Axor MAGNUM 400 User manual

AXOR Industries Service Manual Magnum400TM ver.2 rel.05/'15
1

AXOR Industries Service Manual Magnum400TM ver.2 rel.05/'15
2
All rights reserved. Reproduction in whole or in part is prohibited without prior
written consent of the copyright owner. All specications are subject to change
without prior notication.
This manual has been carefully checked. However, Axor does not assume liability
for errors or inaccuracies.
THIS MANUAL CONTAINS A DESCRIPTION OF MAGNUM400TM
AND A GUIDELINES FOR THE DRIVE'S INSTALLATION;
FOR MORE DETAILS SEE ENCLOSURES ON THE CD PROVIDED WITH THE DRIVE.
USING THE DRIVE INCORRECTLY CAN INJURE PEOPLE OR DAMAGE THINGS.
FULLY RESPECT THE TECHNICAL DATA AND INDICATIONS ON CONNECTION
CONDITIONS.
Release Notes
ver.1 rel.12/'05
New paging.
Insert: Positioning and Homing Procedures.
Corrections.
ver.1 rel.09/'06
New paging.
Update chapters: "General Advices", "Installation", "Interfaces", "Di-
agnostic", "Appendix".
Insert chapter: "7: Applications".
Insert Index.
Corrections.
ver.1 rel.03/'07
Update chapter: "5: Diagnostic".
New chapter reserved to Positioner and Homing procedure.
Update chapter "7: Applications": Reset Fault Function, Emergency
Function, Stop Functions.
Corrections.
ver.2 rel.09/'07 Manual reorganisation: rst base version.
ver.2 rel.02/'08
Regen resistance dimensions insertion.
Min/max dc bus voltege values insertion.
Brake circuit set point insertion.
Corrections.
ver.2 rel.12/'08
Corrections.
Figure pag.31 corrected.
Figure and note pag.39 corrected.
Note pag.40 corrected.
RS485 connection inserted.
ver.2 rel.01/'10 Note about regen resistance inserted.
ver.2 rel.09/'13 Correct note about resistor on RS485 interface.
ver.2 rel.04/'15 Update chapter: "5: Diagnostic".
ver.2 rel.05/'15 Corrections.

AXOR Industries Service Manual Magnum400TM ver.2 rel.05/'15
3
Summary
1) Description
1.1 Description 6
1.2 General view Magnum400 9
1.3 Technical Data 10
1.4 Mechanical Dimension 12
1.5 Product plate and Ordering Code 13
2) Installation
2.1 General Advices 16
2.2 Positioning 19
2.3 Environmental conditions 20
2.4 Cables 21
2.5 Connection to ground and earth 22
2.6 Note about cable shielding 23
2.7 Base installation procedure 24
2.8 Example of base connection 25
2.9 Supply connections 26
2.10 Motor power connection 27
2.11 Relè OK and regen resistance connections 28
2.12 Digital inputs connection 30
2.13 Digital outputs connections 31
2.14 Analog outputs connections 32
2.15 Analog inputs connections 33
2.16 Emulated encoder outputs connection 34
2.17 Pulse/Dir inputs connections 35
2.18 Feedback signals connections 37
2.19 Multidrop connection 39
2.20 Canbus connection 40
2.21 RS485 connection 41
2.22 Magnum400TM power up 42
2.23 Motor Test 43
3) Diagnostic
3.1 Display 46
3.2 Alarms 47
Index 50
Conformity 52

AXOR Industries Service Manual Magnum400TM ver.2 rel.05/'15
4
Enclosures to the manual
On the CD provided with the drive there are the following enclosures (in pdf):
• Operative Modes Manual
• Additional Features Manual
• Speeder One Interface
• Positioner Manual
• Display and Keypad Manual
• Alarms Manual
• ModBus Manual
• CanOpen Reference Manual
• Cables Manual
• Oscilloscope Manual
• Procedures Manual (available only on request)

