Allen-Bradley 843ES CIP Safety Encoders Instruction Manual

Allen-Bradley 843ES CIP Safety Encoders

EtherNet/IP Absolute Encoders: Standard and CIP Safety Models

Bulletin Numbers 843E, 843ES

ATTENTION: Do not attempt to install this device unless the installation instructions have been studied and understood. This document acts as a guide for a typical installation.

Summary of Changes

This publication contains the following new or updated information. This list includes substantive updates only and is not intended to reflect all changes.

Introduction

This publication is to help with proper installation of the EtherNet/IP™ encoder. It provides publication references and guidelines, product specifications, technical data, and cabling recommendations. It is required that installation is in accordance with these instructions and implemented by qualified personnel.

Technical Specifications

Use appropriate screws, bolts, or nuts to mount the flange of the encoder to avoid the risk of tampering. Do not over torque the mounting hardware. The 843ES encoder is intended to be part of the safety-related control system of a machine. Before installation, a risk assessment must be performed to determine whether the specifications of this device are suitable for all foreseeable operational and environmental characteristics of the application. See Specifications for certification information and ratings.

Product Overview

The 843E/843ES encoders are absolute encoders. An absolute encoder has a unique digital output for each shaft position. The use of absolute encoders verifies that true position is always available, regardless of power interruptions to the system. Absolute encoders can be single-turn or multi- turn. The 843ES encoder was designed to help simplify safety applications with the use of controller-based monitoring functions. The 843ES encoder helps make it easier to achieve the desired safety integrity level (SIL) or Performance Level (PL) because it allows the GuardLogix® 5580 or Compact GuardLogix 5380 safety controllers to monitor position and velocity input values directly.

Specifications

Table 1 – General Specifications

Mechanical Specifications

Resolution/Revolution Specifications

Approximate Dimensions

IMPORTANT: To simplify the drawings and information, unless otherwise specified, the general tolerances with tolerance class m (medium) according to ISO 2768-1 apply.

Solid Shaft with Clamping Flange [mm (in.)]

Solid Shaft with Synchro Flange [mm (in.)]

Solid Shaft with Square Flange [mm (in.)]

Hollow Shaft with Stator Coupling 63 mm (2.5 in.) Diameter [mm (in.)]

Hollow Shaft with Stator Coupling 63 mm (2.5 in.) Diameter with Ø6.35 mm (0.25 in.) Hollow Shaft [mm (in.)]

Hollow Shaft Flange with 150 mm (5.9 in.) Torque Arm [mm (in.)]

Hollow Shaft Flange with 150 mm (5.9 in.) Torque Arm and Ø6.35 mm (0.25 in.) Hollow Shaft [mm (in.)]

Application Requirements for Hollow Shaft Encoders

Encoder Installation

Flexible Shaft Couplings

ATTENTION: Rigidly coupling the encoder shaft to the machine shaft causes a failure in either the bearings or the encoder or the bearings of the machine shaft.

IMPORTANT: Both Ethernet ports are provided with a plastic cap. If only one port is used, the cap of the unused port must be tightened at a torque of 1 N•m [8.9 lb•in] to maintain the IP protection level.

Four-pin M12 Ethernet Connector

10…30V

2| —| White| —
3| Voltage –| Blue| Supply Voltage 0V
4| —| Black| —

Mechanical Installation

ATTENTION: Do not connect rigidly the stator and the rotor. The encoder would be mechanically constrained and thus damaged.

• With solid shaft encoders, always use a tolerancecompensating element between the drive shaft and the encoder shaft
• With hollow shaft encoders, always use a tolerancecompensating element between the encoder flange and the drive flange.

IMPORTANT: Comply with the maximum permissible shaft offset.

• Axial offset: < ± 0.25 mm [0.01 in.]
• Radial offset: < ± 0.20 mm [0.008 in.]

The values that are specified for the radial and axial offset are maximum values, which must not occur simultaneously. If shaft displacements nevertheless occur simultaneously, their share in the sum must not exceed 100% of the specified maximum values.

ATTENTION: IEC 61800-5-2 defines the loosening of mechanical connection (between the encoder and the drive) as a fault that requires consideration. Fault exclusion is required for the coupling elements if the control cannot detect this fault. Therefore, design the coupling between the encoder and apparatus for fault exclusion so that any possibility of breakage at the coupling can be ruled out. To achieve this fault exclusion, the encoder mechanical limits and mounting practices in this document must be considered.

