Tolomatic ACS Manual

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

Tolomatic Hardware & Installation Guide: ACS Stepper Drive/Controller
• 1_2 •
1: PRODUCT OVERVIEW
ACS Drive/Controller (3604-9665) Capabilities
• 4, 8, or 16 move command modes (abso-
lute, incremental and jog or home with
analog output echoing position of actuator
from encoder) for infinite position capability
• Ability to reduce holding current for
energy savings
• End point correction
• Zone output based on position
• Force limiting capability
• Configurable digital I/O
(24 VDC Opto-Isolated)
(sourcing or sinking)
• Compatible with most
24/48 VDC stepper motors
• Analog position mode (0-10 VDC or 4-20
mA)
• Pneumatic mode replaces pneumatic
valve logic for simple motion
• ModBus RTU over RS485 provides infinite
positioning
•
Adjustable motion profile parameters
(velocity, accel/decel, force). Parameters are
independently configurable for each move
ACS Drive/Controller (3604-9666, 3604-9667) Additional Capabilities
• EtherNet mode provides infinite
positioning using EtherNet/IP and
Modbus TCP protocols
• Dual EtherNet port with internal switch for
easy daisy chaining
• Analog output for Analog Position Mode
1.1.2 Optional Accessories
Cable Options
Tolomatic offers a motor power cable
with drive and motor mating connectors,
an encoder cable with drive and encoder
connectors, and an I/O cable with drive
mating connector to flying leads. Cables are
available in 3, 5 or 10 meter lengths.
Disc and Cable
Tolomatic software is always available online
at www.tolomatic.com. For your convenience
a software CD and optional USB computer
connections are available:
Tolomatic Motion Interface Software CD
(3604-9526) and a USB Type B cable (3604-
1852)
Brake Cable
Tolomatic offers a 5-meter brake power cable
with drive and brake mating connectors

Tolomatic Hardware & Installation Guide: ACS Stepper Drive/Controller
• 2_1 •
Environment, Dimensions & Mounting
2
2.1 Operating Environment
The ACS Drive is designed to be operated in ambient conditions from 0° – 40°C
(32° – 104°F), and humidity from 0 – 90% non-condensing. There is no ingress
protection (IP) for the drive, so it is important to protect the drive from water and
other conductive contamination. In addition, proper ESD procedures should be
observed to prevent static discharge and damage to electronic components.
ACS Drive Operating Conditions
Ambient Temperature 77° F, 25° C Nominal
Operating Temperature 32°-104° F, 0°-40° C Non Freezing
Storage Temperature 32°-158° F, 0°-70° C
Humidity 0-90% non-condensing
Table 2-1: ACS Drive Operating Conditions
3.55 [90.2] (2) 0.80
[20.3]
(2)
5.80
[147.3]
4.29 [109.0] 0.88
[22.2]
(2)
0.12
[2.9]
TYP.
Ø.17
[4.3]
TYP.
1.38
[34.9]
PART #:
MODEL #:
www.tolomatic.com Made in U.S.A.
RoHS
COMPLIANT
Figure 2-1: ACS Drive Dimensions
WARNING!
Do not expose the drive to
conductive contaminants,
moisture, or exceed
temperature ratings.
2.2 ACS Drive Dimensions

Tolomatic Hardware & Installation Guide: ACS Stepper Drive/Controller
• 2_2 •
2: ENVIRONMENT, DIMENSIONS & MOUNTING
The drive/controller is intended to be mounted vertically (as shown in Figure 2-2) to
provide the vents with enough clearance on the top and bottom of the drive to allow
for air flow. The metal bracket 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 provided the ambient temperature is kept within limits and
the drive is mounted to a metal surface suitable enough to heat sink the drives.
Metal
Mounting
Surface
FLAT MOUNTBOOK MOUNT
Clearance
for Air
Vents
Clearance
for Air
Vents
Metal
Mounting
Surface
Figure 2-2 Mounting the ACS Drive
2.3 Mounting the ACS Drive

Tolomatic Hardware & Installation Guide: ACS Stepper Drive/Controller
• 3_1 •
CD & USB Cable
3
3.1 CD & USB Cable
Tolomatic offers a CD with Tolomatic Motion Interface software, drive firmware and
firmware upgrade utility. A USB type B cable is also available for connecting your
computer to the ACS drive.
ACS Drive Accessories
ITEM TOLOMATIC PART NUMBER
Tolomatic Motion Interface
Software CD 3604-9526
1 meter USB Cable 3604-1852
Table 3-1: CD and USB cable part numbers.
NOTE: The most current
version of software and
firmware is always available
at www.tolomatic.com

Tolomatic Hardware & Installation Guide: ACS Stepper Drive/Controller
• 4_1 •
4.1 ACS Drive and Actuator Basic Setup
Figure 4-1 shows the simple setup of the ACS Drive, the Tolomatic ERD actuator
and the necessary cables and power source.
Figure 4-1: ACS Drive 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
Encoder Cable: Section 5
I/O Cable: Section 5
USB: Section 5
For recommended power supplies: Section 6
ACS Drive Setup
4
SUPPLIED
POWER SOURCE
10 to 52 VDC
USB Type B Cable
to PC
Customer Supplied Power Cable
to Power Input on Drive
I/O Cable from
Drive to PLC
Encoder Cable from
Drive to Motor Encoder
Motor Power
Cable from
Drive to Motor