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AXOR Industries Service Manual Magnum400TM ver.2 rel.05/'15
Chapter 1
Description
1.1 Description 6
1.2 General view Magnum400 9
1.3 Technical Data 10
1.4 Mechanical Dimension 12
1.5 Product plate and Ordering Code 13
1) Description

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AXOR Industries Service Manual Magnum400TM ver.2 rel.05/'15
1.1 Description
OPERATIVE MODES
SPEED CONTROL It is speed piloting utilising a digital reference or an
analogue reference (differential or common mode). standard
TORQUE CONTROL
It is torque piloting utilising a digital reference or an
analogue reference. This function allows you to control the
current from the drive.
standard
POSITION CONTROL
The positioner can be managed via hardware (by using the
digital inputs) or via RS232 (by using the Axor's Speeder
One interface or another ModBus Master). It supports 32
programmable position proles; a single task or a sequence
of tasks are permitted.
The Homing Procedure is implemented. It uses the signal
coming from the homing sensor and eventually the zero
signal of the encoder.
standard
ELECTRICAL AXIS
(GEARING)
It is possible to pilot the drive with the quadrature signals
of an emulated encoder from a Master drive or with the
quadrature signals of an incremental encoder from a Master
motor (Electrical Axis or Gearing).
standard
PULSE/DIRECTION
It is possible to connect the drive to a stepper-motor
controller, piloting it with the +/-Pulse and +/-Dir signals
(Pulse/Dir Mode).
standard
MULTIDROP RS232
It can work in Multidrop, where the rst drive, connected
via RS232 to the Master PC, is piloted with ModBus
communication, while the other drives are piloted with the
duplication of commands using the CanBus interface.
optional
RS485 INTERFACE It is possible to communicate with two or more drives by
using the RS485 interface. optional
CANBUS
It can be congured and controlled using CanBus. It
supports the following Can Open protocols:
• part of the DS301-V4.02
• part of the DSP402-V2.0
optional
Notes:
• The current controller is vectorial with sampling time of 62,5µs.
The velocity and position loop both work with sampling time of 250µs.
• The current commutation is sinusoidal.
FEEDBACK
ENCODER incremental encoder signals + hall signals standard
RESOLVER 2, 4, 6, 8 pole optional
The Magnum400TM is a digital drive capable of piloting both rotary AC brushless motors and linear
motors, up to 30Nm. It can be supplied by a 3-phase voltage equal to 400 or 480Vac.

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AXOR Industries Service Manual Magnum400TM ver.2 rel.05/'15
1.1 Description
DIGITAL INPUTS/OUTPUTS
9 DIGITAL INPUTS
They are programmable for: the limit switch, the holding
brake, the homing and positioning procedures, the emer-
gency stop, the reset alarm, etc.
standard
2 programmable
DIGITAL OUTPUTS
They can be used to send messages from pre-programmed
functions of the drive. standard
EMULATED ENCODER
OUTPUTS
There are 6 pins dedicated to emulated encoder with
different programmed ratios (1/2, 1/4, 1/8, 1/16, 1/32,
1/64, 1/128) between output pulse/rev and encoder/
resolver ones.
standard
ANALOG INPUTS/OUTPUTS
1 ANALOG
COMMON MODE
INPUT (TPRC)
It is used for controlling the current from the drive. standard
1 ANALOG
DIFFERENTIAL or
COMMON MODE
INPUTS (+/-Vref)
It is used for piloting the drive with an analogue speed
reference from an external controller.
standard
2 programmable
ANALOG OUTPUTS
They allow you to visualise by the oscilloscope some of the
drive’s measurement values (for example: the velocity, the
Iq current, etc.).
standard
GENERAL FEATURES
KEYPAD Four buttons (UP-DW-MODE-SET) allow the manual
insertion of data without using a PC. standard
DISPLAY A display with 5 characters visualises: the inserted
values, the drive’s status, the alarms. standard
SPEEDER ONE
SOFTWARE
INTERFACE
It allows you to set and manage all drive’s parameters by
using a PC connected to the drive.
The communication between the drive and PC is done by a
RS232 cable using the ModBUS protocol.
The software works on the following operating systems:
Windows 98, Windows 2000, Windows XP.
standard

