Tolomatic ACS Handbuch
HARDWARE & INSTALLATION
GUIDE
LINEAR SOLUTIONS MADE EASY
LINEAR SOLUTIONS MADE EASY
3604-4183_02_ACS_STEP_HDW
ACS – Actuator Control Solutions
Stepper Drive/Controller and Motors
STEPPER
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.
201611181522
Tolomatic Hardware & Installation Guide: ACS Stepper Drive/Controller
• i •
Contents
List of Figures..................................................................................................iii
List of Tables....................................................................................................iv
Health and Safety Regulations.........................................................................v
Safety Symbols.............................................................................................v
EMC Wiring Guidelines.................................................................................vi
Proper and Safe Use of Product....................................................................vi
Handling and Unpacking.............................................................................. vii
Product Warnings........................................................................................ vii
1. Product Overview ................................................................................. 1_1
1.1 The ACS Drive/Controller for Actuator Control Solutions........................ 1_1
1.1.1 The ACS Drive Overview............................................................. 1_1
1.1.2 Optional Accessories................................................................. 1_2
2. Environment, Dimensions & Mounting ................................................ 2_1
2.1 Operating Environment....................................................................... 2_1
2.2 Dimensions ....................................................................................... 2_1
2.3 Mounting the ACS Drive .................................................................... 2_2
3. CD & USB Cable .................................................................................... 3_1
4. ACS Drive Setup.................................................................................... 4_1
4.1 ACS Drive 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_5
5.6 Brake Output Connection ................................................................... 5_5
5.7 USB 2.0 Connection........................................................................... 5_6
5.8 RS-485 Connection ........................................................................... 5_6
5.8.1 RS-485 Cable Length................................................................ 5_6
5.8.2 RS-485 Grounding .................................................................... 5_7
5.9 Ethernet Connection........................................................................... 5_7
5.10 Cable Routing.................................................................................. 5_7
5.10.1 Ethernet Cable ........................................................................ 5_8
5.10.2 Ethernet Cable Length............................................................. 5_8
Tolomatic Hardware & Installation Guide: ACS Stepper Drive/Controller
• ii •
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_1
6.2 Digital Outputs................................................................................. 6_2
6.2.1 Specifications............................................................................ 6_2
6.2.2 Typical Wiring Diagrams............................................................. 6_3
6.3 Analog Input .................................................................................... 6_4
6.3.1 Specifications............................................................................ 6_4
6.3.2 Equivalent Circuit....................................................................... 6_4
6.4 Analog Output.................................................................................. 6_5
6.4.1 Specifications............................................................................ 6_5
6.4.2 Equivalent Circuit....................................................................... 6_5
6.5 Brake Output ................................................................................... 6_6
6.5.1 Specifications............................................................................ 6_6
6.5.2 Equivalent Circuit....................................................................... 6_6
6.6 Input Power ..................................................................................... 6_6
6.6.1 Drive Specifications ................................................................... 6_6
6.6.2 Typical Input Power Wiring ......................................................... 6_7
6.6.3 Power Supply Selection.............................................................. 6_7
6.6.4 Suggested Power Supplies......................................................... 6_8
7. I/O Timing Diagrams........................................................................... 7_1
7.1 I/O Timing Diagrams......................................................................... 7_1
7.1.1 Move Timing Rules .................................................................... 7_3
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 ................................................... 10_1
Appendix 1.................................................................................................A1_1
Motors.................................................................................................A1_1
Appendix 2.................................................................................................A2_1
Product Warranty .................................................................................A2_1
CONTENTS
Tolomatic Hardware & Installation Guide: ACS Stepper Drive/Controller
• iii •
List of Figures
Figure 2-1 ACS Drive Dimensions......................................................................... 2_1
Figure 2-2 Mounting the ACS Drive....................................................................... 2_2
Figure 4-1 ACS Drive and ERD Actuator Basic Setup ............................................. 4_1
Figure 5-1 Motor Power Connection on ACS Drive................................................. 5_1
Figure 5-2 Motor Power Cable 3604-1708 / 1709 / 1710 .................................... 5_2
Figure 5-3 Encoder Connection on ACS Drive........................................................ 5_2
Figure 5-4 Encoder Cable 3604-1768 / 1769 / 1969 ........................................... 5_3
Figure 5-5 I/O Connection on ACS Drive ............................................................... 5_3
Figure 5-6 I/O Cable 3604-1770 / 1771 .............................................................. 5_4
Figure 5-7 Input Power Connection....................................................................... 5_5
Figure 5-8 Brake Connection................................................................................ 5_5
Figure 5-9 Brake Cable........................................................................................ 5_6
Figure 5-10 USB 2.0 Connection............................................................................ 5_6
Figure 5-11 ACS 2-Wire RS485 with RJ45 Socket .................................................. 5_6
