ELEC TRO-CRAFT* MAX-430 PWM Servo Drive Installation Manual Reliance Matin Control / 6950 Washington Avenue South / Eden Praiie, MN 55344 / 612-842-2600 Vv MOTION CONTROL gm RELIANGE ELECTRIC. 0013-1025-001 RevBContents Introduction u How to Use This Manual ....1...un Reliance Motion Control Product Support. ‘Network of Distributors & Representatives... Application Specialists and Field Service Engineers ‘Support in Europe Bulletin Board Service (BES) Introduction to The MAX-430.... Functional Description ........ 6 Installation 4 Installation. Internal Adjustments.. Jumpers, ‘Mounting, ‘Transformer Sizing AC and DC Power Connections. ee Auxiliary Logic Supply Power... : a 2 Connecting The Motor. eee Logic Inputs and Outputs... : a B Connecting Inputs. ee wld ‘Velocity Command od Sigal (ves) a 4 Aumdliary Input... ae ad Inhibit (NED... 4 Forward and Reverse Amplifier Clamps (FAC, RAC)... 4 Internal Connections (FAC, RAC and INH) «1. See 5) Velocity Clamp (Torque Mode) 0.1mm Sg ‘External Current Limit (Optional)... renee IT Connecting Outputs. a System Status Output (SSO) —— a Motor Current Output (MICO 0-10V), ae 18 ‘Motor Current Output (MCO #10V) . sn 8 ‘Motor Velocity Output (MVO) 7 ats 15 VDC Power Output. a 19 ‘MAX-430 Instruction Manualii____ Contents “Typical Wiring Examples Applying Power for the First Time Setup Checklist. ‘Start-up Procedure with tach (velocity mode). ‘Start-up Procedure without tach (torque mode) Internal Current Limit (ILIM) Balance Control (BAL) ‘Servo Compensation (COMP) Tach Gain (TACH) VCS Gain (VCS), VCS Signal and Scaling (VCS)... CS Signal Input VCS Gain Setting VCS Signal Scaling, Torque Mode Operation Diagnostics/Troubleshooting Monitoring Output .....n0nnnnnn Motor Current Output (MCO 0-10V).. Motor Current Output (MCO #10Y).. Motor Velocity Output (MVO) . Scheduled Maintenance. ....nmnn (Checking and Replacing the Fuses .. Malfunction Diagnosis. Light Emitting Diodes. Test Outputs a ‘Current Command (ICMD) . Motor Current Output (MO)... ‘Motor Velocity Output (VIVO). Specifications Performance Specifications. Electrical Specifications. Input Power Requirements, Physical Specifications. Component Ordering Information PWM Servo Drive ‘Transformers. Reference Drawings Listing of Drawings. Index ‘MAX-430 Instruction Manual ~ pt ttt wma ae neAOOdadgggeTte°o Po Poe. Poe. Po, 9 8.1 ny aed | J as = . — | _ = . {5} o-current |) ‘cOMON ear |) Soru-vereccay 0 gees | ee ne a” ee a - BS Be eur avr au pene tee? rect Gear ai eo Fe eS vewaciry cue p16 co eee eer oe as ee mre Sf — io. he teen _ .— om ee ees So Se aeons | eee 5 a 2 i) elieg ————| et I HT as er oe Kons ail - ete ron Pictorial Index ‘MAX-430 Instruction ManualIntroduction 4 Introduction How to Use This Manual ‘This manual describes the function, theory and application of the Electro-Craft MAX-430 servo ) Gives and provides information related to their performance, operation and maintenance, This ‘manual is addressed to the customer engineer or technician involved in the installation or ‘maintenance of the 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. Reliance Motion Control Product Support Reliance Motion Control product support is available over the phone. When you call, you should. have the MAY-430 Installation Manual at hand. Be prepared to give information on how you have tried to solve the problem. Network of Distributors & Representatives ‘Reliance Motion Control has a wide network of distributors that are trained to support our Products. If you encounter problems please call the distributor or representative where you ‘purchased the product before contacting the factory. Application Specialists and Field Service Engineers In the United States you can reach the Reliance Motion Control factory based support staff by ‘phone between 8:00 AM and 5:00 PM (CST) Monday through Friday at 1-800-328-3983. The application