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AXOR Industries Service Manual Magnum400TM ver.2 rel.05/'15
1.1 Description
HOLDING BRAKE
The drive has circuitry that allows the control of the elec-
tromechanical brake integrated in the motor, which can
be used with motor not running, for blocking the motor's
axis.
The drive supplies the brake with +24Vdc. It can be exter-
nally managed by the user or automatically by the drive.
optional
EMI
FILTER
The drive is equipped with an integrated EMI anti-distur-
bance lter at the 3-phase power supply input and with
another EMI anti-disturbance lter at the auxiliary +24V
power supply input.
standard
REGEN CIRCUIT standard
EXPANSION CARDS There is a slot for expansion card to implement additional
features. optional
SAFETY
SAFETY
The converter is protected from short circuitry, the Max/Min
Voltage, the drive I2t , the Motor I2t , etc.
When there is an alarm the "Relè OK" contact opens and the
motor is stopped, or a message is visualised on the display
without compromising the system's functioning.
standard
BLACK-OUT
DYNAMIC BRAKE
FUNCTION
It stops the motor when there is a black-out. optional
EQUIPMENT
a drive serie Magnum400TM
standard
terminals: M1, M2, M3, M4, M5
Service Manual
a CD-ROM with Speeder One software interface and all enclosures to service
manual
Motor inductance, 3x1.2mH, for cables over 20/25 meters in length
optional
an external braking resistor (500W or 1000W)
CBLS cable for motor feedback signal, encoder/resolver (meter multiple)
CBLS power cable for motors series SuperSAX;
motors series SuperSAX
All optional features have to be requested by using the proper ordering code (see "1.5 Product plate
and Ordering code").

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AXOR Industries Service Manual Magnum400TM ver.2 rel.05/'15
1.2 General view Magnum400
Display and KeyPad
(J1 Connector)
Encoder or Resolver
signals
(M5 Connector)
Motor, brake and
braking circuit
connections
(M3 Connector)
Auxiliary power
supply +24Vdc
(M4 Connector)
Main supply
(J5 Connector)
RS232 comunication
(M2 Connector)
Analog and Digital
Inputs/Outputs
(J3-J4 Connectors)
Can BUS or
RS485 comunication
(M1 Connector)
Encoder emulation,
Pulse/Dir signals

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AXOR Industries Service Manual Magnum400TM ver.2 rel.05/'15
1.3 Technical Data
Nominal Data
Nominal Voltage Vac Three phase: 3x480Vac +10% max, 3x400Vac -10%, 50/60Hz
(Single phase permetted for setup only)
Min/Max dc bus
voltage Vdc 400Vac 480Vac
400Vdc min ÷ 800Vdc max 500Vdc min ÷ 870Vdc max
Auxiliary power
supply
(for back up)
Vdc +24Vdc (0%, +15%) - 1Adc (3Adc with brake)
Size 1,5/3 3,5/7 7/14 10/20 14/28 20/40
Nominal Current Arms 1,5 3,5 7 10 14 20
Peak current for
5 sec. Arms 3 7 14 20 28 40
Dissipation at
nominal current W 30 42 56 88 165 195
Dissipation with
output stage
disabled
W 20
PWM output
frequency kHz 8
Control signals
Optoisolated digital inputs +24Vdc - 7mA (PLC compatible)
Optoisolated digital outputs +24Vdc - 50mA (PLC compatible)
Analog programmable outputs ±10V (±5%)
A common mode analog input (TPRC) ±10V max, 10kOhm input resistance
A differential or common analog input
(+/-Vref) ±10V max, 40kOhm input resistance
Pulse/Dir digital inputs +5V, optoisolated, max. frequency 250kHz
Emulated encoder outputs VOH=2.5V min - IOH=-20mA
VOL=0.5V max - IOL=20mA
Braking Resistance
Internal Resistance 200W - 66Ohm size: 1.5/3, 3.5/7, 7/14
200W - 33Ohm size: 10/20, 14/28, 20/40.
External Resistance
500W - 66Ohm size: 1.5/3, 3.5/7, 7/14.
500W - 33Ohm size: 10/20, 14/28, 20/40.
1000W - 33Ohm +33Ohm 500W size: 1.5/3, 3.5/7, 7/14.
1000W - 66Ohm // 66Ohm 500W size: 10/20, 14/28, 20/40.
Set point values 400Vac 480Vac
695Vdc min ÷ 735Vdc max 815Vdc min ÷ 845Vdc max

