999-126 - Rockwell Automation
Contents
1. Ty Allen Bradley REC Installation esolver to Encod cone a nd Setu p Cat No 4100 5 1 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 orin part without written permission of Allen Bradley Company Inc is prohibited Throughout this m2. 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 ATTENTION 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 ATTENTION 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 ATTENTION 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 public
3. Specification Description Excitation Frequency 4000Hz at 25 Amplitude 4 77V rms 5 Phase Loss Detection The table below details the product performance of the phase loss detection circuit for the REC Specification Description Purpose To detect loss of resolver signals When fault occurs The status indication LED turns from green to red e The 30V DC 2A 125V AC 0 6A rated relay contact output opens Action The motion controller detects loss of feedback After the problem is corrected you can clear the fault for each axis by pushing the reset button on the REC or by using a home request from the motion controller Response range 0 lt resolver shaft speed lt 6000 rpm Response Time The phase loss detection circuit will respond within 180 degrees of resolver element rotation as long as you use no more than 100ft of specified cable The REC has been designed to use Allen Bradley Bulletin 846 and 1326 absolute feedback packages that Resolver inputs feature Harlowe 11BRCX 300 C or equivalent resolver elements The 4 77V rms excitation amplitude has been adjusted so that when you use the resolvers listed above with the REC the strators receive 2V rms 10 Publication 4100 5 2 J une 1998 42 Publication 4100 5 2 June 1998 Index A Absolute Position Update 31 Absolute Strobe Cycle 43 Absolute Strobe Timing 44 C CE requirements 10 Configuration GML Comma
4. lt travel lt 256 and the axis homed after moving it slightly negative of the zero position the controller would think that the axis was near 256 instead of near zero The internal travel range allows the axis to dither about zero by 5 turns thus eliminating unwanted roll over at the alignment position If you homed the axis after moving it slightly negative of 5 the axis position would roll over to just less than 251 When you use a single resolver the absolute travel range is 0 lt travel lt 1 turns for geared resolver packages with a 1 1 gear ratio There is no built in procedure implemented in the control to handle dither about the alignment zero position If you desire a dither feature you can use the algorithm shown below to program a dither value This value is typically a small percentage of the travel range Inside a Home block select eNormal Wait for Completion Inside an If block build the expression eActual Position gt 1 dither value Inside the Redefine Position block Select Relative eSelect Actual Enter 1 When you align the transducer to the physical axis using the Align Absolute Transducer routine the routine adjusts the home position to offset the transducer position to zero Important We recommend that you do not change the home position established by the Align Absolute Transducer routine You can establish a non zero reference point using the GML Redefine Position command aft
5. for installation instructions The REC must be properly grounded to the metal enclosure panel the following diagram shows how to ground the REC to the panel Installation amp Hook Up 11 Figure 2 1 Mounting and Grounding Diagram 10 AWG to Ground Bus REC Mounting Tab Ground Lug Size 1 4 20 or M6 Hardware Internal Star Washers Tapped Hole Minimum of 3 Threads Fe Metal Panel Must be connected to earth ground Scrape paint off panel to insure electrical connection between chassis and grounded metal plate Mount the REC next to a 1394 GMC system or an S Class Compact motion controller 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 Figures 2 2 and 2 3 in this chapter show where to mount the REC ATTENTION To avoid a shock hazard remove all power to the system panel before mounting the REC ATTENTION The 1394 contains stored energy devices To avoid the hazard of electrical shock verify that all voltages are zero 0 00 before proceeding Publication 999 126 February 1996 12 Installation amp Hook Up Figure 2 2 Mounting the REC next to a 1394 GMC on a system panel Wireway 1394 GMC System len Bradley Important The REC can only be mounted on the
6. more than 2 feet of cable is left unsupported The excessive weight of an unanchored cable could pull the plug out of the connector Wiring the REC The REC has two resolver connectors Axis 0 Resolver and Axis 1 Resolver that support single or dual resolvers Each connector comes with two removable 10 position plugs The resolver cable flying leads wire directly to the screw terminals on the plugs Wiring Cable Flying Leads to the Plugs To wire the cable leads to the plug 1 Lookatthe plug to make sure the terminal is open Figure 2 5 shows both an open and a closed terminal Publication 999 126 February 1996 Installation amp Hook Up 17 Figure 2 6 Terminal diagram Terminal open Clamping screws Terminal closed 2 Table 1 Terminal Steps If the terminals are Do this Not open Go to step 3 Open Go to step 4 3 Using a small flat head screwdriver turn the clamping screw counter clockwise several times 4 Usinga proper stripping tool strip the wire insulation back on the cable lead Important All terminals accommodate a maximum of 14 gauge wire 5 Trim the cable lead so that 0 275 inches of metal wire is exposed 6 Insert the cable lead in the appropriate terminal Refer to the proper figures for their locations 7 Use the screwdriver to tighten the clamping screw to the proper torque 0 25 N m 2 2 in lb 8 Verify that the cable lead does not pull out of the terminal Table
