MTS Systems MPA-03 SL User manual

Brushless Servo
Amplifiers
MPA-03/06 SL
2121 South Bridge Street
0101
New Ulm, MN 56073
Part Number 575-00031C
Telephone: 507-354-1616
©MTS Systems Corporation 2001
Fax: 507-354-1611

A Summary of Changes to the MPA-03/06-SL manual (575-00031)
Rev A to Rev B (June 1999)
•Removed all references to “Custom Servo Motors”.
•Corrected “Simulated Encoder Signals” section.
Rev B to Rev C (January 2001)
•Changed the first paragraph under “Warranty and Service” to read:
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.
Rather than:
The amplifier is warranted to be free from defects in workmanship and materials for a
period of 18 months from the original shipment by MTS Automation, or 12 months in
service, whichever comes first.

iii
T A B L E O F C O N T E N T S
Application ................................................................................................................................ 1
Unpacking and Inspection ........................................................................................................ 1
Warranty and Service ............................................................................................................... 1
Service Under Warranty .............................................................................................. 2
Non-Warranty Service ................................................................................................. 2
General Provisions ...................................................................................................... 2
Introduction............................................................................................................................... 3
Features ................................................................................................................................... 3
Specifications ........................................................................................................................... 4
MPA-03/06SL Mechanical Footprint......................................................................................... 5
Base Plate Mounting Options ................................................................................................... 6
Orientation ................................................................................................................................ 7
Feedback Wiring ...................................................................................................................... 8
Motors and Commutation ......................................................................................................... 9
Diagnostic Indicators ................................................................................................................ 10
I/O Wiring and Descriptions...................................................................................................... 11
Simulated Encoder Option........................................................................................................ 12
Simulated Encoder Connector.................................................................................................. 13
Analog Input and Adjustments.................................................................................................. 15
AC Input and Internal Protection .............................................................................................. 16
DC Bus ..................................................................................................................................... 16
Stator Wiring............................................................................................................................. 17
Start-Up .................................................................................................................................... 18
Typical Wiring ........................................................................................................................... 19

1
M P A - 0 3 / 0 6 S L B R U S H L E S S S E R V O
A M P L I F I E R S
Application
This manual is designed to help you install the MaxPlus™ MPA-03/06SL 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

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
These amplifiers are designed to be used with high performance brushless servo motors.
Care has been taken to assure robust operation. Design consideration for electrical transients
have been implemented on the ac power input and all of the I/O lines. The amplifier operates
over an ac voltage range of 80 to 260 Vac from 45 to 65 Hz. The motor feedback device is a
resolver to assure normal operation at elevated motor temperatures of 115°C for the case,
and 155°C for the motor windings. The resolver allows for both position and velocity
feedback. The motor is further protected by a thermal shutdown thermostat in the motor
windings. The amplifier power switching devices are state of the art IGBT modules. The logic
supply is a switch mode design reducing undesired heat. LED indicators for diagnostics are
provided.
Features
• Efficient power conversion
• High frequency switching
• Resolver feedback
• Simulated encoder signals
• ± 10 volts for maximum velocity or torque
• 24 volt I/O for Enable Velocity/Torque mode
• Differential analog channel for command
• LED diagnostic indicators
• Motor thermal protection
• AC, I/O and bridge transient suppression
• Totally self contained space efficient design
• Simple screw terminal interface
• AC inrush protection
• Simple one turn visual adjustments
• MOV overvoltage Bus surge protection

4
Specifications
Parameter Specification
Operating Environment:
Temperature
Humidity
0 to 45°C (32 to 113°F) Maximum, Ambient
0 to 95% noncondensing
Input Interface: Analog Signals
Velocity Command Input
TAC Gradient
Differential Input 0 to ±10 Vdc (15 Vdc Max)
3.0 Volts per 1000 rpm (14-bit mode)
.75 Volts per 1000 rpm (12-bit mode)
24 Volt Logic: Velocity/Torque Mode
Enable
Start (option only)
Velocity/Torque Select
Fault Output (Open Collector)
Ready (option only)
Both of the outputs are open collector (30 Vdc max) and can
sink .15 amps when ON.
Fault Protection: Continuous Current
Shorts (Stator)
Feedback Resolver Tracking
Motor Thermal
Electrical Characteristics:
Input Voltage
80 to 260 Vac
45 to 65 Hz
Single Phase
No Isolation Transformer Required
MPA-03SL:
Output:
Input:
3 amps continuous; 6 amps peak; peak ≤1 second
PWM frequency 18 kHz
Single phase; 5 amps continuous max
DC Bus is ac line dependent
MPA-06SL:
Output:
Input:
6 amps continuous; 12 amps peak; peak ≤1 second
PWM frequency 18 kHz
Single phase, 8 amps continuous max
DC Bus is ac line dependent
Motor/Amplifier Speed and Load
Relationship
The motors maximum speed is
dependent on the bus voltage and
motor KE by the following relationships.
In the Velocity Mode of operation, the
TAC Gradient also would limit the
speed.
(AC Input)/(Motor KE vrms) = Max no load speed.
Max no load speed *.75 = Maximum speed at continuous full
load.
10/TAC Gradient = (MAX no load speed)Krpm
Adjustments: 0 - Peak Current Limit (CL)
Response (RESP)
Signal (SIG)
Balance (BAL)
Speed/Torque Regulation: ±5%
Weight: 3 lbs. max