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AXOR Industries Service Manual Magnum400TM ver.2 rel.05/'15
Motor encoder inputs
Encoder supply +5V @ 220mA (±5%)
Differential encoder inputs
line receiver AM26LS33
Differential hall signal inputs
line receiver AM26LS33
Encoder max. frequency 250kHz
External Protections (fuses or similar)
Size 1,5/3 and 3,5/7 7/14 and 10/20 14/28 and 20/40
Power supply (F2)6A T(Time Lag) 10A T 20A T
Auxiliary power
supply (F3)6A T
External braking
resistor (F4)4A F(Fast) 6A F 6A F
1.3 Technical Data

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AXOR Industries Service Manual Magnum400TM ver.2 rel.05/'15
1.4 Mechanical Dimension
Dimension in: [mm]
UP
MODE DWN SET
AA
B
B
73,5
270
247
284
223
33
UP
MODE DWN SET
NOTE:
The M1 and M2 connectors are located
under the plastic cover.
To open it, push the cover on the
borders (see A), move it down and
remove it (see B).
Mechanical specications
External dimensions mm 284 x 223 x 73,5
Size 1,5/3 3,5/7 7/14 10/20 14/28 20/40
Weight Kg 4,2 4,6

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AXOR Industries Service Manual Magnum400TM ver.2 rel.05/'15
1.5 Product plate and Ordering Code
On the side of each Magnum400TM there is a product plate like the following:
To order a digital drive serie Magnum400TM refer to this ordering code:
Nominal and peak
output current (in
Ampere RMS)
Power
supply
Protection
rating
Environmental
temperature
range
"Cod" is an internal production
code. Use this number for any
enquires.
The "Part. No" gives others descrip-
tive codes about the drive and the
settings.
TYPE: MAGNUM-400-7/14-RX-S-D-1000-EC-EC-RD
ADJ: 7/14A 3000 Rpm Enc
Data 20/09/2004 Ord: 0981/2004 Cod. 93759999
M400 - 20/40 - RXX - S - RO - 0 0 0 0 0 X - 00 - Sxxx
Dumping size:
RXX = Internal standard resistor
R5 = 500W external resisor (opt)
66Ω(for 1.5/3 to 7/14)
33Ω(for 10/20 to 20/40)
R10 = 1000W external resistor (opt)
33Ω + 33Ω da 500W (for 1.5/3 to 7/14)
66Ω // 66Ω da 500W (for 10/20 to 20/40)
Size: 1.5/3, 3.5/7, 7/14, 14/28, 20/40
Drive Model
Protection:
S= Standard
T = Tropicalized
Feedback:
RO = Resolver
EC = Commutation encoder
ER = Encoder or Resolver (both)
Expansion cards:
00 = Not present (std)
Additional features:
0 0 0 0 0 X
CBMD: CanBus + Multidrop Interface
1= Present (opt)
0= Not Present (std)
Not in use
Not in use
RXDB: Black Out Dynamic Brake
1= Present (opt)
0= Not Present (std)
R485: RS485 Interface
1= Present (opt)
0= Not Present (std)
Specic number presence (opt):
S xxx
001÷999=specic number
HBD: Holding Brake Drive
1= Present (opt)
0= Not Present (std)