When installing, follow the descriptions and specifications of the couplings that are used. The coupling influences the system accuracy of the drive unit, so verify that the coupling is stiff and non-slip. Make sure that the shaft couplings are designed so that breakage of the connection can be excluded. Conduct a risk analysis before installation and consider the following aspects:

• Counter-torque of the encoder
• Maximum permissible shocks and vibrations
• Maximum permissible acceleration
• Permissible geometrical deviations in the ideal orientation of the shafts
• Permissible temperatures and humidity ranges
• Required angular accuracy

For this assembly, use only inspected and calibrated tooling that is subject to the quality system. Unless otherwise specified, a friction coefficient of 0.14 is assumed for all screw connections, and a strength property class of 8.8 (metric) or Grade 5 (imperial) is assumed for the screws. Use coated screws, thread locker, or SCHNORR® washers to keep screws secure. We recommend adding additional protection against manipulation by marking the fastening screws with locking varnish or similar.

Mount with a Solid Shaft

IMPORTANT: For solid shaft encoders, a suitable shaft coupling that meets the requirements of the application must be used.

1. Be sure to select the proper size flexible coupling clamp to mate to the encoder shaft. See publication 847-TD001 in Additional Resources on page 6 for encoder accessories.
2. To determine the encoder mounting hole locations, see Approximate Dimensions on page 2.
3. Fasten the encoder and tighten it with three sizes M3 mounting screws (provided with the flange).
4. Tighten the screws at a torque of 1 N•m (8.9 lb•in) and secure them against loosening.
5. Check the shafts for offset. The maximum permissible tolerances depend on the selected shaft coupling.
6. Connect the encoder and load shaft with a flexible coupling.
7. During assembly, protect the coupling element against excessive bending and damage.
8. Center the flexible coupling, screw the coupling without preload, and secure it against loosening.
9. Rotate the machine slowly and verify that the flexible coupling is not deforming beyond specifications.
10. Align the machine to its mechanical zero or home position.

Mount with a Hollow Shaft

• For hollow shaft encoders, the coupling elements (for example, a stator coupling or a compensating torque stop) are factory-mounted.

IMPORTANT

• Verify that the insertion depth of the load shaft into the hollow shaft encoder is ≥25.5 mm (1.0 in.)
• Verify that the mating shaft is chamfered and grease-free.

1. Check the shafts for offset. The maximum allowed shaft connection tolerances are:
   • • Axial offset < ±0.25 mm (0.01 in.)
   • • Radial offset < ±0.20 mm (0.008 in.)
2. Slide the encoder onto the mating shaft until the flex mount rests on the machine’s surface. The minimum insertion depth for a hollow shaft is 25.5 mm (1.0 in.).
   • ATTENTION: The encoder slides freely onto the shaft; if not, do not force. Check the shaft for interferences such as gouges, burrs, rust, or size.
3. Hold the encoder firmly and mark the two mounting holes. (If mounting holes exist, proceed to step 6.)
   • IMPORTANT: Do not stress the flex mount while tightening the screws.
4. Slide the encoder off. To accept M3 (or equivalent) screws, drill and tap the marked holes.
5. Slide the encoder back onto the shaft until the flex mount rests on the machine’s surface.
6. Attach the encoder with two M3 (or equivalent) screws. Screw the stator coupling and the torque stop without preload on the drive flange. Tighten the screws to 1 N•m [8.9 lb•in].
7. Tighten the clamping ring screw to 2.5 N•m (22.1 lb•in).
8. Align the machine to its mechanical zero or home position.

Electrical Installation

ATTENTION

• Make sure that the operating voltage is switched on or off simultaneously for the encoder and the downstream device.
• Electrostatic discharges at the contacts of the connector or at the cable ends could damage or destroy the device. Take appropriate precautionary measures.
• Use a PELV supply voltage source according to IEC 60204-1 complying with the proper operating voltage and the maximum permissible output current.

IMPORTANT

• To connect the encoder, refer to the corresponding operating and safety instructions of the external drive system/encoder evaluation system. When assembling a mating connector, comply with the instructions that are attached to the connector.
• Verify that all required cable wires/connectors are connected before commissioning. Insulate individually all unused ends of the output signals to avoid shortcircuits.
• Route the encoder cable free of any tension, so that no additional force is applied to the encoder. Consider the minimum bending radius of the connection cable.

Connectivity Considerations

ATTENTION: Before connecting or disconnecting the signal cable, always disconnect the power supply and secure it against switching on again.

Consider using the shortest length possible for both Ethernet and power cables. Run Ethernet cables separate from power cables and run the DC power cable away from AC power.

