Rockwell Automation Allen-Bradley ALEC 4100-5.3 User guide

ALEC
AxisLink Encoder
Converter
Cat No. 4100-5.3
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 4100-5.3 - June 1999
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
Terminology . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
Common Techniques Used in this Manual . . . . . . . . . . . . . . . 4
ALEC Product Receiving and Storage Responsibility . . . . . . . . 4
Allen-Bradley Support . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5
On the Web . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5
Chapter 1
Overview
ALEC Description . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7
ALEC Features. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7
ALEC Mechanical Specifications . . . . . . . . . . . . . . . . . . . . . . . 8
Chapter 2
Installation & Hook-Up
Chapter Objectives . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11
Installing the ALEC . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11
Complying with European Union Directives. . . . . . . . . . . . . 11
EMC Directive . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12
Mounting the ALEC . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12
Connecting the ALEC . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13
Wiring the ALEC . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14
Wiring Cable Flying Leads to the Plugs . . . . . . . . . . . . . . 14
Connecting AxisLink . . . . . . . . . . . . . . . . . . . . . . . . . . . 15
Connecting the Encoder. . . . . . . . . . . . . . . . . . . . . . . . . 17
Allen-Bradley 845F, 845H, and 845T Encoders. . . . . . . . . . 18
Allen-Bradley 845K Encoders. . . . . . . . . . . . . . . . . . . . . . . . 18
Allen-Bradley 845P Encoders . . . . . . . . . . . . . . . . . . . . . . . . 19
Connecting a Registration Sensor . . . . . . . . . . . . . . . . . . . . . 20
Using the Registration Input . . . . . . . . . . . . . . . . . . . . . . 21
Power Supply Connector . . . . . . . . . . . . . . . . . . . . . . . . 22
Fault Relay . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 24

Publication 4100-5.3 - June 1999
ii
Chapter 3
Setup
Chapter Objectives . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 27
Setting the Rotary Switches . . . . . . . . . . . . . . . . . . . . . . . . . 27
Selecting the Operation Mode . . . . . . . . . . . . . . . . . . . . 27
Selecting the AxisLink Address . . . . . . . . . . . . . . . . . . . . 28
Selecting the Options Configuration . . . . . . . . . . . . . . . . 29
Encoder Power (12V 5V) . . . . . . . . . . . . . . . . . . . . . . . . . . . 29
Extended Nodes (Extd Node On/Off) . . . . . . . . . . . . . . . . . . 29
Encoder Fault (Enc. Fault On/Off) . . . . . . . . . . . . . . . . . . . . 30
Extended/Standard Length (Extd Length On/Off) . . . . . . . . 30
Extended/Standard Length Termination 1. . . . . . . . . . . . . . . . 30
Extended/Standard Length Termination 2. . . . . . . . . . . . . . . . 30
Extended versus Standard AxisLink. . . . . . . . . . . . . . . . . 31
Allen-Bradley 845 Encoders. . . . . . . . . . . . . . . . . . . . . . 31
Powering the ALEC . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 33
ALEC With GML Commander. . . . . . . . . . . . . . . . . . . . . . . . 34
Adding ALEC to Commander AxisLink Configuration. . . . 34
Chapter 4
Fault Indication & Control Status
Chapter Objectives . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 37
AL LED. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 37
AxisLink Fault . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 38
AxisLink Failing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 38
No Fault . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 39
. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 39
CPU OK . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 39
Encoder OK LED . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 39
Appendix A
Specifications
Equivalent Circuit Diagrams. . . . . . . . . . . . . . . . . . . . . . . . . 45
Appendix B
Upgrading From ALEC Series C to Series D
Summary of Changes . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 47
Physical Dimensions . . . . . . . . . . . . . . . . . . . . . . . . . . . 47
Mode Rotary Switch . . . . . . . . . . . . . . . . . . . . . . . . . . . . 47
AxisLink Address Rotary Switch . . . . . . . . . . . . . . . . . . . 48

Publication 4100-5.3 - June 1999
iii
DIP Switches . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 48
Resetting the Encoder Mode. . . . . . . . . . . . . . . . . . . . . . 49
Encoder OK LED . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 49
Fault Relay . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 50
Index
Index . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 51

Publication 4100-5.3 - June 1999
iv

1Publication 4100-5.3 - June 1999
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
•The purpose of this manual
•Terminology
•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 ALEC (AxisLink 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 ALEC and
describes the procedures necessary to properly install and configure it
into your motion control system.

