Rockwell Automation Allen-Bradley 4100-ESRS Installation And Setup Manual

Brand: Rockwell Automation

Model: Allen-Bradley 4100-ESRS

Type: Installation And Setup Manual

ESRS – Encoder

Signal Reference

Simulator

(Cat. No. 4100-ESRS)

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.

i Publication 4100-IN505A-EN-P - October 2000

Table of Contents

Preface

Using This Manual

Read This Manual . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . P-1

Who Should Use this Manual. . . . . . . . . . . . . . . . . . . . . . . P-1

Purpose of this Manual . . . . . . . . . . . . . . . . . . . . . . . . . . . P-1

Safety Precautions. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . P-2

Contents of this Manual . . . . . . . . . . . . . . . . . . . . . . . . P-3

Related Documentation . . . . . . . . . . . . . . . . . . . . . . . . P-3

Terminology. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . P-3

Common Techniques Used in this Manual . . . . . . . . . . . . . P-4

Product Receiving & Storage Responsibility . . . . . . . . . . . . P-4

Allen-Bradley Support. . . . . . . . . . . . . . . . . . . . . . . . . . . . P-5

Local Product Support . . . . . . . . . . . . . . . . . . . . . . . . . P-5

Technical Product Assistance . . . . . . . . . . . . . . . . . . . . P-5

On the Web . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . P-6

Chapter 1

Overview

ESRS Description. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-1

Principal features of the ESRS. . . . . . . . . . . . . . . . . . . . 1-1

ESRS Front Panel. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-2

ESRS Footprint . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-3

ESRS Principal Specifications . . . . . . . . . . . . . . . . . . . . . . . 1-4

Mechanical Specifications. . . . . . . . . . . . . . . . . . . . . . . 1-4

Environmental Specifications . . . . . . . . . . . . . . . . . . . . 1-4

Power Supply and Fuses . . . . . . . . . . . . . . . . . . . . . . . . . . 1-4

Power Supply Specifications. . . . . . . . . . . . . . . . . . . . . 1-4

Quadrature Output . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-5

Index Pulse . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-5

I/O Filtering . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-5

Chapter 2

Installation

Mounting the ESRS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-2

Enable Input. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-2

External Power Supply . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-6

Publication 4100-IN505A-EN-P - October 2000

Chapter 3

Operation

General . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-1

Indicators . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-1

Controls . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-1

Line Speed . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-1

When Set To Unidirectional. . . . . . . . . . . . . . . . . . . . 3-1

When Set To Bi-directional . . . . . . . . . . . . . . . . . . . . 3-2

Acceleration. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-2

Rounding . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-2

Line Selection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-2

Inputs and Outputs. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-3

Line Speed Ref Out . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-3

Strobe Out. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-3

Ext Line Speed In. . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-4

P1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-4

Enable Voltage . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-5

Enable Input. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-5

Direction Output . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-5

P2. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-6

Options Switch . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-6

Setting the Option Switch. . . . . . . . . . . . . . . . . . . . . . . 3-7

Mode Selection. . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-7

Index Division Ratio Selection. . . . . . . . . . . . . . . . . . 3-8

Maximum Effective Motor Speed . . . . . . . . . . . . . . . . 3-8

Index

1 Publication 4100-IN505A-EN-P - October 2000

Preface

Read This Manual

Read and understand this instruction manual. It provides the

necessary information to let you install, connect, and set up the

Encoder Signal Reference Simulator 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

or set up of the Encoder Signal Reference Simulator.

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

Purpose of this Manual

This manual is an installation and set up guide for the Encoder Signal

Reference Simulator. It describes the procedures necessary to properly

install and configure it into your motion control system.

Publication 4100-IN505A-EN-P - October 2000

Preface

P-2

Safety Precautions

The following general precautions apply to the Encoder Signal

Reference Simulator:

ATTENTION

Electric shock can kill. Make sure the Encoder Signal

Reference Simulator 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 Encoder Signal Reference Simulator 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-IN505A-EN-P - October 2000

Preface

P-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

In order to avoid confusion, we have used the following general terms

in a specific manner within this manual. We define them as follows:

ESRS - Refers to the Encoder Signal Reference Simulator.

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 Encoder

Signal Reference Simulator, its features and

mechanical specifications.

