Tolomatic ACS Manuel
HARDWARE & INSTALLATION
GUIDE
LINEAR SOLUTIONS MADE EASY
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
1.1 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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