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1. PIN NUMBERS SIGNAL CABLE WIRE COLOR 1 ENC A Blue 2 ENC A Orange 3 ENC B Yellow 4 ENC B Gray 5 NA NA 6 NA NA 9 Signal Ground Black 12 5Vdce Red 13 Case Ground NA Table 5 3 Encoder Connection PIN Outs Tolomatic Hardware amp Installation Guide ACS Stepper Drive Controller 5 2 5 CONNECTIONS amp CABLES 118 11 3000 0 m TUBING MOLEX P N 51021 0600 JST P N PHDR 14VS Figure 5 4 Encoder Cable 3604 1768 CABLE TOLOMATIC DRIVE MATING DRIVE MATING ENCODER ENCODER PART NO CONNECTOR CONTACTS MATING MATING CONNECTOR CONTACTS Encoder 3 meter 3604 1768 JST PN JST PN Molex PN Molex PN PHDR 14VS SPHD 001T P0 5 51021 0600 50079 8100 Encoder 5 meter 3604 1769 JST PN JST PN x PN Molex PN PHDR 14VS SPHD 001T P0 5 wd 50079 8100 Table 5 4 Encoder Cable and Connector Parts INS Ne E 5 4 1 0 Connection and Cable AN e 2 L oremi 431 C OTOR z BRAKE COM ys NO 5 5 ndoa on ACS Drive Controller PIN up S SIGNAL CABLE WIRE COLOR cs 1 Input 1 Red Black White 7 2 Input 2 v3 3 Input 3 Red White2. YU RS435 POW ER Figure 5 7 Input Power Connection 5 CONNECTIONS amp CABLES PIN NUMBERS SIGNAL 1 Main Power 24Vdc 2 Keep Alive 24Vdc 3 NA 4 Ground Power Table 5 7 Input Power PIN Outs CABLE INPUT POWER MATING CONNECTOR Customer Supplied OnShore PN ED950 4 Table 5 8 Input Power Cable Parts dS EN 5 6 RS 232 Connection GV connector and will mate with CD The RS 232 port connector is a standard standard RJ12 connectors and cables AN 2NGOD QS mm Figure 5 6 RS 232 Connection Me ACS Stepper Drive Controller uses five signals from the RS 232 port and will Sheed to be properly wired to the PIN diagram shown below RS 232 baud rate is set at 38400 bps 1 stop bit no parity and no flow control The RS 232 cable itself is a straight through cable PIN 4 SHIELD PIN NUMBERS DESCRIPTION 2 3 RX 4 Programming 5 Ground 6 Reset Table 5 9 RS 232 PIN Outs and Connection 5 5 Tolomatic Hardware amp Installation Guide ACS Stepper Drive Controller CONNECTIONS amp CABLES 5 CABLE TOLOMATIC PART NO
3. 6 5 AM Figure 7 1 Input EE 7 1 Vv Figure 7 2 System Startup Timing nasisiraan 7 1 Figure 7 52 400 Move ccrte ne inne 7 1 Figure 7 4 Absolute amp Incremental Move 0 022202 4 7 2 Tolomatic Hardware amp Installation Guide ACS Stepper Drive Controller iii List of Tables Table 3 1 ACS Starter Kit Contes cnet n cte ce et rto d 3 1 Table 3 2 D sub to RJ12 Converter Wiring sse e 3 1 Table 5 1 Motor Power Connection PIN Outs 5 1 Table 5 2 Motor Power Cable and Connector 5 2 Table 5 3 Encoder Connection PIN QUIS ett ttt e 5 2 Table 5 4 Encoder Cable and Connector 5 0022 22 5 3 Table 5 5 Connection PIN 5 5 4 Table 5 6 Cable and Connector T mn 5 4 Table 5 7 Input Power PIN 05 0 00 20 0000000000000 YDD YL Y LDn DF FFyN 5 5 Table 5 8 Input Power Cable ef tette cr 5 5 Table 5 9 RS 232 PIN Outs and Connection GN ns 5 5 Table 5 10 RS 232 Cable Pais s s 1111111 5 5 Table 6 1 Opto isolated Digital Input Specifications 25000 6 1 Table 6 2 Digital Output Specifications 6 3 Table 6 3 Drive Specification S 2 NU e eite 6 4 Table 6 4 Maximum Power Su
4. 4 1 xe SGUD PROC COINS iin atts alate eee i 4 2 e onnections amp Cables 5 1 5 1 Connections amp Cables itti edited iat eta 5 1 MN 5 2 Motor Power Connection and 5 1 VS 5 3 Encoder Connection and 5 2 PO GOMMECHON and e 161 uude CG O y 5 3 5 5 Input Power Connection sss 5 4 Sb hose Nas TF OO O O 5 5 5 7 RS 485 CONNECHON REY 5 6 58 Ethernet FFYN EE FFF EF a 5 6 5 9 C ble ROUMO FN FARA A FAN 5 7 6 Specifications and Wiring 2 22 9999 6 1 LES Digital ena 6 1 S 6 1 6 1 2 WWII 6 2 6 2 Digital UT ES cust utut 6 2 Tolomatic Hardware amp Installation Guide ACS Stepper Drive Controller i 5 FN RFC ROD RTH FO FE 6 2 6 2 2 Typical Wiring Diagrams 6 3 BAPE GWE stant nied a 6 3 0 3 1 DAVE OPEGIMCAUONS
5. RJ12 Customer Supplied or 3604 1787 D sub to RJ12 3604 1782 Table 5 10 RS 232 Cable Parts EN 5 7 RS 485 Connection At the time of publication of this User Guide the RS 485 port is available for future networking capability with the ACS C RS485 Figure SO 485 Connection for Future ACS Drive Controller Neworking Capability 2 5 8 Ethernet Canecton amp At the time of publication of this user guide the ACS Stepper Drive accommodates two Ethernet ports for future networking capability aT LILIAUUE LY 13 7MERNET D Y Figure 5 11 Ethernet Connection for Future ACS Drive Controller Programmability Tolomatic Hardware amp Installation Guide ACS Stepper Drive Controller 5 6 5 CONNECTIONS amp CABLES EN 5 9 Cable Routing Over time liquid contaminants such as oil and cleaning solutions may accumulate on the cables and in the connectors if they are an exposed type To minimize the introduction of contaminants into the connector route the cables so that there is a loop in the cable just prior to its attachment to the connector Two examples are shown below depending on the orientation of the connectors Units mounted in such a way that the co