Figure 5-12 Resistors in Ground Wire to Limit Current............................................. 5_7
Figure 5-13 EtherNet/IP Connection for ACS Drive Programmability.......................... 5_7
Figure 5-14 Cable Routing for Top and Side Mounted Connectors ............................ 5_8
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 Analog Input Equivalent Circuit............................................................. 6_4
Figure 6-10 Analog Output Equivalent Circuit .......................................................... 6_5
Figure 6-11 Brake Output Equivalent Circuit............................................................ 6_6
Figure 6-12 ACS Drive Logic and Main Power Supplies ........................................... 6_7
Figure 6-13 ACS Drive Single Supply – Main Power ................................................ 6_7
Figure 6-14 ACS Drive External Cutoff Switch for Emergency Stop ........................... 6_7
Figure 6-15 Unregulated Power Supply Configuration with Shunt Regulator .............. 6_9
Figure 6-16 Regulated Power Supply Configuration with Blocking Diode .................. 6_9
Figure 6-17 Regulated Power Supply with Blocking Diode and Shunt Regulator ........ 6_9
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
Figure 7-5 Brake Subsystem Timing ..................................................................... 7_2
Tolomatic Hardware & Installation Guide: ACS Stepper Drive/Controller
• iv •
List of Tables
Table 2-1 ACS Drive Operating Conditions........................................................... 2_1
Table 3-1 CD and USB cable part numbers.......................................................... 3_1
Table 5-1 Motor Power Connection pinouts.......................................................... 5_1
Table 5-2 Motor Power Cable and Connector Parts .............................................. 5_2
Table 5-3 Encoder Connection pinouts ................................................................ 5_2
Table 5-4 Encoder Cable and Connector Parts ..................................................... 5_3
Table 5-5 I/O Connection pinouts ........................................................................ 5_4
Table 5-6 I/O Cable and Connector Parts............................................................. 5_4
Table 5-7 Input Power pinouts ............................................................................ 5_5
Table 5-8 Input Power Cable Parts ...................................................................... 5_5
Table 5-9 Brake Pinout....................................................................................... 5_5
Table 5-10 EtherNet/IP pinouts and Connections.................................................... 5_7
Table 5-11 Cable Wire Type versus Cable Length................................................... 5_9
Table 6-1 Opto-isolated Digital Input Specifications.............................................. 6_1
Table 6-2 Digital Output Specifications ................................................................ 6_3
Table 6-3 Analog Input Specifications.................................................................. 6_4
Table 6-4 Analog Output Specifications ............................................................... 6_5
Table 6-5 Brake Output Specifications................................................................. 6_6
Table 6-6 ACS Internal Drive Specifications ......................................................... 6_6
Table 6-7 Maximum Power Supply Current for Tolomatic Motors........................... 6_8
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_2
Table 9-3 Critical Faults...................................................................................... 9_2
Table 10-1 Troubleshooting Descriptions ............................................................. 10_2
Table A-1 Tolomatic Stepper Motor Specifications .............................................. A1_1
Table A-2 Tolomatic Stepper Motor Part Numbers .............................................. A1_1
Table A-3 Encoder Specifications ...................................................................... A1_1
Table A-4 NEMA11, 17, 23 Motor Connection pinouts........................................ A1_2
Table A-5 NEMA34 Motor Connection pinouts.................................................... A1_2
Table A-6 NEMA11, 17, 23 Encoder Connections and Connector pinouts............ A1_2
Table A-7 NEMA 34 - Encoder Connections and Connector pinouts .................... A1_2
Tolomatic Hardware & Installation Guide: ACS Stepper Drive/Controller
• v •
Health and Safety Regulations
Read through the applicable sections of the manual before the equipment is
unpacked, installed or operated. Pay 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.
Tolomatic Hardware & Installation Guide: ACS Stepper Drive/Controller
• vi •
EMC Wiring Guidelines
Cable routing
It is recommended that the power and signal cables for the ACS Drive 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 radii 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, high quality braided or foil with braided shielded cables
are recommended. The standard motor cables provided by Tolomatic have a braided
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)
Fail Safe Emergency Stop Recommendations
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 strictly
forbidden and void all
warranties.
WARNING!
Incorrect wiring can
feedback through the
USB port and damage
your computer. Use good
wiring practices to prevent
ground loops.
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 drive power.
• Do not apply voltages above the maximum rated voltage.
• Do not expose drive to conductive contaminants, moisture, or excessive
temperature.
• Do not disassemble or modify the drive/controller.
• Do not plug and unplug cables while the drive is energized.
Wiring for CE Compliance
• Use a braided shield motor cable such as Igus Chainflex CF140US-07-04.
• See Section 5-2 for motor cable description.
CAUTION!
Proper ESD measures
should be taken to avoid
static electricity from
contacting the signal and
power lines of the drive,
motor and encoder.
Protocols:
•EtherNet/IP • Modbus TCP
Tolomatic Hardware & Installation Guide: ACS Stepper Drive/Controller
• 1_1 •
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).
Currently there are three ACS Drive/Controller choices:
• #3604-9665 - ACS Stepper Drive/Controller, Modbus RTU over RS485
- firmware 36043183UD.tol
• #3604-9666 - ACS Stepper Drive/Controller, EtherNet/IP (Analog Output)
- firmware 36043183UD.tol
• #3604-9667 - ACS Stepper Drive/Controller, Modbus TCP (Analog Output)
-firmware 36043183UD.tol
NOTE: They will collectively be referred to as ACS Drive throughout this guide
1.1.1 ACS Stepper Drive/Controller — Overview
MOTOR POWER
•10 - 52 VDC
Stepper Motors
COM PORT
BRAKE
•USB Com Port
•Active high/low
ACS POWER
•10 - 52 VDC Main Power
•10 - 52 VDC Keep-alive
Power
•24 VDC Brake Power
ETHERNET (OPTION)
DIGITAL I/0
ANALOG I/0
LED INDICATORS
RS485 COM PORT
DUAL PURPOSE HEAT SINK
FEEDBACK
•8 Digital Inputs
•4 Digital Outputs
•24 VDC Opto-Isolated
•Sourcing or Sinking
•Configurable Inputs
•0-10 VDC or 4-20mA
•1 Analog Input
•1 Analog Output (option)
•Modbus RTU (Base Model)
•Removes heat from drive
for optimal performance
• Panel mounting
•Motor Power & Fault
indicators
•For Digital Encoder
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