Tolomatic ACS Manuel

HARDWARE & INSTALLATION

GUIDE

LINEAR SOLUTIONS MADE EASY

3604-4173_00_ACS_HDWINSTL

ACS – Actuator Control Solutions

Stepper Drive/Controller and Motors

Air-Oil Systems, Inc. www.airoil.com

Tolomatic reserves the right to change the design or operation

of the equipment described herein and any associated motion

products without notice. Information in this document is

subject to change without notice.

201102031042

Air-Oil Systems, Inc. www.airoil.com

Tolomatic Hardware & Installation Guide: ACS Stepper Drive/Controller i

Contents

List of Figures ..................................................................................................iii

List of Tables....................................................................................................iv

Health and Safety Regulations........................................................................vi

Safety Symbols .............................................................................................v

EMC Wiring Guidelines ................................................................................ vii

Proper and Safe Use of Product ................................................................... vii

Handling and Unpacking ............................................................................. viii

Product Warnings.......................................................................................viiii

1. Product Overview ..................................................................................1-1

1.1 The ACS Stepper Drive/Controller for Actual Control Solutions ...............1-1

1.1.1 The ACS Stepper Drive/Controller Basic Overview .........................1-1

1.1.2 Optional Accessories .................................................................. 1-1

2. Environment, Dimensions & Mounting .................................................2-1

2.1 Operating Environment ........................................................................2-1

2.2 Dimensions ........................................................................................2-1

2.3 Mounting the ACS Drive/Controller .......................................................2-2

3. Starter Kit ...............................................................................................3-1

4. ACS Drive/Controller Setup ...................................................................4-1

4.1 ACS Drive/Controller and Actuator Basic Setup .....................................4-1

4.1.1 Setup Procedures .......................................................................4-2

5. Connections & Cables ...........................................................................5-1

5.1 Connections & Cables Overview ..........................................................5-1

5.2 Motor Power Connection and Cable .....................................................5-1

5.3 Encoder Connection and Cable ............................................................5-2

5.4 I/O Connection and Cable ....................................................................5-3

5.5 Input Power Connection ......................................................................5-4

5.6 RS-232 Connection ............................................................................5-5

5.7 RS-485 Connection ............................................................................5-6

5.8 Ethernet Connection ............................................................................5-6

5.9 Cable Routing .....................................................................................5-7

6. Specifications and Wiring .....................................................................6-1

6.1 Digital Inputs.....................................................................................6-1

6.1.1 Specifications .............................................................................6-1

6.1.2 Typical Wiring Diagrams ..............................................................6-2

6.2 Digital Outputs ..................................................................................6-2

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ii Tolomatic Hardware & Installation Guide: ACS Stepper Drive/Controller

6.2.1 Specifications .............................................................................6-2

6.2.2 Typical Wiring Diagrams ..............................................................6-3

6.3 Input Power ......................................................................................6-3

6.3.1 Drive Specifications ....................................................................6-4

6.3.2 Typical Input Power Wiring ..........................................................6-4

6.3.3 Power Supply Selection ...............................................................6-5

6.3.4 Suggested Power Supplies ..........................................................6-5

7. I/O Timing Diagrams ............................................................................7-1

7.1 I/O Timing Diagrams..........................................................................7-1

7.1.1 Move Timing Rules .....................................................................7-2

8. Move Select Logic ................................................................................8-1

8.1 Move Select Logic Tables ..................................................................8-1

9. LED Codes and Faults ..........................................................................9-1

9.1 LED Codes ........................................................................................9-1

9.2 Fault Descriptions and Recovery ........................................................9-1

10. Troubleshooting ..................................................................................10-1

10.1.1 Troubleshooting the ACS Drive/Controller .....................................10-1

Appendix 1 ..................................................................................................A1-1

Motors ..................................................................................................A1-1

Appendix 2 ..................................................................................................A2-1

Product Warranty ..................................................................................A2-1

CONTENTS

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Tolomatic Hardware & Installation Guide: ACS Stepper Drive/Controller iii

List of Figures

Figure 2-1 Mounting the ACS Drive/Controller ........................................................ 2-1

Figure 3-1 ACS Drive/Controller and ERD Actuator Basic Setup ............................... 3-1

Figure 5-1 Motor Power Connection on ACS Drive/Controller................................... 5-1

Figure 5-2 Motor Power Cable 3604-1767/1766 ................................................... 5-2

Figure 5-3 Encoder Connection on ACS Drive/Controller ......................................... 5-2

Figure 5-4 Encoder Cable 3604-1768 ................................................................... 5-3

Figure 5-5 I/O Connection on ACS Drive/Controller ................................................. 5-3

Figure 5-6 I/O Cable 3604-1770 ........................................................................... 5-4

Figure 5-7 Input Power Connection ........................................................................ 5-4

Figure 5-8 RS-232 Connection .............................................................................. 5-5

Figure 5-9 RS-232 Pin Connection ........................................................................ 5-5

