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Encoders Frequently Asked Questions

Q: What is a differential line output? per revolution from channel A, and 100 per revolution (PPR). When choosing your
A: Differential output refers to the fact pulses from channel B. This is a total of calibration constant, remember, the closer
that each channel has a complement 200 pulses if your controller can count to 1 the better. The value of the calibration
channel, i.e. Channel A and Channel A both channels (X2 logic). Some controllers constant is your best resolution per pulse
not. A differential line driver is used to can count the rising edge and the falling of the encoder.
edge of each pulse (on both channels)
help increase noise immunity. It also Q: How do I choose the pulses per
thereby increasing the effective resolution
allows you to sink or source more current
by a factor of four (X4 logic), and counting revolution (PPR)?
than a Totem-pole output. A differential A: When choosing the PPR value of the
line driver will work with either a sinking 400 edges per revolution on a 100 PPR
quadrature encoder. This doesn’t mean encoder, you should follow a few simple
or sourcing circuit. It can also help in rules. Make sure that you do not choose a
increasing the distance that a signal is that there are 400 pulses coming from a
100 PPR quadrature encoder. PPR that will exceed the maximum input
transmitted. frequency of the controller (or whatever
Q: What is an open collector output? Q: Why do I need a pull-up resistor? device the encoder is driving). To calculate
A: An open collector output is an NPN A: A pull-up resistor is used to pull the the max frequency of the encoder signal
transistor. An NPN transistor allows the logic high voltage level up to the level (in Hz): simply multiply the speed that the
sinking of current to common. It can be of the operating voltage. This is useful encoder will spin (in revs/sec) by the PPR
thought of as a switch that allows the when the output of the open collector is of the encoder (don’t forget to take X2
circuit to be connected to common after not reaching the voltage level needed to or X4 logic into account if it applies for
the load. This means that a source is indicate a logic high signal or when noise your application). Try to chose a PPR that
required for the output to work. A supply is present on the signal line. When a logic is an even multiple of the value you are
through a load must be connected to the high signal is present, its voltage level will trying to measure or display. For example,
output, otherwise the NPN transistor is be approximately that of the operating if one revolution of the encoder equates
simply creating a path to common, i.e. voltage for an open circuit. The difference to 12 inches of travel, you might chose a
a dry contact. Therefore, if you were to is due to the voltage drop across the pull- 1200 PPR encoder. This can eliminate or
measure the voltage at the output of an up resistor. This is not necessarily true if simplify the need for a calibration constant
open collector that is not connected to the load is referenced to ground. Pull-up or scaling factor and more importantly, it
a supply, you would not see a change in resistors are also used to convert sinking eliminates the possibility of accumulating
voltage. The voltage should be measured devices to sourcing devices, which inverts a rounding error over many cycles of the
across the output load to determine if the the pulse train. encoder. In this example you would be
open collector is working properly. Q: What is the difference between X2 able to measure the travel to a resolution
of 1/100 of an inch. You should also
Q: What is a Totem-pole output? and X4 logic?
consider any 2x or 4x counting logic in
A: A Totem-pole output, sometimes A: Some devices that are commonly your controller. If your controller can “see”
referred to as a push-pull output, is a interfaced to encoders (controllers, pulses on both the A and B channels (2x
bipolar output with active devices that counters, displays) can detect more events logic), then it will count 2400 pulses for
are controlled such that, as the resistance per revolution than the rated PPR output every 12 inches of travel in our example.
of one increases, the resistance of the of a quadrature encoder signal. Because a If the controller counts both the leading
other decreases; so that according to the quadrature encoder provides two channels edge and the trailing edge of each of the
relative states of the two active devices, of pulses, a controller that counts the pulses on both channels (4x logic), then it
the output voltage can swing between pulses on both channels can count twice will count 4800 edges per revolution and
levels approaching the two supply (X2) the PPR output of a given encoder. your effective resolution would increase to
voltages. The term ‘totem-pole output,’ For example, a controller with X2 logic can 1/400 of an inch per count.
as commonly used, does not include count 240 pulses per rev. from a 120 PPR
encoder. Some controllers can count the ( FAQs continued on next page )
three-state outputs. A Totem-pole circuit
can sink current from a voltage source or it rising edge and the falling edge of each Q: How accurate will an encoder be in
can supply current to a sinking device (but pulse (on both channels) thereby counting my application?
only one configuration can be wired at one four times (X4) the PPR rating of the A: Encoders can provide a very accurate
time). encoder (or 480 edges per revolution in indication of rotational position, but it’s
our example). It’s important to remember impossible to say how accurate a given
Q: What is a quadrature output? that a quadrature encoder produces two encoder will be in a real-world application.
A: Quadrature output refers to the use of channels of pulses at a given PPR. X2 or X4 Mechanical inaccuracies and electrical
two output channels (A and B) separated logic refers to how the controller (or other issues such as noise, or lost counts can
by 90 degrees of phase shift. The fact device) interprets those pulse streams. affect the accuracy of any system. A good
that the signals are 90 degrees out of Q: Is shielded cable needed? rule of thumb is to design the system to
phase allows a controller to determine measure from 2 to 5 times more resolution
the direction of rotation, i.e. if channel A A: YES. The use of shielded cable is highly than your desired accuracy. For example: if
leads B then the encoder is spinning one recommended. This is especially true for you wish to accurately measure movement
direction, if B leads A then it is spinning areas in which large amounts of electrical of 1/100th of an inch, you should select
the other direction. Refer to the channel noise exist. If you are having any noise an encoder that can deliver at least 200
timing charts for a graphical view of this problems, or suspect that you might, then counts per inch of resolution. In a rotary
concept. Remember that each channel use a shielded cable. application - if you need accuracy within 6
provides the rated pulses per revolution Q: How do I set my calibration constant? degrees, select an encoder that can deliver
(PPR) for each encoder. For example: with at least 120 counts per revolution ( a
A: The calibration constant can be resolution of 3 degrees) to your controller.
a 100 PPR encoder, there are 100 pulses simplified by selecting the correct pulses

