Rockwell Automation Allen-Bradley 4100-5.2 User guide

AEC
Absolute Encoder
Converter
(Cat. No. 4100-5.2)
Installation and Setup Manual

Important User Information
Because of the variety of uses for the products described in this
publication, those responsible for the application and use of this
control equipment must satisfy themselves that all necessary steps
have been taken to assure that each application and use meets all
performance and safety requirements, including any applicable laws,
regulations, codes and standards.
The illustrations, charts, sample programs and layout examples shown
in this guide are intended solely for purposes of example. Since there
are many variables and requirements associated with any particular
installation, Allen-Bradley does not assume responsibility or liability
(to include intellectual property liability) for actual use based upon
the examples shown in this publication.
Allen-Bradley publication SGI-1.1, Safety Guidelines for the
Application, Installation and Maintenance of Solid-State Control
(available from your local Allen-Bradley office), describes some
important differences between solid-state equipment and
electromechanical devices that should be taken into consideration
when applying products such as those described in this publication.
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
considerations:
Attention statements help you to:
•identify a hazard
•avoid a hazard
•recognize the consequences
Allen-Bradley is a trademark of Rockwell Automation
ATTENTION
!
Identifies information about practices or
circumstances that can lead to personal injury or
death, property damage or economic loss
IMPORTANT Identifies information that is critical for successful
application and understanding of the product.

European Communities (EC)
Directive Compliance
If this product has the CE mark it is approved for installation within
the European Union and EEA regions. It has been designed and
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:
•EN 50081-2 EMC — Generic Emission Standard, Part 2 —
Industrial Environment
•EN 50082-2 EMC — Generic Immunity Standard, Part 2 —
Industrial Environment
This product is intended for use in an industrial environment.
Low Voltage Directive
This product is tested to meet Council Directive 73/23/EEC Low
Voltage, by applying the safety requirements of EN 61131-2
Programmable Controllers, Part 2 - Equipment Requirements and
Tests. For specific information required by EN 61131-2, see the
appropriate sections in this publication, as well as the Allen-Bradley
publication Industrial Automation Wiring and Grounding Guidelines
For Noise Immunity, publication 1770-4.1.
This equipment is classified as open equipment and must be
mounted in an enclosure during operation to provide safety
protection.

iPublication 4100-UM052B-EN-P - October 2001
Table of Contents
Preface
Read This Manual
Read This Manual . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
Who Should Use this Manual. . . . . . . . . . . . . . . . . . . . . . . . . 1
Purpose of this Manual . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
Safety Precautions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2
Contents of this Manual . . . . . . . . . . . . . . . . . . . . . . . . . . 3
Related Documentation . . . . . . . . . . . . . . . . . . . . . . . . . . 3
Terminology . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
Common Techniques Used in this Manual . . . . . . . . . . . . . . . 4
AEC Product Receiving and Storage Responsibility . . . . . . . . . 5
Allen-Bradley Support . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5
Local Product Support . . . . . . . . . . . . . . . . . . . . . . . . . . . 5
Technical Product Assistance . . . . . . . . . . . . . . . . . . . . . . 6
On the Web . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6
Chapter 1
Overview
AEC Description . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7
AEC Features . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8
AEC Mechanical Specifications. . . . . . . . . . . . . . . . . . . . . . . . 8
Chapter 2
Installation & Hook-Up
Chapter Objectives . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11
Installing the AEC . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11
Complying with European Union Directives. . . . . . . . . . . . . 11
EMC Directive . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12
Mounting the AEC. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12
Connecting the AEC . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15
Connecting the AEC to the 1394 . . . . . . . . . . . . . . . . . . . 16
Connecting the AEC to the Compact. . . . . . . . . . . . . . . . 17
Connecting the AEC to the 1756-MO2AE. . . . . . . . . . . . . 19
Wiring the AEC . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 21
Wiring Cable Flying Leads to the Plugs . . . . . . . . . . . . . . 21
The SSI Connector . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 22