6. 6 4 6 3 2 Typical Input Power Wiring 1 ere tert ntes 6 4 0 3 3 UST enis 6 5 6 3 4 Suggested Power Supplies esses 6 5 7 Timing ool oboe 7 1 7 1 VO Timing BITE 2 7 1 7 1 1 Move Timing 7 2 8 Move Select 09 Q 8 1 8 1 Move Select Logic Tables 8 1 9 LED Codes and Faults I eee 9 1 LED COU ES euet oma 9 1 9 2 Fault Descriptions and reg S 9 1 10 Troubleshooting 10 1 10 1 1 ACS Drive Controller ipod 10 1 Appendix 1 1 1 1 1 Appendix 20 2 1 Pr cir Se ee ee HEFY FWYN AYN FF FERN 2 1 4 Va ii Tolomatic Hardware amp Installation Guide ACS Stepper Drive Controller List of Figures Figure 2 1 Mounting the ACS Drive Controller 2 0 2 1 Figure 3 1 ACS Drive Controller and ERD Actuator Basic 3 1 Figure 5 1 Motor Power Connection on ACS 5 1 Figure 5 2 Motor Power Cable 3604 1767 1766 5 2 Figure 5 3 Encoder Connection on ACS Drive
7. 6 SPECFICATIONS amp WIRING 24V POWER SUPPLY gt INPUT gt INPUT COMMON I e e Figure 6 3 Input Source PNP Connection 24V POWER SUPPLY gt INPUT COMMON gt 0 SS e 2 o Figure 6 4 Input Sink switche Connection o US c POWER SUPPLY S 6 2 gt INPUT gt INPUT COMMON gt INPUT amp V e Figure 6 5 Input Sink NPN Connection EN 6 2 Digital Outputs 6 2 1 Specifications The ACS Drive Controller has four digital outputs These digital outputs are opto isolated from the drive circuitry and can be configured for sinking or sourcing The outputs are protected against over current and short circuit conditions Once an over current condition is present the output turns off until the load is removed 6 2 Tolomatic Hardware amp Installation Guide ACS Stepper Drive Controller SPECIFICATIONS amp WIRING SSS gt OUT 33 6 INTERNAL CIRCUITRY gt OUT Figure 6 6 Output Circuit Vv Digital Output Specifications Maximum Switched Voltage 24V S Output Voltage drop 20mA 2 Q Maximum Continuous Current Sn Fold Back Current 30uA Update Rate 10KOhm Load Output Leakage Current m Table 6 2 Digital Output 6
8. 4 Input 4 Green White 5 Input 5 Blue White 6 Input 6 White Black Red 7 Input 7 White Red 8 Input 8 Orange Red 9 Input COM Green Black 10 Output 1 Red Black 11 Output 1 White 12 Output 2 White Black 13 Output 2 Blue 14 Output 3 Blue Black 15 Output 3 Orange 5 3 Tolomatic Hardware amp Installation Guide ACS Stepper Drive Controller CONNECTIONS amp CABLES 5 PIN NUMBERS SIGNAL CABLE WIRE COLOR 16 Output 4 Orange Black 17 Output 4 Red 20 Case Ground Shield 23 NA Blue Red 24 NA Red Green 25 NA Green 26 NA Black Red 27 NA Green Black White 28 NA Black White Red 29 Signal Ground eS Black 30 Analog Ground Black White Table 5 5 1 0 Connection PIN Outs GV Figure 5 6 1 0 Cable 3604 1770 4 00 101 6 FLYING LEADS TOLOMATIC DRIVE MATING CONNECTOR DRIVE MATING CONTACTS xo PART NO L ter 3604 1770 JST PN PHDR 30VS JST PN SPHD 001T PO 5 5 meter 3604 1771 JST PN PHDR 30VS JST PN SPHD 001T PO 5 5 6 1 0 Cable and Connector Parts 4 EN 5 5 Input Power Connection A CAUTION Reversing polarity of the input power will damage the actuator drive electronics Tolomatic Hardware amp Installation Guide ACS Stepper Drive Controller The input power is connected via pins on the drive with customer supplied cabling The input power mating connector is supplied by Tolomatic
9. Tolomatic EXCELLENCE IN MOTION HARDWARE amp INSTALLATION GUIDE ACS Actuator Control Solutions Raa and Motors LINEAR SOLUTIONS MADE EASY 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 Contents List OF iic Fy yd ii List of Tables sese iv Health and Safety 015 2 vi NS LET oy R aana TTT TTT Taa V EMC FN rd d d ac df d c FE FF vii Proper and Safe Use of anode cocos vii Handling and Unpacking sss viii Product i viiii 1 Product af eee 1 1 1 1 The ACS Stepper Drive Controller for A ontrol Solutions 1 1 1 1 1 The ACS Stepper Drive Contr Ner asie OVE VIGW 1 1 1 1 2 Optional Accessories 1 1 2 Environment Dimensions amp PNEU 2 1 2 1 Operating Environment E E E 2 1 2 2 DIMENSIONS renien w 2 1 2 3 Mounting the ACS BrNe Contrall amp i e retener erae recs 2 2 E N 3 4 ACS Driv Controller sis ssl 4 1 4 1 AQSDrive Controller and Actuator Basic
