Rockwell Automation Allen-Bradley ALEC 4100-5.3 Installation And Setup Manual
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Rockwell Automation Allen-Bradley ALEC 4100-5.3 Installation And Setup Manual

Rockwell Automation Allen-Bradley ALEC 4100-5.3 Installation And Setup Manual

Axislink encoder converter
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ALEC
AxisLink Encoder
Converter
Cat No. 4100-5.3
Installation and Setup Manual

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Summary of Contents for Rockwell Automation Allen-Bradley ALEC 4100-5.3

  • Page 1 ALEC AxisLink Encoder Converter Cat No. 4100-5.3 Installation and Setup Manual...
  • Page 2 Reproduction of the contents of this copyrighted publication, in whole or part, without written permission of Rockwell Automation, is prohibited. Throughout this manual we use notes to make you aware of safety...
  • Page 3 European Communities (EC) If this product has the CE mark it is approved for installation within the European Union and EEA regions. It has been designed and Directive Compliance tested to meet the following directives. EMC Directive This product is tested to meet the Council Directive 89/336/EC Electromagnetic Compatibility (EMC) by applying the following standards, in whole or in part, documented in a technical construction file:...

  • Page 5: Table Of Contents

    Table of Contents Preface Read This Manual Read This Manual ....... . . 1 Who Should Use this Manual.
  • Page 6 Chapter 3 Setup Chapter Objectives ....... 27 Setting the Rotary Switches ......27 Selecting the Operation Mode .
  • Page 7 DIP Switches ....... . . 48 Resetting the Encoder Mode ..... . 49 Encoder OK LED .
  • Page 8 Publication 4100-5.3 - June 1999...

  • Page 9: Preface

    Preface Read This Manual Read and understand this instruction manual. It provides the necessary information to let you install, connect, and set up the ALEC for safe, reliable operation. This preface covers the following topics: • Who should use this manual •...

  • Page 10: Safety Precautions

    Preface Safety Precautions The following general precautions apply to the ALEC: Electric shock can kill. Make sure the ALEC is safely ATTENTION installed in accordance with the Installation and Set-up chapters of this manual. Avoid contact with electrical wires and cabling while power is on. Only trained service personnel should open the electrical cabinet.

  • Page 11: Terminology

    Preface Contents of this Manual Chapter Title Contents Preface Describes the purpose, background, and scope of this manual. Also specifies the audience for whom this manual is intended. Overview Provides a general description of the ALEC, its features and mechanical specifications. Installation &...

  • Page 12: Common Techniques Used In This Manual

    Preface AxisLink - is an IMC S Class option which links multiple motion controllers and ALECs to provide real-time axis coordination between their axes in distributed multi-axis system. Virtual Axis - An axis on one motion controller, which is linked to an axis on another motion controller or ALEC via AxisLink.

  • Page 13: Allen-Bradley Support

    See the Related Documentation section of this chapter for the publication numbers of other manuals that can help with this product. The Rockwell Automation Technical Support number is: 1-603-443-5419 On the Web For information about Allen-Bradley, visit the following World Wide Web site: http://www.ab.com/...
  • Page 14 Preface Publication 4100-5.3 - June 1999...

  • Page 15: Overview

    Chapter Overview ALEC Description The ALEC is a single-axis AxisLink Encoder Converter which interfaces a single incremental encoder to Allen-Bradley IMC S Class motion controllers via AxisLink. As such, it provides a master encoder input for IMC S Class motion controllers or 1394 GMC systems without the need to sacrifice a full servo axis for use as a master encoder input.

  • Page 16: Alec Mechanical Specifications

    Overview The optically isolated encoder input accepts 5 Volt differential quadrature signals from standard incremental encoders. 5V and 12V DC are available from the ALEC for powering the encoder. An optically isolated registration input which latches encoder position is provided for direct interface to a position registration sensor. This input can be used directly with 5V or 24 V devices.
  • Page 17 Overview Package Specifications Package size 300.23 x 130.175 x 48.26 mm and (in.) (11.82 x 5.125 x 1.9) Product weight 1.68 kg and (lbs.) (3.69) Material Painted Steel Publication 4100-5.3 - June 1999...
  • Page 18 Overview Publication 4100-5.3 - June 1999...

  • Page 19: Installation & Hook-Up

    Chapter Installation & Hook-Up Chapter Objectives Read this entire chapter before beginning to mount, connect, or wire any of the components to the ALEC. It is the responsibility of the installer to see that the installation conforms to the directions in this manual and local codes and procedures.