Tolomatic Hardware & Installation Guide: ACS Stepper Drive/Controller
• 4_2 •
4: ACS DRIVE/CONTROLLER SETUP
4.1.1 Setup Procedures
1. Install drive/controller and actuator into appropriate fixtures.
2. Wire the power supply to the drive. See Section 6: Power Supply Selection.
3.
Wire input and output signals to the desired logic device. See Section 5:
Connections and Cables.
4. Attach motor and encoder cables.
5. Attach programming cable and install the Tolomatic Motion Interface software.
6. Configure ACS Drive.
7. Program the logic device.

Tolomatic Hardware & Installation Guide: ACS Stepper Drive/Controller
• 5_1 •
All cables for the ACS Drive 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.
12345
Figure 5-1: Motor Power Connection on ACS Drive
ACS CONNECTOR
(ON-SHORE)
PIN NUMBERS
SIGNAL CABLE WIRE COLOR
MOTOR
CONNECTOR
(TYCO)
1Motor A- Black 6
2Motor A+ Green 3
3 Shield Shield 2
4Motor B+ Red 1
5Motor B- White 4
Table 5-1: Motor Power Connection pinouts
Connections & Cables
5
5.1 Connections and Cables Overview
5.2 Motor Power Connection and Cables
WARNING!
Do not connect or
disconnect motor cables
while the drive is powered.
MOTOR
CONNECTION
USB
COM PORT
ENCODER
CONNECTION
I/O
CONNECTION
RS485
COM PORT
POWER
CONNECTION
ETHERNET
PORTS
LED
INDICATORS
BRAKE
CONNECTION

Tolomatic Hardware & Installation Guide: ACS Stepper Drive/Controller
• 5_2 •
5: CONNECTIONS & CABLES
A
1.00 MAX.
[25.40 MAX.]
1.00
[25.40] 1.00 [25.40]
On Shore P/N: OSTTJ055153
SHRINK TUBING
01
1.00 MAX.
[25.40 MAX.]
TYCO P/N: 1586000-6
Figure 5-2: Motor Power Cable 3604-1708/ 1709 / 1710 / 2228 / 2229 / 2230
CABLE
TOLOMATIC
PART NO.
DRIVE MATING
CONNECTOR
MOTOR MATING
CONNECTOR
MOTOR
CONTACTS DIM. "A"
Motor Power:
3-meter
3604-1708 On Shore PN
OSTTJ055153
Tyco PN:
1586000-6
Tyco PN:
1586314-3
3 m
118"
Motor Power:
5-meter
3604-1709 On Shore PN
OSTTJ055153
Tyco PN:
1586000-6
Tyco PN:
1586314-3
5 m
197"
Motor Power:
10-meter
3604-1710 On Shore PN
OSTTJ055153
Tyco PN:
1586000-6
Tyco PN:
1586314-3
10 m
394"
34 Motor Power:
3-meter
3604-2228 On Shore PN
OSTTJ055153
Phoenix Contact:
1786200 None 3 m
118"
34 Motor Power:
5-meter
3604-2229 On Shore PN
OSTTJ055153
Phoenix Contact:
1786200 None 5 m
197"
34 Motor Power:
10-meter
3604-2230 On Shore PN
OSTTJ055153
Phoenix Contact:
1786200 None 10 m
394"
Table 5-2: Motor Power Cable and Connector Parts
NOTE: For CE compliance use a quality braided shield cable such as
Igus Chainflex CF140US-07-04. See Appendix 1 for motor pinout chart.
The ACS Drive has an encoder port that supports differential signal quadrature
encoders. Single ended encoders may be used with additional external circuitry. It is
highly recommended to use differential encoders as they are more resistant to signal
noise. The drive can supply +5VDC power to the feedback device up to 100mA.
1
214
13
1
214
13
Figure 5-3: Encoder Connection on ACS Drive
PIN NUMBERS SIGNAL CABLE WIRE COLOR
1ENC A+ Blue
2ENC A- Orange
3ENC B+ Yellow
4ENC B- Gray
5 NA NA
6 NA NA
9Signal Ground Black
12 +5VDC Red
13 Case Ground NA
Table 5-3: Encoder Connection pinouts
5.3 Encoder Connection and Cable

