Table of Contents
Troubleshooting
Related Manuals for Electro-Craft MAX-430
Summary of Contents for Electro-Craft MAX-430
- Page 1 Click to Go Back to OEM Menu MAX-430 PWM Servo Drive Instruction Manual Rockwell Automation/Electro-Craft 6950 Washington Avenue South Eden Prairie, MN 55344 I G H T O M P A N Y I G H T O L U T I O N...
- Page 2 Printed in the United States of America. Information contained in this manual is subject to change without notice. Electro-Craft is a trademark of Rockwell Automation. UL and cUL are registered trademarks of Underwriters Laboratories. Other trademarks cited are the property of their respective owner.
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Page 3: Table Of Contents
Introduction to the MAX-430 ........ - Page 4 PPENDIX MAX-400 to MAX-430 Replacements ....... Power Connector .........
- Page 5 List of Figures IntroList of Figures Pictorial Index ......... . . Intro-8 Introduction HAPTER...
- Page 6 Intro-6 List of Figures Component Ordering Information HAPTER 0.625 kVA Transformer, Part Number 9077-0640 ..... . . 1.8 kVA Transformer, Part Number 9077-0639 ......3.6 kVA Transformer, Part Number 9077-0638 .
- Page 7 HAPTER Diagnostics/Troubleshooting HAPTER MAX-430 System Problem Symptoms and Possible Causes ....4-3 LED Fault Conditions ......... . . 4-4...
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Page 8: Pictorial Index Intro-8
Intro-8 Pictorial Index IntroPictorial Index Intro page 3-3 page 4-5 page 2-10 page 2-10 page 2-10 page 2-13 page 4-4 page 2-13 page 2-12 page 2-10 page 2-10 page 2-10 page 4-5 page 2-12 page 2-12 page 2-15 page 2-12 page 2-15 page 2-15 page 2-15... -
Page 9: Hapter
MAX-430 drive. It is assumed that the reader is trained in the use of mechanical and electrical test equipment and is familiar with basic servo system maintenance procedures. -
Page 10: Functional Description
The command signal to the power drive can be monitored at the ICMD output. The MAX-430 is a 16 kHz pulse-width modulation (PWM), switching type drive that reduces system power losses. Motor speed is precisely controlled down to a maximum torque, low velocity condition. -
Page 11: Hapter
Internal Adjustments Jumpers There are jumpers on the velocity regulator board of the MAX-430 to indicate desired operation of the Forward and Reverse Amplifier Clamps and the System Status Output (FAC, RAC, and SSO). There are also jumpers used to indicate desired operation of the optically isolated tran- sistors on FAC, RAC and inhibit (INH) inputs. -
Page 12: Jumper Locations
Installation Inputs and Outputs with Jumpers P6 through P9A (continued) ABLE Jumper Pins Position Operation Page External Opto Power Customer supplies power (24V) to opto’s on 2-11 FAC, RAC and INHibit inputs. External Sourcing Opto’s Opto’s are sourcing inputs (pulled up to 24V 2-11 by external power when true). -
Page 13: Mounting
Example: You are using a MAX-430 drive and 0644-35-021 motor, and you are unsure of the exact speed and torque in your application. Look at the speed/torque curve for your drive/motor combi- nation as shown in the Electro-Craft catalog and use the values for the worst case continuous speed and torque. -
Page 14: Ac And Dc Power Connections
Installation AC and DC Power Connections AC input power to the MAX-430 must be supplied by an isolation transformer with an output of 20-85 VAC. Refer to “Transformer Sizing” on page 2-3. Alternatively the MAX-430 may be supplied with 30-120 VDC. -
Page 15: 230 Vac Input Power/Motor Wiring
Installation Intro 230 VAC Input Power/Motor Wiring IGURE Intro +(30-120) VDC Input Power/Motor Wiring IGURE The isolated AC supply may be common to more than one drive as shown in the “Multiple Axis Power Wiring” diagrams below. The power leads from each drive should terminate at the trans- former terminals as shown on the drawing. -
Page 16: Multiple Axis Power Wiring (Individual Secondaries) (Recommended Method)
Installation Intro Multiple Axis Power Wiring (Individual Secondaries) IGURE (Recommended Method) P/N 0013-1025-001 Rev F... - Page 17 Installation Intro Multiple Axis Power Wiring (One Secondary) IGURE (Alternative Method) Instruction Manual...