10. 2 2 Diagrams N gt OUTPUT LOAD SUPPLY o e N 24V POWER SUPPLY Figure 6 7 Digital Output Sinking Connection OUTOUT gt OUTPUT OUTOUT Figure 6 8 Digital Output Sourcing Connection m lt LOAD Tolomatic Hardware amp Installation Guide ACS Stepper Drive Controller 6 SPECFICATIONS amp WIRING EN 6 3 Input Power 6 3 1 Drive Specifications CAUTION ACS Internal Drive Specifications Voltage above the absolute Current Maximum 4A maximum can result in Voltage Nominal 20 28 V permanent damage to Over Voltage 30V the ACS internal drive Under Voltage 18V components Absolute Maximum Voltage 35V Logic Current Draw Maximum 24V 100 Table 6 3 ACS Internal Drive Specifications A warnine GV Do not reverse bias the 1 Drive will shut down at 30V any voltage above the vie max voltage can result in permanent power inputs Doing so damage RS will result in permanent 2 Drive will turn off below 18V N damage to the drive The drive and logic keep alive powesshare the same ground Drive logic circuitry can be powered from the eee input or the main drive power A WARNING i NS 6 3 2 Typical Wiring Diagrams Do not short circuit the FUSE motor power the power xo PA connect
11. Controller sss 5 2 Figure 5 4 Encoder Cable 3604 1768 Teg onerare erra ran 5 3 Figure 5 5 1 0 Connection on ACS Drive Controller sse 5 3 IST oe FO CAD DDAETH 10 5 4 Figure 5 7 Input Power Connection 5 4 Figure 5 8 RS 232 Connection f ee eene cnin 5 5 Figure 5 9 RS 232 Pin Connection cc AGA AU UE 5 5 Figure 5 10 RS 485 Connection for Future ACS Grive Controller Programmability 5 6 Figure 5 11 Ethernet Connection for c US Programmability 5 6 Figure 5 12 Cable Routing for Top an Mounted Connectors 5 7 Figure 6 1 Digital Input Circuit e mrs 6 1 Figure 6 2 Input Source s a pL 6 1 Figure 6 3 Input a CONNECTOR PANN YR 6 2 Figure 6 4 Input Sink switched COMME COE rc eid eedem 6 2 Figure 6 5 Inp NSinR NPN Connection see 6 2 Figure 6 6 Quiput E FEE A NN 6 3 Figure 6 7 digital Output SINKING rr 6 3 Figure Digital Output Sourcing 000 000 6 3 e 9 ACS Drive Controller Logic and Main Power Supplies 6 4 6 10 ACS Drive Controller Single Supply Main 6 4 igure 6 11 ACS Drive Controller External Cutoff Switch for Emergency Stop
12. VG Table A 6 NEMA23 Motor Connection PIN Outs ENCODER Connections US Digital PN E8P 500 197 D D M B Molex Mating Connector 510221 0600 Molex Contacts 50079 8100 WIRE COLOR MOLEX PIN SIGNAL Blue 2 ENC A Orange 3 ENC A Yellow 5 ENC B Gray 6 ENC B Black 1 Signal Ground Red 4 5VDC Table A 7 Encoder Connections and Connector PIN Outs Tolomatic Hardware amp Installation Guide ACS Stepper Drive Controller 1 2 Appendix 2 Product Warranty Tolomatic Inc warrants all products manufactured by it to be free from defects in material and workmanship for a period of one year from date of shipment by Tolomatic If within this period any product is proven to be defective by Tolomatic the product will either be repaired or replaced at Tolomatic s option This warranty shall not apply to 1 Products not manufactured by Tolomatic Warranty of these products will conform and be limited to the warranty actually extended to Tolomatic by its supplier 2 Damage to the product caused by circumstances bee control of Tolomatic such as negligence improper maintenanc O storage 3 This warranty shall be void in the case of any or alterations made to the product by parties other than Tolomatic The foregoing warranties are exclusive and iQ of all other express and implied warranties Tolomatic is not subject to obligations or liabiliti
13. is set too low Determine if power supply has enough current Check to see if any faults being generated Verify that the drive has been configured properly for the actuator No response from drive 1 0 Verify the enable signal is on mode 2 Verify that all of the 1 0 are configured properly 3 Verify wiring to the actuator and drive Red and Green LEDs on both Verify serial programming cable and cycle power to solid and no communication drive 2 Verify that the RJ12 cable is a reversed type 3 Verify all connections are plugged in securely Table 10 1 Troubleshooting Descriptions Tolomatic Hardware amp Installation Guide ACS Stepper Drive Controller 10 1 Appendix 1 Motors There are currently three different motor selections available from Tolomatic a NEMA 11 NEMA 17 and NEMA 23 available for operation with the ACS Drive Controller Each motor is available with an optional differential incremental encoder All motors come with a short 150mm cable and connector on the motor body Tolomatic Motor Specifications SPEC NEMA 11 NEMA 17 NEMA 23 Resistance 350 249 150 Inductance 2 3 mH 4 5 mH 3 7 mH Rated Current 1 Arms 1 5 Arms 2 Arms Maximum Torque 0 813 in Ibs 4 6 25 in Ibs 1500 89 PM 1050 RPM Degree per Step 1 8 1 8 1 8 Rot