14
AXOR Industries Service Manual Magnum400TM ver.2 rel.05/'15

15
AXOR Industries Service Manual Magnum400TM ver.2 rel.05/'15
Chapter 2
Installation
2) Installation
2.1 General Advices 16
2.2 Positioning 19
2.3 Environmental conditions 20
2.4 Cables 21
2.5 Connection to ground and earth 22
2.6 Note about cable shielding 23
2.7 Base installation procedure 24
2.8 Example of base connection 25
2.9 Supply connections 26
2.10 Motor power connection 27
2.11 Relè OK and regen resistance connections 28
2.12 Digital inputs connection 30
2.13 Digital outputs connections 31
2.14 Analog outputs connections 32
2.15 Analog inputs connections 33
2.16 Emulated encoder outputs connection 34
2.17 Pulse/Dir inputs connections 35
2.18 Feedback signals connections 37
2.19 Multidrop connection 39
2.20 Canbus connection 40
2.21 RS485 connection 41
2.22 Magnum400TM power up 42
2.23 Motor Test 43

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AXOR Industries Service Manual Magnum400TM ver.2 rel.05/'15
2.1 General Advices
During the transport of the drive respect the following indications:
• the transport must be made by qualied personnel;
• avoid shocks;
• the temperature range must be between -25°C and +55°C;
• the max. humidity must be 95% (without condensation);
• The converters contains elements which are sensitive to electrostatic discharges. These elements
can be damaged by careless manipulation.
Discharge static electricity from your body before touching the converter.
Avoid contact with material that insulates well (synthetic bres, lms of plastic material and so
forth).
• we suggest to check the motor condition at its arrival to survey eventual damages.
Transport
The unused drives must be storage in an environment having the following characteristics:
• temperature from -25°C to +55°C;
• max. relative humidity 95% (without condensation);
• max. time with the drive powered off (without supply connections):
drive having a power supply ≥ 220VAC 1 year
drive having a power supply ≤ 145VAC (200VDC) 2 years
After this time, before enable the drive, it is necessary activate the capacitors following this procedure:
remove all electrical connections, then supply the input terminals of the supply with the main voltage
(three phase or single phase) for 30 minutes.
In details:
- for the drive having a power supply equal to 380VAC: power it by using a single phase (or three
phase) supply equal to 220VAC;
- for the drive having a power supply equal to 220VAC: power it by using a single phase (or three
phase) supply equal to 110÷130VAC.
In order to avoid this procedure, we suggest to power on the drive with its rated voltage for 30 minutes,
before the max. time is reached.
Storage
The drives does not need maintenance.
Otherwise:
• if the casing is dirty: clean it with isopropanol or similar;
• if the drive is dirty: the cleaning is reserved to the producer;
• if the fans are dirty: clean them by using a dry brush.
Maintenance
The disposal should be carried out by a certied company.
Disposal

17
AXOR Industries Service Manual Magnum400TM ver.2 rel.05/'15
• This manual is exclusively addressed to technical personnel with the following require-
ments:
- Technician with knowledge on movimentation of elements sensitive to electrostatic
discharges (for the transport).
- Technician with appropriate technical training and with vast knowledge on electrotech-
nics/drive technical eld (for the installation and operation of servodrives).
Using the drive incorrectly can injure people or damage things. Fully respect the technical
data and indications on connection conditions.
• As well as the points described in this manual, current regulations regarding safety and accident
prevention must be followed in order to prevent accidents and residual risks.
• The user must analyse possible machine risks and take the necessary measures to avoid injuries to
people and damage to things because of unpredictable movements.
• The converters contains elements which are sensitive to electrostatic discharges. These elements can
be damaged by careless manipulation.
Discharge static electricity from your body before touching the converter.
Avoid contact with material that insulates well (synthetic bres, lms of plastic material and so
forth).
• During operation, the converter surface can become hot. Protect the user from accidental contact
and keep the indicated distances from all objects.
• Never loosen electrical connections while the servoampliers are being powered.
The appropriate terminals of the drive must always be connected to earth as instructed in this manual.
After having disconnected the converters from the supply current, always wait at least 5 minutes before
touching the powered components (e.g. contacts) or loosening connections.
• Switch off the converter and wait at least 5 minutes before opening it. Remove the fuses or switch
off the main switch before removing the drive. When opening, place the converter on a surface that
does not belong to the electrical panel.
• The residual charges in the capacitors can remain at a dangerous level for up to 5 minutes after dis-
connection from the mains. Measure the voltage at the intermediate circuit (+AT/-AT) and wait until
it is below 15V.
• The command and power connections can still hold current even when the motor has stopped.
•The Magnum400TM is equipped with electronic protections that deactivate it in case of irregularities.
The motor, as a result, is not controlled and can stop or go into neutral (for a time determined by the
type of system).
•During installation, avoid letting any residue with metallic components fall inside the drive.
2.1 General Advices
Security standard