specialists can assist you with troubleshooting problems as well as ideas for how to approach your application. Should your problem require on-site assistance, there are field service engineers available that can assist you. eo The appliation specials cn sls reached via fx at 1-612-942-3636, The fox machine is open Zt hous? aps aeck Fons wl te answered ding rear uses hus ony ‘MAX-430 Instruction Manual2 Introduction » Safety ‘Support in Europe In Europe, support for the MAX-430 can be obtained through Reliance Electric, Electro-Craft Limited. The support staff may be reached by telephone between 8:30 and 17:30 local time, ‘Monday throught Friday at [44] 270-580142, or via fax at [44] 270-580141 Bulletin Board Service (BBS) Ifyou have a modem, technical bulletins are available through the BBS. You can reach the Reliance Motion Control BBS 24 hours a day, 7 days a week at 1-612-942-3618, Safety It is necessary to wait at least 60 seconds before working on the drive when main power has been. turned off and auxiliary power is not being supplied to the drive. When there is 24 volts being supplied to the auxiliary power input, main power will dissipate immediately on power down. However, if there is no power being supplied to the auxiliary power input, main power must dissipate through a resistor, and it will take at least 60 seconds before the voltage is at a safe level, Introduction to The MAX-430 ‘The “System Functional Diagram” of the Electro-Craft MAX-430 drive is shown on the following page. MAX-430 series drives are designed to drive permanent magnet, brushtype, DC servo motors. The drives and motors are intended for use in a broad range of industrial servo applications, including machine tool and robotic applications, and are used in torque, velocity and position type servo systems. Each drive is a self-contained unit, ready for mechanical installation and electrical interconnections to the AC power transformer, motor-tachometer, and controller. ‘MAX-430 Instruction ManualIntroduction 3. v Functional Description ‘The Electro-Craft MAX-430 is a controllable power source for brushtype, DC servo motors. ‘Usually configured as a controlled velocity system, the drive interfaces with a controller which provides an analog voltage signal proportional to the desired motor velocity. The MAX-430 drive can also operate in torque mode (or current mode), such that a controller provides an analog voltage signal proportional to the desired motor torque. Refer to the “System Functional Diagram” shown below. The MAX~430 drive contains circuitry for protection of both motor and. drive from effects of various overlodd and short circuit conditions. 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. 3s pase 30-120 voc ms 7 sept $i rer a | ey, | ns wat —{_—_— o = _ e) _ ——— A> seta) ee sas sae) 0 verter BPRS ee Ay sso) System status gurst Fup 6 REV CLAWS i a BIT CLA Pein u Live cm -¢ i rom ae | =e) cn Fak ‘System Functional Diagram (MAX-430 Instruction Manual4____ Installation + installation Installation Installation All wiring and mechanical instructions described in this section should be made with reference to the “Simplified Circuit Diagram” and the “Outline, Mounting and Adjustments Diagram” on pages 45 and 46. Also see “Input Power/Motor Wiring” diagrams starting on page 8. 