14. 12 cable and D sub to RJ12 Converter 3 1 Tolomatic Hardware amp Installation Guide ACS Stepper Drive Controller STARTER KIT 3 The D sub to RJ12 converter should to be wired as follows WIRE COLOR Yellow Green Table 3 2 D Sub to RJ12 Converter Wiring NOTE The brown wire is not used amp NOTE Pinout assumes RJ12 cable is reversed c O NN N Tolomatic Hardware amp Installation Guide ACS Stepper Drive Controller 3 2 ACS Drive Controller Setup 4 1 ACS Drive Controller and Actuator Basic Setup Figure 3 1 shows the simple setup of the ACS Drive Controller the Tolomatic ERD actuator and the necessary cables and power source Customer Supplied Power Cable to Power Input on Drive Cable from Drive to PLC RS 232 Cable to PC Encoder Cable from Dri to Motor Encoder TN Motor Power Cable from Drive to r Figure 3 1 ACS Drive Controller and ERD Actuator Basic Setup Please refer to the following sections and page numbers for cable part numbers and wiring specifications Motor Power Cable Section 5 pages 5 1 to 5 2 Encoder Cable Section 5 pages 5 2 to 5 3 0 Cable Section 5 pages 5 3 to 5 4 RS 232 Cable Section 5 page 5 5 For recommended power supplies Section 6 pages 6 5 to 6 6 4 1 Tolomatic Hardware amp Installation Guide ACS Stepper Drive Controller ACS DRIVE CONTROLLER SETUP 4 E 4 1 1 Setup Procedures T 2 Install d
15. 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 E 1 1 1 ACS Stepper Drive Controller Basic Overview dV Cnm PURPOSE HEAT SINK Removes heat from drive for optimal performance Panel mounting DUAL ETHERNET PORTS COMING SOON elnternal switch for daisy chaining up to 255 ACS axes Protocols Ethernet IP e Modbus Ethernet TCP IP DIGITAL 1 0 8 Digital Inputs 4 Digital Outputs 24 Vdc Opto Isolated DAC POWER NPN or PNP CONNECTION Configurable e MOTOR POWER 4 24Vdc 24Vdc Stepper Motors LED INDICATORS RS485 COM PORT Power amp Fault indicators il 15232 COM PORT Drive Configuration Port ACS Basic Drive Controller 3604 9651 Capabilities 4 8 or 16 move command modes End point correction absolute incremental or jog for infinite position capability Adjustable motion profile parameters Zone output based on position Force limiting capacity velocity accel decel
16. NG The ACS drive controller is designed to be operated in ambient conditions from 0 40 C 32 104 F and humidity from 0 90 non condensing There is Do not expose the drive to no ingress protection IP for the drive so it is important to protect the drive from conductive contaminants coming in contact with water or other conductive contamination In addition proper moisture or exceed ESD procedures should be observed to prevent static discharge and damage to ACS Stepper Drive Controller Operating Conditions Ambient Temperature 77 F 25 C Nominal Operating Temperature 32 104 F 0 40 C Non freeing C Storage Temperature 32 158 F 02 70 C Humidity 0 90 non condensing Table 2 1 ACS Operating Conditions 1 38 a BT 34 9 H 2 PART MODEL SERIAL www tolomatic com Made in U S A 0 17 4 3 TYP 0 12 OK 2 9 4 29 09 0 TYP U Figure 2 1 ACS Drive Controller Dimensions 2 1 Tolomatic Hardware amp Installation Guide ACS Stepper Drive Controller ENVIRONMENT DIMENSIONS amp MOUNTING 2 EN 2 3 Mounting the ACS Drive Controller The drive controller is intended to be mounted vertically to provide the vents with enough clearance on the top and bottom of the drive to allow for air flow The metal b
17. Table 5 1 Motor Power Connection PIN Outs 5 1 Tolomatic Hardware amp Installation Guide ACS Stepper Drive Controller CONNECTIONS 4 CABLES 5 The ACS Drive Controller has a maximum output of 2 5A peak 196 85 5000 0 TYCO P N 1586000 6 TYCO P N 794954 6 A ORF ILS B Figure 5 2 Motor Power Cable 3604 1767 1766 CABLE TOLOMATIC DRIVE MATING DRIVE MOTOR MOTOR PART NO CONNECTOR co 5 MATING CONTACTS CONNECTOR Motor Power 3 meter 3604 1766 Tyco PN Q PN Tyco PN Tyco PN 794954 6 586315 3 1586000 6 1586314 3 Motor Power 5 meter 3604 1767 Tyco Tyco PN Tyco PN Tyco PN oe 6 1586315 3 1586000 6 1586314 3 Table 5 2 Motor Power Cable and tor Parts EN 5 3 Encoder Connection and The ACS Drive Contr chas an encoder port that supports differential guadrature encoders Single e encoders may be used with additional external circuitry It is highly recommeneded to use differential encoders as they are more resistant to noise issues can supply 5Vdc power to the feedback device up to 100mA A gt STolematic cai H HER Jd as LC ENCOBER MOTOR BRAKE COM ENCODER Figure 5 3 Encoder Connection on ACS Drive Controller
18. all warranties 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 vi Tolomatic Hardware amp Installation Guide ACS Stepper Drive Controller HEALTH AND SAFETY REGULATIONS Handling and Unpacking CAUTION When unpacking and handling care should be taken not to drop the drive controller as this can damage the connectors and internal electronics Proper ESD measures should be taken to avoid static electricity from Product Warnings contacting the signal The following precautions should be observed to prevent erratic behavior power lines of the drive damage motor and encoder 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 the motor leads should provide enough resistance and inductance dangerous peak currents from occurring Do not reverse bias the power unit Do not apply voltages above rated voltage Do not expose drive to contaminants moisture or excessive temperature Do not dissassemble SN odi the drive controller oe Tolomatic Hardware amp Installation Guide ACS Stepper Drive Controller vii Product Overview 1 1 The ACS Stepper Drive