2 Installation Provides the steps needed to successfully

mount and wire the Encoder Signal Reference

Simulator.

3 Operation Provides information on using the ESRS.

For Read This Document Document Number

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

Instructions for using the Ultra Plus 1398 Ultra Plus User Manual 1398-5.1

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-IN505A-EN-P - October 2000

Preface

P-4

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.

• When we refer you to another location, the section name

appears in italics.

• 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. See example

below.

• An important table indicates critical information. See the

following example.

Product Receiving &

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

Failure to observe these warnings may cause damage

to the unit, unexpected and/or uncontrolled

movement of peripheral equipment, and your health

and safety.

IMPORTANT

Identifies information that is critical for successful

application and understanding of the product.

Publication 4100-IN505A-EN-P - October 2000

Preface

P-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.

Publication 4100-IN505A-EN-P - October 2000

Preface

P-6

The Rockwell Automation Technical Support numbers are:

in Europe: (+44) 1270 580142

in North America (603) 443-5419

On the Web

For information about Allen-Bradley, visit the following World Wide

Web site:

http://www.ab.com/

1 Publication 4100-IN505A-EN-P - October 2000

Chapter

Overview

ESRS Description

The Encoder Signal Reference Simulator (ESRS) generates a digital

speed reference for a motor and encoder feedback combination. In

practice the ESRS would be connected to the Master Encoder input of

a drive. The ESRS then generates quadrature pulses with selectable

index (i.e. marker) which a drive forces its motor/encoder to follow.

The ESRS operates in either unidirectional or bi-directional mode as

selected by the Options switch located on the printed circuit board

(PCB) of the ESRS. The rounding and acceleration functions are

operational in all modes and for all inputs including STOP.

Principal features of the ESRS

• Selectable Internal and External Line Reference inputs plus Stop.

• Separate Enable input, with status indication, allows for remote

control.

• Rate of acceleration and deceleration continuously variable

between 1.5 and 15 seconds.

• Five positions of rounding plus “OFF”.

• Powered with a single +5V or +12V DC input voltage taken from

either the drive’s Encoder connector or external power supply.

• User selectable Index pulse in the range 2

, 2

counts.

• Motor speed selectable in the range 1875 to 15000 RPM.

• Product housed in a rugged steel box with mounting tabs.

• Operates in Unidirectional and Bi-directional mode.

• Separate square wave “STROBE” output, which is synchronized

with the Index pulse, for triggering stroboscopes, oscilloscopes,

and so forth.

• Analog output indication of commanded speed.

Publication 4100-IN505A-EN-P - October 2000

1-2

Overview

• Digital output indicates phase of quadrature pulse train (i.e.

direction of motor rotation).

ESRS Front Panel

The following illustration shows the placement and labelling of major

items on the ESRS front panel.

Figure 1.1 ESRS Front Panel Layout

ON ENABLED

LINE SPEED

MIN MAX

ACCEL

MIN MAX

QUALITY

OFF MAX

ROUNDING

SELECTION

INT

STOP

EXT

LINE

SPEED

REF

OUT

STROBE

OUT

EXT

LINE

SPEED

4100 - ESRS

Publication 4100-IN505A-EN-P - October 2000

Overview

1-3

ESRS Footprint

The following figure shows the footprint of the ESRS with fixing hole

dimensions and drilling details.

Figure 1.2 ESRS Dimensions

43.18 mm (1.7 in)

254 mm (10 in.) with

cable clearance

342.9 mm (13.5 in)

152.4 mm (6 in)

ON ENABLED

LINE SPEED

MIN MAX

ACCEL

MIN MAX

QUALITY

OFF MAX

ROUNDING

SELECTION

INT

STOP

EXT

LINE

SPEED

REF

OUT

STROBE

OUT

EXT

LINE

SPEED

4100 - ESRS

323.85 mm (12.75 in)

7.62 mm (0.3 in)

7.92 mm (0.312 in) DIA.

101.6 mm (4 in)

Publication 4100-IN505A-EN-P - October 2000

1-4

Overview

ESRS Principal

Specifications

Mechanical Specifications

Environmental Specifications

Power Supply and Fuses

Power Supply Specifications

Table 1.A Mechanical Specifications

Enclosure Type Steel case with integral mounting feet on rear edge.

