RESOLVER TO ENCODER CONVERTER

with HALL EFFECT SIMULATION

MODEL 2785502 FOR MOTOR CONTROL APPLICATIONS
*** APPLICATIONS ***
Ideal For Closed Loop Positioning Systems
Machine Tools
Servo Motor Control
Spindle Motor Control
PLC Positioning Control
Index/Rotary Tables
Transfer Lines
Positioning Systems
Robotic Applications
Dispensing Systems

*** ADVANCED FEATURES ***

RESOLVER TO DIGITAL INTERFACE
Easy to Use and Easy to Set Up
Works with R11, R25, or most any Simplify Retrofits
Synchro/Resolver Panel Mount or DIN Rail Option
Incremental encoder output signals Fast Non-Phase Locked Loop Design (No Lag)
Makes resolvers as easy to use as an encoder Highly Accurate
Jumper Selectable line counts 250, 256, 500, 512, Tuned Filter for Noise Immunity
1000, 1024, 2000, and 2048 A-quad-B with Index A-Quad-B, Index and Complements
and complements TTL/Line Driver Outputs
Jumper Selectable Excitation Frequency Quadrature encoder signals to 4 mHz
VEGAincluding
2779501 for
2.5,Inductosyn
5.0, and 10Scale
kHz Applications Single +5 vDC Supply Operation
Loss of Signal Detection
With the VEGA 2785502 converter you can have both Fault Signal Output (Line Driver, Open Collector,
the ruggedness of a resolver and the digital simplicity of and Active Pull-Up)
an encoder interface. The 2785502 can be used with Status LED’s for Power, A, B, Z, Hall A, Hall B,
almost any resolver. The INDEX/MARKER pulse Hall C, Signal HI, Signal MID, and Fault
(Channel Z) will occur once per transducer cycle at the Configurable Fault signal conditioning for Fail-
zero degree position. Safe operations
Compact Design and Easy to Install

2785502 SPECIFICATIONS

Excitation: 2.5, 5, or 10 kHz SIMULATED HALL EFFECT OUTPUTS

Max Load: 250 mA
Resolver Input: 0.8 to 10 Vrms The 2779502 Resolver to Digital Converter uses the
Power Requirements: 5 vDC @ 300 mA resolver signals to produce three Hall type signals at TTL
Drive Capacity: 200 mA levels to duplicate the signals required by drives using Hall
Mechanical: 2.825 x 4.75 x 1.00 effect sensors to determine the shaft position for
Accuracy: +/- 2 arc minutes commutation purposes. This makes the 2779502 IDEAL for
retrofitting Drives for AC Servomotors requiring indicators of
CONVERTER ACCURACY AND TRACKING RATE motor shaft position in order to properly commutate the
winding power.
The 2785 board was designed for high speed applications. PRICING AND DELIVERY
The standard converter accuracy is +/- 2 arc minutes. When
using 1000 line counts per excitation phase, with one phase Model Description Price Delivery
= .1000 inch and x4 quadrature, the resolution will be 2785502 Resolver to Digital w/Hall $700.00 In Stock
.000025 inch per count with 1200 IPM the maximum tracking 2785DIN DIN Rail Kit $ 24.00 In Stock
rate. 2785CK1 Solder Connector Kit $ 17.00 In Stock
2785CK2 Crimp Connector Kit $ 27.00 In Stock
2785502 RH Rev. H
 VEGA 2785502 RESOLVER TO ENCODER SPECIFICATIONS AND CONNECTIONS
P1 RESOLVER CONNECTOR QUADRATURE OUTPUT
The VEGA 2785 series of converter boards come standard with
PIN# FUNCTION COLOR
RS-422-A differential drivers and provide up to 40 mA into a 100
1 Sine HI Red ohm differential load. These outputs are also TTL compatible.
2 Sine LO Black
3 Sine Shield SHLD The quadrature (Channel A+ and Channel A-, Channel B+ and
4 Cosine HI Yellow Channel B-) is the default configuration of the 2785 series of boards.
5 Cosine LO Blue A count is considered to occur whenever there is a transition in
6 Cosine Shield SHLD either the Channel A or Channel B output signals. The phase
7 Feedback HI Red/Wht relationship of the two signals indicates the direction of motion as
8 Feedback LO Yel/Wht shown in the figure below.
9 Feedback Shield SHLD
10 +5 vDC (*External) N/A QUADRATURE OUTPUT FORMAT