19. atically once the fault condition is present All critical faults will disable the motor when they occur To P faults the fault condition cannot be present The enable input Ub then raised Safety Faults Table Positive Limit Switch Positive limit switch has been reached If configured as a stop motion motion will be allowed in the reverse direction The fault will be cleared once the positive limit switch input is no longer active and a move in the negative direction is in Negative Limit Switch The negative limit switch has been reached If configured as stop motion motion will be allowed in the positive direction The fault will be cleared once the negative limit switch input is no longer active and a move in the positive direction is in Tolomatic Hardware amp Installation Guide ACS Stepper Drive Controller 9 1 9 LED INDICATORS AND FAULTS Safety Faults Table Position Error encoder is present the position error fault can be enabled If encoder position and commanded postion differ by a larger magnitude than the position error the position error fault will be activated If fault is configured as a stop motion fault will be cleared on next move command NOTE If force is less than 100 a position will not be triggered Instead and hold If an input is configured as an E stop and fault is enabled the fault will be activated when the signal level on the pin is high If fault is configured as a 29 o
20. d 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 followigg meaning A paneer Indicates a very hazardous situation NN avoided could result in death or serious injury This signal t is Y to the most extreme situations WARNING Indicates a potentially hazar death or serious injury CAUPON Indica potentially hazardous situation which if not avoided may result in pr damage minor or moderate injury A A CAUTION amp Indicates hot surfaces Avoid contact Vv ous situation which if not avoided could result in NOTE Information that requires special attention is stated here Tolomatic Hardware amp Installation Guide ACS Stepper Drive Controller HEALTH AND SAFETY REGULATIONS S 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 groun
21. ding When cabling the system shielded cables are recommended standard cables provided by Tolomatic have an overall shield with drain Wi es The metal angle bracket on the drive controller is also a case be tied to earth ground To minimize EMI and ensure system reliability ill shield drain wires from all cables should be tied to a common earth grounds S Proper and Safe Use of Prodiit Protection circuits and extern es A fuse should be added to t power line to protect the drive controller and A WARNING power supply from any ial over current conditions that may occur See Section 6 specificatiogs amp e Wiring page 6 6 The manufacturer takes no responsibility whatsoever if the equipment is modified or if the mean ai safe e stop is highly recommended to ensure equipment and equipment is used in any personal Safety The e stop should provide a means to remove main power from the t nd prevent any unwanted motion way beyond performance 2 0 cease and prevent any unwanted motio Fail Safe Emetpency Stop Recommendations specifications aN Unauthorized Device Damage Prevention modifications or changes To prevent permanent damage to the device proper care should be taken not to to the equipment are exceed published voltage current temperature and load ratings In addition proper stricly forbidden and void Wir ng should be verified and safety measures checked before applying power
22. es for consequential damages RN A2 1 Tolomatic Hardware amp Installation Guide ACS Stepper Drive Controller Copyright 2011 Tolomatic Inc All rights Reserved All brand and product names are trademarks of their respective owners Information in this document is believed to be accurate at time of publication 201102031630 4 v Tolomatic EXCELLENCE IN MOTION 3800 County Road 116 Hamel MN 55340 Phone 763 478 8000 Toll Free 1 800 328 2174 Fax 763 478 8080 Email help tolomatic com www tolomatic com