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 andthe System Status Output (FAC, RAC, and $80). There are also jumpers usd to indicate desired operation of the optically isolated transistors on FAC, RAC and inhibit INH) inputs, Refer tothe chart below for operation ofthe {inputs and outputs with jumpers P6 through P9A inthe different positions, Also see “Internal Connections” on page 15. Jumper | Position Operation Page 6 | FACILIMIT | Current reduced to 5% of peak current in the 4 forward direction when FAC is clamped. ‘*FAC | No torque in the forward direction when FAC is [14 DISABLE _| clamped. ‘Table continued on next page. MAX-430 Instruction Manual | ARMA AAAHAARAARORAREHHEHOECEEECESFPAGIRIBDITIIL GO LT,Installation ‘Table continued from previous page. Jumper | Position Operation Page P7 RAC ILIMIT | Current reduced to 5% of peak current in the 14 reverse direction when RAC is clamped. “RAC | Notorquein the reverse direction when RACis | 14 DISABLE _| clamped. PB “Internal | Optically isolated transistors (opto's) on FAC, 15 Opto Power | RAC and INH inputs are powered internally by the drive External Opto | Customer supplies power (24V) to opto’s on 15 Power FAC, RAC and INHibit inputs. PBA “Source | Opto’s are sourcing inputs (pulled up to 24V 15 Opto’s _| when true). ‘Sinking | Opto’s are sinking inputs (pulled down to OV 15 Opto’s_| when tru) P9&P9A | SSORelay | System Status Output is controlled by a relay 17 "SSO Open | System Status Output is controled by an open 7 Collector | Collector transistor * Indicates Factory Settings ‘nde Factory Setngs Jumper Locations P bb 5 ‘MAX-430 Instruction Manual6 ___ Installation + Mounting Mounting ‘The drive must be mounted in the vertical position (heat sink fins must be vertical) away from other heat producing devices. In multiple axis applications, a minimum of 1 inch separation between each chassis is recommended. See “Outline, Mounting and Adjustments Diagram” on page 45. Transformer Sizing ‘The MAX-430 requires an isolation/step-down transformer. To size a transformer for a MAX- 430 the power output (KVA) of each axis must be known. This can be derived by calculating the horsepower for each axis. ‘Transformer single phase KVA rating = (Sum of each motors average output power) x 2.0 Speed xTorque 746 Watts, KVA KVA = > Xx 2. 63,025 HP” 1,000 Watts Speed is in units of RPM Torque is in units of Ib-in Note - The factor of 2.0 is used as an estimate of drive module and motor losses. If you are using the Electro-Craft system sizing program (Systex), the average speed and average torque data has already been calculated and can be used in the above equation. 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 combination as shown in the Electro-Craft catalog and use the values for the worst case continuous speed and torque. 2000 RPM x 7 Ib 746Watts, KVA 63,025 HP 1,000 Watts KVA 20 ‘Transformer size = 0.331 KVA ‘MAX-430 Instruction Manual nmeeanaannnacanananeecescQqceoeceoesesreaaaag2ee70FInstallation 7 ‘Select a transformer that can provide enough voltage for the application. This can be determined WV ‘by looking at the maximum speed of the application and the voltage constant (Kz) of the motor selected. (=) (ier Wing Rem Pak Caren) 15= DCs vo Ke = Volts/krpm Max. Speed = rpm ‘Motor Winding Resistance = Peak Current = Amps 1.5 = 50% safety and losses v2 ‘Tapped voltage from transormer 2 ‘MAX-430 Instruction Manual8 Installation « AC and DC Power Connections AC and DC Power Connections AC input power to the MAX-430 must be supplied by an isolation transformer with an outpat of 20-85 VAC. Refer to “Transformer Sizing” on page 6. Alternatively the MAX-430 may be ‘supplied with 30-120 VDC. ‘The grounding connection for AC and DC power, chassis and motor must be connected as shown in the following wiring diagrams. ‘Note= ‘All TBI terminals must be tightened to 9 Tb-in. 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Gub in 8 Dv SINGLE anTS aPPLICATIONS As 1e gunn st a cowectea 10 TEI-8 OP CHASSIS: GROUND AS SOHN OTR AC TO at Di tonelaey fad isicd Pate SMIELOED CARE BC USED +80-120) VDC Input Power/Motor Wiring ‘MAX-430 Instruction Manualinstallation * AC and DC Power Connections: ia | | | Ay f 20-85 VAC 4 20-88 a ‘Multiple Axis Power Wiring (Individual Secondaries) ‘MAX-430 instruction Manual (Recommended Method) 12-14 ANG WIRING | KEEP THE LEADS As SHORT AS POSSIBLE nD AXcuass v ruse 200