7. or equivalent driver IC e A resolver phase loss circuit that detects the loss of resolver signals e Normally open fault outputs for each encoder channel e A watchdog LED for each encoder conversion channel e An on board reset switch that resets both axes e An absolute home request that remotely clears corrected faults for each axis independently e A rugged steel housing with mounting tabs Publication 4100 5 2 J une 1998 8 Overview REC Mechanical Specifications Publication 4100 5 2 J une 1998 330 2 mm 13 0in koa amp 1 i A B Reset Axis0__ Axis 1 ok CDK A B 9 8 7 6 5 4 3 2 1 Axis 0 Resolver Axis 0 Encoder Power amp Drives Axis 1 Encoder 9 8 7 6 5 4 3 2 1 e 44 45 mm 1 75 in e The ability to be powered with a single18 36 V DC power supply e Automatic resolver phase compensation for accurate position tracking Figure 1 1 shows the placement and labeling of major items on the REC front panel Figure 1 1 REC front panel I I 203 2 mm 8 0 in with cable clearance Use 1 4 20 or M6 A bolt typical 2 places 342 9 nm 13 5 in ee 152 4 mm 6 0 in gt Package Specifications Package size 342 9 x 152 4 x 44 45 mm and in 13 5 x 6 0 x 1 75 Product weight 2 27 kg and Ibs 5
8. resolver Specification Number of resolver inputs Description 2 conversion channels each capable of supporting single or dual resolver packages Resolver type Transmitter rotor primary Excitation amplitude 4 77V rms 5 at a 4000Hz 20 Resolver transformation ratio 0 45 to 1 Strator to Rotor 5 Zss 275 Ohms Maximum Resolver phase shift Each conversion channel self compensates within the range of 25 degrees maximum resolver phase shift rotor to strator Publication 4100 5 2 June 1998 Specification Supported resolver packages 39 Description 1326AB MOD VD1 x single resolver package x rotor to input shaft ration X 1 2 2 5 0r5 1326AB MOD VD 256 255 dual resolver package 256 255 is the master to vernier gear ratio Use cable 1326AB CVUxx for the specified Bulletin 1326 resolver packages above Xx length in feet 100 ft maximum 846 S abcd R2 e single resolver package a mounting configuration b connector style c connector location d gear ratios R2 Harlowe resolver element 11BRCX 300 C or equivalent e replaces c if mating connector is supplied Use cable 845AB CA i xx xx length in feet up to 100 ft Strobe Inputs Type Source Impedance Maximum active Voltage Minimum Inactive Voltage Current Sourcing Active Low 10k Ohm 0 6V DC 2 2V DC Encoder Output Specifications The table below detai
9. the position relative to the actual position of the axis and then compensates this position relative to the actual position of the axis After the alignment procedure completes successfully the axis and resolver package are adjusted to read zero at this position If you are using a dual resolver package the alignment procedure will also synchronize both internal resolver elements by electronically offsetting them to zero This eliminates the need for the user to manually perform this procedure To align the absolute transducer 1 Select Align Absolute Transducer A black dot appears in the radio dial next to the text Important If the axis is not still when you align or home the resolver package the position information will be incorrect The axis must be still before performing the alignment procedure Important When executing the alignment procedure on a servo axis feedback is momentarily disabled and then enabled again if the error checking features do not detect an error in the motion controller If the axis has stored energy or the ability to move during the time feedback is disabled you have to apply a breaking mechanism to the axis before you execute an alignment routine For single resolver packages the alignment routine reads the absolute position of the transducer If no encoder noise or loss faults occur the routine completes successfully The motion controller negates the read position and stores it in its working mem
10. wiring codes for more information Power Supply Requirements Use a 12W power supply with 24V DC output to power the REC Use a larger supply if you want to run multiple RECs or other devices Figure 2 11 shows where to connect the power supply ot the REC Important Choose a power supply that complies with the regulations and agencies in your area Figure 2 11 Wiring the Power Supply cable leads to the REC Plug A PlugB 10 Q 5 IS 3 Q 4 IO 8 O 3 24V DC 7 2 Power IO 6 S 1 Supply 18 36V DC Power ground Cable shield Important Anchor the cable so that no more than 2 feet of cable is left unsupported The excessive weight of an unanchored cable could pull the plug out of the connector REC Internal Power Requirements The REC converts the input power into its internal power requirements using a DC to DC converter The input power 500V DC is isolated from the internal circuitry and the chasis of the REC However the common mode voltage of the input power with respect to the chassis must not exceed 100V DC Important The REC is equipped with protection and filtering circuits at various input output and power terminals You must earth ground the REC at a stable poiint for this circuitry to operate properly The earth ground is applied to the REC through the chassis at the mounting tasbs of the enclosure Publication 999 126 February 1996 22 Instal
11. 0 Material Painted Steel Chapter Objectives Installing the REC Complying with European Union Directives Chapter 2 Installation amp Hook Up Read this entire chapter before beginning to mount connect or wire any of the components to the REC 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 e European Union Compliance e Mounting the REC e Connecting the REC to the 1394 GMC system e Connecting the REC to the Compact motion controller e Wiring the REC to the resolver package e Wiring the Power amp Drives connector e Wiring the drives signal for an S Class Compact e Connecting a Fault relay The REC 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 REC make sure it has been configured correctly and that the resolver package drives and control devices controller are connected to it correctly The information contained in this document pertains to the Resolver to Encoder Converter REC an Allen Bradley product If the REC is installed within the European Union or EEA regions and has the CE mark the following regulations apply EMC Directive The REC is tested to meet Council Directive 89 336 Electromagnetic Compatibility EMC in accordance wit
12. 2 Cable Leads If the cable lead Do this Pulls out of the terminal Repeat steps 3 through 9 again Does not pull out of the terminal Repeat steps 3 through 9 for the next terminal Publication 999 126 February 1996 18 Installation amp Hook Up Figure 2 7 Wiring a 1326AB MOD VD 256 Master Vernier Dual Resolver package to the Axis 0 Resolver plugs or the Axis 1 Resolver plugs on the REC Plug A Plug B 20 Green N 10 Red D O 1 f XX Black R IS 9 XX Black F 7 Resolver 18 X Violet M O 8 Assembly Q 17 iole Q 7 Orange E ef 1326AB MOD VD 256 uth CX BlackP SE XX Black ee z BlueJ White A 15 5 XX Black K XX Black B e 14 4 H 23 3 ie Fault 12 Q 2 C 4 11 Chassis Ground re JO 1 Chassis Ground I lia IL Diet ess 1326 CVUxx Cable Internal fault relay contact Important Anchor the cable so that no more than 2 feet of cable is left unsupported The excessive weight of an unanchored cable could pull the plug out of the connector Figure 2 8 Wiring a 1326AB MOD VD x x resolver package to the Axis 0 Resolver plugs or the Axis 1 Resolver plugs on the REC Plug A Plug B 20 10 19 9 SE S