  • Page 20: Emc Directive

    Installation & Hook-Up EMC Directive The ALEC is tested to meet Council Directive 89/336 Electromagnetic Compatibility (EMC) in accordance with Article 10 (1). The following directives apply: • EN 50081-2 EMC-Generic Emission Standard, Part 2-Industrial Environment. • EN 50082-2 EMC-Generic Immunity Standard, Part 2-Industrial Environment.

  • Page 21: Connecting The Alec

    Installation & Hook-Up To avoid a shock hazard, remove all power to the system ATTENTION panel before mounting the ALEC. The mounting tabs should be bolted firmly to the metal enclosure. The following diagram shows the proper method of mounting to make sure the ALEC is grounded.

  • Page 22: Wiring The Alec

    Installation & Hook-Up See the “Setup” Chapter in this manual for instructions on setting these switches. The following section details how to wire the : • AxisLink cable • Incremental Encoder • Registration Input • Power connector • Fault Relay Wiring the ALEC There are several connectors on the front of the ALEC.

  • Page 23: Connecting Axislink

    Installation & Hook-Up Table 2.1 Terminal Steps If the terminals are: Do this: Not open Go to step 3 Open Go to step 4 2. Using a small, flat-head screwdriver, turn the clamping screw counter-clockwise several times. 3. Using a proper stripping tool, strip the wire insulation back on the cable lead.
  • Page 24 Installation & Hook-Up Figure 2.3 Wiring the AxisLink Connector AxisLink Wiring Extended Length Standard Length Yellow Blue Shield Shield AxisLink Cable AxisLink Cable Clear Black A-B 1770-CD Carol C8014 Belden 9463 Belden 9182 *Install termination resistor only if this is the first or last module on the AxisLink line.

  • Page 25: Connecting The Encoder

    Installation & Hook-Up Connecting the Encoder Encoders are connected to the ALEC using a supplied cable assembly. Two encoder cable assemblies are available as shown in the following table. Table 2.3 ALEC Encoder Cable Assemblies Order Number Length 4100-CAE15 15 feet (4.5 meters) 4100-CAE30 30 feet (9 meters) The encoder cable assemblies shown in the preceding table are...

  • Page 26: Allen-Bradley 845F, 845H, And 845T Encoders

    Installation & Hook-Up all the way to the right for 5V encoders. See the “Setup” chapter in this manual for information on selecting the encoder voltage. The required mode must be selected before applying ATTENTION power to the ALEC. Improper voltage applied to the encoder can cause damage to the encoder, the ALEC, and to the operator.

  • Page 27: Allen-Bradley 845P Encoders

    Installation & Hook-Up Table 2.5 ALEC Connections for AB 845K Encoders ALEC Signal 4100-CAExx Encoder Encoder Wire Color Wire Color Signal Power B+ Input Common Black Black B+ Return Allen-Bradley 845P Encoders If you are using an Allen-Bradley 845P-SHC14-xx3 incremental encoder, use the following table for your connections.

  • Page 28: Connecting A Registration Sensor

    Installation & Hook-Up Connecting a Registration The ALEC provides a high-speed optically isolated registration input. If required in your application, this input can be used to latch the Sensor position of the encoder when the registration sensor is activated. The registration input requires 2.5 mA at 5V DC or 24V DC to operate.

  • Page 29: Using The Registration Input

    Installation & Hook-Up Figure 2.6 Current-sourcing Registration Sensor Power Current-sourcing Supply Registration − Sensor Supply Output Common *Use 5V terminal and 5V power supply for 5V sensors. Use 24V terminal and 24V power supply for 24V sensors. Recommended cable is Belden 9501 or equivalent. The connections shown in the figures are typical.

  • Page 30: Power Supply Connector

    Installation & Hook-Up making them more susceptible to interference. For these devices, the ON current can be raised by a shunt resistor across the registration input, as shown in the following diagram. Figure 2.7 ALEC Terminal Block ALEC AxisLink Terminal Block Normal 24V Registration Connections...
  • Page 31 Installation & Hook-Up The pin layout and functionality for this connector are shown in the following table. Table 2.7 Power Supply/Fault Relay Pin Functions Power Supply Pin Position Pin Function from Top Common Power (18-36V DC) Fault N/O Relay Contact Reference - The following diagram illustrates the power connections for the ALEC.