18
AXOR Industries Service Manual Magnum400TM ver.2 rel.05/'15
•Protect the converter from excessive mechanical vibrations in the electrical box.
•Check that the main supply and the nominal current are coherent with the rating of the drive. Be
sure that the voltage between the connectors L1-L2-L3 is not greater than 10% of the nominal values.
An excessively high voltage causes the breakdown of the load circuitry and of the drive.
•The Magnum400TM is equipped with an integrated EMI anti-disturbance lter at the 3-phase power
supply input and with another EMI anti-disturbance lter at the auxiliary +24V power supply input.
Being implicit to lter operation the deviation towards earth or mass of the undesired frequencies,
ensure that these devices can produce leakage currents towards earth, which are measurable in mil-
liAmpers. Please remember that "leakage currents" must be considered when settings differential
devices in order to avoid useless interventions.
For safety reasons connect the prepared terminal to earth before powering the drive. Incorrect con-
nections make lter operation unreliable.
2.1 General Advices

19
AXOR Industries Service Manual Magnum400TM ver.2 rel.05/'15
The Magnum400TM is made to be xed vertically to the bottom of the electrical box in order to
guarantee reliable cooling, respecting the following distances:
2.2 Positioning
Note: Arrange the power components (converters, main's lters, resistors, terminals, ... ) in bins of
the electrical panel different from those reserved to the command or control systems (PLC, PC, CNC,
regulators, ...). This improves the level of immunity to interference of the system.
UP
MODE DWN SET UP
MODE DWN SET UP
MODE DWN SET
30
(1.18)
30
(1.18)
30
(1.18)
30
(1.18)
Ecc.
270
(10.62)
45
(1.77)
45
(1.77)
mm
INCHES
Cable duct
Cable duct
Conductive mounting panel
(zinc-coated)
The drive must be afxed
utilizing 2 or 4 socket
head screws DIN 912,
M5, paying attention that
the dissipating surface
and the mounting panel
maintain as much con-
tact as possible, in order
to guarantee maximum
thermal dissipation.

20
AXOR Industries Service Manual Magnum400TM ver.2 rel.05/'15
During the storage and the installation respect the followings environmental conditions:
2.3 Environmental conditions
Condizioni ambientali
Storage temperature -20°C...+55°C
Working environmental temperature
From 0°C to +45° C (no derating).
From +45°C to +55°C the drive must be derated
2.5%/°C in reference to nominal and peak current.
Humidity From 10% to 85%
Altitude
Up to 1000m without restriction.
From 1000 to 2500m of altitude the converter must be
derated in the output current of 1.5% every 100m.
Enclosure protection IP20
Pollution level
LEVEL 2 (Norm EN60204/EN50178)
The drives are designed to be utilized in an electrical
box protected against the inltration of polluting agents
such as water, oil, conductive dust and others.
Notes:
• The electrical box must have suitably ltered air vents.
Leave the necessary space both above and below the converters.
• Periodically check drive case and fans for excess dust or dirt, that could interfere with the correct
dissipation of the drive.
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