FACTORY AUTOMATION

Rotary Encoders
Frequently Asked Questions

PEPPERL+FUCHS
 INDEX.

1.0 Incremental Encoder.

1.1 How to choose Pulse per Revolution.

1.2 How far can I place Encoder from my system.

1.3 Is Shielded cable needed.

1.4 Is coupling required.

1.5 What is differential line driver.

1.6 What is open collector output.

1.7 What is totem pole output.

1.8 What is push-pull output.

1.9 What is sinking and sourcing input.

1.10 What is quadrature output.

1.11 What is the difference between quadrature and x4 logic.

1.12 What are A and B channels used for.

1.13 What is Index pulse.

1.14 Why do I need a pull up resistor.

1.15 Do I need to shut down my machine to change an encoder.

1.16 What equipment do I need to troubleshoot an encoder.

2.0 What is difference between Absolute & Incremental Encoder.

2.1 What is Gray code.

2.2 How to convert Gray code to binary.

FA – Product Management Division PEPPERL + FUCHS
Singapore

1.0 Incremental Encoder.

1.1 How do I choose the Pulses Per Revolution (PPR)?

When choosing the PPR value of the encoder, please keep a few simple rules in mind.

a. Make sure that you do not choose a PPR that will cause you to exceed the maximum
frequency of your controller or encoder.
b. Check for the motor shaft speed, the speed and pulses put together should not exceed
the encoder & controller max operating frequency.
c. Try to choose a PPR that is close to the value you wish to display, this eliminates the
need for scaling. For example, If you wish to display 12 inches for every revolution
choose a 12PPR encoder. If you wish to display 12.00 inches, choose 1200 PPR.
d. Do not forget the multiplication factor of the controller's input. Most controllers have X2 or
X4 logic. If it is X2 logic, choose a 600 PPR for a 12.00 display; and the 300 PPR to
display 12.00 for X4 logic controller.

1.2 How far away can I place an encoder from my system?

There is no set answer to this question. Many factors play a role in determining the maximum
length of cable that can be used to connect the units together. The largest problem with running
long lengths of cable is that the cable becomes more susceptible to noise. This is due to the
capacitance of the cable, the cable acting as an antenna, and the loss of power through the
cable. The maximum distance of cable can be achieved by following some basic wiring
principles.

a. Do not run the cable near objects that create a lot of electrical noise. This includes AC
motors, Arc welders, AC power lines, and transformers.
b. Use twisted pair cabling when using the signal and its compliment, and shielded cabling
when running any type of signal.
c. Use plastic disc coupling to eliminate noise interference & grounding problem
d. Use the highest voltage available for the output voltage. For example if the encoder will
output 5 to 24 volts, then use 24 volts. Use an Open Collector or Differential Line Driver
output with a differential receiver so that the maximum amount of current can be
sink/sourced.
e. If you are using the encoder as an input to more than 1 controller, use a signal amplifier.
This is also a good way to help increase the distance a signal can travel. Typical
maximum distances for a Differential Line Driver are around 100 ft.or more when using a
differential input, and for an Open Collector the distance is around 35 ft.

1.3 Is shielded cable needed?

YES. The use of shielded cable is highly recommended. This is especially true for areas in which
large amounts of electrical noise exist. If you are having any noise problems, or suspect that you
might, then use a shielded cable.

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Singapore

1.4 Is coupling required?

YES. The use of coupling protects the encoder shaft bearings & avoids torque transfer from the
motor shaft to the encoder. Couplings also compensate the angular, radial and axial
displacements.

1.5 What is a Differential Line Driver Output?

A differential output refers to the fact that each channel has a complement channel, i.e. Channel
A and Channel A not. A differential line driver is used to help increase noise immunity. A
differential line driver also allows you to sink or source more current then a Totem Pole output. A
differential line driver will work both with a sinking or sourcing circuit. It can also help in
increasing the distance in which a signal is transmitted.

1.6 What is an Open Collector Output?

For an NPN transistor
The open collector output is the unconnected collector of an NPN transistor made available to
the external circuitry. It switches to ground when active (ON). The Emitter of the transistor is
typically connector to the ground (either 0V or –ve supply) and the base is driven by a positive
control voltage signal. Thus the transistor “translates” the low current and low voltage output of
a logic device to provide an output that can switch a higher current and voltage to the specified
limits of the transistor. This type of output can be used with pull-up resistor to translate a logic
level from one voltage to another, or to drive lamps, relays etc that have a positive voltage on
one terminal and require a switch to ground to activate.
For a PNP transistor the logic is simply reversed.

1.7 What is a Totem Pole Output?

A Totem Pole output is essentially the same as a Push Pull output; however, it is the terminology
commonly used when referring to a TTL device. The major difference between it and a Push Pull
is the amount of current that it can sink or source. The Totem Pole output can sink/source less
current then a Push Pull output is capable of sinking or sourcing. The other major difference is
the output voltage between the two. The Totem Pole is a 5V DC signal only, where the Push Pull
will follow the input voltage.

1.8 What is a Push Pull Output?

A Push Pull output is an output that allows you to connect either a sinking or sourcing circuit.
This type of an output allows you to sink more current than a Totem Pole output and follow the
input voltage. A Push Pull output is chosen when an Open Collector output will not work with the
controller that is connected to the encoder.