Tolomatic Hardware & Installation Guide: ACS Stepper Drive/Controller
• 5_3 •
5: CONNECTIONS & CABLES
1
2
3
4
5
9
1
2
12
3
MOLEX P/N:
51021-0600
JST P/N:
PHDR-14VS
6
BLK
BLU
ORG
RED
YEL
GRY 4
01
118.11 [3000.0]
MOLEX P/N: 51021-0600 JST P/N: PHDR-14VS
SHRINK TUBING
ALL CONDUCTORS ARE 20 AWG
USE OVERALL SHIELD WITH 20 AWG DRAIN WIRE
CONDUCTOR COLORS ARE UNIQUE
RoHS COMPLIANT
MUST BE RATED 60°C OR BETTER
COLOR OF JACKET IS GRAY
100V MIN WORKING VOLTAGE
CABLE TO BE TESTED FOR CONTINUITY AND SHORTS
BAG INDIVIDUALLY
Figure 5-4: Encoder Cable 3604-1768 / 1769 / 1969
FOR NEMA 11, 17, 23 MOTORS
CABLE
TOLOMATIC
PART NO.
DRIVE MATING
CONNECTOR
DRIVE MATING
CONTACTS
ENCODER MATING
CONNECTOR
ENCODER MATING
CONTACTS
Encoder:
3-meter 3604-1768 JST PN:
PHDR-14VS
JST PN:
SPHD-001T-P0.5
Molex PN:
51021-0600
Molex PN:
50079-8100
Encoder:
5-meter 3604-1769 JST PN:
PHDR-14VS
JST PN:
SPHD-001T-P0.5
Molex PN:
51021-0600
Molex PN:
50079-8100
Encoder:
10-meter 3604-1969 JST PN:
PHDR-14VS
JST PN:
SPHD-001T-P0.5
Molex PN:
51021-0600
Molex PN:
50079-8100
FOR NEMA 34 MOTORS
CABLE
TOLOMATIC
PART NO.
DRIVE MATING
CONNECTOR
DRIVE MATING
CONTACTS
ENCODER MATING
CONNECTOR
ENCODER MATING
CONTACTS
Encoder:
3-meter 3604-1971 JST PN:
PHDR-14VS
JST PN:
SPHD-001T-P0.5
Molex PN:
15-04-5104
Molex Inserts PN:
14-60-0058
Encoder:
5-meter 3604-1972 JST PN:
PHDR-14VS
JST PN:
SPHD-001T-P0.5
Molex PN:
15-04-5104
Molex Inserts PN:
14-60-0058
Encoder:
10-meter 3604-1973 JST PN:
PHDR-14VS
JST PN:
SPHD-001T-P0.5
Molex PN:
15-04-5104
Molex Inserts PN:
14-60-0058
Table 5-4: Encoder Cable and Connector Parts
NOTE: See Appendix 1 for encoder pinout chart
1
2
29
30
1
2
29
30
Figure 5-5: I/O Connection on ACS Drive
JST #PHDR-30VS
PIN NUMBERS SIGNAL CABLE WIRE COLOR
1Input ISO 1 Red/Black/White
2Input ISO 2 Orange/Green
3Input ISO 3 Red/White
4Input ISO 4 Green/White
5Input ISO 5 Blue/White
6Input ISO 6 White/Black/Red
7Input ISO 7 White/Red
5.4 I/O Connection and Cable

Tolomatic Hardware & Installation Guide: ACS Stepper Drive/Controller
• 5_4 •
5: CONNECTIONS & CABLES
8Input ISO 8 Orange/Red
9Input ISO 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
16 Output 4 - Orange/Black
17 Output 4 + Red
20 Case Ground Shield
23 *Step Input Blue/Red *Not yet supported
24 *Direction Input Red/Green by software
25 NA Green
26 NA Black/Red
27 Analog Out GRN/Black/White
28 Analog In Black/White/Red
29 Signal Ground Black
30 Signal Ground Black/White
Table 5-5: I/O Connection pinouts
1
2
3
4
5
JST P/N:
PHDR-30VS
6
RED/BLK/WHT
9
7
12
11
8
16
29
27
24
23
13
17
14
15
28
26
20
25
30
ORG/GRN
RED/WHT
GRN/WHT
BLU/WHT
WHT/BLK/RED
WHT/RED
ORG/RED
GRN/BLK
WHT
WHT/BLK
BLU
BLU/BLK
ORG
ORG/BLK
RED
RED/BLK
BLU/RED
10
RED/GRN
GRN/BLK/WHT
BLK/WHT/RED
BLK
BLK/WHT
GRN
BLK/RED
118.11 [3000.0]
JST P/N: PHDR-30VS
SHRINK TUBING FLYING LEADS
ALL CONDUCTORS ARE 20 AWG
USE OVERALL SHIELD WITH 20 AWG DRAIN WIRE
CONDUCTOR COLORS ARE UNIQUE
RoHS COMPLIANT
MUST BE RATED 60°C OR BETTER
COLOR OF JACKET IS GRAY
100V MIN WORKING VOLTAGE
CABLE TO BE TESTED FOR CONTINUITY AND SHORTS
BAG INDIVIDUALLY
1.00 MAX.
[25.40 MAX.]
4.00 [101.6]
1.00
[25.40] 1.00 [25.40]
Figure 5-6: I/O Cable 3604-1770 / 1771
CABLE TOLOMATIC
PART NO.
DRIVE MATING CONNECTOR DRIVE MATING CONTACTS
I/O: 3-meter 3604-1770 JST PN: PHDR-30VS JST PN: SPHD-001T-P0.5
I/O: 5-meter 3604-1771 JST PN: PHDR-30VS JST PN: SPHD-001T-P0.5
Table 5-6: I/O Cable and Connector Parts