23. ested Power Supplies Switching Power Supplies Power Output CUI PN VGS 25 24 CUI PN VGS 50 24 50W CUI PN VGS 75 24 ANC 75W TDK Lambda PN LS150 24 5 150W aN Table 6 5 Recommended Switching Power m S Linear Regulated Power Power Output Power One PN 24 4 2246 28W Power One PN n 6 AG 80W Power One 4 4 8 115W Table 6 6 2 Regulated Power Supplies ing ulated Power Supplies Power Output Acopian PN U24Y500 120W PN U24Y350 84W pant 6 7 Recommended Linear Unregulated Power Supplies Fuses Slow Blow Type Bus Fuse 4A Logic Power Fuse 1A Table 6 8 Fuses 6 6 Tolomatic Hardware amp Installation Guide ACS Stepper Drive Controller 1 0 Timing Diagrams Ew 7 1 1 0 Timing Diagrams The opto isolated digital inputs require a minimum of 2ms of time to guarantee that the input signal is registered by the drive This is an important consideration to take into account especially if limit switches are used If limit switches are used careful consideration should be used to prevent missed triggering due to high velocities Output timing assumes 10K load 2ms min 2ms min F3 INPUT dS Figure 7 1 Input Requirement 59 amp s max SYSTEM M STATUS T ARTUP SYSTEM READY INPUT MAIN POWER Figure 7 2 System St Ti
24. force Parameters Configurable digital 1 0 are independently configurable for each 24 Vdc Opto Isolated NPN or PNP VE Compatible with most Ability to reduce holding current for 24 Vdc stepper motors energy savings 1 1 Tolomatic Hardware amp Installation Guide ACS Stepper Drive Controller PRODUCT OVERVIEW 1 Future Capabilities Currently in Development OPERATING MODES NETWORKING CAPABILITIES e Stepper mode pulse direction e Ethernet protocols Analog position mode 0 10Vdc or Ethernet I P for integration with 4 20mA Allen Bradley PLCs Pneumatic modes Modbus TCP RTU for integration with most other PLCs amp 5 Ethernet TCP IP Dual ethernet ports with internal switch daisy chaining eM RTU over 5 485 N N 1 1 2 Optional Access v Cable Options RN Tolomatic offers a motor power cable with drive and motor mating connectors an encoder cable with drive and encoder connectors and an 1 0 cable with drive mating connector to flying leads Cables are available in either 3 meter or 5 meter lengths Tolomatic offers a Starter Kit Part No 3604 9044 for use with optional USB computer connections The kit includes USB to RS 232 converter Adapter cable for RJ12 to D sub Tolomatic Motion Interface Software CD Tolomatic Hardware amp Installation Guide ACS Stepper Drive Controller 1 2 Environment Dimensions amp Mounting 2 1 Operating Environment A WARNI
25. ic tables below NOTE 1 MS stands for Move Select NOTE 2 1 On 0 Off Table 8 1 4 Move Conran Mode Logic Table 8 2 8 Move Commands Mode Logic Tolomatic Hardware amp Installation Guide ACS Stepper Drive Controller 8 1 8 MOVE SELECT LOGIC 16 Move Commands Mode Logic Table wv ws m2 m4 EN UM NE o i o o L 7 o Y ej o 9 o o Ho i i 0 P o 1 n o 1 0 o i oasa o Jo i i 1 7 ___ i 1 1 Table 8 3 16 AO ands Mode Logic XS os v 8 2 Tolomatic Hardware amp Installation Guide ACS Stepper Drive Controller LED Codes and Faults 9 1 LED Codes Motor is not powered Motor is powered Red On and Solid A critical fault has occured Red On and Blinking A safety fault has occured Table 9 1 LED Indicators also be cleared by the PC software Faults that r blinking red LED indicator are cleared automatically once the fault longer present N a 9 2 Fault Descriptions and Re y faults and critical faults Safety faults are Faults are broken up into configurable If a is enabled and configured for disable motor the fault To clear a fault the enable input needs to be ire then raised Faults can will be latched until j leared in the same manner as the critical faults If the fault is configured as a motion the fault will be cleared autom
26. k curr nt without faulting out 22 es power irom The ACS Drive Contkoller is intended to run off of an isolated DC power source The power supply that will be required will depend on the motor power needed condition The drive in the instaffation If operating more than one drive on the same power supply add emergency stop function the power supply rating for each actuator Maximum power supply current should not be relied on for motors are shown below when safety is required f Maximum Power Supply Requirements for Tolomatic Motors It is recommended to O MOTOR MAXIMUM AMPERAGE MAXIMUM WATTS 24 VDC disconnect only the 11 23A 55 2 power and keep ti er 17 3 4A 81 6 GE AAE ESR EL 0 4h AO o1 0 0 NEMA 23 4A Table 6 4 Maximum Power Supply Current for Tolomatic Motors To size the power supply the following formula can also be used to estimate maximum current required Motor Current amps rms 2 2 0 1 For example if the motor is rated at 1 Arms the calculation would look like 1 Arms 2 2 0 1 2 3 Tolomatic Hardware amp Installation Guide ACS Stepper Drive Controller 6 5 6 SPECFICATIONS amp WIRING The drive can supply a maximum of 2 5A peak 1 77 Arms so the drive will not use more than 4 Amps Supply power current x 24V Example If 2 3A is needed 2 3A x 24V 55 2W 6 3 4 Sugg