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ii
The Control Connector. . . . . . . . . . . . . . . . . . . . . . . . . . 24
Fault Relay 24
Analog Servo Command Pass Through (For Compact Only) . . . . 26
Power Supply Connector . . . . . . . . . . . . . . . . . . . . . . . . 27
Chapter 3
Setup
Chapter Objectives . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 29
Setting the Rotary Switches . . . . . . . . . . . . . . . . . . . . . . . . . 29
Configuration Switch Tables . . . . . . . . . . . . . . . . . . . . . . . . 30
Configuration Switch A . . . . . . . . . . . . . . . . . . . . . . . . . 30
Configuration Switch B . . . . . . . . . . . . . . . . . . . . . . . . . 31
Powering the AEC. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 32
AEC With GML Commander . . . . . . . . . . . . . . . . . . . . . . . . 32
Adding AEC to your Commander Diagram . . . . . . . . . . . 32
Setting the Transducer Resolution. . . . . . . . . . . . . . . . . . . . . . . . . 33
Selecting Homing Procedure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 33
Aligning Absolute Encoder . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 34
Chapter 4
Operation
Chapter Objectives . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 35
Absolute Position Update . . . . . . . . . . . . . . . . . . . . . . . . . . 35
Incremental Position Output . . . . . . . . . . . . . . . . . . . . . . . . 35
Position at Start-up . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 36
Chapter 5
Fault Indication & Control Status
Chapter Objectives . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 37
Transducer Faults. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 38
Encoder Faults. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 38
Internal Faults . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 39
No Faults. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 39
Appendix A
Specifications
Equivalent Circuit Diagrams. . . . . . . . . . . . . . . . . . . . . . . . . 44

Publication 4100-UM052B-EN-P -October 2001
iii
Appendix B
Strobe Position For Applications Not Using the 1394 or Compact
Absolute Strobe Cycle . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 47
Absolute Strobe Timing . . . . . . . . . . . . . . . . . . . . . . . . . . . . 48
Incremental Strobe Period . . . . . . . . . . . . . . . . . . . . . . . . . . 49
Index

Publication 4100-UM052B-EN-P - October 2001
iv

1Publication 4100-UM052B-EN-P - October 2001
Preface
Read This Manual
Read and understand this instruction manual. It provides the
necessary information to let you install, connect, and set up the AEC
for safe, reliable operation. This preface covers the following topics:
•Who should use this manual
•The purpose of this manual
•Terms
•Common techniques used in this manual
•Allen-Bradley support
Who Should Use this
Manual
You should read this manual if you are responsible for the installation,
set up or operation of the AEC (Absolute Encoder Converter).
If you do not have a basic understanding of the products listed below,
contact your local Allen-Bradley representative for information on
available training courses before using this product.
•S Class Compact motion controller
•1394 GMC System module
•GML (Graphic Motion Language) Commander software
Purpose of this Manual
This manual is an installation and set up guide for the AEC and
describes the procedures necessary to properly install and configure it
into your motion control system.

Publication 4100-UM052B-EN-P - October 2001
Preface 2
Safety Precautions
The following general precautions apply to the AEC:
ATTENTION
!
Electric shock can kill. Make sure the AEC is safely
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.
This product contains stored energy devices. To
avoid hazard of electrical shock, verify that all
voltage on the capacitors has been discharged
before attempting to service, repair, or remove this
unit. You should only attempt the procedures in
this manual if you are qualified to do so and
familiar with solid-state control equipment and the
safety procedures in publication NFPA 70E and
BS-EN60204.
The system integrator is responsible for local safety
and electrical codes.
ATTENTION
!
An incorrectly applied or installed product can result
in component damage or a reduction in product life.
Wiring or application errors, such as undersizing or
inadequate DC supply, or excessive ambient
temperatures can result in a malfunction.
The AEC contains ESD (Electrostatic Discharge)
sensitive parts and assemblies. Static control
precautions are required when installing, testing,
servicing, or repairing this assembly. Component
damage can result if ESD control procedures are not
followed. If you are not familiar with static control
procedures, refer to Allen-Bradley publication
8000-4.5.2, Guarding Against Electrostatic Damage or
any other applicable ESD Protection Handbook.