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 For the latest prices, please check AutomationDirect.com.
1-800-633-0405

Encoders Frequently Asked Questions

Q: How far away can I place my encoder Gray code is used to prevent errors as can be wired for use with either sinking
from my system? transitions to the next state occur. An or sourcing inputs. If used with a sinking
A: There is no set answer to this question. example of how an error could occur input, one side of the pushbutton would
Many factors play a role in determining would be when both values in the be wired to +VDC and the other side wired
the maximum length of cable that can be sequence were true. This can occur due to to the sinking input. If used with a sourcing
used to connect the units together. The the timing sequence and the capacitance input, one side of the pushbutton would
largest problem with running long lengths of the cable. The transition from 0011 to be wired to 0V and the other side wired to
of cable is that the cable becomes more 0100 could cause 0111 to be generated the sourcing input.
susceptible to noise. This is due to the for a couple of microseconds. With gray
capacitance of the cable, the cable acting as code this is not possible since only one bit
an antenna, and the loss of power through changes state at any given time.
the cable. The maximum distance of cable Q: How do I convert Gray code to
can be achieved by following some basic binary?
wiring principles. Do not run the cable near
objects that create a lot of electrical noise.
A: The conversion from Gray code to
binary is simple.
This includes AC motors, arc welders, AC
power lines, and transformers. Use twisted Step 1: Write the number down and copy
pair cabling when using the signal and its the left most digit under itself.
compliment, and shielded cabling when Step 2: Add the highlighted binary digit
running any type of signal. Use the highest to the Gray code immediately up and to
voltage available for the output voltage. the right of it. So, 1 plus 1 is 0 dropping
For example, if the encoder will output 5 the carried digit. Write the result next to
to 24 volts, then use 24 volts. Use an open the binary digit just added. Drop all of the
collector or differential line driver output carried digits.
with a differential receiver so that the
maximum amount of current can be sink/ Step 3: Repeat Step 2 until the number
sourced. If you are using the encoder as is completed. Fortunately, many PLCs
an input to more than one controller, use have easy-to-use Gray code conversion
a signal amplifier. This is also a good way instructions available.
to help increase the distance a signal can Q: What is a sinking or sourcing Input?
travel. Typical maximum distances for a
differential line driver are around 100 feet
A: The terms sinking and sourcing
inputs simply refer to the current flow in
or more when using a differential input. For
a transistor. This means that the inputs
an open collector the distance is around 35
require a voltage (current) and a load to
feet.
operate.
Q: Why use an absolute encoder? Sinking inputs:
A: An absolute encoder has each position
of the revolution uniquely numbered. • Require the external circuit to supply
This means that instead of an output of voltage/current.
pulses, you get an output that is a specific • “Sink” the supplied voltage (current).
value in a binary format. This is very useful
• Will be OFF when there is 0V on the
when exact positioning is a must. If the
terminal.
power should be lost, the actual value of
the position will be known when power is • Will be ON when there is +VDC on the
restored, since each location in an absolute terminal.
encoder’s revolution is a unique binary Sourcing inputs:
value. The exact position will be known
even if the controller loses power and the • Require the external circuit to provide
process is moved. a path to 0V.
Q: What is Gray code? • “Source” voltage (current) into the
A: Gray code is a form of binary. The external circuit.
difference between Gray code and binary • Will be OFF when there is +VDC on
is the method of incrementing to the next the terminal (no current is flowing
number. In Gray code, only one digit may from the input).
change states for every increment. This • Will be ON when there is 0V on the
means the count sequence would look terminal (current is flowing from the
something like this: 0, 1, 3, 2, 6, and 7. This input).
is different than standard binary, where the
sequence would be 0, 1, 2, 3, 4, and 5. A pushbutton (with a set of N.O. contacts)

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