Figure 5-10 RS-485 Connection for Future ACS Drive/Controller Programmability ...... 5-6

Figure 5-11 Ethernet Connection for Future ACS Drive/Controller Programmability ..... 5-6

Figure 5-12 Cable Routing for Top and Side Mounted Connectors ............................. 5-7

Figure 6-1 Digital Input Circuit ............................................................................... 6-1

Figure 6-2 Input Source (switched) Connection ....................................................... 6-1

Figure 6-3 Input Source (PNP) Connection ............................................................. 6-2

Figure 6-4 Input Sink (switched) Connection .......................................................... 6-2

Figure 6-5 Input Sink (NPN) Connection ................................................................. 6-2

Figure 6-6 Output Circuit ...................................................................................... 6-3

Figure 6-7 Digital Output Sinking Connection ......................................................... 6-3

Figure 6-8 Digital Output Sourcing Connection ....................................................... 6-3

Figure 6-9 ACS Drive/Controller Logic and Main Power Supplies ............................. 6-4

Figure 6-10 ACS Drive/Controller Single Supply – Main Power .................................. 6-4

Figure 6-11 ACS Drive/Controller External Cutoff Switch for Emergency Stop ............. 6-5

Figure 7-1 Input Requirement ................................................................................ 7-1

Figure 7-2 System Startup Timing ......................................................................... 7-1

Figure 7-3 Jog Move Timing .................................................................................. 7-1

Figure 7-4 Absolute & Incremental Move Timing..................................................... 7-2

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iv Tolomatic Hardware & Installation Guide: ACS Stepper Drive/Controller

List of Tables

Table 3-1 ACS Starter Kit Contents ....................................................................... 3-1

Table 3-2 D-sub to RJ12 Converter Wiring ........................................................... 3-1

Table 5-1 Motor Power Connection PIN Outs ........................................................ 5-1

Table 5-2 Motor Power Cable and Connector Parts ............................................... 5-2

Table 5-3 Encoder Connection PIN Outs ............................................................... 5-2

Table 5-4 Encoder Cable and Connector Parts ...................................................... 5-3

Table 5-5 I/O Connection PIN Outs ....................................................................... 5-4

Table 5-6 I/O Cable and Connector Parts .............................................................. 5-4

Table 5-7 Input Power PIN Outs ........................................................................... 5-5

Table 5-8 Input Power Cable Parts ....................................................................... 5-5

Table 5-9 RS-232 PIN Outs and Connection ......................................................... 5-5

Table 5-10 RS-232 Cable Parts ............................................................................. 5-5

Table 6-1 Opto-isolated Digital Input Specifications ............................................... 6-1

Table 6-2 Digital Output Specifications ................................................................. 6-3

Table 6-3 Drive Specifications .............................................................................. 6-4

Table 6-4 Maximum Power Supply Current for Tolomatic Motors ............................ 6-5

Table 6-5 Recommended Switching Power Supplies ............................................. 6-6

Table 6-6 Recommended Linear Regulated Power Supplies ................................... 6-6

Table 6-7 Recommended Linear Unregulated Power Supplies ................................ 6-6

Table 6-8 Fuses .................................................................................................. 6-6

Table 8-1 4 Move Commands Mode Logic ............................................................ 8-1

Table 8-2 8 Move Commands Mode Logic ............................................................ 8-1

Table 8-3 16 Move Commands Mode Logic .......................................................... 8-2

Table 9-1 LED Indicators ...................................................................................... 9-1

Table 9-2 Safety Faults ........................................................................................ 9-1

Table 9-3 Critical Faults ....................................................................................... 9-2

Table 10-1 Troubleshooting Descriptions .............................................................. 10-1

Table A-1 Tolomatic Motor Specifications ............................................................ A1-1

Table A-2 Tolomatic Motor Part Numbers ............................................................ A1-1

Table A-3 Encoder Specifications ....................................................................... A1-1

Table A-4 NEMA 11 Motor Connection PIN Outs .................................................A1-2

Table A-5 NEMA 17 Motor Connection PIN Outs .................................................A1-2

Table A-6 NEMA 23 Motor Connection PIN Outs .................................................A1-2

Table A-7 Encoder Connections and Connector PIN Outs ..................................... A1-2

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Tolomatic Hardware & Installation Guide: ACS Stepper Drive/Controller v

Health and Safety Regulations

Read completely through the applicable sections of the manual before the

equipment is unpacked, installed or operated. Pay careful attention to all of the

dangers, warnings, cautions and notes stated in the manual.

Serious injury to persons or damage to the equipment may result if the information

in the manual is not followed.

Safety Symbols

Items that are specifically marked DANGER!, WARNING!, CAUTION! or NOTE! are

arranged in a hierarchical system and have the following meaning:

DANGER!

Indicates a very hazardous situation which, if not avoided, could result in death or

serious injury. This signal word is limited to the most extreme situations.

WARNING!

Indicates a potentially hazardous situation which, if not avoided, could result in

death or serious injury.