Verify that no other devices with high interference levels such as frequency converters, solenoid valves, or contactors, are connected to the same power supply as the encoder. Otherwise, use suitable voltage filtering. We recommend shielded twisted-pair cables for both Ethernet and power connections. These cables help avoid disruptions of signals from electrical noise and from mechanical vibration and shock that are common in most industrial environments. When installing the shielded cables, you must follow the recommended installation guidelines to avoid ground loops. You must comply with the maximum permissible connection cable length.

For shielded Ethernet cables, you must provide an equipotential grounding network that overlays the existing electrical grounding and bonding system for safety and fire. If you cannot provide an equipotential ground and the second connection from the encoder is going to a switch, install a patch panel to break the shield to the switch. Switches typically connect jack shield directly to the ground lug, which connects the shield directly to ground.

Diagnostics

After switching on the power supply, wait at least 10 seconds until the encoder is ready for operation and interfaces are ready for communication. The encoder communicates with the digital interface after this period.

Device not configured

Fast flashing during safety

commissioning

Link 1/Link 2 Status Indicator (1)| Short Description
---|---
OFF| No link/power OFF
Green solid| Ethernet connection is established
Green flashing| Data transmission/port active

• The Ethernet link status indicators (Link 1 and Link 2) display the status of the physical connection on the Ethernet interface.

Rotary Switches

• Set switches in the range of 001…254 to set IP address 192.168.1.xxx (where xxx represents the switch settings)
• Subnet mask = 255.255.255.0
• Gateway address = 192.168.1.1
• It is recommended to set the rotary switches to a valid number before installing the module
• If rotary switches are not set to a valid number, the encoder attempts to use the BOOTP/DHCP server to set the IP address
• The encoder is shipped with this configuration:
  • BOOTP/DHCP enabled
  • Rotary switches set to 999 — when applicable

ATTENTION: The EtherNet/IP communication module must be assigned a fixed network address. The IP address of this module must not be provided dynamically. Failure to observe this precaution can result in unintended machine motion or loss of process control.

Declaration of Conformity

• For the Declaration of Conformity, visit rok.auto/certifications

Additional Resources

To download publications, visit rok.auto/literature and search for the following publication numbers.

Cordsets and Field Attachables Technical Data,

publication 889-TD002

| Provides technical specifications for power cables and

attachables.

Ethernet Media Specifications Technical Data,

publication 1585-TD001

| Provides technical specifications for Ethernet media

cables and accessories.

High-Resolution Incremental Optical Encoders

Tech Data, publication 847-TD001

| This publication includes descriptions of Allen-Bradley®

encoder accessories.

Kinetix® 5700 Safe Monitor Functions Safety

Reference, publication 2198-RM001

| Provides information on controller-based safety

functions.

EtherNet/IP Absolute Encoders: Standard and CIP Safety Models User Manual,

publication 843-UM001

| Provides information on configuration and operation of 843E EtherNet/IP and 843ES CIP Safety encoders.
EtherNet/IP Network Devices User Manual, publication ENET-UM006| Information on how to build and use EtherNet/IP communication modules in Logix 5000™ control systems.
Guidance for Selecting Cables for EtherNet/IP Networks, publication ENET- WP007| Provides guidance on the selection of cables based on the application, environmental conditions, and mechanical

requirements.

System Design for Control of Electrical Noise, publication GMC-RM001| Provides information, examples, and techniques that are designed to minimize system failures caused by electrical noise.
Open DeviceNet Vendors Association (ODVA) Media Planning and Installation Manual, publication PUB00148R0| Provides information on Equipotential grounding and bonding.
Safety of Machinery – Safe Related Parts of Control Systems, standard ISO 13849| Provides safety requirements and guidance on the principles for the design of safety-related parts of

control systems.

Functional safety of Electrical/Electronic/ Programmable Electronic safety- related systems, standard IEC 61508| Provides considerations when electrical/electronic/ programmable electronic systems are used to conduct safety functions.
Industrial Automation Wiring and Grounding

Guidelines, publication 1770-4.1

| Provides general guidelines for installing a

Rockwell Automation® industrial system.

Product Certifications website,

rok.auto/certifications

| Provides declarations of conformity, certificates, and

other certification details.

Waste Electrical and Electronic Equipment (WEEE)

• At the end of life, this equipment should be collected separately from any unsorted municipal waste.

Rockwell Automation maintains current product environmental compliance information on its website at rok.auto/pec.

Your comments help us serve your documentation needs better. If you have any suggestions on how to improve our content, complete the form at rok.auto/docfeedback. For technical support, visit rok.auto/support.

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References

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