  • Page 32: Fault Relay

    Installation & Hook-Up sure you correct the wiring before replacing the fuse with a 2A Slow Blow, 1/4 x 1 1/4 fuse of the same type for continued protection. Do not apply power to the ALEC until the Mode switch ATTENTION is set correctly and all other connections have been made.
  • Page 33 Installation & Hook-Up A typical fault detection scheme may require additional circuitry when used in applications where the ALEC fault contacts do not have sufficient capacity to drive a fault detection circuit directly. Publication 4100-5.3 - June 1999...
  • Page 34 Installation & Hook-Up Publication 4100-5.3 - June 1999...

  • Page 35: Setup

    Chapter Setup Chapter Objectives The ALEC is used in conjunction with the 1394 GMC System or the S Class Compact motion controller and an encoder. It is not a stand-alone product and must be configured to work with the hardware connected to it. This involves specific steps that are determined by the make and model of the hardware connected to the ALEC.

  • Page 36: Selecting The Axislink Address

    Setup The update rate for the ALEC must match the servo rate ATTENTION for the motion controller. The following table lists the switch setting and its accompanying frequency. Switch positions 8 through F are reserved by IMPORTANT Allen-Bradley for future use. Table 3.1 ALEC Operating Modes Mode Servo Position...

  • Page 37: Selecting The Options Configuration

    Setup Extended AxisLink then the ALEC can make use of any of the settings available on the AxisLink Address rotary switch. In Standard AxisLink only switch settings 0 through 7 IMPORTANT are available for use. Selecting the Options Configuration Located on the front panel of the ALEC are 6 DIP switches for setting the operating options.

  • Page 38: Encoder Fault (Enc. Fault On/Off)

    Setup Encoder Fault (Enc. Fault On/Off) This DIP switch (number 3) enables or disables the encoder fault. When the switch is in the On position (switch set to left), Encoder Fault is enabled. This means that when the ALEC detects a loss of encoder signal, the Encoder OK LED goes off, the CPU OK LED goes off, and the Fault Relay is opened.

  • Page 39: Extended Versus Standard Axislink

    Setup Extended versus Standard AxisLink AxisLink has two modes of operation: Standard and Extended. In standard mode the maximum AxisLink cable length for the connected modules is limited to 85 feet (25 meters). In extended mode modules can be connected as needed on the AxisLink cable for up to 410 feet (125 meters).
  • Page 40 Setup Table 3.3 Alec Modes for Use with Allen-Bradley Encoders For Allen-Bradley Set Mode Switch Set DIP Switch 1 Encoder Model for Encoder Voltage 845F-SJxZ14-xxYx... 0 - 7 845F-SJxZ24-xxYx... 0 - 7 845H-SJxx14xxyx... 0 - 7 845H-SJxx24xxYx... 0 - 7 845K-SAxZ14-xxY3 0 - 7 845K-SAxZ24-xxY3...

  • Page 41: Powering The Alec

    Setup Check the status of other devices connected to the same ATTENTION AxisLink cable before pressing the Reset button on the ALEC. Powering the ALEC After setting the Mode and AxisLink Address switches and making the necessary connection as described in the installation section of this manual, you can apply power to the ALEC.

  • Page 42: Alec With Gml Commander

    Setup ALEC With GML The ALEC is used with a GML Commander configured for AxisLink or Extended AxisLink. Before Commander can download a diagram to Commander the ALEC, the Mode rotary switch must be set to the same servo update rate as any motion controllers or other ALECs connected to the same AxisLink cable.
  • Page 43 Setup 10. Download the diagram. AxisLink is not enabled until the diagram is downloaded. IMPORTANT Once AxisLink is enabled, the AL LED should be green. If the AL LED is red, reset the ALEC by pressing the Reset button on the front panel of the ALEC box.
  • Page 44 Setup Publication 4100-5.3 - June 1999...

  • Page 45: Fault Indication & Control Status

    Chapter Fault Indication & Control Status Chapter Objectives This chapter covers the ALEC operation status. There are three status LEDs on the front panel of the ALEC. These LEDs provide “at-a-glance” monitoring of the system. The three LEDs monitor different aspects of the ALEC/AxisLink system. The LEDs are labeled: AL, CPU OK, and Encoder OK.

  • Page 46: Axislink Fault

    Fault Indication & Control Status cause other control devices to work erratically which could cause machine damage or personal injury. Pressing the Reset Button on the ALEC can result in ATTENTION erratic behavior in other attached control devices. This can create a dangerous situation for both the machine and the operator.

  • Page 47: No Fault

    Fault Indication & Control Status No Fault A green AL LED indicates AxisLink is running properly. This is the normal condition after power up and while the link is working. Table 4.1 AL LED Status Indicators AL LED Status Condition AxisLink Fault At least 256 link errors - AxisLink Shuts Down...
  • Page 48 Fault Indication & Control Status Publication 4100-5.3 - June 1999...

