Table of Contents

1.1 Overview Regulator .....................................................................................2

1.1.1 Mains Connection.......................................................................................2

1.1.2 Supply 24 V .................................................................................................2
1.1.3 Motor Connection .......................................................................................3
1.1.4 Motor Encoder ............................................................................................3
1.1.5 Auxiliary Encoder .......................................................................................3
1.1.6 Digital 24V ...................................................................................................3
1.1.7 Analog .........................................................................................................4
1.1.8 „24V+“ and „GND“......................................................................................4
1.1.9 CAN..............................................................................................................4
1.1.10 RS232 ..........................................................................................................5
1.1.11 Emergency Stop .........................................................................................5
1.1.12 RCS Relay ...................................................................................................5
1.1.13 ID's ...............................................................................................................5
1.1.14 Resistance Values ......................................................................................6
1.1.15 Optical Display ...........................................................................................7
1.1.16 Error LED's ..................................................................................................8
1.1.17 Regulator Wiring.........................................................................................9
1.1.18 Accessories ................................................................................................9
1.1.19 Article Numbers of ACS Servo Controllers ..............................................9
1.1.20 Article Numbers of Servo Motors............................................................10
1.1.21 Controller Diagram ...................................................................................10

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1.1 Overview Controller

PE 1

L1 2

L2 3
Mains Supply
L3 4 3x230VAC /
DC+ 5
1x325VDC
X1 DC-
Power6Supply

CAN-ID 1
CAN-ID 2 CAN-ID
Supply 24VDC
24V+ 3
GND 4
Emergency 5
RCS-Rel 6 Emergency Stop
X2 RCS-Rel
Security 7
RCS-ID
RCS-ID
8
9 RCS-ID
Ready
Power
RCS
Error

CAN CAN-Bus
9X 8X

Analog Inputs
Analog Output
X3 Auxiliary Auxiliary-Encoder

RS-232
X4 RS232
Puls-IN 1
24V+ 2
IN1 3
IN2 4 Digital Inputs
IN3 5
GND 6
X5 OUT1
Digital 7
OUT2
GND
8
9
Digital Outputs

Motor-Encoder

X6 Encoder

U 1

V 2
Motorconnection
W 3
X7 PE
Motor 4

Picture 1: Connections

1.1.1 Mains Connection

Alternating voltage 3 x 230VAC
Direct voltage 1 x 325VDC

The servos ACSXXX-D are rectifireless and cannot run with alternating voltage. These controllers are
also recognizable as the terminal labels L1, L2 und L3 are missing. An ACS with rectifier can supply
three further servo controllers.

1.1.2 Supply 24 V
The digital power supply is on the security connector. The voltage must be between 20..32VDC. On
power on, the current is 1.8 A for 8 ms to start the 24V converter. The current consumption with
switched off power level is about 450mA, with switched on power level about 600mA.

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1.1.3 Motor Connection
The phase's sequence strictly has to be kept. The cable shield is connected to the bottom of the
controller (C-profile in the machine).

1.1.4 Motor Encoder

An incremental encoder with commutation signals will be used. The maximum current supply is
250mA.
Pin Signal
1 5V
2 GND
3 +A
1 4 +B
9 5 +C
6 +U
7 +V
8 +W
9 AOUT
10 -A
11 -B
12 -C
13 -U
14 -V
15 -W

Picture 2: pin assignment encoder connector DSUB15

1.1.5 Auxiliary Encoder

An incremental encoder can be used as a supplementary feedback sensor. The maximum current
supply is 100mA.
The auxiliary encoder uses the inputs from the analog interface. Therefore, a controller with an
auxiliary encoder cannot use its analog inputs and outputs anymore.

1.1.6 Digital 24V

4x Digital input IN1 .. IN3, pulse-IN
2x Digital output OUT1 .. OUT2

Via software it is possible to choose between the internal pull-up and pull-down resistor for the digital
outputs. Initially, the pull-down is active.
The pulse-IN can be used as a normal, but unfiltered input. Additionally, a capture function is
provided (e.g. strip monitoring).
The outputs supply a current of maximum 150mA.

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1.1.7 Analog
2x Analog input -10 .. +10V AIN1 .. AIN2 (10bit)
1x Analog output 0 .. +10V AOUT (PWM 2.5kHz)

Pin Signal
1 24V
1 2 AIN1+
6
3 AIN2+
4 GND
5 GND
6 +5V
7 AIN1-
8 AIN2-
9 AOUT

Picture 3: pin assignment auxiliary connector DSUB9

1.1.8 „24V+“ and „GND“

These pins are for supplying energy directly to sensors and switches.

1.1.9 CAN
1x CAN Both connectors are connected galvanically.

1
CAN_H
2
CAN_L
3

5
RCS-24V
6
RSA
7
ASB
8
RCS-GND

Picture 4: pin assignment RJ45

The entire data exchange to the controllers will be handled over the field bus CAN. Several servos
can be connected to the same bus wire. A termination impedance has to be plugged in on both sides
of the CAN bus. Otherwise communication problems may arise due to reflections on the bus,.

