G3 Motion System Installation Manual

Important Safety Instructions

• Read and follow these instructions step-by-step.
• Keep them for future reference.
• Install in accordance with the manufacturer's instructions and heed all warnings.
• Do not use this apparatus near water.
• Only clean with a dry cloth.
• Do not block any ventilation openings.
• Do not install near any heat sources such as radiators, heat registers, stoves, or other apparatus (including amplifiers) that produce heat.
• Do not defeat the safety purpose of the polarized or grounding-type plug. A polarized plug has two blades with one wider than the other. A grounding-type plug has two blades and a third grounding prong. The wide blade or the third prongs are provided for your safety. If the provided plug does not fit into your outlet, consult an electrician for replacement of the obsolete outlet.
• Protect the power cord from being walked on or pinched particularly at plugs, convenience receptacles, and the point where they exit from the apparatus.
• Only use attaching hardware/accessories specified by the manufacturer.
• Use only with the cart, stand, tripod, bracket, or table specified by the manufacturer, or sold with the apparatus. When a cart is used, use caution when moving the cart/apparatus combination to avoid injury from tip-over.
• Unplug this apparatus during lightning storms or when unused for long periods of time.
• Refer all servicing to qualified service personnel. Servicing is required when the apparatus has been damaged in any way, including damage to power-supply cord or plug, liquid has been spilled or objects have fallen into the apparatus, the apparatus has been exposed to rain or moisture, does not operate normally, or has been dropped.
• Do not expose this apparatus to dripping or splashing and ensure that no objects filled with liquids, such as vases, are placed on the apparatus.
• To completely disconnect this apparatus from the AC Mains, disconnect the power supply cord plug from the AC receptacle.
• The mains plug of the power supply cord shall remain readily operable.
• Do not expose batteries to excessive heat such as sunshine, fire or the like.

[high-voltage warning] The lightning flash with arrowhead symbol within an equilateral triangle is intended to alert the user to the presence of uninsulated "dangerous voltage" within the product's enclosure that may be of sufficient magnitude to constitute a risk of electric shock to persons.

[important information] The exclamation point within an equilateral triangle is intended to alert the user to the presence of important operating and maintenance (servicing) instructions in the literature accompanying the product.

[manufacturer disposal contact] This symbol indicates that you must communicate with the manufacturer for disposal of the equipment.

WARNING: To reduce the risk of fire or electric shock, do not expose this apparatus to rain or moisture.

Introduction

D-BOX Motion Systems are evolutive and scalable. Integrated into a seat, platform or simulator, they are designed to simulate a range of textures and scalable axes of movement. Whatever you require, D-BOX can help you select the best arrangement of actuators.

Components of the D-BOX Motion System:

• Motion System: A complete architecture of hardware and software providing motion.
• Actuator: An assembly of motor and mechanics providing movements and vibrations.
• Actuator Control Module (ACM): Provides power and control to the actuators. Controls the power sent to the motor and adjusts the precise rotation according to the feedback from an encoder within the actuator.
• Communication Module: Electronic component used to transmit motion code, converting a signal format to another one.
• Motion Source: Various applications generating motion data for the D-BOX Motion System.

When integrating your D-BOX system, please comply with the following guidelines. If you must deviate from the guidelines, please contact D-BOX to ensure the system is still used as prescribed.

Operating Conditions

The D-BOX Motion System shall be operated in controlled environmental conditions, per the following specifications:

• Power Requirements: 100–230VAC, 60Hz, 0.63A, Output: +48VDC, compatible with CAN – USA and EU power systems.
• Operating Temperature Range: 0–40°C
• Operating Hygrometry: 10–50%
• Maximum Operating Altitude: 2000 meters above sea level

Software - Motion Core

The D-BOX Motion System requires the installation of the Motion Core application on the host PC. The application is available for download on the D-BOX website (www.d-box.com). Please follow the Motion Core instructions for installation and use.

Software - Motion System Configurator

NOTE: D-BOX upgrades the ACM firmware on a regular basis. D-BOX therefore recommends that you update your equipment to the latest firmware version, upon reception, with the Motion System Configurator.

Each ACM comes with a default configuration based upon the Motion System architecture. The table below lists the factory configurations. The letters describing the actuator position refer to the next table.

Motion System Configuration and Actuator Positioning

You may have a configuration requirement different from the factory configuration. If this is the case, you need to change it using the Motion System Configurator to modify the configuration BEFORE you install your Motion System. The D-BOX Motion System Configurator application attributes a specific ACM port to each actuator position.