13. 2 SSI Connector 18 Publication 4100 5 2 June 1998 Allen Bradley a Rockwell Automation Business has been helping its customers improve A Rochwell Automation productivity and quality for more than 90 years We design manufacture and supporta broad Allen Bradley range of automation products worldwide They include logic processors power and motion control devices operator interfaces sensors and a variety of software R ockwell is one of the world s leading technology companies Worldwide representation nn NY Argentina e Australia e Austria e Bahrain e Belgium e Brazil e Bulgaria e Canada e Chile e China PRC e Colombia e Costa Rica e Croatia e Cyprus e Czech Republic e Denmark e Ecuador e Egypt e El Salvador e Finland e France e Germany e Greece e Guatemala e Honduras e Hong Kong e Hungary e Iceland e India e Indonesia e Ireland Israel Italy Jamaica Japan Jordan Korea Kuwait Lebanon Malaysia Mexico Netherlands New Zealand Norway Pakistan Peru Philippines e Poland e Portugal e Puerto Rico e Qatar e Romania e Russia CIS e Saudi Arabia e Singapore e Slovakia e Slovenia e South Africa Republic e Spain e Sweden e Switzerland e Taiwan e Thailand e Turkey e United Arab Emirates e United Kingdom e United States e Uruguay e Venezuela e Yugoslavia Allen Bradley Headquarters 1201 South Second Street Milwaukee WI 53204 USA Tel 1 414 382 2000 Fax 1 414 382 4444 Publicati
14. A Specifications Equivalent Circuit Diagrams eee 39 Appendix B Strobe Position For Applications Not Using the 1394 or Compact Absolute Strobe Cycle scorri lot 43 Absolute Strobe Timing iii 44 Incremental Strobe Period 45 Index Publication 4100 5 2 June 1998 Read This Manual Who Should Use this Manual Purpose of this Manual Preface Preface 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 e Who should use this manual e The purpose of this manual e Terms e Common techniques used in this manual e Allen Bradley support 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 e S Class Compact motion controller e 1394 GMC System module e GML Graphic Motion Language Commander software This manual is an installation and set up guide for the REC resolver to encoder converter and describes the procedures necessary to properly install and configure it into your motion control system Publication 999 126 February 1996 2 Preface
15. E 3 O 17 7 1326AB MOD VD xx 16 6 15 O 5 14 4 O p 1 3 E Axis Fault Q 12 2 TO ra 11 Chassis Ground 11Q 1 Chassis Ground 1326 CVUxx Cable Important Anchor the cable so that no more than 2 feet of cable is left unsupported The excessive weight of an unanchored cable could pull the plug out of the connector Publication 999 126 February 1996 Installation amp Hook Up 19 Figure 2 9 Wiring an 846 S xxxx R2 x single resolver package to the Axis 0 Resolver plug or the Axis 1 Resolver plug on the REC Plug A Plug B 20 AX ren Q 10 846 5 ABCD R2 E 19 9 Resolver Assembly Q 18 8 7 Red D 17 7 o Black F z T White A O 5 XX Black B H4 O 4 13 3 E k Axis Faut Q 12 Q 2 cs Ne JQ 11 ChassisGround 4 11 Chassis Ground a ni ui i 845AB CA ixx Cable Internal fault relay contact Important Anchor the cable so that no more than 2 feet of cable is left unsupported The excessive weight of an unanchored cable could pull the plug out of the connector Connecting the Resolver to the Plug After you have wired the resolver cable leads to the plugs insert the plugs in the resolver connectors on the REC Figure 2 10 shows where the resolver plugs connect to the REC Important We designed and tested the REC to work with Allen B
16. Setup 27 2 If your system uses a Select Single resolver package Absolute Dual resolver package Absolute MV If you select Absolute_MV an Assembly Part menu that contains a list of supported Allen Bradley dual resolver part number appears Note Currently the REC supports the 1326AB MOD VD 256 255 dual resolver package The Custom menu choice located in the Assembly Part menu allows you to enter a custom master vernier dual resolver turns range Currently the REC supports the 1326AB MOD VD 256 255 resolver with a turns range of 256 Allen Bradley is reserving the Custom menu choice for future dual resolver packages if you want to use a master vernier resolver other than the 1326AB MOD VD 256 255 dual resolver package consult Allen Bradley to verify that it is supported Setting the Transducer Position Units With the Axis window still open set the transducer position units To set the transducer position units 1 From the Configure menu select Position Units The Position Units options appear 2 Entera value into the Transducer Counts Unit field The units you enter into the Position Units field depend on the application When you use the REC it is important to know the number of counts received from the transducer per position unit The REC sends 4096 counts to the motion controller per resolver element revolution and dual resolver package shaft revolution 3 When you are finished making all of your mo
17. anual we use notes to make you aware of safety considerations ATTENTION Identifies information about practices or circumstances that can lead to personal injury or death property damage or economic loss Attention statements help you to e identify a hazard e avoid the hazard e recognize the consequences Important Identifies information that is critical for successful application and understanding of the product GML ULTRA IMC SCAN bus Flex I O DTAM PanelView and SLC are trademarks PLC is a registered trademark of Allen Bradley Company Inc x 3 Table of Contents Preface Read This Manual viarie 1 Who Should Use this Manual 1 Purpose of this Manual uses 1 Safety PIRCAUTIONS oil 2 Contents of this Manual 3 Related Documentation i 3 Terminology srt eolico nai 3 Common Techniques Used in this Manual 4 Product Receiving amp Storage Responsibility 4 Allen Bradley Support 5 Local Product Support 5 Technical Product Assistance 5 Chapter 1 Overview AEC Description risol aki 7 AEC Feat res sta De ne nn trs rat er 7 AEC Mechanical Specifications 8 Chapter 2 Installation amp Hook Up Chapter Objectives issus dissident 9 Installing the AEC unread 9 Complying with European Union Directives 9 EMC Dir