Enclosure Size English (inch)

11.6 x 13.5 x 1.7

Metric (mm)

295 x 343 x 43

Table 1.B Environmental Specifications

Operating Storage

Temperature

0 to 60

C -40 to 70

Humidity

95% non condensing @ 60

Table 1.C Power Specifications

Input Voltage +5 or +12V DC. Both ± 5%

Current Draw Approximately 0.6A DC

Overcurrent Protection Overcurrent protection is provided by

separate +5V (F102) and +12V (F103) PCB

mounted fuses rated at T1.6A. A spare

fuse (F101) is also provided on the PCB.

If +5V and +12V are applied

simultaneously, the ESRS selects

the +12V input.

The ESRS is intended to take its

power from the encoder supply of

the target equipment. However, the

user should establish that this

supply has sufficient capacity to

provide the current indicated above.

If necessary, an additional power

supply is required – see

Chapter 2:

Installation

Publication 4100-IN505A-EN-P - October 2000

Overview

1-5

Quadrature Output

Index Pulse

I/O Filtering

Table 1.D Quadrature Output

Number of quadrature outputs provided. One

Output format Incremental quadrature with Index pulse.

Output data type RS422 TTL Levels.

Quadrature output frequency 0 to 275kHz.

Quadrature output phase Forward is defined as A phase leading B.

Reverse is defined as B phase leading A.

Table 1.E Index Pulse

Index division ratios.

Selectable in the range : 2

, 2

pulses.

Index pulse type Gated

The index pulse is high (Logic 1 or

True) only when the selected

division ratio has been satisfied and

the A and B phases are High.

Table 1.F I/O Filtering

High Frequency Filtering. High Frequency filtering is provided on all

power, digital and analog I/O lines as

appropriate.

Over-Voltage Clamping Over-voltage clamping is provided on the

power supply inputs, the quadrature and

index outputs, and the “EXT LINE SPEED

IN” input.

Publication 4100-IN505A-EN-P - October 2000

1-6

Overview

1 Publication 4100-IN505A-EN-P - October 2000

Chapter

Installation

The ESRS is designed to be mounted in an electrical cabinet via the

mounting tabs on its back panel. For all applications, this installation

method should be observed. Before powering up your ESRS, make

sure it has been configured correctly and that all peripheral

equipment has been correctly connected to it.

The following safety points must be observed when installing the unit:

• The 5V or 12V DC supply must be electrically isolated from all

other supplies with higher potentials.

• The 0V (common) side of the 24V DC supply must be connected

to a safety ground.

• The unit is intended for installation and use within an electrical

control cabinet in a normal industrial environment.

• When used in an electrical cabinet, the case of the ESRS must be

bonded to the cabinet via the mounting feet.

ATTENTION

Do not apply power to your ESRS when it is part of a

control system without first establishing that this will

not have any adverse effects.

Do not make or break any electrical connections to

your ESRS while power is applied.

Do not change any option switch settings on your

ESRS while power is applied.

Failure to observe the above warnings may cause

immediate and uncontrolled movement of controlled

hardware, damage to the ESRS, peripheral

equipment, and your health and safety.

Publication 4100-IN505A-EN-P - October 2000

2-2

Installation

Mounting the ESRS

The ESRS must be properly grounded to the metal enclosure panel.

The following diagram shows how to ground the ESRS to the panel.

Figure 2.1

Mounting and Grounding Diagram

Enable Input

There are several ways in which the Enable Input can be wired. The

diagrams on the following pages indicate the various connection

options.

The following diagram shows how to connect the ESRS to continually

enable the device from the internal Enable supply.

#10 AWG to

Ground Bus

Ground

Lug

Internal Star Washers

ESRS Mounting Tab

Size 1/4 - 20 or M6

Hardware

Tapped Hole

(Minimum of 3 Threads)

Metal Panel

(Must be connected to

earth ground.)

Scrape paint off panel to insure

electrical connection between

chassis and grounded metal plate.

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Rockwell Automation Allen-Bradley 4100-ESRS Installation And Setup Manual

Brand: Rockwell Automation

Model: Allen-Bradley 4100-ESRS

Type: Installation And Setup Manual

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Rockwell Automation Allen-Bradley 4100-ESRS Installation And Setup Manual

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