A good practice is to replace the sticker on your ACM to reflect the new configuration.

Actuator Positions:

The letters represent the position of the actuators:

• LEGEND: FL, FC, FR, BL, BC, BR, SU, SW, Y
• POSITION: Front-Left, Front-Center, Front-Right, Back-Left, Back-Center, Back-Right, Surge, Sway, Yaw

Diagram Description: A visual representation of actuator positions labeled FL, FC, FR, BL, BC, BR, SU, SW, Y, showing their relative placement on a platform.

For example: For a typical roll, pitch, heave configuration with 4 vertical actuators, actuators at positions 1 and 2 connect to the Master ACM and actuators at positions 3 and 4 connect to the Slave ACM. For additional details on the ACM configuration, please read the Motion System Configurator Guide.

Communication Module - KCU-1P

The KCU-1P is a communication module that transmits the data from the Motion Source to the first ACM in the chain.

Diagram Description: Image of the D-BOX KCU-1P module showing ports labeled MASTER OUT, USB, POWER, and DC 48V output. It also displays warnings related to electrical shock and opening the unit.

CAUTION: Avoid connecting the KCU-1P into the USB port of a Windows PC before the Motion Core application has been installed. Although the application installs itself as soon as the KCU-1P is connected to the computer, it requires driver files to complete the installation process.

CAUTION: The KCU-1P works with a D-BOX G2 or G3 ACM. Never connect the KCU-1P to an ACM-I (G1).

The KCU-1P comes with an installation bracket and a power supply. It has 2 ports and a power input jack.

KCU-1P Power up

At power up, the front LED shows the status of the KCU-1P.

Power up sequence:

• RED: 48V power present but no USB connection.
• ORANGE: Connected to the PC USB port, drivers are installed. The unit is ready to operate.
• GREEN: Active Motion.

NOTE: One KCU-1P can provide the motion signal for a maximum of 20 daisy-chained ACM G3.

Actuator Control Module

ACM G3 families and compatibility

There exist multiple ACM in the G3 architecture. The following table outlines the ACM G3 compatibility with different actuator models.

NOTE: ACMs are programmed to work with a specific actuator model and at a specific place in the architecture (Master/Slave). Thus, ACMs are not interchangeable.

NOTE: In the G3 architecture, the ACMs are only compatible with a G3 actuator (motor and mechanics). Different generations of components are not compatible with each other.

ACM Connections

Depending on the ACM position in the system, it is programmed either as:

• MASTER: First ACM in a Motion System
• SLAVE: All following ACMs

Diagram Description: Series of diagrams illustrating typical ACM connection configurations for a single Motion System, showing one Master ACM, one Master and one Slave ACM, and one Master and two Slave ACMs, all connected in a chain and linked to the KCU-1P.

ACM G3 LED Status

Actuator

Maximum axial load

The following table shows the maximum axial load for each actuator.

¹You can find the reference to the maximal axial load in System Monitor - part of Motion Core. The Newton units are a reference to the load perceived by each motor but can't be converted into actual Newtons. Therefore D-BOX uses the eponym index.

• Make sure that the weight on the platform is no higher than the maximum supported weight.
• Make sure that the weight is evenly distributed among the actuators of the platform (as centered as possible).

Weight Distribution

Each actuator has an individual maximal payload as previously mentioned. When integrating the Motion System on a platform, D-BOX recommends balancing the center of gravity (CG) of the platform to ensure each actuator supports an equal load. The following figures show equal distribution of weight with 2, 3 or 4 actuators.

Diagram Description: Figures illustrating equal distribution of weight for 2, 3, and 4 actuators, showing the placement of actuators (FL, FR, BL, BR, BC, SW, Y, SU) and the center of gravity (CG).

Actuator Acceleration

The D-BOX Motion System can produce a 1G acceleration or greater. However, to avoid risks of injury for the user or damage to the equipment, D-BOX recommends calibrating the Motion System to produce a maximum of 1G, using the control panel - see information on Motion Core. An acceleration above 1G can make the platform jump. Jumping can be observed when the actuator takes off from the ground. The following figures show a piston jumping in its cup.

Diagram Description: Two diagrams illustrating an actuator piston: one "Actuator sitting in the ending" and another "Actuator jumping out of the ending".

The shock of a piston falling back down in its cup reverberates on the top bearing of the piston, which takes the hit to protect the motor. As it progressively wears, the bearing also becomes noisier, reducing the service life of the ball nuts and screw. Avoid actuator jumping in the cup.