Publication 4100-UM052B-EN-P - October 2001
Preface 3
Contents of this Manual
Related Documentation
The following documents contain additional information concerning
related Allen-Bradley products. To obtain a copy, contact your local
Allen-Bradley office or distributor.
Chapter Title Contents
Preface Describes the purpose, background, and scope of this manual. Also specifies
the audience for whom this manual is intended.
1Overview Provides a general description of the AEC, its features and mechanical
specifications.
2Installation Provides the steps needed to successfully mount and wire the AEC to an SSI
device and the S Class Compact Motion Controller or the 1394 GMC system.
3 Set-Up Provides the guidelines for setting up and configuring the AEC.
4Operation Provides information on Absolute and Incremental Position.
5Fault Indication &
Control Status
Provides information on fault and status indicators and types of faults.
Appendix A Specifications Provides physical, electrical, environmental, and functional specifications for
the AEC.
Appendix B Strobe Position Contains additional information about setting the strobe for those users
connecting their AEC to a controller other than the S Class Compact Motion
Controller or the 1394 GMC system.
For Read This Document Document Number
Programming Allen-Bradley motion controller with GML GML Commander Reference Manual GMLC-5.2
Instructions for installation and set-up for the 1394 GMC
system
1394 Digital, AC, Multi-Axis Motion Control
System User Manual
1394-5.0
Instructions for installation and set-up for the S Class
Compact motion controller
IMC S Class Compact Motion Controller
Installation and Set-up Manual
999-122
An article on wire sizes and types for grounding electrical
equipment (North American standards)
National Electrical Code Published by the
National Fire
Protection
Association of
Boston, MA.
An article on wire sizes and types for grounding electrical
equipment (European standards).
BS-EN 60204 Electrical Equipment of
Machines
Published by British
Standards Institute
A complete listing of current Allen-Bradley documentation,
including ordering instructions. Also indicates whether the
documents are available on CD-ROM or in multi-languages
Allen-Bradley Publication Index SD499
A glossary of industrial automation terms and abbreviations Allen-Bradley Industrial Automation Glossary AG-7.1

Publication 4100-UM052B-EN-P - October 2001
Preface 4
Terminology
In order to avoid confusion, we have used the following general terms
in a specific manner within this manual. We define them as follows:
Transducer - the SSI device is considered a transducer for the
purposes of this manual.
Encoder - Refers to the AEC connector that goes to the 1394 GMC
System or the S Class Compact motion controller. The cable from the
controller attaches to the AEC at the Encoder connector.
For specific definitions of other terms used in industrial automation,
see the Allen-Bradley Industrial Automation Glossary (publication
number AG-7.1).
Common Techniques Used
in this Manual
The following conventions are used throughout this manual:
•Bulleted lists such as this one provide information, not
procedural steps.
•Numbered lists provide sequential steps or hierarchical
information.
•Words that you type or select appear in bold.
•When we refer you to another location, the section name
appears in italics.
ATTENTION
!
The exclamation point inside of a triangle, followed
by the word “ATTENTION”indicate circumstances
that can lead to personal injury, death, property
damage or economic loss.
IMPORTANT Identifies information that is critical for successful
application and understanding of the product.

Publication 4100-UM052B-EN-P - October 2001
Preface 5
AEC Product Receiving and
Storage Responsibility
You, the customer, are responsible for thoroughly inspecting the
equipment before accepting the shipment from the freight company.
Check the item(s) you receive against your purchase order. If any
items are obviously damaged, it is your responsibility to refuse
delivery until the freight agent has noted the damage on the freight
bill. Should you discover any concealed damage during unpacking,
you are responsible for notifying the freight agent. Leave the shipping
container intact and request that the freight agent make a visual
inspection of the equipment.
Leave the product in its shipping container prior to installation. If you
are not going to use the equipment for a period of time, store it:
•in a clean, dry location
•within an ambient temperature range of 0 to 85°C (32 to 185°F)
•within a relative humidity range of 5% to 95%, non-condensing
•in an area where it cannot be exposed to a corrosive
atmosphere
•in a non-construction area
Allen-Bradley Support
Allen-Bradley offers support services worldwide, with over 75 Sales/
Support Offices, 512 authorized Distributors and 260 authorized
Systems Integrators located throughout the United States alone, plus
Allen-Bradley representatives in every major country in the world.
Local Product Support
Contact your local Allen-Bradley representative for:
•sales and order support
•product technical training
•warranty support
•support service agreements

Publication 4100-UM052B-EN-P - October 2001
Preface 6
Technical Product Assistance
If you need to contact Allen-Bradley for technical assistance, please
review the information in this manual first. Then call your local
Allen-Bradley representative. For the quickest possible response, we
recommend that you have the catalog numbers of your products
available when you call. 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/

7Publication 4100-UM052B-EN-P - October 2001
Chapter 1
Overview
AEC Description
The AEC is an absolute encoder converter. It receives the absolute
position sent by the SSI transducer and changes it to an incremental
quadrature signal that the 1394 GMC System module and the S Class
Compact motion controller can use.
The AEC is designed to accept outputs from absolute encoders, linear
displacement transducers, or any other measuring device, which
transmits its measured values over an SSI. Several devices are
supported with various combinations of counts per turn and number
of turns. These are defined in the Setup chapter of this manual.
Parallel output devices are not supported.
The AEC provides two independent channels from absolute to
incremental quadrature conversion. The resolution of each channel is
set via rotary switches and each one can operate with a transducer
using a different supply voltage. (Although the supply voltages may
be different, they are not isolated. The grounds must be of equal
potential.) Each channel can be individually strobed to obtain new
absolute or incremental position information.

