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MAXPLUS 231 OPTION SPINDLE AMPLIFIER

By Cheryl Lane,2014-11-26 16:57
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MAXPLUS 231 OPTION SPINDLE AMPLIFIER

    MAXPLUS 231 OPTION SPINDLE AMPLIFIER

    Application

    This manual is designed to help you install the MaxPlus? 231 Option Spindle 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 two years from the original shipment by MTS Automation.

    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:

    MTS Automation Customer Service

    (507) 354-1616

    (800) 967-1785

    MondayFriday, 8:004:30 Central Time

     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.

    Continued on next page

    1

    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. Next day shipment for overnight delivery, freight collect, is available at an

    expediting charge of $100. The defective unit is to be returned via regular UPS, freight prepaid,

    upon your receipt of the replacement.

Non-Warranty Service

     Return your defective unit, freight prepaid, and it will be repaired on a time and material basis and

    returned within three weeks of receipt.

     OR contact your local distributor or MTS Automation Customer Service for a factory-repaired

    exchange unit, which is available at a flat rate price, assuming the defective unit is in repairable

    condition and is returned freight prepaid. Next day shipment for overnight delivery, freight collect,

    is available at an expediting charge of $100.

General Provisions

    Except as specifically modified by this warranty statement, all MTS Automation Conditions of

    Sale and Warranty shall apply.

    2

    Introduction

    The 231 Spindle Amplifier was designed to be used with the MPM1094R-1092 spindle motor.

    This motor is wound in a WYE configuration with four windings in each leg of the WYE that

    are connected with a system of relay switches mounted on the side of the motor that change

    the motor KE and KT. This allows up to 20 horsepower in four speed ranges, eliminating the

    need for any complex mechanical gear reductions.

    The TAC output of the amplifier is scaled to the speed ranges as follows:

    Low Speed 1 690 rpm TAC output = .69 volts

    Med Low Speed 2 1630 rpm TAC output = 1.63 volts

    Med High Speed 3 3300 rpm TAC output = 3.3 volts

    High Speed 4 6600 rpm TAC output = 6.6 volts

    The amplifier features overcurrent sensing which will cause the amplifier to shut down and

    produce an overcurrent fault if the continuous current rating of the amplifier is exceeded by

    20%.

    The amplifier also has an I/O selectable orient feature which causes the motor shaft to rotate

    at a fixed 1 rev per sec rate in a CCW direction viewed from the shaft end of the motor.

    Ramping of the command input signal for a time period that is user selectable using DIP

    switches from 2 to 10 seconds, can be enabled and disabled through the I/O connector.

    An analog dc voltage output that is proportioned to the output current.

    The CONT (continuous) horsepower is available continuously. The INT (intermittent)

    horsepower is available for 3-5 minutes. Operation above the CONT rating will result in a

    motor thermal fault condition. The ratings indicated are for motors applied with fan cooling. If

    the fan is not used, the ratings have to be deteriorated by 20%.

    Spindle Sizes Available

CONT INT Required Amplifier Input Required

    Amplifier Voltage Motor

    13 24 MPA-75-SPN 230 Vac MPM1904R-1092

    * This combination of amplifier and motor require the insertion of external inductors in the RST leads of the motors. These inductors deteriorate high speed torque. On the high speed winding, horsepower

    ratings are typically 1/2.

    There are other 230 Vac amplifiers and motors, but they must be configured as factory

    specials.

    3

Specifications

    Parameter Specification Operating Environment:

     Temperature 0 to 45?C (32 to 113?F) Maximum, Ambient

     Humidity 0 to 95% noncondensing Input/Output Interface: Analog Signals

     Velocity Command Input Differential input 0 to ?10 Vdc(15 Vdc Max)

     Velocity Output 1 volt per 1000 rpm

     Current Output 10 volts = Rated Current 24 Volt Logic: Enable

    Speed

    Shift

    Ramps

    Orient

    Slow Output (open collector)

    Fault Output (open collector)

    Note: +30 volts open circuit; .15 amps max when ON

    Fault Protection: Shorts (Stator)

    Amplifier Temperature

    Feedback Resolver Tracking

    Motor Thermal

    HI-BUS

    Encoder Simulation: TTL Differential Output Plus Index

    Phase Quadrature

    Line Count - 1024 Adjustments:

     0 to Rated Current Limit (CL)

    Response (RESP)

    Auxiliary (AUX)

    Signal (SIG)

    Balance (BAL) Speed/Torque Regulation ?5%

    Max Speed 6600 rpm Encoder Signals:

     Resolution 1024 lines

     Accuracy:

     Resolver Cable Length: Max. Error:

     15 foot ?20 minutes

     25 foot ?20 minutes

     50 foot ?30 minutes

     100 foot ?40 minutes

    Motor Inductance:

    .5 mh inductors must be installed in each of the R, S, and T

    phases of the motor. The following inductor is available for

    this application:

     IND-100-.5MH

4

    MPA-80-231-SPINDLE Mechanical Footprint

    NOTE.31.5 RECOMMENDED

    SIDE VIEWFRONT VIEW

    14.613.6

    B1.0"

    DCA

    Summary of Amplifier Dimensions

    MODEL A in. B in. C in. D in. MPA-80-231 8.5 6.5 1.3 10.63

     If front cover is attached, additional

    clearance of .2 should be allowed.