18. ation 8000 4 5 2 Guarding Against Electrostatic Damage or any other applicable ESD Protection Handbook Publication 999 126 February 1996 Preface 3 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 1 Overview Provides a general description of the REC its features and mechanical specifications 2 Installation Provides the steps needed to successfully mount and wire the REC to a Resolver and the S Class Compact Motion Controller or the 1394 GMC system 3 Set Up Provides the guidelines for setting up and configuring the REC Appendix Specifications Provides physical electrical environmental and A functional specifications for the AEC 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 Read This Document Document Number Programming Allen Bradley motion controller with GML GML Commander User Manual v4 01 GMLC 5 1 GML Commander Reference Manual v4 01 GMLC 5 2 Instructions for installation and set up for the 1394 GMC system 1394 Digital AC Multi Axis Motion Control 1394 5 0 System User Manual Instructions for installation and set up for the S Class Compact IMC S Class Compact Motion Controller 999 122 motion co
19. ation 999 126 February 1996 REC Description REC Features Chapter 1 Overview The REC converts a single or dual Master Vernier resolver input signal to an A Quad B quadrature encoder output signal The A Quad B quadrature output signal can be directly connected to the 1394 GMC System module or the S Class Compact motion controller In operation the REC uses differential quadrature encoder output signals to send incremental position data to the motion controller based on the position of the resolver Absolute position can be sent to the motion controller for re calibration The REC provides an independent fault detector with normally open relay contacts and an LED indicator for each axis The relay fault outputs can be e used to disable external devices in the event of a fault e incorporated into the machine s E stop string e incorporated into other protective circuitry The REC can trigger an encoder loss fault when it is used with the 1394 GMC system module or the S Class Compact The REC has the following features e Two AQB quadrature encoder output channels e Two resolver input channels that support Allen Bradley single or dual resolver packages e Resolution of 12 bits per resolver rotor rotation e The ability to interface directly with the Allen Bradley 1394 GMC System and the S Class Compact motion controller e The ability to provide differential A and B quadrature encoder output signals using 26C31
20. ct Receiving and Storage Responsibility Resolver Package An electrical mechanical device that has a single input shaft and one or more resolver elements The resolver elements are geared to the input shaft The following conventions are used throughout this manual e Bulleted lists such as this one provide information not procedural steps e Numbered lists provide sequential steps or hierarchical information e Words that you type or select appear in bold e 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 e Important Identifies information that is critical for successful application and understanding of the product 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
21. d by the REC fault relay when you switch AC The fault connections shown above are typical You can modify them to fit the requirements of your application Encoder Loss Detection Circuit Publication 999 126 February 1996 Installation amp Hook Up 25 The 1394 GMC System and S Class Compact motion controller have an encoder loss circuit that detects when the encoder drivers are disabled When the REC faults e The REC disables the encoder drivers e The REC signals an encoder loss fault ot the controller Important The Transducer Loss Detection feature is an option in the Edit Axis window in GML We recommend that you keep the transducer loss detection feature enabled in the motion controller Consult your motion controller s Installation and Setup Manual User Manual and GML Programming Manual for more information about how to apply this feature Publication 999 126 February 1996 26 Installation amp Hook Up Publication 999 126 February 1996 Chapter Objectives Adding the REC to your GML Diagram Chapter 3 Setup The REC was designed to complement the 1394 GMC System or the S Class Compact motion controller and not intended to be used as a stand alone product This manual assumes that you are running GML Graphical Motion Language version 3 81 or greater and using Firmware 3 3 or greater This chapter contains the information you need to e Configure the motion controller using GML e Align res
22. difications select Save The Axis window disappears Publication 999 126 February 1996 28 Setup On Line Axis Setups Publication 999 126 February 1996 Axis hookup and servo parameters can be readily handled through the GML On Line Manager Setup functions For example the Motor Encoder Test and the Align Absolute Transducer procedure are just two of the functions that can be controlled using GML The On Line Manager provides you with an interactive means of setting up your motion controller axes The sections below show how to use these functions to help setup the REC Refer to your controller s Installation and Setup Manual User Guide and GML Programming Manual for more information on how to use the On Line Setup functions Important Before you proceed with On Line Setups verify that the REC is installed correctly and that the GML program is configured properly Selecting Axis Drive Data Downloads Before you proceed with On Line setups you have to download your GML diagram to the motion controller so that the information contained in the diagram can be made available to the motion controller To transfer the axis specific setup parameters from the diagram to the motion controller you have to select the Axis Drive Data Downloads option in GML before you download the diagram To select Axis Drive Data Downloads 1 From the menu bar select Definitions The Definitions window appears 2 Select Control Options The Con