27. ming S STOP e m S ENABLE 10ms min C em N O MOTION SELECT ET P d sS LINES A Vv 2ms min __N START MOTION 2ms min gt lt 2ms max lt COMPLETE OUTPUT Figure 7 3 Jog Move Timing Tolomatic Hardware amp Installation Guide ACS Stepper Drive Controller 7 1 7 1 0 TIMING DIAGRAMS r Wn Pn 5 L 2ms min _ N A ENABLE 2ms min 2ms min INPUT lt START MOTION 2ms min gt 2 min MOTION SELECT LINES X 2ms 5 amp AS MOTION COMPLETE OUTPUT N N Figure 7 4 Absolute amp Incremental Move 7 1 1 Move Timing Rules 1 While the Motion Conp signal is low the drive will ignore Start Motion pulses and Motiongsplection lines 2 If the enable sler is low or E stop signal is high the drive will ignore start motion pu Va 7 2 Tolomatic Hardware amp Installation Guide ACS Stepper Drive Controller Move Select Logic E 8 1 Move Select Logic Table The three operating modes 4 8 16 move commands require digital inputs to select the desired move for execution The digital inputs are called Move Select 1 through 4 51 54 in the digital input map To select the desired move command refer to the three log
28. nnectors are on the bottom surface of the actuator require no looping NN O Top N Mount jae Loop Ry Q C xo Figure 5 12 R Routing for Top and Side Facing Connectors 4 S V 5 7 Tolomatic Hardware amp Installation Guide ACS Stepper Drive Controller Specifications amp Wiring E 6 1 Digital Inputs 6 1 1 Specifications The ACS Drive Controller has a total of 8 opto isolated digital inputs These digital inputs are optoisolated from the controller s drive circuitry and can be wired either as sinking or sourcing of the digital inputs have a common return 5K INPUT KT x Z Cue mw INPUT COMMON C Figure 6 1 Digital Input Circuit cO Opto isolated Digita t Specifications Input Voltage Range N to 28Vdc On State Voltage Range h 16 to 28Vdc Off State Voltage Range AS 0 to 5Vdc On State Current RN 16Vdc minimum 1 9 24Vdc 3 4mA 28Vdc maximum 4 2mA Nominal Inp edance 24V 7KQ Off Stat ent maximum 0 4mA Up maximum 2ms Gaps 1 Opto Isolated Digital Input Specifications V 6 1 2 Typical Wiring Diagrams N Y O 24V POWER SUPPLY gt INPUT COMMON GND Figure 6 2 Input Source switched Connection Tolomatic Hardware amp Installation Guide ACS Stepper Drive Controller 6 1
29. or Doing so may o damage the drive power c X po KEEP ALIVE electronics The motor ANS R SUPPLY 24V POWER SUPPLY cable is part of the current POWER GROUND lt lt 1 7 L gt Ked regulation circuitry short occuring V the motor leads should provide enough resistance and inductance to prevent je dangerous peak currents from occurring CASE GROUND lt 11 Figure 6 9 ACS Drive Controller Logic and Main Power Supplies 24V POWER SUPPLY POWER GROUND lt CASE GROUND lt Figure 6 10 ACS Drive Controller Single Supply Main Power 6 4 Tolomatic Hardware amp Installation Guide ACS Stepper Drive Controller SPECIFICATIONS amp WIRING 6 FUSE MAIN POWER lt FUSE KEEP ALIVE lt o Y p POWER GROUND lt 24V POWER SUPPLY CASE GROUND lt 77 EXTERNAL CUTOFF bae STOP Figure 6 11 ACS Drive Controller External cut for Emergency Stop xO WARNING 6 3 3 Power Supply Selection All installations should Both unregulated and regulate er supplies can be used to power the ACS Drive Controller Unregulate lies can be a better choice depending on the provide means 0 application as they have a larger output capacitance which can make them better hardware emergency stop lt t supplying pea
30. or Inertia 0 006 BARS 0 028 Ib in 2 0 075 Ib in 2 Table A 1 Tolomatic Motor Specificatig atic Motor Part Numbers 0 TOLOMATIC PART NUMBER NEMA 11 with Encoder 3604 1780 mom Encoder 3604 1779 17 with Encoder 3604 1776 A A 17 without Encoder 3604 1775 NEMA 23 with Encoder 3604 1778 M NEMA 23 without Encoder 3604 1777 V Table A 2 Tolomatic Motor Part Numbers Encoder Specifications MOTOR TYPE ENCODER CABLE CONNECTOR CABLE TERMINAL PART NUMBER PART NUMBER Bipolar Stepper Differential 500 line 794954 6 50212 8000 1 8 per Step 2000 count post quad Table A 3 Encoder Specifications 1 1 Tolomatic Hardware amp Installation Guide ACS Stepper Drive Controller NEMA11 Motor Connections TYCO Mating Connector 51065 0600 Molex Terminals 50212 8000 WIRE COLOR TYCO PIN MOLEX PIN SIGNAL Black 6 6 3 4 B Red 1 3 A Blue 4 1 A Table A 4 NEMA11 Motor Connection PIN Outs NEMA17 Motor Connecfions TYCO Mating Connector PHR 6 JST inals 5 002 0 55 WIRE COLOR TYCO PIN e JST PIN SIGNAL Black 6 SS 1 B Green Q 3 B Red 4 A S SN Blue 6 A Table A 5 NEMA17 d aing PIN Outs NEMA23 Motor Connections T Connector XHP 6 JST Terminals SXH 001T P0 5 OLOR TYCO PIN JST PIN SIGNAL 6 1 B 2 3 3 Red 1 4 A Blue 4 6 A