COUNTING UP COUNTING DOWN

P2 POWER CONNECTOR CHAN A+ CHAN A+
PIN# FUNCTION COLOR
*1 +5 vDC Red
*2 DC Ground Black
CHAN A- CHAN A-

P3 ENCODER CONNECTOR
CHAN B+ CHAN B+
PIN# FUNCTION COLOR
1 DC Ground Black
2 Channel A+ Grey
3 Channel B+ Yellow CHAN B- CHAN B-
4 Channel Z+ Blue
5 DC Ground Black
CHAN Z+ CHAN Z+
6 DC Ground Black
7 DC Ground Black
8 Fault (TTL) Blu/Red
9 DC Ground Black
10 +5 vDC (*External) Red CHAN Z- CHAN Z-
11 Hall A N/A 0 1 2 3 4 0 1 2 3 4
12 Hall B N/A
13 DC Ground Black
14 Channel A- Violet HALL EFFECT OUTPUT
15 Channel B- Orange
Motors with Hall Effect Sensors and magnet are arranged to provide
16 Channel Z- Green
an output from the sensors to which the magnet is adjacent. The
17 +5 vDC (*External) Red magnet may be adjacent to one sensor or between two sensors. When
18 +5 vDC (*External) Red it is between two sensors, both sensors output a signal. This permits
19 !Fault (Configurable) Red/Blk the detection circuitry to resolve the motor shaft position into 6 different
20 !Fault (TTL) Blu/Blk sectors. The 278502 produces signals that emulate the Hall Effect
21 Reserved N/A sensors for a seamless interface.
22 Reserved N/A
23 Reserved N/A
HALL EFFECT OUTPUT FORMAT
24 Hall C N/A
25 Active Pull-Up vDC Blu/Wht
HALL A

HALL B

HALL C

ABC State 101 001 011 010 110 100 101 001
 JUMPER SETTINGS

FREQUENCY SELECTION FAULT MODE OUTPUT SELECTION

The 2785 series of converters provide selectable excitation The 2785 converter board provides several methods of interface
frequencies via SWB1 jumpers B1 and B2. Most Resolver for fail safe fault detection. Pins 8 and 20 on the P3 connector
applications are tuned to 2.5 kHZ. provide a differential fault signal interface. Pin 19 on the P3
connector provides the open collector or active pull-up method of
The 2785 also provides jumper selection of the active filter network fault signal interface. The A quad B signals can also be tri-stated
for the return signal to provide the maximum noise immunity at the during a fault condition for interface to systems with quadrature fault
selected frequency. For the typical Resolver application operating at detection.
2.5 kHZ both J10 and J11 jumpers should be installed. For
excitation frequencies above 2.5 kHZ both jumpers should be DIFFERENTIAL FAULT SIGNAL SET-UP
removed. For low level signal condition at 2.5 kHZ J10 can be Install J4 on pins 2-3. The jumper setting on J3 does not affect the
removed to achieve a x4 internal gain. differential signals and can be removed.

DECIMAL/BINARY SELECTION OPEN COLLECTOR FAULT SIGNAL SET-UP

The 2785 converter card provides both decimal and binary Remove jumper J3. The jumper on J4 does not effect the open
counting modes. Installing SWB1 jumper B3 selects binary counting collector signal but does effect the A quad B signals. If the system
mode to provide selection between 256, 512, 1024, and 2048 line interfacing to the 2785 board does not have quadrature fault
counts. Removing jumper B3 selects the decimal counting mode to detection the J4 jumper should be installed on pins 2-3. The open
provide selection between 250, 500, 1000, and 2000 line counts. collector device is capable of sinking up to 40 vDC @ 600 mA