23. ective si lori lori 9 Mounting the AEC culi pria 10 Connecting the ABC sel MR 13 Connecting the AEC to the 1394 14 Connecting the AEC to the Compact 15 Wire the AFC elle 16 Wiring Cable Flying Leads to the Plugs 16 The SSI Conn elor case torrione 18 The Control Connector 19 Fault Relay ascii 19 Analog Servo Command Pass Through 21 Power Supply Connector 22 Publication 4100 5 2 J une 1998 ii Table of Contents Chapter 3 Setup Chapter Objective Suone nee tee 25 Setting the Rotary Switches 25 Configuration Switch 26 Configuration Switch B i 26 Powering the ABC italia 27 AEC With GML Commander 28 Adding AEC to your Commander Diagram 28 Setting the Transducer Resolution 28 Selecting Homing Procedure 29 Aligning Absolute Encoder 29 Chapter 4 Operation Chapter OBjeclives iced heals 31 Absolute Position Update 31 Incremental Position Output 31 Position at Start up ilo it 32 Chapter 5 Fault Indication amp Control Status Chapter Objectives siro lado ani 33 Transducer Faults santa sihareiteens 34 Encoder Faults iii 34 Internal Faults 1 ira iaia 35 No Fanlisacadlinisr lata dado 35 Appendix
24. er a Home command Defining the Redefine Position Command After you have executed the home command you need to define the Redefine Position Command To define the Redefine Position Command 1 Create a Redefine Position block and place it next to the Home Axis block 2 Double click on the Redefine Position block Setup 33 3 Select the axis you are configuring The name of the axis appears in the field 4 Select Relative from the Mode menu The word Relative appears in the field Note This feature compensates for any dither that may occur while executing the program 5 Select Actual from the Position menu The word Actual appears in the field 6 Entera positive or negative value to redefine the current actual position Note If the axis was previously aligned to zero the actual position is zero 7 Select Save The Redefine Position window disappears Publication 999 126 February 1996 34 Setup Publication 999 126 February 1996 Figure A 6 I g B B 6 4 3 2 1 Specifications AEC Front Panel Appendix A Figure A 1 shows the terminal locations for the REC The following tables provide the pin numbers and their respective descriptions Important Refer to Wiring Axis 0 and Axis 1 Resolvers for wiring your Allen Bradley resolver package to the REC Resolver Connector Terminal Description Plug Plug B 20 Cosine high 10 Cosine high 19 Cosine low 9 Co
25. h Article 10 1 The following directives apply e EN 50081 2 EMC Generic Emission Standard Part 2 Industrial Environment e EN 50082 2 EMC Generic Immunity Standard Part 2 Industrial Environment The REC 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 Publication 999 126 February 1996 10 Installation amp Hook Up Mounting the REC Publication 999 126 February 1996 To meet CE requirements the following are required The REC must be mounted in an IP 54 rated metal enclosure on a metal panel e All equipment must be bonded e You must use the specified Allen Bradley cables e The REC is designed to function without maintenance when operated in the environment specified in this manual e Under normal conditions the REC 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 Before mounting the REC 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
26. h axis This is a four foot cable that connects Axis 0 Encoder or Axis 1 Encoder connector on the REC to the J3 J4 JS or J10 encoder feedback connector on the 1394 Important This cable is polarity sensitive Important The REC does not require power from the 1394 to operate nor does it provide power to the 1394 However the 1394 requires a separate SV power supply to run its interface circuitry The 1394 interface circuitry requires 0 325A to operate Any additional devices connected to the 1394 such as incremental encoders can require an additional 0 2A per device check your device for the precise requirements To connect the encoder cables 1 Insert the 12 pin plug labeled REC AEC in the Axis 0 Encoder or Axis 1 Encoder connector on the REC 2 Insert the 12 pin plug labeled 1394 in the J3 J4 J5 or J10 encoder feedback connector on the 1394 3 Wire the remaining auxiliary power labeled ENC PWR to the SV DC power supply The red wire is 5V and the black is a 5 common Important When using multiple Encoder devices we recommend you wire all of the auxiliary power cables to the same 5V DC power supply Installation amp Hook Up 15 Figure 2 4 Connecting the Encoder Cables and the 5V Power Supply to the 1394 Wireway 1394 GMC System fen Bradley Axis 0 Encoder Connector Imp
27. lation amp Hook Up Wiring the Drives Signal for a Compact Connecting a Fault Relay Publication 999 126 February 1996 When using the REC with an S Class Compact the drive reference signals 10V are passed from the Compact to the REC at terminals 8 9 and 10 on plug A Axis 1 and at terminals 3 4 and 5 on Plug B Axis 0 To wire the drives signal 1 Connectthe drive signal to the servo amplifier using a twisted shielded cable Belden 9501 or equivalent Wire the cable leads to the appropriate Power amp Drives plugs ofr the required axis Figure 2 12 shows where to connect the drives reference signals to the Power amp Drives connector Both Axis 0 and Axis 1 can have drive signals present at their connectors Note You do not need to wire the drive reference signal to the 1394 because it handles the reference signal output internally Figure 2 12 Wiring the Drive Reference Signal to an S Class Compact Motion Controller Plug A Plug B 10 1 Reference O 5 0 Reference Ref 1 Q 4 0 Reference Servo Q 3 0 Reference Shield Amplifier Axis 0 Ref Ref Servo Amplifier Axis 1 Ref Important Anchor the cable so that no more than 2 feet of cable is left unsupported The excessive weight of an unanchored cable could pull the plug out of the connector The REC is equipped with a fault detector that handles internal logic voltage malfunctions and