This behavior is typical when running the platform with no or light weight. There are no guidelines as to minimum weight; this is highly dependent on the actuators position, the motion code, the simulator weight, simulator structure and weight distribution.

Distance between actuators

Respect the minimum distance between actuators for adequate movement of the platform. Measure the distance from a square surface enclosing all actuators - see example below. Respecting the spacing guidelines ensures proper interaction of the Motion System with the actuator endings, and proper lateral force transfer.

Diagram Description: A diagram showing a square surface enclosing actuators, with dimension 'A' indicating the minimum spacing between actuators.

Actuator alignment

When using 4 actuators, install them per a square or rectangular pattern. Avoid other patterns - e.g. trapezoid.

Diagram Description: Diagrams illustrating adequate actuator alignment (square/rectangular with a checkmark) and inadequate actuator alignment (trapezoid with an 'X').

Actuator straightness

During installation, the actuators should always remain straight to limit radial loading. Radial loading could result in premature wear of the actuators.

Diagram Description: Diagrams showing an actuator in an adequate position (straight, lateral forces = 0) and an inadequate position (tilted, lateral forces ≠ 0).

Level surface

All actuators must be level on the same flat surface for optimal operations. Different levels could result in premature wear of the actuators.

Diagram Description: Diagrams showing actuators on an equal level surface and actuators on an unbalanced level surface.

Motion System Accessories

Use only D-BOX certified accessories. Using accessories that are not D-BOX certified voids the warranty and can result in damages to the Motion System.

Power converter

Past generation of D-BOX products were 120V native and to be used with a custom step-down transformer made specifically to respect certification requirements for 230V configurations. The G3 systems can be ordered in 120V or 230V version without an external step-down transformer.

CAUTION: 120V and 230V ACM are NOT THE SAME PRODUCT. They need different internal components and need to be ordered from the factory for the right configuration.

As D-BOX is not providing an external step-down transformer, you will need to assure power conversion by your own means if needed. To select your converter, please follow the power requirement listed in the spec sheets for your specific configuration.

Other than power requirement, D-BOX would like to suggest the use of an isolated converter to avoid risks of electrical shock. If a non-isolated converter is selected, please make sure to secure ground connection.

Pivot

When using a 2-actuator Motion System, D-BOX provides a pivot as a third attachment point to ensure proper actuator movement. D-BOX suggests locating the pivot near the center of gravity, to support most weight and allow equal weight distribution on the actuators.

NOTE: the closer the actuators are to the CG, the larger the movement you get. A CG that's very close would create strong forces on actuators and might reduce stability. Make sure that actuators are always under charge.

Diagram Description: Diagram showing a pivot placement relative to the center of gravity (CG) for a 2-actuator system, with arrows indicating "Back" and "Front".

Captive Endings

Go to the Removal/Installation section for details about the captive endings.

Diagram Description: Images of the two components of a D-BOX captive ending: a "Ball joint" and a "Spacer Retainer".

Ball joint

There are 2 models of ball joints.

Diagram Description: Images of two ball joint models, labeled "OEM" (for 6in - AC360 actuators) and "OEM LITE" (for 1.5in - AC211, AC10 and 3in - AC231 actuators).

Spacer retainer

The spacer-retainer allows specific movements of the ball joint on both x and y axes, thus eliminating any constraints during the movement of the platform. There are 3 models of spacer retainer. All spacer retainers can be fitted on any model of ball joint.

• 0 axis: allowing no movement in x and y axis.
• 1 axis: allowing movement only on 1 axis (x or y).
• 2axes: allowing movement on 2 axes (x and y).

CAUTION: Respect the orientation to avoid any damage to the components of the platform.

Diagram Description: Diagrams showing spacer retainer configurations for 2 actuators and pivot, 3 actuators, and 4 actuators. It also shows the "OUTWARD" marking on the top surface of the spacer retainer for positioning.

1.5-inch actuator - AC218

Here are installation instructions for the D-BOX ball joints. Make sure all the parts are clean before installation.

CAUTION: Never operate the AC218 actuator without the pivot installed. Operating the AC218 actuator without the pivot leads to irreparable damages to the actuator.

Diagram Description: Diagrams illustrating the AC218 actuator with a pivot installed and a warning symbol (X) over an AC218 actuator without a pivot.

Removal

Unscrew bolt (4) with the ½ hex key and remove washer (3) and pivot (2) from the actuator (1).

Apply threadlocker Loctite 263 to the threaded section of bolts (3) and ball joint (4).

Installation

Install pivot (2) on actuator (1) with bolts (3). Torque bolts to 50 lbf in.

