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MTS Systems MPA-460 ACE-01 Manual

Brushless servo amplifier
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M P A - 4 6 0 A C E - 0 1 B R U S H L E S S S E R V O
A M P L I F I E R
Application
This manual is designed to help you install the MaxPlus™ amplifier.
Unpacking and Inspection
Carefully unpack the amplifier and inspect it for visible damage. Check items against the
packing list. Report any missing or damaged items to your supplier.
Warranty and Service
The amplifier is warranted to be free from defects in workmanship and materials for a period
of 18 months from the original shipment by MTS Automation, or 12 months in service,
whichever comes first.
During the warranty period, a defective amplifier unit will be repaired or replaced as outlined
below.
Before requesting return authorization, please try to verify that the problem is within the
amplifier, and not with external devices.
To arrange for repair or replacement, please contact:
•
You must provide the model and serial number from the labels on the amplifier.
•
You must provide an explanation as to why the unit is being returned.
•
You will be issued a return authorization number which must be marked on the return shipment
and on all correspondence.
MTS Automation Customer Service
(507) 354-1616
(800) 967-1785
Monday–Friday, 8:00–4:30 Central Time
Continued on next page
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Summary of Contents for MTS Systems MPA-460 ACE-01

  • Page 1 M P A - 4 6 0 A C E - 0 1 B R U S H L E S S S E R V O A M P L I F I E R Application This manual is designed to help you install the MaxPlus™ amplifier. Unpacking and Inspection Carefully unpack the amplifier and inspect it for visible damage.
  • Page 2 Warranty and Service (continued) Service Under Warranty • Return your defective unit, freight prepaid, and it will be repaired and returned within two weeks of receipt via regular UPS, freight prepaid. • Upon request, a factory-repaired replacement unit will be sent via regular prepaid UPS, within 4 working days.
  • Page 3 Introduction MPA Amplifiers represent a series of amplifiers that are high performance, reliable, and efficient. The amplifiers are designed to be used with high performance brushless servo motors. Extreme care has been taken to assure robust operation. Design consideration for electrical transients have been implemented on the ac inputs and all I/O lines.
  • Page 4 Sizes Model Continuous Amps Peak Amps MPA-100-460 MPA-100-230 Features • Efficient power conversion • High frequency switching • Resolver feedback or Hall-effect commutation • Simulated quadrature encoder signals (with resolver feedback) • ±10 Vdc for maximum velocity or torque • 24 volt I/O for ±LIMIT, RESET, VEL/TORQUE mode •...
  • Page 5 100 amps continuous; 165 amps peak; peak ≤ 5 seconds Output: MPA-100-460 PWM frequency 10 kHz MPA-100-230 DC Bus and output voltage is AC line dependent The motor's maximum speed is dependent on the bus voltage and motor KE by the following relationships: Motor/Amplifier Speed and Load Relationship: (AC Input)/(Motor KE Vrms) = Maximum no load speed.
  • Page 6 Parameter Specification Encoder Signals: Resolution 250, 360, 400, 500, 720, 1000, 1024, 2000 and 4096 lines Accuracy: Resolver Cable Length: Max. Error: 15 foot ±20 minutes 25 foot ±20 minutes 50 foot ±30 minutes 100 foot ±40 minutes Weight: MPA-100-460/230 75 lbs.
  • Page 7 MPA-100-460/230 Mechanical Footprint CURRENT MPA100-460 +24V -24V RESET T/S+ T/S- ENCODER POWER PWM MODE LIM+ RMS MODE LIM- INPUT INVERT MOTOR SELECT FLTINV ENCODER COM- MODE CONTINUOUS AUX- SHORTS MOTOR AUX+ AMPLIFIER FDBK HI-BUS RESET LIMIT VELOCITY COMP COS GND SIN GND RESOLVER SHIELD...
  • Page 8 Control Interface and User Configuration Locations CURRENT 100% shielded cable is foil and braid. The pairs do not have to be twisted. The resolver MPA100-460 wiring should not be run adjacent to any non-shielded high voltage wires, such as the motor wires (RST).
  • Page 9 Resolver Feedback Wiring SHIELD SHIELD THERM GND THERM SWITCH SIN GND COS GND REF GND 100% Shielded Reference Frequency 2 kHz 20-25 VP-P SIN/COS 0 TO 5 V Maximum rms Winding Thermostat...
  • Page 10 Motors and Commutation The amplifier can commutate 6-pole, 8-pole, 12-pole, and brush motors in its standard configuration and other factory options are available. DIP switch SW6 allows for configuration changes and switches one through three determine the choice. Amplifiers are shipped set for 6-pole operation.