28. left side when looking directly at the mounted 1394 of the 1394 GMC System This is due to cable specifications and module expansion of the 1394 Publication 999 126 February 1996 Installation amp Hook Up 13 Figure 2 3 Mounting the REC next to an S Class Compact motion controller S Class Wirewa Compact ra AB I Mess AB Allen Bradley TCS Class Optional Second REC for Axis 2 and 3 Axis 0 Axis Servo and Servo and Feedback Feedback Important The REC can be mounted on either side of the S Class Compact motion controller on the system panel Connecting the REC The following section details how to connect the REC encoder connectors to the 1394 GMC System and the S Class Compact motion controller ATTENTION Do not attempt to make any electrical connections to the REC while power is applied Doing so risks damage to the REC peripheral equipment and your health and safety Publication 999 126 February 1996 14 Installation amp Hook Up Publication 999 126 February 1996 ATTENTION The REC does not support the removal or the insertion of any connectors when under power The power disturbance can result in unintended machine motion loss of process control or an electrical arc that can cause an explosion in a hazardous environment Connecting the REC to the 1394 Connect the REC to a 1394 GMC System using the encoder cable catalog number 1394 GR04 for eac
29. ls the electrical specifications of the encoder output Specification Number of encoder outputs 2 0 and 1 Description Type of encoder output Incremental quadrature with marker EIA RS 422 level Equivalent line count 4096 counts under 4X decode mode Maximum update rate 1 6 MHz Marker output Synchronized 180 degrees to A channel See figure A 2 for a picture of the output for the three channels Figure A 7 Marker Output Publication 4100 5 2 J une 1998 40 Product Performance Publication 4100 5 2 June 1998 Important The marker pulse is synchronized to the resolver element s zero position which is not necessarily the axis zero position Power Supply Specifications The table below details the electrical specifications of the power supply Specification Description power input requirements 18 to 36 V DC at 12W maximum Note Input has reverse polarity protection Resolver to Encoder Conversion The table below details the product performance of the resolver to encoder conversion for the REC Specification Description Resolution 12 bits per revolution Repeatability 1 LSB 5 3 arc minutes Acceleration error 5 6 e 3 LSBs at 100 rev sec Dynamic following error 5 LSBs at 6000 RPM Resolver element shaft speed 0 to 6000 RPM 41 Excitation Oscillator The table below details the product performance of the excitation oscillator for the REC
30. nabled again if the error checking features do not detect an error in the motion controller If the axis has stored energy or the ability to move during the time feedback is disabled you have to apply a breaking mechanism to the axis before you execute a homing routine Important If the axis is not still when you home a dual resolver package the position information will be incorrect Depending on your application a breaking mechanism may be required to stabilize the axis before you execute a home command in the motion controller If you installed and configured your system for a dual resolver package you can set the axis for linear positioning When you define the axis to be linear the 256 turn dual resolver package s internal absolute travel range is 5 lt travel lt 251 turns The motion controller uses a home command to determine the absolute position of the axis After a home command the REC incrementally reports any movements back to the motion controller This new information builds upon the absolute value obtained during homing and can cause the position of the axis to exceed the range in either direction However during an absolute home command the initial absolute position of the 256 turn dual resolver package can only be obtained within the range above Publication 999 126 February 1996 32 Setup Defining a Non Zero Home Position Publication 999 126 February 1996 If the travel range was defined to be 0
31. nder Adding to a Commander Diagram 28 Aligning Absolute Encoder 29 Selecting Homing Procedure 29 Setting the Transducer Resolution 28 Connecting the AEC to the 1394 14 to the Compact 15 D Definitions encoder 4 transducer 3 Description 7 E European Union Directives EMC Directive 9 F Fault Indication Encoder Faults 34 Internal Faults 35 No Faults 35 Transducer Faults 34 Features List 7 Fuse 27 I Incremental Position Output 31 Incremental Strobe Period 45 M Mounting the AEC Index next to a 1394 12 next to a Compact 13 P Pin Functions Control Connector 21 Power Supply 22 SSI Connector 18 Pin Numbering Control Connector 21 Power Supply 23 SSI Connector 18 Position at Start up 32 Powering the AEC 30 R Related Documentation 3 Rotary Switches Setting 25 Switch A 26 Switch B 26 S Specifications Connector Locations Control 37 Encoder 37 Power 38 SSI 37 Environmental 38 Mechanical 38 Mechanical Module 38 Package 8 Pin Numbers 37 Strobe Position Absolute Position Transfer Protocol 44 Absolute Position Transfer Timing 44 Incremental Strobe Period Protocol 46 Incremental Strobe Timing Period 46 Support Publication 4100 5 2 J une 1998 48 Index Allen Bradley 5 local product 5 technical product assistance 5 W Wiring Cable Flying Leads 16 Control Connector Analog Servo 21 Fault Relay 19 Power Supply 2
32. ntroller Installation and Set up Manual An article on wire sizes and types for grounding electrical National Electrical Code Published by the equipment North American standards National Fire Protection Association of Boston MA An article on wire sizes and types for grounding electrical BS EN 60204 Electrical Equipment of Machines Published by British equipment European standards Standards Institute A complete listing of current Allen Bradley documentation Allen Bradley Publication Index SD499 including ordering instructions Also indicates whether the documents are available on CD ROM or in multi languages A glossary of industrial automation terms and abbreviations Allen Bradley Industrial Automation Glossary AG 7 1 Terminology The following terms are specific to this product For a complete listing of Allen Bradley terminology refer to the Allen Bradley Industrial Automation Glossary publication number AG 7 1 Resolver Element A small electrical mechanical device that has a single winding on the rotor and a pair of windings on the stator that are electrically positioned at right angles to each other When the rotor winding is excited with an AC reference signal the stator windings produce AC voltage outputs that vary in amplitude according to the sine and cosine of the shaft position Publication 999 126 February 1996 4 Preface Common Techniques Used in this Manual REC Produ