    5

    Signal/Wiring Overview

    POWER

    FEEDBACK

    SHLD

    SHLD

    GND

    TS

    GNDSIN

    GND

    COS

    GND

    REF

    LIMITRESETHI-BUSMOTORFEEDBACKAMPLIFIERSHORTSCONTINUOUSCURRENT

    MARKENCODER

    I/OGND

    ORIENTBALRAMPS

    GNDCUR-COM

    +COM

    RESPCUR

    TAC

    GNDSIGFLTSHFTAUXSLOW

    SPD

    ENB

    RESET

    6

    Feedback Wiring

    MOTOR PC CARD

    MOTORFEEDBACK100% SHIELDEDJ1SHLDREFSHLDRREF GNDEGNDCOSWINDING THERMOSTATSCOS GNDTSOSINGNDLSINSIN GNDVSINTHERMEREFERENCE FREQUENCYGNDTHERMRCOS 2KHZ 20-25 VP-PCOSSHIELDSIN/COS 0-5V MAX RMSGNDREFREFJ2120 VACL1LIMITSRESETL2PHI-BUSELOW SPD 1MOTOREFEEDBACKSPD 2DAMPLIFIERSSPD 3SHORTSECONTINUOUSHIGH SPD 4LCURRENTMARK

     100% shielded cable is foil and braid.

    The pairs do not have to be twisted. The

    resolver wiring should not be run adjacent

    to any non-shielded high voltage wires,

    such as the motor wires (RST). If the

    wiring cannot be separated, the RST

    motor leads should also be 100% shielded.

    It is highly recommended that factory

    cable sets or wiring be provided.

    Thermostat

If the motor is equipped with a winding thermostat that is normally closed, it can be

    connected between terminals 7 and 8 of the feedback wiring connector. If an excess

    temperature thermal condition exists as indicated by an open thermostat, amplifier current is

    disabled.

     The resolver mating connector is in the

    box on the motor.

    7

    Diagnostic Indicators

LED INDICATION

    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-This is a bi-colored LED that produces either red or COLOR) green as a function of load. The intensity increases

     with load. Red indicates positive torque and green

    indicates negative torque.

    There are seven faults that will reduce amplifier current to zero.

LED INDICATION

    STATOR SHORTS If shorts in the stator wiring occur, this comes ON.

    AMPLIFIER An 85?C thermostat is mounted to the amplifiers IGBT THERMAL heat sink and shunt load. If an excess temperature is

    sensed, this fault occurs.

    FEEDBACK WIRING For most resolver wiring errors, defective resolvers or

    tracking rate errors caused by the resolver, this fault

    occurs.

    MOTOR THERMAL If an excess thermal condition exists in the motor, this

    fault occurs.

HI-BUS If excess DC voltage or a failure of the shunt circuit

    occurs, this fault occurs.

    RESET During the first second of power up or if the reset input

    is active, this LED will be ON.

LIMIT This LED is ON if the motor is running.

LED INDICATION

    POWER(GREEN) If logic +5 Vdc is ON then this LED is ON.

    8

    Simulated Encoder Signals

    For external counting or position control, a 9-pin D type female connector that has TTL differential 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)

    ENCODERSIMULATION CONNECTOR

    P11A\6EXTERNAL CONTROLLERA2SIGNALS AND GNDB7B\3M8M\4GND95

    COMMENTS:

    1) THE AMPLIFIER OUTPUTS ARE RS422 DIFFERENTIAL LINE DRIVER COMPATIBLE

    2) THEY SHOULD BE CONNECTED TO COMPATIBLE DIFFERENTIAL RECEIVERS

    3) THE BEST SHIELDING APPROACH WOULD BE TO CONNECT THE SHIELD AT THE AMPLIFIER END ONLY

    4) ALL SIX WIRES AND A GND CONNECTION SHOULD BE CONNECTED AT THE CONTROLLER END

    The phase relationship of channels A, B and M are as follows for CW rotation:

     PINSIG

    1A\

    6A

    2B

    7B\

    3M

    8M\

    The marker pulse is about .5 degrees in width. The above illustration is for 1024 line condition.

    The above signals are TTL differential outputs from a DS26LS31 differential driver. The logic 0 is typically between 0 and .5 volts and logic 1's are typically between 3.3 and 4 volts.

    9

    I/O Wiring and Descriptions

    The amplifier has five inputs and two outputs. These inputs and outputs are designed to interface to a 24 volt logic system. The amplifier is shipped so that the operation of the inputs is as follows.

    With no wires connected to ENB, SPD, or SHFT, the amplifier is not enabled and normal operation will not occur. The inputs are activated by connecting them with a switch closure to any of the provided GND terminals.

    I/O WIRINGENCODERJ1 EXAMPLEREFRREF GNDI/OECOSSCOS GNDGNDOSINLORIENTSIN GNDBALVRAMPSTHERMEGNDTHERMRSHIELDCUR-COM120 VAC+COM

    CURRESPJ2120 VACTACL1SIGGNDL2FLTLOW SPD 1AUXSHFTSPD 2SLOWSPD 3SPDHIGH SPD 4ENB

    RESET

    *NOTE: CLOSE ONE SWITCH AT A TIME

    The actual decision as to open or closed switches occurs at a voltage level between 5-8 volts DC. Less than 5 volts is active; greater than 8 volts is inactive.

    The Enable (ENB) Input must be ON (grounded) to allow the amplifier to be enabled.

    The Shift (SHFT) and Speed (SPD) Inputs are used in conjunction with switches or relays that are connected to the winding select connector on the motor to select the four available speed-torque ranges of the motor:

    Amplifier Inputs Motor Inputs

     SHFT SPD

    LOW 1 690 rpm GND GND Connect L1 to LOW SPD 1

    2 1630 rpm GND OPEN Connect L1 to SPD 2

    3 3300 rpm OPEN OPEN Connect L1 to SPD 3

    HI 4 6600 rpm OPEN OPEN Connect L1 to HI SPD 4

    A 10 volt command signal will produce the above speeds. The 3 speed is produced with a 5 volt command.

    10

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