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Page 18: Auxiliary Logic Supply Power
Auxiliary power input at TB1 pins 9 and 10, only the logic supply is powered. This is useful when the operational status of the MAX-430 drive is needed at the SSO output (P1 pin 6) without applying main power. See “AC and DC Power Connections” on page 2-4. -
Page 19: External Interface Connections
Installation Intro Proper shielding is recommended. The shield may be connected to common (P1 pin 4) or to common on controller end of wire. The connections shown are with factory default jumper settings. See “Internal Connec- tions (FAC, RAC and INH)” on page 2-11, for details on connections for other jumper set- tings. -
Page 20: Connecting Inputs
2-10 Installation Connecting Inputs Velocity Command Signal (VCS) Function This input controls motor speed and direction. When a positive voltage is applied to pin 1 with respect to pin 2, the motor shaft will rotate CW as viewed from the shaft end of the motor. A negative voltage applied to pin 1 with respect to pin 2 will result in counterclockwise (CCW) rotation. -
Page 21: Internal Connections (Fac, Rac And Inh)
Installation 2-11 Connection FAC: P1 pin 9 RAC: P1 pin 10 (Refer to “Internal Connections (FAC, RAC and INH)” below.) Internal Connections (FAC, RAC and INH) The following circuit diagrams apply to FAC, RAC and INH inputs, so that all three inputs must operate in the same manner. -
Page 22: Velocity Clamp (Torque Mode)
2-12 Installation Intro Active High: Supply + 22-28 VDC +15V To enable the drive, or to release the forward or P1-7 reverse amplifier clamps, hold input at common. 1.0k 3.3k External power must be supplied to P1-7. INHIBIT P1-8, Opto P1-9 Switch Status... -
Page 23: Connecting Outputs
System Status Output (SSO) Function This output signal provides information on the operational status of the MAX-430 drive. With jumpers P9 and P9A in the SSO open collector output setting shown in the figures “SSO - Open Collector Sourcing” and “SSO - Open Collector Sinking”, the SSO signal is assigned a logic level “1”... -
Page 24: Sso - Normally Closed Relay With Internal Power
2-14 Installation Intro CUSTOMER MAX-430 SERVO DRIVE CONTROLLER +15 VDC +15VDC 1 2 3 FAULT = Open Relay 1 2 3 SSO+ ON = OK +15VDC COM SSO - Normally Closed Relay with Internal Power 2.14 IGURE Intro CUSTOMER MAX-430 SERVO DRIVE... -
Page 25: Motor Current Output (Mco 0-10V)
Installation 2-15 Motor Current Output (MCO 0-10V) Function The motor current output is an analog voltage which is proportional to the motor current. The scaling of this signal is proportional to the absolute value of the motor current, such that MCO is 10V when motor current is either 30 amps or -30 amps (±10%). -
Page 26: Typical Wiring Examples
2-16 Installation Typical Wiring Examples Intro The connections shown are with jumpers in factory default settings. See “Internal Connec- tions (FAC, RAC and INH)” on page 2-11 for details on connections for other jumper set- tings. Isolated Logic Interface Connections 2.17 IGURE The following diagram illustrates how the forward and reverse amplifier clamps can be wired... -
Page 27: Cw Remote Vcs Control
Installation 2-17 This diagram shows wiring and resistors needed when control in the clockwise direction only is desired. Intro CW Remote VCS Control 2.19 IGURE Bi-directional control is illustrated in the following diagram. Intro CW/CCW Remote VCS Control 2.20 IGURE The following diagram shows wiring and resistors needed when control in the counterclockwise direction only is desired. -
Page 28: Torque Control
MAX-430 drive. The 50 kW potentiometer may be adjusted to obtain the desired speed ratio between the two drives. Two MAX-430 drives can also be wired for a torque sharing application. The wiring is the same as below, except the voltage to the second drive is supplied from the MCO output on P2 pin 7 instead of the MVO output. -
Page 29: Applying Power For The First Time