33. olver packages e Use a resolver package with a linear axis e Define a non zero home position Using the REC the 1394 GMC System and S Class Compact can support single resolver and dual resolver packages Follow the procedures below when you setup your GML diagram Selecting the REC as a Transducer After you have defined your application in GML select the REC as your transducer To select the REC 1 From the menu bar select Definitions The Definitions menu appears 2 Select Axis Use The Axis Configuration window appears 3 Select the axis that interfaces with the REC resolver converter output channel A check mark appears next to the text 4 Select Edit The Axis Configuration edit window for the axis you checked appears 5 From the Transducer menu select the REC The word REC appears in the field 6 If you are using a Go to 1394 GMC System Setting the Transducer Counts per Motor Revolution for the 1394 S Class Compact motion controller Setting the Homing Position Publication 999 126 February 1996 26 Setup Publication 999 126 February 1996 Setting the Transducer Counts per Motor Revolution for the 1394 You have to adjust the Transducer Counts per Motor Revolution parameter when you use an external transducer to close the servo position loop This parameter is used to scale internal variables for tuning the axis With the Axis Configuration edit window open set the transducer count
34. on 4100 5 1 June 1998 PN 999 126 Supercedes Publication 999 126 February 1996 Copyright 1998 Allen Bradley Company Inc Printed in USA
35. ortant Anchor the cable so that no more than 2 feet of cable is left unsupported The excessive weight of an unanchored cable could pull the plug out of the connector Connecting the REC to the Compact To connect the REC to the S Class Compact motion controller use the encoder cable catalog number 4100 RCS3T for each axis This three foot cable connects the Axis 0 Encoder or the Axis 1 Encoder connector on the REC to the Axis 0 1 2 or 3 servo and feedback connector on the S Class Compact The Compact sends the drive servo output signal through the 4100 RCS3T cable Figure 2 4 shows where to connect the encoder cable to the REC and the Compact Important This cable is NOT polarity sensitive To connect the Encoder cable 1 Insert one 12 pin plug in the Axis 0 Encoder or Axis 1 Encoder connector on the REC 2 Insert the remaining 12 pin plug in the Axis 0 1 2 or 3 servo and feedback connector on the Compact Publication 999 126 February 1996 16 Installation amp Hook Up Figure 2 5 Connecting the Encoder Cables to the Compact S Class Wireway Compact Allen Bradley TMC Class 4100 RCS3T Axis 0 Encoder Connector Axis 1 Encoder Connector Axis 0 Axis 1 Axis 2 Axis 3 Servo and Servo and Servo and Servo and Feedback Feedback Feedback Feedback Important Anchor the cable so that no
36. ory For absolute devices the home position is used as a home offset and is added to the transducer s actual position during a homing command Publication 999 126 February 1996 30 Setup Publication 999 126 February 1996 For Example Assume the actual position of the absolute transducer is 1 at the alignment point After alignment the home position home offset variable equals 1 Therefore the axis position is defined as 1 1 0 Assume the axis is moved one unit and the position of the absolute transducer is now 2 If you execute a home command at this point the axis position is 2 1 1 For dual resolver packages the alignment routine uses the home position and a transparent parameter called Vernier Offset to calculate the alignment position The Home Position stores the master resolver element position offset and Vernier Offset stores the vernier resolver element offset 2 Select Execute If Do this The Align Absolute Transducer Go to step 3 window appears A GML Error window appears 1 Check your application program 2 Check your REC installation procedures 3 Move the axis to its minimum travel position The alignment rou tine will define this position as zero 4 Select OK to align the position to zero 5 While the alignment routine is running verify that you have selected the proper absolute device the absolute device you selected shows up in the window that appears while
37. prior to installation If you are not going to use the equipment for a period of time store it e inaclean dry location e within an ambient temperature range of 0 to 85 C 32 to 185 F e within a relative humidity range of 5 to 95 non condensing e in an area where it cannot be exposed to a corrosive atmosphere e ina non construction area Publication 999 126 February 1996 Allen Bradley Support Preface 5 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 e sales and order support e product technical training e warranty support e 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 1 800 GMC TECH Publication 999 126 February 1996 Preface Public
38. radley resolver packages and cables up to 100 ft If you use longer cables or cables other than those specified the product does not perform as specified Publication 999 126 February 1996 20 Installation amp Hook Up Figure 2 10 Connecting the Resolver Cable to the REC Wireway Axis 0 resolver connector Axis 1 resolver connector To Resolver 1 To Resolver 0 Important Anchor the cable so that no more than 2 feet of cable is left unsupported The excessive weight of an unanchored cable could pull the plug out of the connector Wiring the Power and Drives The Power amp Drives connector comes with two removable 5 position Connector plugs The connectors provide input power for the REC and the drive reference signal outputs for the S Class Compact Input power enters the connector through the following pins e pin 1 18 36V DC e Pin 6 power ground e Pin 7 chasis ground Wire Requirements The REC draws 12W maximum 0 5A at 24V DC Use the appropriate gauge wire to accommodate the current draw of the REC while maintaining 18V DC minimum at the Power amp Drives connector Refer to local wiring codes Important The plug accommodates a maximum of 14 guage wire Publication 999 126 February 1996 Installation amp Hook Up 21 Important You must use both 5 position plugs when you power up the REC We recommend you use twisted shielded wire that is UL listed Refer to local