CHANNEL Z NORMAL/INVERTED SELECTION ACTIVE PULL-UP FAULT SIGNAL SET-UP

The 2785 converter board provides jumper selectable inversion of Install jumper J3. The active pull-up interface is a fail-safe design
the Z Channel (Index) for systems requiring an active low signal. so that in a loss of power condition the 2785 will still drop the fault
Jumper J2 pins 2-3 select the channel Z Normal mode and pins 1-2 signal on Pin 19 of the P3 connector. The source voltage for the
select the Channel Z Inverted mode. Pull-up must be provided on Pin 25 of the P3 connector and can
range from 5-40 vDC. The jumper on J4 does not effect the active
LINE COUNT SELECTION pull-up signal but does effect the A quad B signals. If the system
The 2785 converter board provides 8 jumper selectable line interfacing to the 2785 board does not have quadrature fault
counts. Binary counts are selected by installing SWB1 jumper B3 detection the J4 jumper should be installed on pins 2-3.
and installing the appropriate combination of jumpers B4 and B5.
Most systems using encoder style feedback are set to the x4 TRI-STATE A-QUAD-B FAULT SIGNAL SET-UP
quadrature counting mode so that the effective quadratue counts Install a jumper on J4 on pins 1-2. The 2785 board will Tri-State
are 4 times greater than the physical line count of the encoder. the A-Quad-B signals as well as the Z Channel (Index/Marker
Pulse) during a Fault condition. The +/- Fault TTL signals located
HIGH/LOW SPEED INTERPOLATION on P3 pins 8 and 20 are also Tri-Stated and are NOT a valid
The 2785 converter board provides jumper selectable interpolation interface with this set-up. This interface will allow an immediate
rates for the A quad B signals. Installing SWB1 jumper B6 selects Fault sense by equipment with loss of signal detection with out the
the high speed interpolation. For positioning systems with the need for additional Fault detection circuitry.
maximum feedrate of less than 1200 IPM the LS INTERP should be
selected. For high speed positioning systems with feedrates greater
than 1200 IPM the HS INTERP should be selected.

FUNCTION B1 B2 B3 B4 B5 B6 B7 B8 Quadrature Counts

2.5 kHZ 0 0
5.0 kHZ 1 0
10.0 kHZ 0 1
Reserved 1 1
Decimal Count 0
Binary Count 1
250/256 Lines 0 0 1000 Decimal/1024 Binary
500/512 Lines 1 0 2000 Decimal/4048 Binary
1000/1024 Lines 0 1 4000 Decimal/4096 Binary
2000/2048 Lines* 1 1 8000 Decimal/8192 Binary*
Low Speed Interp 0
High Speed Interp 1
1 Hall Cycle/Rev 0 0
2 Hall Cycle/Rev 1 0
3 Hall Cycle/Rev 0 1
4 Hall Cycle/Rev 1 1
- Figure 1.0 -
* High Resolution Option Only

VEGA CNC 1270 Souter Boulevard Troy, MI 48083 USA (248) 585-3600
 RESOLVER SET-UP PROCEDURE

1) Install the 2785 board as described in the application 9) Jumpers JB7-8 are used to select the number of motor
drawing 2785502. poles per resolver pole (see jumper table Fig. 1.0).

2) Select the fault signal conditioning method by setting 10) Turn the gain potentiometer fully counter-clockwise.
the JB2 and JB3 jumpers as described in the Then turn the gain potentiometer clock-wise until the
JUMPER SETTINGS section and the jumper table MID LED comes on. The signal return on “STG1” test
(Fig. 1.0) based on the application requirements. point should now be 3.8 volts peak to peak. Phase the
position loop if necessary by reversing the Sine HI and
3) Select the Z Channel inverted option by setting J2 to Sine LO wires to reverse the count direction. At this
short pins 2 and 3. The DEFAULT is non-inverting point the basic set-up is complete and the position loop
and having pins 1 and 2 shorted on J2. can now be closed. Set the position loop gain of the
servo system and then continue to Step 11.
4) Select the excitation frequency by JB1-2 of SWB1
(see jumper table Fig. 1.0). 2.5 kHZ is the DEFAULT 11) After the position loop has been closed the phase
setting with both jumpers removed. balance of the 2785 board can be adjusted. To adjust
the phase balance of the 2785 board, observe the
5) Select the passive filter setting by J11 for the excitation return on the “STG1” test point. Adjust the
corresponding frequency setting. The DEFAULT oscilloscope to 100 mvDC per division and offset the
setting is for a board set to 2.5 kHZ and J11 is signal so that just the peak of the signal is visible. Jog
installed. the axis at 30% of its feedrate. If the phase is
unbalanced the peak of the sine wave will bounce and
6) Select the counting style of Binary or Decimal by JB4 become blurred. Adjust the balance pot on the 2785 to
of SWB1 (see jumper table Fig. 1.0). Decimal is the achieve 20 mvDC or less bounce.
DEFAULT setting with the jumper removed.

