MTS Systems MAXPLUS 231 User manual

1
M A X P L U S 2 3 1 O P T I O N S P I N D L E A M P L I F I E R
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
[phone]
[phone]
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

2
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.

3
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
Amplifier Input
Voltage
Required
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.

4
Specifications
Parameter Specification
Operating Environment:
Temperature
Humidity
0 to 45°C (32 to 113°F) Maximum, Ambient
0 to 95% noncondensing
Input/Output Interface: Analog Signals
Velocity Command Input
Velocity Output
Current Output
Differential input 0 to ±10 Vdc(15 Vdc Max)
1 volt per 1000 rpm
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
Accuracy:
Resolver Cable Length:
15 foot
25 foot
50 foot
100 foot
1024 lines
Max. Error:
±20 minutes
±20 minutes
±30 minutes
±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

5
MPA-80-231-SPINDLE Mechanical Footprint
.5 RECOMMENDED
D
SIDE VIEW
C
B
A
1.0"
.31
N
O
T
E
13.6 14.6
FRONT VIEW
Summary of Amplifier Dimensions
MODEL A in. B in. C in. D in.
MPA-80-231 8.5 6.5 1.3 10.63
NOTE
If front cover is attached, additional
clearance of .2 should be allowed.

6
Signal/Wiring Overview
AUX
SIG
RESP
CUR
BAL
RESET
FEEDBACK
SHLD
SHLD
GND
GND
GND
GND
REF
COS
TS
SIN
CONTINUOUS
LIMIT
RESET
HI-BUS
MOTOR
FEEDBACK
AMPLIFIER
SHORTS
CURRENT
MARK
ENCODER
POWER
I/O
GND
ORIENT
RAMPS
GND
-COM
+COM
CUR
TAC
GND
FLT
SHFT
SLOW
SPD
ENB

7
Feedback Wiring
100% SHIELDED
COS
WINDING THERMOSTAT
REFERENCE FREQUENCY
2KHZ 20-25 VP-P
SIN/COS 0-5V MAX RMS
FEEDBACK
SHLD
SHLD
GND
GND
GND
GND
REF
COS
TS
SIN
CONTINUOUS
LIMIT
RESET
HI-BUS
MOTOR
FEEDBACK
AMPLIFIER
SHORTS
CURRENT
MARK
SIN
REF
MOTOR
J2
120 VAC
L1
L2
LOW SPD 1
SPD 2
SPD 3
HIGH SPD 4
J1
REF
REF GND
COS
COS GND
SIN
SIN GND
THERM
THERM
SHIELD
R
E
S
O
L
V
E
R
MOTOR PC CARD
S
P
E
E
D
S
E
L
NOTE
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.
NOTE
The resolver mating connector is in the
box on the motor.

8
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-COLOR) This is a bi-colored LED that produces either red or
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 THERMAL An 85°C thermostat is mounted to the amplifiers IGBT
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.

9
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.
1
6
2
7
3
8
4
9
5
A\
A
B
B\
M
M\
GND
EXTERNAL CONTROLLER
SIGNALS AND GND
ENCODER
SIMULATION CONNECTOR
P1
T
Y
P
I
C
A
L
E
N
C
O
D
E
R
C
A
B
L
E
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
100% SHIELD
(FOIL AND BRAID)
The phase relationship of channels A, B and M are as follows for CW rotation:
P
I
N
S
I
G
1 A\
6 A
2 B
7 B\
3 M
8 M\
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.

10
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.
J2
120 VAC
L1
L2
LOW SPD 1
SPD 2
SPD 3
HIGH SPD 4
J1
REF
REF GND
COS
COS GND
SIN
SIN GND
THERM
THERM
SHIELD
R
E
S
O
L
V
E
R
120 VAC
*NOTE: CLOSE ONE
SWITCH AT A TIME
AUX
SIG
RESP
CUR
BAL
RESET
ENCODER
I/O
GND
ORIENT
RAMPS
GND
-COM
+COM
CUR
TAC
GND
FLT
SHFT
SLOW
SPD
ENB
I/O WIRING
EXAMPLE
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.

11
Ramps are enabled by default. Grounding PIN 12 (ramps) disables ramping. Grounding PIN
13 (orient) causes the motor shaft to rotate at 1 rps.
There is a connector for control purposes inside the motor. The four possible speed ranges
are identified as LOW 1, 2, 3, and HI 4. The user has to devise the logic as to how to operate
the relays based on the amplifier control inputs.
There are two outputs, Fault and Slow. These are open collector (NPN 2N7053) transistors
with their emitters connected to GND. Each output can be connected to a +30 Vdc maximum
open circuit voltage source. Each transistor will sink .15 amps when it is ON.
The Fault Output turns ON if there is a fault, and the slow output turns ON if the motor is
stopped or moving slowly as an indication that the Shift Input can be changed.
The amplifier should be disabled when the motor windings are switched.