Applying Power for the First Time HAPTER Setup Checklist As an option, the drive and motor could be set up on a test bench before installation, by following the Start-up Procedure. Intro WARNING If the polarity of the tachometer is not connected to the drive correctly, the motor will run away which could damage the load and may cause bodily injury. -
Page 30: Start-Up Procedure With Tach (Velocity Mode)
Applying Power for the First Time Start-up Procedure with Tach (Velocity Mode) This procedure assumes the motor is not connected to a load initially and a controller interface is not connected to the drive. During the procedure the motor is connected to the load. 1. -
Page 31: Internal Current Limit (Ilim)
Applying Power for the First Time 13. Set the velocity command at approximately 0 VDC from the voltage source, and apply power to the drive (with drive still enabled). Rotate the VCS gain potentiometer to the full CW position. 14. Slowly increase the voltage applied at VCS+ from the velocity command voltage source from 0 VDC to the maximum command (generally ±10 VDC) and adjust the TACH gain for the desired maximum motor RPM. -
Page 32: Vcs Gain (Vcs)
VCS Signal and Scaling (VCS) The MAX-430 drive can be more finely tuned by looking at the response to a step VCS input on an oscilloscope. The equipment needed is a signal generator and an oscilloscope. -
Page 33: Applying Power For The First Time
Applying Power for the First Time Intro System Response to a Step VCS Input IGURE Instruction Manual... -
Page 34: Start-Up Procedure Without Tach (Torque Mode)
Applying Power for the First Time Start-up Procedure without Tach (Torque Mode) This procedure assumes the motor is not connected to a load and a controller interface is not connected to the drive. 1. Connect motor wiring. Refer to “AC and DC Power Connections” on page 2-4 2. -
Page 35: Torque Mode Operation
Torque Mode Operation Operation The MAX-430 drive can also operate in torque mode (or current mode), such that a controller would provide an analog voltage signal proportional to the desired motor torque. For use as a torque drive, a jumper must be installed from P2 pin 1 to P2 pin 2. With the VCS gain fully clockwise, a 10 volt VCS signal applied to the drive will yield a 30 amp output to the motor. - Page 36 Applying Power for the First Time P/N 0013-1025-001 Rev F...
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Page 37: Hapter
Diagnostics/Troubleshooting HAPTER Monitoring Outputs Motor Current Output (MCO 0-10V) Function The motor current output is an analog voltage which is proportional to the motor current. The scaling of this signal is proportional to the absolute value of the motor current, such that MCO is 10V when motor current is either 30 amps or -30 amps. -
Page 38: Scheduled Maintenance
To check and/or replace either fuse: 1. Measure voltages at TB1 pin 6 and pin 7 and at TB1 pin 9 and pin 10 to insure incoming power is OFF. Make sure that the green READY LED is OFF. Remove the MAX-430 cover. -
Page 39: Malfunction Diagnosis
Diagnostics/Troubleshooting Malfunction Diagnosis MAX-430 System Problem Symptoms and Possible Causes ABLE Symptoms Possible Causes Motor inoperative. No AC power to the drive Faulty wiring to motor No ± 15 VDC at P2. Power supply defective ± 15 VDC regulators defective No voltage between MT+, MT- terminals. -
Page 40: Light Emitting Diodes
Diagnostics/Troubleshooting Light Emitting Diodes Power LED (Green) The flyback power supply is monitored by this LED. Whenever power is applied to the drive, this indicator will be on. If any of the following conditions occur, the output stage will be disabled also. To clear any fault, the Inhibit input must be switched to the disabled condition to reset the fault latch. -
Page 41: Test Outputs
Diagnostics/Troubleshooting Test Outputs Intro Current Command (ICMD) This output is the command current signal to the power amplifier. The scaling of this signal is approximately ± 3.5 volts = ± 30 amps. This output should be used for trou- bleshooting purposes only. Motor Current Output (MCO) The motor current output is an analog volt- age which is proportional to the motor cur-... - Page 42 Diagnostics/Troubleshooting P/N 0013-1025-001 Rev F...
