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
Monday–Friday, 8:00–4:30 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
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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.
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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.
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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
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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.
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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
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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.
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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.
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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.
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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.
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