Publication 4100-UM052B-EN-P - October 2001
8Overview
AEC Features
The AEC has the following features:
•Two fully independent axes capable of absolute to incremental
quadrature conversion.
•Each channel can support independent absolute transducer
input.
•User selectable resolution.
•Fixed transducer acquisition speed of 400 kHz.
•Each axis provides one differential quadrature output.
•Fixed quadrature output frequency of 800 kHz.
•Independent +5 V DC, + 15 V DC, and +24 V DC transducer
voltages.
•Selectable for incremental strobes or internal 1ms timebase.
•Interfaces directly to Allen-Bradley 1394 GMC System and S
Class Compact motion controllers.
•Normally open and normally closed status outputs for each axis.
•Bicolor LED status indication for each axis.
•An on-board reset switch that resets both axes.
•Absolute Home request remotely clears corrected faults and
resets system on a per axis basis.
•Single 18-36 V DC input voltage power requirement.
•A rugged steel case for greater protection. The case has
pre-drilled mounting tabs.
AEC Mechanical
Specifications
The following figure shows the placement and labeling of major items
on the AEC front panel.

Publication 4100-UM052B-EN-P - October 2001
Overview 9
Figure 1 AEC front panel
330.2 mm (13.0 in.)
Use 1/4 -20 or M6
bolt (typical 2 places)
44.45 mm (1.75 in.)
203.2 mm (8.0 in.) with
cable clearance
342.9 mm (13.5 in.)
152.4 mm (6.0 in.)
AEC
Reset
Axis 0 Axis 1
A
B
A
B
Axis 1 Axis 0
2
1
SSIControl
ConfigurationConfiguration
Switches Switches
Encoder EncoderPower
SSI Control
AB
10
9
8
7
62
5
4
3
1
8
7
62
4
3
1
5
AB
10
9
8
7
62
5
4
3
1
8
7
62
4
3
1
5
Package Specifications
Package size
mm and (in.)
342.9 x 152.4 x 44.45
(13.5 x 6.0 x 1.75)
Product weight
kg and (lbs.)
2.27
(5.0)
Material Painted Steel

Publication 4100-UM052B-EN-P - October 2001
10 Overview

11 Publication 4100-UM052B-EN-P - October 2001
Chapter 2
Installation & Hook-Up
Chapter Objectives
Read this entire chapter before beginning to mount, connect, or wire
any of the components to the AEC. It is the responsibility of the
installer to see that the installation conforms to the directions in this
manual and local codes and procedures. This chapter covers the
following topics.
•European Union Compliance
•Mounting the AEC
•Connecting the AEC to the 1394 GMC system
•Connecting the AEC to the Compact motion controller
•Connecting the AEC to the 1746-MO2AE
•Wiring the SSI transducer to the AEC
•Wiring the Control connector
•An example of a Fault relay
•Wiring the Power connector
Installing the AEC
The AEC is designed to mount in an electrical cabinet using the
flanges on its back panel. This installation method should be observed
for all applications. Before powering the AEC, make sure it has been
configured correctly and that the transducer(s) and control devices
(controller) are connected to it correctly.
Complying with European
Union Directives
The information contained in this document pertains to the Absolute
Encoder Converter (AEC), an Allen-Bradley product. If the AEC is
installed within the European Union or EEA regions and has the CE
mark, the following regulations apply.

Publication 4100-UM052B-EN-P - October 2001
12 Installation & Hook-Up
EMC Directive
The AEC 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.
The AEC, as described in this document, is intended for use in an
industrial environment and is not intended for use in a residential,
commercial, or light industrial environment.
To meet CE requirements, the following are required:
•The AEC must be mounted in an IP 54 rated metal enclosure on
a metal panel.
•All equipment must be bonded.
•You must use the specified Allen-Bradley cables.
•The AEC is designed to function without maintenance when
operated in the environment specified in this manual.
•Under normal conditions, the AEC should not require any
periodic maintenance. However, if conditions are less than ideal
and any superficial dust has accumulated on the controller over
time, remove the dust carefully. Also, it is recommended to
periodically inspect all cables for abrasion and all connectors for
proper seating.
Mounting the AEC
Before mounting the AEC, verify that the 1394 GMC System or the S
Class Compact motion controller is installed correctly. Refer to the
1394 Digital AC Multi-Axis Motion Control System User Manual
(publication 1395-5.0) or the IMC 23/x Installation and Set-up Manual
(publication 999-122) for installation instructions.
The AEC must be properly grounded to the metal enclosure panel.
The following diagram shows how to ground the AEC to the panel.