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Page 43: Hapter
Specifications HAPTER Performance Specifications ABLE ± 10% Peak Motor Current ±30.0 Amps ± 10% Maximum Continuous Motor Current ±15.0 Amps Motor Supply Voltage 30-120 VDC Minimum Load Inductance 0.5 mH Min. Current Loop Bandwidth 1000 Hz Min. Deadband Zero Electrical Specifications ABLE ±... -
Page 44: Inrush Currents
Large capacitive AC input filters cause high surge currents when power is applied to any drive. The following figures show the inrush current for the main AC power on a MAX-430 as mea- sured at the primary and secondary taps of the transformer. -
Page 45: Hapter
Component Ordering Information HAPTER Ordering PWM Servo Drive ABLE Part Number Description MAX-430 MAX-430 Serve Drive 9077-0677 Kit, Fuse, F1, F2 (F1 Littelfuse 225004) (F2 Littelfuse 225001) 0020-1354-209 Terminal Block Mating Connector, 10 position, quantity (1) (2 connectors per drive) -
Page 46: Kva Transformer, Part Number 9077-0640
Component Ordering Information Intro 0.625 kVA Transformer, Part Number 9077-0640 IGURE P/N 0013-1025-001 Rev F... -
Page 47: Kva Transformer, Part Number 9077-0639
Component Ordering Information Intro 1.8 kVA Transformer, Part Number 9077-0639 IGURE Instruction Manual... -
Page 48: Kva Transformer, Part Number 9077-0638
Component Ordering Information Intro 3.6 kVA Transformer, Part Number 9077-0638 IGURE P/N 0013-1025-001 Rev F... -
Page 49: Kva Transformer, Part Number 9077-0637
Component Ordering Information Intro 3.6 kVA Transformer, Part Number 9077-0637 IGURE Instruction Manual... - Page 50 Component Ordering Information P/N 0013-1025-001 Rev F...
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Page 51: Hapter
Reference Drawings HAPTER Listing of Drawings ABLE Drawing Number Description 9077-0674 Simplified Circuit Diagram See Figure 7.2 9077-0675 Outline, Mounting and Adjustments Diagram See Figure 7.1 Intro Outline, Mounting and Adjustments Diagram IGURE Instruction Manual... -
Page 52: Reference Drawings
Reference Drawings Intro Simplified Circuit Diagram IGURE P/N 0013-1025-001 Rev F... - Page 53 Overcurrent fault LED turns on. Motor Current Output The MCO output (P2, pin 7) on the MAX-430 is scaled so that 10 Volts equals 30 Amperes of motor current. The MAX-400 scaled 1.5 Volts at 30 Amperes. The higher Voltage results in more accurate current readings.
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Page 54: Differences From The Max-400
Differences from the MAX-400 P/N 0013-1025-001 Rev F... -
Page 55: Diagnostics/Troubleshooting
Current Command 4-5 Current Mode 1-2, 2-12, 2-17, 2-18, 3-7 Maintenance 4-2 CW Remote VCS Control 2-17 Malfunction Diagnosis 4-3 CW/CCW Remote VCS Control 2-17 MAX-400 to MAX-430 Replacement A-1 Foldback Motor Current Output Multi-Axis Power Wiring Diagnostics/Troubleshooting 4-1 Power Connector... -
Page 56: Specifications
Help-2 Index of Topics Physical Specifications 5-1 Power Wiring 2-6 2-4, 2-6 AC Power Auxiliary Power Product Support Help-5 RAC 2-1, 2-10 RAC Disable 2-1 RAC ILIMIT 2-1 Reverse Amplifier Clamp 2-1, 2-10 Safety 1-1 Servo Compensation 3-3 Setup Checklist 3-1 Sinking Opto’s 2-1, 2-2, 2-11, 2-12 Sourcing Opto's 2-1, 2-2, 2-11 Spare Parts 6-1... - Page 57 Documentation Improvement Form HelpDocumentation Improvement Form Mail or Fax: Rockwell Automation - Electro-Craft Technical Writing Applications Group Internal Use: 6950 Washington Avenue South Eden Prairie, MN 55344 DIF #______________ Fax: 612-942-3636 Manual Number: _______________________ Page Number:__________________________ Comments: Please give page numbers and specific paragraphs that the change will affect. Include markups from the document or attach additional pages if necessary.
- Page 58 Help-4 Documentation Improvement Form First Fold Second Fold P/N 0013-1025-001 Rev F Tape...
- Page 59 [44] 1270-580142, or via fax at [44] 1270-580141. Bulletin Board Service (BBS) If you have a modem, you can reach the Electro-Craft BBS 24 hours a day, 7 days a week at 1-612-942-3618. The following services are available through the BBS: Example application programs.
- Page 60 Rockwell Automation/Electro-Craft MAX-430 6950 Washington Avenue South PWM Servo Drive Eden Prairie, MN 55344 3600 – main Instruction Manual 3636 – fax 3983 – technical support P/N 0013-1025-001 Rev F...
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