Picture 5: CAN Abschlussstecker

This means that there are no open CAN pins allowed in the system. Always a bus cable or a
termination plug must be inserted.

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1.1.10 RS232
1x RS232

Picture6: USB connector for serial interface

For debug purposes it is possible to connect a PC via this serial interface. You can work directly with
the controller, using the program ,System Designer Tool '.

1.1.11 Emergency Stop

As soon as there is GND on the emergency input, the motor will be stopped immediately and will
remain in this position until this error has been acknowledged.

1.1.12 RCS Relay

The RCS relay must be looped-in the emergency stop circuit of the machine. In case of an intra-
regulator discrepancy, this contact is released whereby the mains voltage is discharged. The
maximum values of the relay are 80V voltage and 2A power.

1.1.13 ID's
The machine has a resistor coding for the CAN bus as well as for the RCS.

CAN-ID 1
CAN-ID
24V+
2
3
1 CAN
GND 4
Notstop 5
RCS-Rel 6
RCS-Rel 7

R
RCS-ID 8
RCS-ID 9 RCS

Picture 7: ID Coding

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1.1.14 Resistance Values

The resistances are defined as showed in the following chart:

R Coding RCS
Art. No. Can Id Art. No.
[Ohm] Range
68 A 0026793 1 0026572
150 B 0026794 2 0026573
270 C 0026795 3 0026574
390 D 0026796 4 0026575
470 E 0026797 5 0026576
680 F 0026798 6 0026577
820 G 0026799 7 0026578
1k H 0026800 8 0026579
1k3 I 0026801 9 0026580
1k8 K 0026802 10 0026581
2k2 L 0026803 11 0026582
3k M 0026804 12 0026583
3k6 N 0026805 13 0026584
4k7 O 0026683 14 0026756
6k2 P 0026684 15 0026757
7k5 Q 0026806 16 0026758
9k1 R 0026685 17 0026759
11k S 0026807 18 0026760
13k T 0026808 19 0026761
16k U 0026809 20 0026762
20k V 0026810 21 0026763
27k W 0026811 22 0026764
39k X 0026812 23 0026765
68k Y 0026686 24 0026766
180k Z 0026813 25 0026767

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1.1.15 Optical Display
The machine's status is displayed with the four LEDs as follows:

Ready LED1 (grün)

Power LED2 (grün)
RCS LED3 (gelb)
Error LED4 (rot)

Picture 8: Layout LED's

LED Colour Action Sense

1 green off No voltage 24V
blink 1:1 RCS plausibility check failed (RCS ID correct?)
on Controller ready
2 green off Load voltage on, power off
blink 1:1 Load voltage on 325 VDC, power off
on Controller active, power on
3 yellow off Automatic (ASA on, ASB on)
blink 1:3 Discrepancy (ASA off, ASB on), only HW channel in automatic
blink 3:1 Discrepancy (ASA on, ASB off), only SW channel in automatic
on Setup (ASA off, ASB off)
4 red off No error
blink Error code (refer to 1.1.16)
on Emergency stop (emergency input at GND) or error on other
regulator at the same Bus

Picture 9: Signification LED

If all 4 LED's are permanently switched on, the bootloader is active. This can be in the following
cases:
- no outfile has been downloaded
- active download of an outfile
- while executing a SW-Reset (short flashing of all LED's)
- the bootloader connecter was plugged

Green ready LED blinks RCS-ID does not correlate with the SW-RCS limits

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1.1.16 Error LED's
In case of errors, the red LED is periodically blinking and displays with the number of light impulses
the error number.

No Error Possible Causes

1 Lag error Mechanical impediment, acceleration too fast
2 Error speed sensor Encoder's wire or connector faulty
3 Overspeed motor Limitations or controller inputs are not valid
4 Phases monitoring motor Defective motor cable
5 Liveguarding CAN Defective CAN bus wire or ID resistance
6 Ground fault motor Defective motor connections or insulations
7 Short-circuit motor Defective motor cable or motor
8 Overload Supply voltage too high, break ramp too steep
9 Underload Supply connection or supply voltages defective
10 -
11 Excess temperature Load or environment temperature too high
12 Storage error Short-circuit on clamps
13 Short-circuit of digital output Check wiring (eventually load too high)
14 DSP calculation time Executing program or firmware corrupt
15 Slip Wire too heavy or straightener too stiff
16 RCS Wrong RCS ID, ev. set-up motion parameters too high
17 Status error HC05 RCS controller boot problem -> restart
18 DSP illegal address Written in forbidden storage unit
19 Overload powerstage I2t – monitoring power stage (too hot)
20 Overload motor I2t – monitoring motor (too hot)

Red LED permanently on Emergency stop on clamp active or emergency stop due to
an error on another regulator at the same bus

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