12
Analog Inputs, Outputs, and Adjustments
Inputs
There is one analog input channel for the command input. This is a differential input and it is
summed with a TAC feedback amplifier that controls velocity.
AUX
SIG
RESP
CUR
BAL
RESET
ENCODER
I/O
GND
ORIENT
RAMPS
GND
-COM
+COM
CUR
TAC
GND
FLT
SHFT
SLOW
SPD
ENB
}
ANALOG INPUT
WIRING EXAMPLE
GND
–COMMAND SIGNAL
+COMMAND SIGNAL
CURRENT
TAC
GND
Normal operation of the command signal is to apply a + voltage (pin #9) with respect to GND
(pin #11) and get clockwise rotation of the shaft. ±10 volts is then used to control velocity and
the SIG pot is used for velocity adjustments. If the + COMMAND voltage is applied to the -
COMMAND signal input, then an opposite shaft rotation occurs.
The current limit of the amplifier can be adjusted with the CUR pot from 0 (full CCW) to 100%
(peak full CW). It is a good idea during start-up to adjust the CUR pot to its full CCW position
and increase it slowly CW to assure normal operation.
During start-up the BAL adjustment can be used to reduce/stop any low speed CW/CCW drift
caused by imbalance between the external command voltage and the amplifier.
The response adjustment (RESP) is adjusted from CCW to CW to achieve crisp operation.
This should be optimized on the high speed winding.

13
The location of these adjustments is directly below the I/O wiring.
NOTE
The pot labeled AUX controls the speed of
the spindle orient feature and need not be
adjusted by the user.
F
E
E
D
B
A
C
K
A
N
D
I
/
O
C
O
N
T
R
O
L
A
S
S
E
M
B
L
Y
AUX
SIG
RESP
CUR
BAL
RESET
ENCODER
I/O
GND
ORIENT
RAMPS
GND
-COM
+COM
CUR
TAC
GND
FLT
SHFT
SLOW
SPD
ENB
Outputs
Two diagnostic outputs are the dc voltage proportional to velocity and the dc output
proportional to current/torque. The nominal TAC gradient changes based on the selected
speed ranges of 690, 1630, 3300, and 6600 rpm, and is ±1 volt per 1000 rpm. The current
gradient is 10 volts equals the continuous rating.

14
Analog Inputs (Specific Interface Requirements)
The analog input channel is a differential input amplifier to allow controllers that have
differential output drivers a three wire connection that excludes potential ground loops. When
differential modes of operation are used, the command input is based on 5 volts equaling
maximum input and the analog ground from the external controller must be connected to the
MPA drives GND connection. A +5 volt connection to the COM+ terminal and a -5 volt
connection to the COM- terminal is equal to a +10 command voltage. This is what a
differential input is and an analog GND connection is required. The rotational direction of the
motor will be CW viewed from the shaft end of the motor. To change directional rotation the
COM+ and COM- connections must be reversed.
14
13
12
11
10
9
8
7
6
5
4
3
2
1
CMD
GND
COM–
COM+
–
+
12
3
–
+
12
3
–
+
12
3
GND
–
+
COMMAND
TYPICAL EXTERNAL CONTROLLER
WITH DIFFERENTIAL DRIVERS
MPA AMPLIFIER
I/O AND ANALOG INPUTS
MPA AMPLIFIER
The most typical input to the command input is a simple two wire interface consisting of a
command voltage with respect to a GND. The GND potential must be connected to the MPA
GND connection associated with the analog channel and the command voltage can be
connected to either the COM+ or COM- input to determine the rotational characteristic
required. A positive command voltage with respect to GND connected to the COM+ terminal
will cause CW rotation as viewed from the shaft end of the motor. The unused input, COM+
or COM-, should be connected to GND.
14
13
12
11
10
9
8
7
6
5
4
3
2
1
CMD
GND
COM–
COM+
–
+
12
3
–
+
12
3
GND
–
+
COMMAND
MOST COMMON EXTERNAL CONTROLLER
WITH SINGLE ENDED DRIVER
MPA AMPLIFIER
I/O AND ANALOG INPUTS
MPA AMPLIFIER

15
Jumper Selections
RESET I/O WIRING
S
I
M
U
L
A
T
E
D
ENCODER FEEDBACK WIRING
DIP 1
ON
1 2 3 4
JP4
JP9
JP11
JP3
JP19
JP3 BI-POLAR
ABSOLUTE (STANDARD)
The position of this jumper determines the kind of dc voltage proportional to current that is a
diagnostic signal at the (CUR) output of the I/O connector. With the shorting pin in the bipolar
position, the output CUR signal is plus for positive current and minus for negative current. The
voltage range is plus and minus ten where ten equals the amplifiers continuous current. With
the jumper in absolute, the proportional voltage is always positive for either plus or minus
motor current.
JP4 SLOW (STANDARD)
AT SPEED
The position of this jumper determines the type of output at the I/O terminals (SLOW) output.
In the slow position, the output turns ON if the tac voltage is low, indicating slow speed and
safe to alter amplifier and motor speed select inputs. When the jumper is at the at speed
position, then the operation of the slow output is altered so that it is ON if the ramp generator
output equals the ramp command inputs. This would mean that the motor is at the command
speed.