  • Page 11: Diagnostic Indicators

    Diagnostic Indicators Mark (RED) This is an output that comes ON at the resolver zero position and can be used in conjunction with alignment procedures. The zero position is about .5 degrees. Current (BI-COLOR) This is a bi-color LED that can be either red or green as a function of load. Red indicates positive torque and green indicates negative torque.
  • Page 12 Simulated Encoder Signals For external counting or position control, 9-pin D type female connector that has TTL complimentary outputs is provided. This simulates quadrature encoder channel A and channel B signals. A differential mark signal is also available. TYPICAL ENCODER CABLE 100% SHIELD (FOIL AND BRAID) ENCODER...
  • Page 13 SW8 is provided as a means to determine the resolution of the simulated encoder signals. The default factory configuration is 1024 lines. Lines 2000 (14-bit only) 1024 (default) 1000 4096 (14-bit only) The normal factory configuration of 2-Channel quadrature provides for output resolution of 12 bits or 4096 counts per revolution.
  • Page 14 I/O Wiring and Descriptions The amplifier has four inputs and one output. These inputs and output are designed to interface to a 24 volt logic system. The amplifier is shipped so that the operation of the inputs are as follows. With no wires connected to RESET, + LIMIT, - LIMIT, or VEL/TORQUE, the amplifier is enabled and normal operation will occur in a velocity mode.
  • Page 15 As the polarity of the inputs may vary depending on the application, a DIP switch is provided to allow for an inversion of the function. DIP switch SW7 switches 1, 2, 3, and 4, are used for this purpose. Input Switch Number Factory Setting RESET...
  • Page 16 Analog Inputs, Outputs and Adjustments Inputs There are two analog input channels; one for command and one for auxiliary. Both of these channels are differential inputs and both are summed with a TAC feedback differential amplifier that controls velocity. ANALOG INPUT ENCODER WIRING EXAMPLE –...
  • Page 17 During start-up the BAL adjustment can be used to reduce/stop any low speed CW/CCW drift caused by imbalance between the external command voltage and the amplifier. Once connected to loads, the crispness of motion (step response) and stability can be optimized with the RESP and LEAD pots.
  • Page 18 The analog input channels employ differential input amplifiers to allow controllers that have true differential output drivers to use a three wire connection that excludes potential ground loops. When a true differential command is used, the command or auxiliary input is based on 5 volts maximum input on each side of the differential input, and the analog ground from the external controller must be connected to the amplifiers GND connection.
  • Page 19 R-D Converter Resolution SW2 is used to set the resolution of the resolver to digital converter. The amplifier is configured from the factory for 12-bit mode. Mode 12-bit (default) 14-bit The motor speed and TAC gradients are affected by these settings. Mode Maximum Speed 12-bit...
  • Page 20 DIP Switch SW3 - Velocity Signal Processing REF– 3 1 REF+ TP23 R155 200K U39A R154 – LM358 R159 R137 R156 R157 R158 390K 200K 100K C109 .022M .047M EXTERNAL BRUSHLESS R138 R139 INTERNAL RESOLVER...
  • Page 21 Lead/Lag Compensation SW1 is provided as a means to alter the amplifier's lead/lag network. Switches 1-4 can be switched ON to allow for forward compensation of the TAC signal in the summing node of the differential amplifier used for the velocity loop. This signal had the effect of damping the loop, and is an effective method to control large inertia loads.