  • Page 49: Specifications

    Appendix Specifications Figure A.1 shows the front panel layout showing the dip switches, pin Figure A.1 ALEC Front Panel locations, rotary switches, and LEDs for the ALEC. The following tables provide explanations for the rotary switches, dip switches, and pins. Reset Table A.1 Mode Rotary Switch Settings CPU OK...
  • Page 50 Specifications DIP Switches numbered 4, 5, and 6 must all be set to the ATTENTION same position. Table A.3 AxisLink Connector Pin location Standard Extended Length Length Blue Black Middle Shield Shield Bottom Clear Yellow Table A.4 Incremental Encoder Connector Common Encoder Power...
  • Page 51 Specifications Table A.6 Environmental Specification Specification Description Operating Temperature 0 to 50 Storage Temperature -40 to 85 Humidity 95% non condensing @ 50 Table A.7 Electrical Specifications Specifications Descriptions Power Input 18 - 36 Volts DC; 12 Watts maximum Fuse 2A Slow Blow, 1/4 x 1 1/4 Protection Reverse voltage via front panel fuse...
  • Page 52 Specifications Table A.8 Encoder Input Specifications Specification Description Encoder Minimum Voltage +/- 3.0V differential (A - A\, B - B\) Input Impedance (see Encoder Input Equivalent Circuit diagram, figure A.6) Encoder Power 5V DC or 12V DC +/- 4% at 0.5A maximum available from ALEC Table A.9 Registration Input Specifications Specification...

  • Page 53: Equivalent Circuit Diagrams

    Specifications Table A.10 AxisLink Specifications Specifications Descriptions Descriptions Standard Extended Length Length Maximum Number of Nodes 8 with Standard 8 with Standard Address; 16 Address; see with Extended table in Address Extended Versus Standard AxisLink in the Setup chapter of this manual.
  • Page 54 Specifications Figure A.2 Encoder Input Equivalent Circuit 400 pF A+ or B+ or Z+ A- or B- or Z- 400 pF Includes encoder loss detection circuitry on A and B quadrature channels. This value is 10.5k for Marker (Z) Channel. Figure A.3 Registration Input Equivalent Circuit 470pF 1.5V...

  • Page 55: Upgrading From Alec Series C To Series D

    Appendix Upgrading From ALEC Series C to Series D The ALEC Series D has undergone some changes that affect the mounting, wiring, and configuring of the ALEC when upgrading from an ALEC series C to an ALEC series D. Summary of Changes Physical Dimensions The length and width of the box have seen no appreciable difference in size.

  • Page 56: Axislink Address Rotary Switch

    Upgrading From ALEC Series C to Series D Table B.1 Comparative Frequency Values Switch Setting ALEC Series C ALEC Series D 250 Hz Reserved Not available Reserved The Mode switches in the Series D no longer control the encoder power output voltage. The Encoder Output voltage is now controlled by the position of DIP switch 1.
  • Page 57 Upgrading From ALEC Series C to Series D Resetting the Encoder Mode The following table shows the differences between series C and series D for setting the switches for the update frequency and the output voltage for the encoder. Table B.3 Comparative Switch Settings Update Rate Setting for ALEC series Setting for ALEC series D...
  • Page 58 Upgrading From ALEC Series C to Series D Fault Relay The power connector has been enlarged to contain two more pins. The top two pins are used for connecting power and the bottom two pins are for connecting a fault relay. For more detailed information about any of the changes made to the ALEC series D, review the material in this manual.
  • Page 59 Index AL LED Fauilts ALEC With GML Commander AxisLink no fault Allen-Bradley Support Fault Relay AxisLink Address rotary switch faults AxisLink faulted AxisLink Failing AxisLink Fault Features, Fuse, CE requirements Commander Installing the ALEC AxisLink Configuration Comparative Frequency Values Comparative Switch Settings Mode rotary switch Configuration Mode Settings...
  • Page 60 Index Environmental Support Incremental Encoder Connector Allen-Bradley Support Mechanical Allen-Bradley, mechanical Local Product Support Mechanical, local product, Mode Rotary Switch Settings Technical Product Assistance Package, technical product assistance, Registration Input support Specifications Encoder input On the Web Summary of Changes AxisLink Address Rotary Switch Encoder OK LED Wiring...
  • Page 61 Back Cover Publication 4100-5.3 - June 1999 Supersedes Publication 4100-5.3 -July 1998 © 1999 Rockwell International Corporation. Printed in the U.S.A.

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