16
J
P
1
9
S
P
I
N
D
L
E
O
R
I
E
N
T
E
N
A
B
L
E
disabledenabled
(STANDARD)
The position of this jumper determines whether the shaft will turn at 1 rps when PIN 13 is
grounded.
J
P
1
1
O
R
I
E
N
T
D
I
R
E
C
T
I
O
N
CW (viewed from shaft end)CCW
(STANDARD)
The position of this jumper determines which direction the motor will turn when the orient
feature is enabled.
J
P
9
RESETABLE
FAULTS
(STANDARD)
NON
RESETABLE
FAULTS
When JP9 is in the left position (default) the amplifier must be power cycled to reset any faults.
In the right position, the faults can be cleared with the reset button or by toggling the enable
input.
Spindle Ramp Times
DIP 1 Switch Settings (0 = off, 1 = on)
1 2 3 4 TIME (sec)
0 0 0 0 2.00
1 0 0 0 3.00
0 1 0 0 3.45
1 1 0 0 4.00
0 0 1 0 5.20
1 0 1 0 5.40
0 1 1 0 5.90
1 1 1 0 6.10
0 0 0 1 8.00
1 0 0 1 8.20
0 1 0 1 8.80
1 1 0 1 9.00
0 0 1 1 9.40
1 0 1 1 9.75
0 1 1 1 10.10
1 1 1 1 10.40

17
AC Input and Internal Protection
A branch circuit disconnect must be provided in front of the amplifier.
Model Three Phase Power
MPA-80-231 60 amps 80-260 Vac
AC power wiring must be consistent with any local codes, national electric codes, and be able
to withstand the voltage current ratings applied.
A (ground) terminal is supplied and should be connected to earth ground.
Internal Protection
These amplifiers have internal AC Input fuses and a shunt fuse internal to the rear cover. All
of these fuses are intended to avoid catastrophic failures. These fuses are substantially larger
than needed. In the event that any of these fuses become defective, the amplifier must be
repaired by a factory technician.

18
Grounding
The ac supply source for the amplifier is supposed to be bonded to earth ground.
Typical WYE Secondary
L
1
(
H
O
T
)
L2 (HOT)
L3 (HOT)
GND
EARTH
GROUND
Typical Delta Secondary
EARTH
GROUND
L2 (HOT)
GND
L
1
(
H
O
T
)
L3 (HOT)
These are the two most typical transformer configurations and failure to ground these properly
could void warranty. These are 230 Vac.

19
There are too many transformers to depict all combinations. The MPA amplifier does not care
where the earth ground is. This example is a delta secondary.
Delta Secondary
L2 (NEUTRAL)
GND
L
1
(
H
O
T
)
L3 (HOT)
EARTH
GROUND
In this example, L2 became ground.

20
Power/Grounding Requirements
The following information covers the grounding requirements of 3-phase servo amplifiers
manufactured by MTS Automation. It has been found when an amplifier has been connected
to a transformer with an ungrounded secondary, premature amplifier failure will occur.
The 3-phase MPA amplifiers require the AC power (L1, L2, L3, and Ground) be derived from a
transformer which has it's secondary intentionally bonded to earth ground. This means that
some point on the secondary must be connected to an earth ground with no exceptions (see
examples A1, A2, A3). Do not assume just because there are three power leads with a ground
available at an installation, that this is a valid configuration. Some facilities are supplied with
13,200 volts AC which is reduced to 460 volts AC via a transformer. However, the secondary
of this transformer usually is not grounded as in an ungrounded delta secondary (Example
U3). Each installation or facility is unique and the power distribution must be inspected or
measured to make sure the transformer secondary is, in fact, tied to earth ground. A machine
or system built and tested at one facility, may fail at another site due to incorrect transformer
configurations.
There are two common transformer secondary configurations. They are the Wye and the Delta
secondary. Most problems are found with an ungrounded Delta secondary connection. The
examples show acceptable (A1, A2, and A3) and unacceptable (U1, U2, U3) configurations.
If it is not possible to visually inspect the transformer configuration, you can electrically
measure the line voltages to verify a correctly grounded transformer secondary.
A properly grounded secondary (wye or delta) will have certain voltage characteristics when
measured with an AC voltmeter:
• A properly grounded wye secondary will read the same voltages when measuring all three legs,
phase to ground (A1).
• A properly grounded wye or delta secondary will read the same voltage when measuring all three
legs phase to phase (A1, A2, A3).
A properly grounded delta with high leg (A2) and delta with grounded leg (A3) show different
characteristics when measuring phase to ground.
• In example A2 (Delta with high leg), the two low legs (L1 and L2) must be the same voltage when
measured phase to ground.
• In example A2 (Delta with high leg), the high leg (L3), when measured phase to ground, will read
twice the value of L1 or L2 to ground.
• In example A3 (Delta with grounded leg), L1 and L2 must be the same voltage when measured
phase to ground.
If the measured voltages at the installation do not correspond with the above, or the
transformer secondary is, in fact, ungrounded, one of the following steps must be done:
A) Ground the secondary of the transformer if it is electrically and mechanically possible.
B) Add an isolation transformer and ground the secondary per acceptable connection.
If unsure, ask a licensed electrician to perform the above steps.