  • Page 22: Overspeed Shut Down

    DIP Switch SW1 — Lead/Lag Compensation TACH U31A .047M TL084A .22M .47M .47M LEAD .22M .047M 200K 200K 200K CURRENT COMMAND 200K 200K C135 RESP BALANCE LM358 5.1K XRB1C Overspeed Shut Down The overspeed shut down circuit converts the TAC gradient into an absolute value for comparison to a factory set preset value.
  • Page 23 Default DIP Switch Settings and Summary Comment Lead/Lag 12-bit mode Options Commutation Encoder (1024L) SW1 determines the lead lag compensation networks, and is usually only modified to improve stability on high inertia loads. SW2 is used to alter the operation of the R-D converter and is preset to the 12-bit mode. This switch setting is only altered to achieve higher line density simulated encoder selections or higher TAC gradients.
  • Page 24 AC Input and Internal Protection A branch circuit disconnect must be provided in front of the amplifier. For 460 volt models, only three phase power may be applied. Model Three Phase MPA-100-460 80 amps NOTE Use the table above as a guideline when selecting the size of disconnecting devices.
  • Page 25 Grounding The ac supply source for the amplifier should be bonded to earth ground. Typical WYE Secondary L1 (HOT) L2 (HOT) L3 (HOT) EARTH GROUND Typical Delta Secondary L1 (HOT) L2 (HOT) L3 (HOT) EARTH GROUND These are the two most typical transformer configurations and failure to ground these properly could void warranty.
  • Page 26 The MPA amplifier does not care where the earth ground is. This example is a delta secondary. Delta Secondary L1 (HOT) L3 (HOT) L2 (NEUTRAL) EARTH GROUND In this example L2 becomes ground.
  • Page 27 Power/Grounding Requirements The following information covers the grounding requirements of 3-phase servo amplifiers manufactured by MTS Automation. It has been found when an amplifier has been connected to a transformer with a floating secondary, premature amplifier failure may occur. The 3-phase MPA amplifiers require the AC power (L1, L2, L3, and Ground) be derived from a transformer which has it's secondary intentionally bonded to earth ground.
  • Page 28 Example 1 shows a typical factory configuration. It shows a ungrounded delta secondary and there is existing equipment already running. on line. This equipment could be simple 3- phase induction motors where an ungrounded secondary is not an issue. However, before a 3-phase MPA amplifier, or a machine utilizing 3-phase amplifiers, can be connected, an isolation transformer, with a grounded secondary must be installed.
  • Page 29 Stator Wiring The locked rotor stator current is equal to the amplifiers continuous rating and for either low speed or locked rotor conditions the stator must withstand this continuous rating. Derating the stator wiring for three phase operation should not be done. Model Locked Rotor MPA-05-460...
  • Page 30 Shunt Loads Regenerative energy during deceleration causes the normal voltage on the drives bus to increase. The amount of energy is application dependent and relates to total inertia. In general the drives internal shunt load can dissipate this energy within the constraint that the load inertia is not more than 20 times that of the rotor but, this is a guideline.

  • Page 31: Thermal Characteristics

    Thermal Characteristics These drives are specified to operate at a 45° C ambient. As all internal electronics are rated to at least 60° C, operation in an ambient temperature above 45° C is possible; however, the full rated continuous current rating may not be achieved before a thermal fault limit is reached.
  • Page 32 EXS-50/100-460 Mechanical Footprint 16.0" 15.5" 0.5" 8.5" 1.0" 9.5" 5.6"...
  • Page 33 "-S" Separated Supply Option The -S option amplifier allows for the removal of the dc voltages from the power devices within the amplifier that form the outputs RST. This is accomplished by removing the main ac (bridge) input. The amplifier should be disabled prior to the removal of power and should not be enabled until this power is restored.
  • Page 34 Typical "–S" Three Phase 460V Amplifiers...
  • Page 35 "-T" Brushless TAC Option The MPA amplifiers use resolver feedback. The resolver provides positional information for commutation of the motor, simulated encoder signals and a velocity signal for the amplifier when the velocity mode is selected. In some instances, the quality of the velocity signal derived from the resolver to digital converter compromises performance because of 2-Pole cyclic position ripple.
  • Page 36 Typical Motor Connector B R O W N / W H I T E T A C R E T P I N K + 1 2 T A N – 1 2 O R A N G E / W H I T E T A C G R E E N G N D...
  • Page 37 Start-Up Once normal wiring is verified, power can be applied to the amplifier. Assure the DIP switch and jumpers are set as required. Default settings are for 6 pole motors on the amplifiers. Inputs Reset, +Limit, and -Limit are not going to disable the amplifier if they are not connected.

  • Page 38: Typical Wiring

    Typical Wiring...

This manual is also suitable for:

Mpa-100-460Mpa-100-230