CAUTION!

Indicates a potentially hazardous situation which, if not avoided, may result in

property damage, minor or moderate injury.

CAUTION!

Indicates hot surfaces. Avoid contact.

NOTE!

Information that requires special attention is stated here.

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vi Tolomatic Hardware & Installation Guide: ACS Stepper Drive/Controller

EMC Wiring Guidelines

Cable routing

It is recommended that the power and signal cables for the ACS drive/controller be

routed as far apart as possible to minimize system noise.

NOTE! The standard cables from Tolomatic are not flex rated and have a minimum

bend radius of 3.75 inches. Any repeated flexing or excessive bending can result in

broken conductors and intermittent faults.

Shielding and grounding

When cabling the system, shielded cables are recommended. The standard cables

provided by Tolomatic have an overall shield with drain wires. The metal angle

bracket on the drive/controller is also a case ground and should be tied to earth

ground. To minimize EMI and ensure system reliability, all shield drain wires from all

cables should be tied to a common earth ground.

Proper and Safe Use of Product

Protection circuits and external fuses

A fuse should be added to the input power line to protect the drive/controller and

power supply from any potential over current conditions that may occur. (See

Section 6: Specifications & Wiring, page 6-6)

Fail Safe Emergency Stop Recommendations

A means for a fail safe e-stop is highly recommended to ensure equipment and

personal safety. The e-stop should provide a means to remove main power from the

actuator to cease and prevent any unwanted motion.

Device Damage Prevention

To prevent permanent damage to the device, proper care should be taken not to

exceed published voltage, current, temperature, and load ratings. In addition, proper

wiring should be verified and safety measures checked before applying power.

Personal Safety

During normal operation the motor can become hot. It is highly recommended to

display proper safety notices and implement proper safety measures to prevent

contact with hot surfaces.

HEALTH AND SAFETY REGULATIONS

WARNING!

The manufacturer takes no

responsibility whatsoever

if the equipment is

modified or if the

equipment is used in any

way beyond performance

specifications.

Unauthorized

modifications or changes

to the equipment are

stricly forbidden and void

all warranties.

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Tolomatic Hardware & Installation Guide: ACS Stepper Drive/Controller vii

HEALTH AND SAFETY REGULATIONS

Handling and Unpacking

When unpacking and handling, care should be taken not to drop the drive/controller

as this can damage the connectors and internal electronics.

Product Warnings

The following precautions should be observed to prevent erratic behavior or

damage:

• Do not short circuit the motor power at the power connector. Doing so may

damage the drive power electronics. The motor/cable is part of the current

regulation circuitry. For a short occurring in a motor, the motor leads should

provide enough resistance and inductance to prevent dangerous peak currents

from occurring.

• Do not reverse bias the power unit.

• Do not apply voltages above the maximum rated voltage.

• Do not expose drive to conductive contaminants, moisture, or excessive

temperature.

• Do not dissassemble or modify the drive/controller.

CAUTION!

Proper ESD measures

should be taken to avoid

static electricity from

contacting the signal and

power lines of the drive,

motor and encoder.

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1-1 Tolomatic Hardware & Installation Guide: ACS Stepper Drive/Controller

Product Overview

1.1 The ACS Stepper Drive/Controller for Actuator Control Solutions

Tolomatic’s ACS drive/controller is a stepper drive and controller intended for use

with electric actuators. Tolomatic's Motion Interface software allows the user to

select the compatible Tolomatic electric linear actuator of choice. The software

automatically sets most of the necessary parameters to create the desired motion

of the selected actuator reducing setup and programming time. (See Tolomatic

Motion Interface Software Manual 3600-4167 for more information).

1.1.1 ACS Stepper Drive/Controller— Basic Overview

ACS Basic Drive/Controller (3604-9651) Capabilities

• 4, 8, or 16 move command modes

(absolute, incremental or jog) for infinite

position capability

• End point correction

• Zone output based on position

• Force limiting capacity

• Configurable digital I/O

(24 Vdc Opto-Isolated)(NPN or PNP)

• Compatible with most

24 Vdc stepper motors

• Adjustable motion profile parameters

(velocity, accel/decel, force). Parameters

are independently configurable for each

move

• Ability to reduce holding current for

energy savings

Dual EthErnEt ports

Digital i/0

rs232 CoM port

lED inDiCators

rs485 CoM port

Dual purposE hEat sink

powEr

ConnECtion

Motor powEr

FEEDbaCk

COMING SOON!

• Internal switch for daisy chaining up to 255 ACS axes

Protocols:

• Ethernet/IP • Modbus TCP • Ethernet TCP/IP

• 8 Digital Inputs

• 4 Digital Outputs

•24 Vdc Opto-Isolated

• NPN or PNP

• Configurable

• Drive Configuration Port

COMING SOON!

• Networking Port

• Removes heat from drive

for optimal performance

• Panel mounting

• 24Vdc

•24Vdc Stepper Motors

•Power & Fault indicators

•For Digital Encoder

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