7) Select the line count per revolution by setting JB4-5

of SWB1 (see jumper table Fig. 1.0). 1000 lines per
revolution (4000 quadrature counts per revolution) is
the DEFAULT setting with JB4 installed and JB5
removed.

8) Select the interpolation rate of the A-Quad-B signals

by setting JB6 of SWB1 (see jumper table Fig. 1.0).
High Speed Interpolation is the DEFAULT setting
with JB6 installed.

LED STATUS INDICATORS TEST POINTS

CHA = Channel A State Indicator GND = Analog Ground

CHB = Channel B State Indicator PA+ = Sine HI (2.6 vDC Peak to Peak)
CHZ = Channel Z (Index/Marker) Indicator PA- = Sine LO (2.6 vDC Peak to Peak)
PWR = Power Status Indicator PB+ = Cosine HI (2.6 vDC Peak to Peak)
PB- = Cosine LO (2.6 vDC Peak to Peak)
HEA = Hall Effect A State Indicator (S1)
HEB = Hall Effect B State Indicator (S2) SIG = Signal Return (1.4-18.0 vDC Peak to Peak)
HEC = Hall Effect C State Indicator (S3) STG1 = Stage 1 Signal (3.8 vDC Peak to Peak)
SCL = Tracking Clock
FLT = Loss of Signal Indicator
MID = Return Signal Proper Indicator
HSG = High Signal Indicator

VEGA CNC 1270 Souter Boulevard Troy, MI 48083 USA (248) 585-3600
 TROUBLE SHOOTING

SYMPTOM CHECKS SOLUTION

No Power LED Check +5 vDC +5 vDC Present Board Failure – Replace
board
Fault LED (Low Signal) Remove power and ohm between “PA+“ Resistance values are less than 30 ohms –
Continuous and “PA-“ note value. Ohm between “PB+” Check for shorts between “PA-“ and “PA+” as
and “PB-“ note value. well as ground. Check for shorts between “PB-“
and “PB+” as well as ground.
Check “PA+” and “PB+“test point for 2.6 Signal not present Board Failure – Replace
volts peak to peak sine excitation board
Check “PA-” and “PB-“test point for 2.6 Signal not present Board Failure – Replace
volts peak to peak sine excitation board
Check “SIG” test point for 4.0 volts peak to Adjust Pre-Amp to achieve 4.0 volts peak to
peak peak
Check “STG1” test point for 3.8 volts peak Repeat Step 10 of the Resolver Set-Up
to peak Procedure
Fault LED (Low Signal) Check “PA+” and “PB+“test point for 2.6 Signal not present Board Failure – Replace
Intermittent volts peak to peak sine excitation board
Check “PA-” and “PB-“test point for 2.6 Signal not present Board Failure – Replace
volts peak to peak sine excitation board
Remove power and ohm between “PA+“ Resistance values differ by more than 3 ohms
and “PA-“ note value. Ohm between “PB+” of each other Check resolver windings –
and “PB-“ not value. Replace slider or cables
Remove power and ohm between “PA+“ Resistance values are less than 30 ohms –
and “PA-“ note value. Ohm between “PB+” Check for shorts between “PA-“ and “PA+” as
and “PB-“ note value. well as ground. Check for shorts between “PB-“
and “PB+” as well as ground.
Cyclic Error Check “STG1” test point for bounce Repeat step 11 of the Resolver Set-Up
Procedure
Remove power and ohm between “PA+“ Resistance values are less than 30 ohms –
and “PA-“ note value. Ohm between “PB+” Check for shorts between “PA-“ and “PA+” as
and “PB-“ note value. well as ground. Check for shorts between “PB-“
and “PB+” as well as ground.
Remove power and ohm between “PA+“ Resistance values are differ by more than 3
and “PA-“ note value. Ohm between “PB+” ohms of each other Check resolver windings
and “PB-“ note value. – Replace resolver or cables
Check “PA+” and “PA-“test point for 4.0 Signal not present Board Failure – Replace
volts peak to peak sine excitation board
Check “PB+” and “PB-“test point for 4.0 Signal not present Board Failure – Replace
volts peak to peak sine excitation board
HSG LED (High Signal) Check “STG1” test point for 3.8 volts peak Repeat Step 10 of the Resolver Set-Up
Continuous to peak Procedure
HSG LED (High Signal) Check “STG1” test point for 3.8 volts peak Follow procedures described in the Fault LED
Intermittent to peak (Low Signal) Intermittent section
MID LED (Signal Midpoint) Signal Proper No Problem… Life is Good
Continuous
MID LED (Signal Midpoint) Check “STG1” test point for bounce Repeat step 11 of the Resolver Set-Up
Intermittent Procedure