Screw the threaded section of ball joint (4) in the actuator (3). Use a torque wrench with a 5/8 crow foot socket to tighten the ball joint (4) in the actuator. Torque to 170 lbf in.

Place spacer (5) at its required location. Make sure the holes in the spacer are aligned with the holes in the floor and place the actuator and ball joint assembly in spacer (5).

Diagram Description: Diagrams showing the steps for removing and installing the AC218 actuator, including part identification and torque specifications.

Slide retainers (6) on spacer (5) and in the slot on the ball joint. Align the holes in the retainers with the holes in the spacer. Use 5/16 bolts to tighten the spacer and retainers to the floor.

NOTE: the way the ball joint is anchored to the floor is the same for all actuators – 1.5", 3", and 6".

Diagram Description: Diagrams showing retainers being slid onto the spacer and ball joint, and then secured to the floor with bolts.

3-inch actuator - AC231

Removal

Unscrew bolt (1) with the 3/8 hex key and remove pivot (2) and spacers (3) from the actuator. Unscrew bolt (4) with the 4mm hex key and (optional) remove H-bracket (5) from the actuator.

Diagram Description: Diagrams illustrating the removal of parts for the 3-inch actuator AC231, including bolt sizes and part labels.

Installation

Add Loctite 263 to the threaded section.

Screw the threaded section in the actuator (1). Use a torque wrench with a 5/8 crow foot socket to tighten the ball joint assembly (2) in the actuator. Torque to 170 lbf in.

Place spacer (3) at its required location. Make sure the holes in the spacer are aligned with the holes in the floor and place the actuator and ball joint assembly in spacer (3).

Diagram Description: Diagrams showing the installation steps for the 3-inch actuator AC231, including applying threadlocker, tightening the ball joint assembly, and placing the spacer.

Slide retainers (4) on spacer (3) and in the slot on the ball joint. Align the holes in the retainers with the holes in the spacer. Use 5/16 bolts to tighten the spacer and retainers to the floor.

Diagram Description: Diagrams showing retainers being slid onto the spacer and ball joint, and then secured to the floor with bolts for the 3-inch actuator AC231.

6-inch actuator - AC360

Removal

Unscrew bolt (1) with the ½ hex key and remove pivot (2) and spacer (3) from actuator (4).

Diagram Description: Diagrams illustrating the removal of parts for the 6-inch actuator AC360, including bolt sizes and part labels.

Installation

Add Loctite 263 to the threaded section.

Screw the threaded section in the actuator (1). Use a torque wrench with a 5/8 crow foot socket to tighten the ball joint assembly (2) in the actuator. Torque to 170 lbf in.

Place spacer (3) at its required location. Make sure the holes in the spacer are aligned with the holes in the floor and place the actuator and ball joint assembly in spacer (3).

Diagram Description: Diagrams showing the installation steps for the 6-inch actuator AC360, including applying threadlocker, tightening the ball joint assembly, and placing the spacer.

Slide retainers (4) on spacer (3) and in the slot on the ball joint. Align the holes in the retainers with the holes in the spacer. Use 5/16 bolts to tighten the spacer and retainers to the floor.

Diagram Description: Diagrams showing retainers being slid onto the spacer and ball joint, and then secured to the floor with bolts for the 6-inch actuator AC360.

AC218 ACTUATOR REPLACEMENT

Removal

Remove the screws holding the center ACM cover. Then remove the remaining screws from the actuator cover and gently pull the actuator cover from the ACM.

Diagram Description: Images showing the removal of the ACM cover and access door, and the identification of encoder and power cables for an actuator.

Each actuator is identified by a letter. Each actuator has two cables: a power cable and an encoder cable. Identify both cables related to the actuator you wish to remove. Unplug both cables.

Installation

Plug both power and encoder cables in the ACM.

Install the actuator cover with screws. Install the center ACM cover with screws.

Contact Information

Thank you for purchasing a D-BOX Motion System, the most immersive experience for the simulation and game markets. We strongly advise that you read the guidelines before assembling and using your Motion System. Do not hesitate to contact D-BOX if you have questions.

D-BOX SUPPORT

Address: 2172 rue de la Province, Longueuil, QC, Canada

By Email: support@d-box.com

By Phone:

• Toll free CAN/US: 1-888-442-3269 ext.931
• Other regions: 1-450-442-3003 ext.931

Support Business Hours:

• Monday to Friday: 8h00 to 20h30 (UTC-5)
• Saturday & Sunday: 8h30 to 17h00 (UTC-5)