39. resolver phase loss faults The fault detector consists of e An internal relay contact output that opens for each axis e An LED indicator that turns red for each axis e An encoder driver disabler for each axis Start Stop String 24V DC Start ae i r ti Qu HO 1 crt Fault String 0 Installation amp Hook Up 23 The relay output can be used to disable external devices or incorporated into your machine s E stop string or other protective circuitry for fail safe protection The REC provides Form_C Normally Open contacts to disable external equipment in the event of a malfunction Important Both the fault relay and the LED Axis OK are activated during normal operation and deactivated during a malfunction The fault output relay contacts are UL listed and CSA certified for 1A at 30V DC Figures 2 13 and 2 14 are examples of typical fault relays Figure 2 13 A typical Normally Open Fault status contact DC REC Fault contact Common located at Axis 0 1 O Resolver connector CRI Publication 999 126 February 1996 24 Installation amp Hook Up Figure 2 14 Typical Fault Relay for Switching AC DC 24V DC The REC Fault contact is located Common O at the Axis 0 and Axis 1 O resolver connector AC AC Hot Common Start Stop SU n Start Stop String O O O O IA CRI 5 K ey Fault String 0 CR1 We recommend that you use an external relay controlle
40. s per motor revolution To set the transducer counts per motor revolution 1 From the Configuration menu select Drive Motor 1394 Note IfaGML Info window appears note the information and select 2 Entera value in the Transducer Counts Mtr Rev field If the Ratio Do this between the motor shaft and the Enter 4096 resolver package input shaft si 1 1 between the motor shaft and the Adjust the value to compensate for resolver package input shaft is not the ratio refer to the examples for 11 more information For Example If the motor shaft to resolver package shaft gear ration is 10 1 every time the resolver package shaft makes one revolution the motor shaft makes ten enter 409 6 Please note that this example is valid for single dual packages that have a resolver element to input package shaft gear ration of 1 1 For Example If the resolver package to resolver element shaft gear ratio is 2 5 1 every time the internal resolver element makes one revolution the resolver package shaft makes 2 5 and the motor shaft to resolver package shaft is 10 1 every time the resolver package shaft makes one revolution the motor makes ten enter 4096 2 5 10 163 84 3 Go to Selecting the Homing Procedure Selecting the Homing Procedure With the Axis Configuration edit window open set the homing position To set the homing position 1 From the Configure menu select Homing The homing options appear
41. sine low 18 Stator shields 8 Stator shields 17 Sine high 7 Sine high 16 Sine low 6 Sine low 15 Cosine high 5 Cosine high 14 Rotor low 4 Rotor low 13 Rotor shield 3 Rotor shield 12 Chassis ground 2 Chassis ground 11 Fault normally open 1 Fault common Power amp Drives Connector Terminal Descriptions The table below shows the terminal descriptions for the Power amp Drives connector Plug A Plug B 10 1 Reference 5 0 Reference 9 1 Reference 4 0 Reference 8 1 Reference shield 3 0 Reference shield 7 Chassis ground 2 Not Used 6 Power ground 1 18 36V DC Publication 4100 5 2 J une 1998 38 Encoder Connector Terminal Descriptions The table below shows the terminal descriptions for Axis 0 and Axis 1 A B 12 7 6 Z 11 B 5 B 10 A 4 A 9 Strobe 3 No Connection 8 Reference Shield Input 2 Strobe 7 Reference Input 1 Reference Input Environmental Specifications Operating and Storage Conditions The table below details the environmental specifications of the REC Specification Description Operating Temperature 0 to 60 C Storage Temperature 40 to 70 C Humidity 95 non condensing 60 C Electrical Specifications Resolver Specifications The table below details the electrical specifications for the
42. the axis is aligning 6 If the transducer alignment Do this Was successful 1 Select OK 2 Go to the Updating the Diagram section Was unsuccessful Check your GML diagram Updating the Diagram Once the Alignment routine completes successfully the resolver offsets Home Position and Vernier Offset and axis specific information gathered during on line setups is stored in the motion controller s working memory You must update your diagram to include your latest changes To update your diagram Homing the Axis Using a Resolver Package with a Linear Axis Setup 31 1 While still in the Enter Setups window select Tuning Complete Save Data Update Diagram 2 Select Execute The diagram updates and the Do Setups window disappears 3 Select Exit Online The Online Manager window disappears The motion controller executes a home command to determine the absolute position of the resolver package To execute the home axis command 1 Double click on the Home Axis block in your GML diagram 2 Select Wait for Completion An X appears in the check box 3 Select Save The Home Axis window disappears Important Before you use any of the position information sent by the REC you have to home the axis because the home command configures the REC for single resolver or dual resolver package applications Important When executing the homing procedure on a servo axis feedback is momentarily disabled then e
43. trol Options window appears 3 Select Axis Drive Data Downloads An X appears next to the text 4 Select Save The Control Options window disappears Running a Motor Encoder Test Use the Motor Encoder Test to check the electrical connection of the servo drive and encoder interface and to establish the correct rotational direction of the servo drive and encoder Establishing these motor and encoder polarities helps prevent runaway axis when the feedback loop is closed To select a Motor Encoder Test 1 From the menu bar select Diagram The Diagram menu appears 2 Select Online The Online Manager window appears 3 Select Download Diagram The program downloads to the con troller 4 When the download is finished select Enter Setups The Do Set ups window appears Setup 29 5 Select Motor Encoder Test A black circle appears in the radio dial next to the text 6 Select Execute Refer to your GML Programming Manual and your motion controller s Installation and Setup User Manual for more information on Motor Encoder Tests Aligning the Absolute Transducer After you have completed the Motor Encoder Test you need to align the resolver package position to the axis position Using the Align Absolute Transducer procedure you can randomly attach the transducer to the physical axis You do not need to match the actual position of the resolver package to the actual position of the axis because the alignment routine reads
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