Publication 4100-5.3 - June 1999
Preface 2
Safety Precautions
The following general precautions apply to the ALEC:
ATTENTION
!
Electric shock can kill. Make sure the ALEC 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-EN
60204.
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 ALEC 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 4100-5.3 - June 1999
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.
Terminology
Knowledge of the following terms are necessary to the understanding
of the ALEC. For additional definitions refer to the Allen-Bradley
Industrial Automation Glossary, (publication number AG-7.1).
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 ALEC, its
features and mechanical specifications.
2Installation &
Hookup Provides the steps needed to successfully mount and wire the ALEC to an incremental
encoder and the AxisLink cable.
3Set-Up Provides the guidelines for setting up and
configuring the ALEC.
4Fault 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 ALEC.
Appendix B Upgrading From
ALEC Series C to
ALEC Series D
Provides a summary of changes from series C
to series D. Contains tables for comparing the
differences between the two series.
For Read This Document Document Number
Programming Allen-Bradley motion controller with GML GML Commander User Manual v4.01
GML Commander Reference Manual v4.01 GMLC-5.1 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 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 4100-5.3 - June 1999
Preface 4
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.
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.
•
•
ALEC 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.
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 4100-5.3 - June 1999
Preface 5
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
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/

Publication 4100-5.3 - June 1999
Preface 6

7Publication 4100-5.3 - June 1999
Chapter
1
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.
The ALEC also allows easy remote location of the master encoder for
connection to an existing machine.
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 systems. The ALEC encoder
appears to the AxisLinked IMC S Class motion controllers as a virtual
axis. This virtual axis can be used by the motion controllers as a
master axis in electronic gearing, cam, lineshaft, and synchronization
applications.
ALEC Features
The ALEC has the following features:
•Plug and Play - no software setup required.
•Single 18-36V DC power input with reverse voltage protection
makes installation and hookup easy.
•Isolation of all external connections from the microprocessor
logic for reliable performance.
•4MHz maximum feedback count rate allows high speed
operation without sacrificing resolution.
•Optically isolated high-speed position registration input for
position synchronization and registration applications.
•Interfaces directly to Allen-Bradley 1394 GMC System and
S Class Compact motion controllers.
•Normally Open status output.
•Bicolor LED status indication.
•Pre-engineered encoder cable assemblies available.
•A rugged steel case for greater protection. The case has
pre-drilled mounting tabs.
The ALEC is based on an 80C31 microprocessor running at 16MHz. A
CPU watchdog circuit with front panel LED indicator (CPU OK) is
provided for fault indication and connection to a Normally Open Fault
Relay.

Publication 4100-5.3 - June 1999
8Overview
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.
AxisLink communication with IMC S Class motion controllers is
controlled by a dedicated communication chip. An address selector
switch is provided on the front panel to set the address of the ALEC
on AxisLink. A front panel AxisLink status LED (AL) is also provided.
The ALEC includes a switching power supply with fused 18-36V DC
input which provides separate outputs for the optically-isolated
encoder input and AxisLink communication channel.
ALEC Mechanical
Specifications
Figure 1.1 shows the placement and labeling of major items on the
ALEC front panel as well as the physical dimensions.
Figure 1.1 ALEC front panel
285.75 mm (11.25 in.)
Use 1/4 -20 or M6
bolt (typical 2 places)
48.26 mm (1.9 in.)
190.5 mm (7.5 in.) with
cable clearance
300.23 mm (11.82 in.)
130.175 mm (5.125 in.)
ALEC
Fuse
Common
24V DC
Fault Power
Relay Input Registration
Input
Incremental
Encoder Input
Encoder OK
AxisLink
1
2
AxisLink
Address
Mode
AL CPU OK
Reset
12V/5V
Extd Node On/Off
Enc. Fault On/Off
Extd Length On/Off
Extd Term 1 On/Off
Extd Term 2 On/Off

Publication 4100-5.3 - June 1999
Overview 9
Package Specifications
Package size
mm and (in.) 300.23 x 130.175 x 48.26 (11.82 x 5.125 x 1.9)
Product weight
kg and (lbs.) 1.68 (3.69)
Material Painted Steel

Publication 4100-5.3 - June 1999
10 Overview

11 Publication 4100-5.3 - June 1999
Chapter
2
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. This chapter covers the
following topics.
•European Union Compliance.
•Mounting the ALEC.
•Connecting AxisLink.
•Connecting the Encoder.
•Allen-Bradley Encoders.
•Connecting a Registration Sensor.
•Using the Registration input.
•Wiring the power supply.
•Wiring a Normally Open Fault Relay.
Installing the ALEC
The ALEC 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 ALEC, make sure it has been
configured correctly and that the encoder and AxisLink cable are
connected to it correctly.
Complying with European
Union Directives
The information contained in this document pertains to the AxisLink
Encoder Converter (ALEC), an Allen-Bradley product. If the ALEC is
installed within the European Union or EEA regions and has the CE
mark, the following regulations apply.
ATTENTION
!
Do not attempt to make any electrical connections to the
ALEC while power is applied. Doing so risks damage to
the ALEC, external components, and your health.

Publication 4100-5.3 - June 1999
12 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.
The ALEC, 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 ALEC must be mounted in an IP 54 rated metal enclosure
on a metal panel.
•All equipment must be electrically bonded.
•You must use the specified Allen-Bradley cables.
•The ALEC is designed to function without maintenance when
operated in the environment specified in this manual.
•Under normal conditions, the ALEC 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 ALEC
Before mounting the ALEC, 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.
Mount the ALEC on a metal enclosure panel using two 1/4 -20 or M6
bolts. Refer to the Mechanical Specifications in the Overview chapter
of this manual for mounting dimensions.