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Prepared By: Prakash Company Registration No.: 199003130E
FA – Product Management Division PEPPERL + FUCHS
Singapore

1.9 What is a Sinking or Sourcing input?

Sinking and Sourcing inputs simply refer to the current flow in a transistor. This means that
they require a voltage and a load to operate. A sinking input requires the voltage and load
to be present before connecting it to the circuit. This means that it is "sinking" the current
to ground for the circuit. A sourcing input must be before the load in the circuit. This
means that it is "sourcing" the current to the circuit. Voltage and a load must be present in
either case to detect a voltage change at the input. The same is true for sinking or
sourcing outputs.
Sinking Sourcing

1.10 What is a Quadrature output?

Quadrature output refers to the fact that the signals A and B are separated by 90 degrees of
phase shift with A leading B or B leading A depending on the direction of rotation.

1.11 What is the difference between Quadrature and x4 Logic?

Quadrature output refers to the phasing of the output signals. When the output signals, signal A
and B, are 90 degrees out of phase with each other, the output is said to be in quadrature. This
is the only thing that the term quadrature implies.

X4 Logic denotes how the controller will interpret the signal that it is receiving. This is done by
translating each edge of the pulse detected for the A and B channel into its own pulse. This
translation takes place in the controller and not at the encoder.

This means if you order a quadrature encoder with 120 pulses per revolution, the output of
signal A and B will be out of phase by 90 degrees. It does not mean that for every one revolution
that the encoder gives you 480 pulses. The multiplication of the pulse occurs at the controller.

This document serve as a reference guide for user. 5

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FA – Product Management Division PEPPERL + FUCHS
Singapore

1.12 What are the A not and B not Channels used for?
The A not and B not channels are the compliments of the A and B channels. This means that
when signal A is high, signal A not is low and when A is low, signal A not is high. The same is
true for any signal that has a compliment. This is commonly used to keep noise to a minimum.
Some input cards will accept both the A and A not signal. It then compares the two signals to
help eliminate common mode noise that may have been picked up on the line. This is done by
accepting a pulse only when signal A is high and signal A not is low. This is true for any channel
that has a compliment, signal A was used only as an example. This is commonly called a
Differential Output.

1.13 What is the Index pulse (strobe, Z, and I.)?

It is the absolute reference added to an incremental encoder. It is also known as home position.
It signifies a full rotation of the encoder disk.

1.14 Why do I need a pull up resistor?

A pull up resistor is used to "pull" the logic high voltage level up to the level of the operating
voltage. This is useful when the output of the Open Collector is not reaching the voltage level
needed to indicate a logic high signal or when noise is present on the signal line.

1.15 Do I need to shut down my machine to change an encoder?

The best method is to power down the unit. If the supply voltage is accidentally shorted or
grounded, it will damage the encoder.

1.16 What equipment do I need to troubleshoot an encoder?

An oscilloscope or specially designed encoder tester. A basic multimeter will do for basic
diagnostics such as power supply and low speed pulse outputs. Any advanced pulse detection
and diagnostics needs to be performed by a trained technician and an oscilloscope.

2.0 What is the difference between an absolute and an incremental encoder?

Answer: There are a few subtle differences between absolute and incremental rotary encoders.
Incremental encoders have output signals that repeat over the full range of motion. It is
important to understand that each mechanical position is not uniquely defined. When the
incremental encoder is turned on, the position of an incremental encoder is not known since the
output signals are not unique to any singular position. An absolute encoder has each position of
the revolution uniquely numbered. This means that instead of an output of pulses, you get an
output that is a specific value in a binary format. This is very useful when exact positioning is a
must. Since each location in an absolute encoder's revolution is a unique binary value, if the
power should be lost, the actual value of the position will be known when power is restored. The
exact position will be known even if the controller losses power and the process is moved.
This document serve as a reference guide for user. 6
Internet http://www.pepperl-fuchs.com Copyright PEPPERL+FUCHS PTE LTD Part No. PFS_Encoder_FAQ
Prepared By: Prakash Company Registration No.: 199003130E
FA – Product Management Division PEPPERL + FUCHS
Singapore

2.1 What is Gray code?

Gray Code is a form of binary. The difference between Gray code and binary is the method of
incrementing to the next number. In Gray code only one digit may change states for every
increment. This means the count sequence would look something like this 0,1, 3, 2, 6, and 7.
This is different than standard binary, where the sequence would be 0, 1, 2, 3, 4, and 5.
Gray Code Binary
0000 0 0000 0
0001 1 0001 1
0011 2 0010 2
0010 3 0011 3

Gray code is used to prevent errors as transitions to the next state occur. An example of how an
error could occur would be where both values in the sequence where true. This can occur do to
the timing sequence and the capacitance of the cable. The transition from 0011 to 0100 could
cause 0111 to be generated, with Gray code this is not possible.

2.2 How do I convert Gray code to Binary?

The conversion from Gray Code to binary is simple. Gray
Step 1 Write the number down and copy the left most digit 11011
Code
under itself.
1 Binary
Step 2 Add the highlighted binary digit to the Grey code
immediately up and to the right of it. So 1 plus 1 is 0 dropping Gray
11011
the carry. Write the result next to the binary digit just added. Code
Drop all of the carried digits. 10 Binary

Step 3 Repeat Step 2 until the number is completed. Gray

11011
Code
100 Binary
Gray
11011
Code
1001 Binary
Gray
11011
Code
1 0 0 1 0 Binary

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Internet http://www.pepperl-fuchs.com Copyright PEPPERL+FUCHS PTE LTD Part No. PFS_Encoder_FAQ
Prepared By: Prakash Company Registration No.: 199003130E