VEGA CNC 1270 Souter Boulevard Troy, MI 48083 USA (248) 585-3600
 A B C D E F G H J K L

01 1MC
01
1DS ALLEN BRADLEY 2098-DSD

01 1MTR
DC+ 1
02 ALLEN BRADLEY
1326AB-B2E-11
01 SHUNT A K1
COL 2
03 CONECTION
E K2 2TS
THERMO SWITCH

01 PASSIVE SHUNT (IF REQUIRED)

AB Part No. 2090-USCR-P900 3
04
D B1

01 C B2
BRAKE
05
TB2 MOTOR POWER
CONNECTIONS [2TB-1]
01 BROWN F T1 SERVO
(+) U MOTOR
06
DC BUS
[2TB-2] T2
01 BLACK I
(-) V
07

[2TB-3] T3
01 BLUE B
W
08
G
[2TB-4]
01 GREEN YELLOW H
L1 GND
09

MOTOR POWER RESOLVER

01 L2 CABLE SHIELD CLAMP
10 PRIMARY POWER

01 L3
11
AC INPUT POWER
CONNECTIONS

RED/WHT

YEL/WHT

YELLOW
01 GND

BLACK
12

BLUE
RED
01 L1
13 AUX

G
C

H
A

J
I
AUXILIARY POWER
01 L2

WHT

GRN
RED
AUX

BLK

BLK

BLK
14

01
15
CN1

01 31
16 ENABLE

01 32
17

01 33
18

01 29 I/O
+24 vDC POWER
19
P1

4
2

6
7

5
43 1RD
01
20 SINE HI

COSINE HI
SHIELD

SHIELD

SHIELD
FEEDBACK HI

SINE LO

COSINE LO
FEEDBACK LO

DCR
DRIVE OK
01 44
21
10 FEET MAX
01 27 I/O CN2 P3
DC RETURN COMMON
22
1 BLACK 2
CHAN A+ CHAN A+
23 ANALOG 2 WHT/BLK 14 VEGA
01
23 OUTPUT CHAN A- CHAN A- R/D BOARD
22 ANALOG 3 RED 3 2785502
CHAN B+ CHAN B+
COMMON
01 4 WHT/RED 15
24 CHAN B- CHAN B-
5 GREEN 4
CHAN Z+ CHAN Z+
01 10 WHT/GREEN 16
25 CHAN Z- CHAN Z-
BLUE

01 12 WHT/BLUE 11
26 S1 HALL A
13 YELLOW 12
S2 HALL B
01 8 WHT/YELLOW 24
27 S3 HALL C
14 GRAY 17 P2
EPWR_5V +5 vDC
01 6 WHT/GRAY 1
DC GND

COMMON DC GND
+5 vDC

28
CHASIS 0229
SHIELD
2

01
1

29

SCALE
N/A
VEGA CNC
NAME:
UNLESS OTHERWISE SPECIFIED TOLERANCES ON
DIMENSIONS 2 PLACES .010 3 PLACES .005
DRAWN
ANGLE 2 BREAK ALL SHARP EDGES .005
REMOVE ALL BURS CODY 2785502
FINISH
1270 SOUTER BLVD. CHECKED
CODY Ultra 3000
TROY, MI 48083 ENGINEER
WLH Retrofit
DATE