31. pply ads Tolomatic 6 5 Table 6 5 Recommended Power LIU S S 6 6 Table 6 6 Recommended Lirfegr Regulated Power Supplies 6 6 Table 6 7 Recommend Kar Unregulated Power Supplies 6 6 Table 6 8 Fuses Gay YU NER CF OR SEE 6 6 Table 8 1 4 Mode i dete ts 8 1 Table 8 2 e Commands Mode Logic eeenn 8 1 Table 8 Move Commands Mode LOG 8 2 Table 9 1 MUR 9 1 Saus 9 1 able 9 3 atts c 9 2 Vv able 10 1 Troubleshooting Descriptions 10 1 Table A 1 Tolomatic Motor 5 0002 999 A1 1 Table A 2 Tolomatic Motor Part Numbers een A1 1 Table A 3 Encoder Specifications senes A1 1 Table 4 NEMA 11 Motor Connection PIN OUS see A1 2 Table A 5 NEMA 17 Motor Connection PIN 0202 2 A1 2 Table A 6 NEMA 23 Motor Connection PIN Outs een A1 2 Table A 7 Encoder Connections and Connector PIN A1 2 iv Tolomatic Hardware amp Installation Guide ACS Stepper Drive Controller Health and Safety Regulations Read completely through the applicable sections of the manual before the equipment is unpacked installed or operate
32. racket should also be mounted to a metal surface for best thermal dissipation A 2 inch head space is recommended from the drive vents to another surface to ensure the proper Ambient temperature ratings are maintained It is recommended to have a minimum of 1 inch spacing between drives This spacing may be relaxed providing the ambient temperature is kept within limits and the drive is mounted to a metal surface suitable AN to heat sink the drives Metal Mounting Surface Su MM U A d Clearance for 4 Air Vents U amp v BOOK MOUNT FLAT MOUNT Figure 2 1 Mounting the ACS Drive Controller Tolomatic Hardware amp Installation Guide ACS Stepper Drive Controller 2 2 Starter Kit Me 3 1 Starter Kit Tolomatic offers a basic Starter Kit for the ACS stepper drive controller that can be used to convert a USB connection to a serial port The kit includes an RJ12 cable a D sub to RJ converter a USB to RS232 converter and a CD with the Tolomatic Motion Interface software MOTIO 900 328 2174 Www N INTERFACE SOF AC8 Drive Controller Starter kit PN 3604 9044 ITE TOLOMATIC PART NUMBER PART NUMBER NS AT S 26 6 6 B 7 R R AT 23065 R USA19 HS Tolomatic Motion Interface 3604 9526 Software CD Table 3 1 ACS Starter Kit Contents Tolomatic also offers a Programming Cable Kit 3604 9043 which includes the RJ
33. rive controller and actuator into appropriate fixtures Wire the 24Vdc power supply to the drive See Section 6 Power Supply Selection Wire input and output signals to the desired logic device See Section 5 Connections and Cables Attach motor and encoder cables Attach serial programming cable and install the Tolomatic Motion Interface software Configure ACS Drive Controller amp Program the logic device Tolomatic Hardware amp Installation Guide ACS Stepper Drive Controller 4 2 Connections 4 Cables 5 1 Connections and Cables Overview All cables for the ACS Drive Controller can be ordered through Tolomatic with the exception of the power supply When using cables other than those provided by Tolomatic reference the cable mating connector style to ensure the proper cabling is supplied FUTURE ETHERNET EXPANSION 0 CONNECTION ENCODER CONNECTION MOTOR CONNECTIO POWER CONNECTION COM PORT COM PORT eati 5 2 Motor Power Connection and Cables WARNING Do not connect or BRAX disconnect motor cables S while the drive is powered 691 4 Jo MOTOR Figure 5 1 Motor Power Connection on ACS Drive Controller PIN NUMBERS SIGNAL CABLE WIRE COLOR 1 Motor A Red 2 Shield Shield 3 Motor B Green 4 Motor A White 6 Motor B Black
34. tion it will be cleared once the E stop input is 10 efe Motion will not be allowed until E stop Table 9 2 Safety Faults SN niticelFaults Table Feedback Error Feedback device is malfunctioning If ershert circuit occurs from output to ground this fault will be ggered Drive Over Temp Q Drive temperature is greater than the maximum allowed temperature 75 C Drive OverVoltage Main power voltage exceeds the maximum voltage 30V DriveWnder Voltage Main power voltage below the minimum voltage 18V 9 3 Critical Faults 9 2 Tolomatic Hardware amp Installation Guide ACS Stepper Drive Controller Troubleshooting 10 1 Troubleshooting 10 1 1 Troubleshooting the ACS Drive Controller Troubleshooting Table SYMPTOM TROUBLE POSSIBLE CAUSE RESOLUTION No communication to drive Check power connection Verify the wiring of the communication cable Verify baud rate and serial port number Verify that the cable is plugged in securely 5 Verify are up to date Actuator cannot move load 1 NY is too large ave is too much friction AN Side load is excessive lt lt 5 Current limits are set too low Te o N 4 Power supply does not have enough current capability Drive is overhe gina 1 Ambient temperature is too high 2 Cooling is insufficient is operating erratically Current is set to low Following error
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