Replace Obsolete Controllers

Owned by Jack Degrano
Last updated: Apr 12, 2024 by Corey Boyles
3 min read

Replace obsolete controllers

ACR Conversion Reference
5/2/07 

The ISA ACR controllers are obsolete. This document will help convert/migrate older ACR controllers to newer technology with minimal changes to the application.

ACR Controllers share the same language; however subtle differences in hardware may effect the implementation of certain programs for one type of controller that are imported to another. Typically these changes are minor, such as an adjustment in user I/O, or a simple change in code to reflect the addition of Drive I/O. Most of these subtle differences - such as system memory- are detailed below. 

NOTE: PCI Cards will NOT work in DOS applications

We suggest the following replacements be made:

1200 to 9000
1500 to 1505
2000 to 1505, 8020 or 9000
8010 to 8020 or 9000

Note All Standalone controllers should be replaced with a 9000

 

Table 1. ACR Controller Memory table

 

ACR Model Standard Memory (AX) Expanded Memory (BX)
1200 128 KB 512 KB
1500 128 KB n/a
1505 512 KB n/a
2000 128 KB 512 KB
8010 512 KB 2 MB
8020 512 KB 2 MB
9000 1 MB n/a

 

2000 to 1505

The 2000 is ISA the 1505 is PCI. All commands referencing FIFO should reference DPCB.

The ACR1505 Interrupt Select is handled through the Plug and Play of the PCI card whereas ISA configuration may be handled through BIOS.

1505 has a faster processor -120 MFLOPS- than the 2000 -50 MFLOPS- 

1505 I/O 16in 16out 16configurable and REQUIRES an Opto-22 Rack the 2000 has 32 I/O and is expandable to 288. 
NOTE: If the expansion I/O was utilized on the 2000, the 1505 is not a suitable replacement and the 8020 should be used. 

Analog inputs can be either 12 or 16 bit on the 1505, the 2000 can only accept 12 bit. 

The DAC GAIN on the ACR1505 is inverted as the default setting in the firmware. This will need to be accounted for by adjusting encoder multiplier (MULT command) OR changing the DAC gain to a positive value (Change -3276.8 to 3276.8)

The Step and Direction are differential rather than the 2000's open collector.
2000 to 8020
The 2000 is ISA the 8020 is PCI. All commands referencing FIFO should reference DPCB.

The ACR8020 Interrupt Select is handled through the Plug and Play of the PCI card whereas ISA configuration may be handled through BIOS.

8020 has a faster processor -120 MFLOPS- than the 2000 -50 MFLOPS- 

2000 has 32 and is expandable to 288. The 8020 has 64 and can expand to 320. 
When using ACR controller cards that do not have 64 I/O (ACR1200, ACR1500, ACR2000), the unused Input and Output Bits should not be used in programming

 

8010 to 8020

Special care must be taken when replacing existing ACR ISA bus controller cards with an ACR8020 PCI bus controller card.

Although the P1A, P1B, P3, and P4 connectors are direct pin for pin replacements for the ACR8000 and ACR8010, the physical position of these connectors is different. The component placement on a PCI card is reverse that of an ISA card. This means the placement of the connectors is in the opposite order.

Please consult the hardware manuals for the ACR8020 and the hardware manual for the existing card to be sure the cabling is correct before applying power.

NOTE: Plugging in the incorrect cable can cause damage to the ACR8020 and the system components.

Any ACR Controller to the ACR9000

Stand alone 120-240VAC

Axes Count: 9000 currently has up to 8 (9030 and 9040 will support 16 or More Axes over Ethernet Powerlink)
Drive Enable is different:

The DRIVE ON command only works with the ACR9000. All other ACR Controllers must manually set the Enable output(s). There are two options: change the enable code/routine to accommodate the Drive I/O of the 9000, or, disable the Drive I/O (Bit 8468 for Axis0, viewable under Quaternary Axis flags)

The Drive I/O also monitors for encoder faults, drive fault inputs, and End of Travel sensors.

Requires 24V Motion Enable input

I/O acts as a contact closure on the 9000 rather than a sinking/sourcing output

I/O expansion is through CanOpen Network with PIO modules rather than expansion boards.

NOTE: THERE IS NO WATCHDOG RELAY ON THE ACR 9000