THIS DOCUMENT CONTAINS PROPRIETARY INFORMATION 10-05-06

MATERIAL AND SUCH INFORMATION MAY NOT BE DISCLOSED TO W.O.#
OTHERS FOR ANY PURPOSE OR USED FOR MANUFAC- 2785 SIZE DRAWING NUMBER CHANGE
TURING PUPOSES WITHOUT WRITTEN PERMISION FROM
INNOVATIVE SUPPORT SERVICES INC.
SHEET NO.

1 OF 1 A 2785502
 4.3500
C22 Q2 RA1
+
C39 +
L1

10 mF

22 mF
PA+

PA-

PB+

PB-

GND
C23 C31

SWB1
+ +

P3
R2

R3
P1 1 C32

10 mF

22 mF

.01
+

100*
R13
C33

.1
L2 10 mF
C10 C13 1

.47
+
C24 U10

.1
U6

Trim
R14

2.2K*
R27

AD9709
U1

R15

100*
BAL

EP1C3T100C6
C25 P4

.1
C14C15
L3

.47

100*
+
R28 1
.47

Trim
+
R29
R4

R5

.47 08/04/06
C16+

100*
.47
R30 +

L4 C17+

22 mF
RP2 +
C26
J11 C18 U7
FREQ
22 mF

+ C34 +

J10 R41

10 mF

22 mF

10K
+
C27
RA2
10 mF
.03*

680*

C3 C11 J2
C19 Q3 C28
+

2.825 L5

.01
R31 R42

C35

10 mF
270*

100K* 10K*

C4 U4
100

C12 R16 1 2.4000

1K

10K
U2 C29

.1
33K*

R6 R17
AVLS32

EGA
AD8618

C36
33K*

1K*

R7 R18 +

L6

22 mF
.01*

3.3K*

C5 R19 U8 20 MHz
2785 C37
7404
6.8K

C6
.01

D1 R20 U5
1
.1
1K*

C7 5711 X1
.47

R21 C30
.1

+
2222

C40

+
4.7K

2.2K

C8 5711 C41 +
.47

R22
AD8564

R32

100 mF
Q6
GAIN U3 D2
3.3K*

68K

15K

R8 R23 R33 100 mF

C38 U9 26LS31
2907
LT1817

J4
6.8K*

4.7K

22 mF
R9 C20 R34
.47

C42

.1
RP1

+
Q5
3.3K*

3.3K*

120K

R10 R24 R35

P2 GND
10
2907

R1
.0022

220*

Trim

10K

C1 R11 R25 R36

2K

L8 L7

+5vDC
C2 1.0 R12 R37 Q4
220

Trim

27K

4.7K

R26
HSG
MID
FLT

HEC
HEB
HEA
PWR
CHZ
CHB
CHA
R43
.015

39K

C21
.1

SIG STG1 SCL R38 J3

Q1 C9

4.750

SCALE
N/A
VEGA CNC
NAME:
UNLESS OTHERWISE SPECIFIED TOLERANCES ON
DIMENSIONS 2 PLACES .010 3 PLACES .005
DRAWN
ANGLE 2 BREAK ALL SHARP EDGES .005
REMOVE ALL BURS WLH 2785
FINISH
1270 SOUTER BLVD. CHECKED
CODY Resolver/Inductosyn
TROY, MI 48083 ENGINEER
WLH to Digital Converter
DATE

THIS DOCUMENT CONTAINS PROPRIETARY INFORMATION 08-02-06

MATERIAL AND SUCH INFORMATION MAY NOT BE DISCLOSED TO W.O.#
OTHERS FOR ANY PURPOSE OR USED FOR MANUFAC- 2785 SIZE DRAWING NUMBER CHANGE
TURING PUPOSES WITHOUT WRITTEN PERMISION FROM
INNOVATIVE SUPPORT SERVICES INC.
SHEET NO.

1 OF 1 A 2785200