindowsME, Windows NT, Windows 2000 or Windows
XP (recommended).
Communications: RS232 Serial COM port or USB port.
PHYSICAL SPECIFICATIONS -
Enclosure 12 oz., 4" X 8" X 2", lightweight impact resistant ABS material

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TI5000 EXManual

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Model TI-5000EX

Software Version 3.3

Mitchell Electronics, Inc.

180B Mill Street

Copyright 2006 Mitchell Electronics, Inc.

1.1 OVERVIEW ........................................................................................................................................................... 1

2.1 BASIC OPERATION ............................................................................................................................................... 9

2.2.2.4 ERROR ........................................................................................................................................................ 19

2.6.1.4 ENCODER SELECTION.................................................................................................................................. 49

2.6.5.5.1 DATA DISPLAY.......................................................................................................................................... 73

2.6.11.2.3.1 ABSOLUTE ENCODER UPDATE TEST ................................................................................................. 101

3 TESTING AND ENCODER BACKGROUND INFORMATION ........................................................................................ 140

3.1 TERMINOLOGY ................................................................................................................................................. 140

4 SPECIFICATIONS ................................................................................................................................................. 149

4.1 ELECTRICAL SPECIFICATIONS .......................................................................................................................... 149

Figure 2.1 TI-5000EX Pictorial ................................................................................................................................. 8

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1. Easily perform tests on pulse based devices such as incremental encoders.

1.2 HOW TO USE THIS MANUAL

1.3 SETUP AND SOFTWARE INSTALLATION

1.3.1 HARDWARE CONNECTIONS

1.3.2 SOFTWARE INSTALLATION

A summary of the software installation is as follows:

1.3.2.1 WINTI5000EX PC SOFTWARE INSTALLATION

1.3.2.2 PC USB DRIVER INSTALLATION

1.3.2.3 DOWNLOAD PROGRAMS TO THE TI-5000EX USING WINTI5000EX

1.4 NEW IN THIS RELEASE

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Testing for various encoders follows 3 easy steps.

Figure 2.1 TI-5000EX Pictorial

2.1 BASIC OPERATION

2.1.2.1 TEST AND MOTOR REPAIR MENU

2.1.2.2 SYSTEM SETUP MENU

2.1.2.2.1 SYSTEM DATA TAB

2.1.2.2.2 USER OPTIONS TAB

2.1.2.2.3 DOWNLOAD TI-3000/TI-5000EX SOFTWARE TAB

2.1.2.3 HELP MENU

2.1.3 TEST BUTTONS

2.1.3.1 DATA DISPLAY BUTTON

2.1.3.2 LINE LEVELS BUTTON

2.1.3.3 COUNT TEST BUTTON

2.1.3.4 CONTINUOUS COUNT TEST BUTTON

2.1.3.5 PHASE TEST BUTTON

2.1.3.6 MEMORY TEST BUTTON

2.1.4 MISCELLANEOUS BUTTONS

2.1.4.1 SELECT FEEDBACK BUTTON

2.1.4.1.1 ENCODER/RESOLVER RADIO BUTTONS

2.1.4.1.2 ENCODER MANUFACTURER MENU

2.1.4.1.3 ENCODER TYPE MENU

2.1.4.1.4 MOTOR MANUFACTURER (MEMORY) MENU

2.1.4.1.5 COUNTS PER REVOLUTION BUTTON

2.1.4.2 DISPLAY PINOUT BUTTON

2.1.4.3 SAVE REPORT TO FILE BUTTON

2.1.4.4 PRINT REPORT BUTTON

2.1.4.5 POLES MENU

Currently, 2, 4, 6, or 8 poles may be selected.

2.2 SERIAL ENCODER GENERAL INFORMATION

2.2.1 DATA DISPLAY

2.2.1.1 ENCODER SELECTION

2.2.1.3 POSITION COUNT

2.2.1.4 ENCODER STATUS

2.2.2 COUNT TEST

2.2.2.6 STUCK BITS