5
MPA-03/06SL Mechanical Footprint
"L" bracket design can be mounted either flat or right angle.
.2
0
0 6.38
A
A
AA
5
.
7
0
11.6
11.4
TOP VIEW
A
A
0 .7 1.4 2 *2.8 All dimensions in inches
A = .178 diameter thru hole
Dimensions: 11.6L X 6.38W X 3.0H Max
*The AN-06 is 0.8 taller than the AN-03

6
Base Plate Mounting Options
Bottom View
0
06.0
11.6
9.96
1.16
.30
A
AA
11.4
B
B
.20
0
.
4
2
AA
A
5
.
2
2
6
.
3
8
B
B
All dimensions in inches
A = .178 diameter thru hole
B = #10-32 standard pem nut

7
Orientation
TB2
TB1
T
O
P
V
I
E
W
ENCODER INTERFACE
(OPTION)
PERSONALITY INTERFACE
(OPTION)
1
7
1
18

8
Feedback Wiring
TB1
1
18
SIG
BAL
RESP
CUR 100% SHIELDED
REFERENCE FREQUENCY
2KHZ 20-25 VP-P
SIN/COS 0-5V MAX RMS
WINDING THERM
SIN
REF
COS
1
2
3
4
5
6
7
8
17
REF
REF GND
SIN
SIN GND
COS
COS GND
THERM SWITCH
THERM GND
SHIELD
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.

9
Motors and Commutation
The amplifier can commutate 4-pole, 6-pole, 8-pole, and brush motors in its standard
configuration and other factory options are practical. JP3 and JP4 allow for configuration
changes. Drives are shipped set for 6-pole operation. Never change these jumpers with
power on.
JP3
JP4
JP3 JP4 MOTOR TYPE
OUT OUT BRUSH
IN OUT 6-POLE
OUT IN 4-POLE
IN IN 8-POLE
For brush motor operation, no resolver alignment is required and the R lead connects to
armature (+) and the T lead connects to armature (-). (+) (-) will cause clockwise rotation from
the shaft end of the motor.

10
Diagnostic Indicators
SIG BAL RESP CUR
TB1
CONTINUOUS
SHORTS
FEEDBACK WIRING
M
O
T
O
R
T
H
E
R
M
A
L
POWER ON
There are four faults that will reduce amplifier current to zero.
LED INDICATION
CONTINUOUS If a load condition exists that causes the amplifier to
produce more than its continuous rating, this fault
occurs.
STATOR SHORTS/
POWER DEVICE
If stator shorts or most major wiring errors of the stator
occur, this fault occurs. This output also comes on if the
power device becomes too hot.
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.
POWER(GREEN)
If logic +5 Vdc is on then this LED is on.

11
I/O Wiring and Descriptions
The amplifier has three 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
are as follows.
With no wires connected to VEL/TORQUE, ENABLE, or START, the amplifier is disabled and
normal operation will not occur. The inputs are activated by connecting them with a switch
closure to any of the provided GND terminals.
TB1
1
18
SIG
BAL
RESP
CUR
24 VDC
SUPPLY
+–
18
16
15
14
13
12
FAULT
READY START
ENABLE
DISABLE
TORQUE
VELOCITY
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 VEL/TORQUE Input determines the drive mode. When the switch is open, the Velocity
mode is selected. When the switch is closed, the Torque mode is selected.
The ENABLE Input must be on to enable the drive.
The START Input (option only) can be used by the personality interface option as a way to
start motion.
The FAULT Output will come on when a fault condition occurs. This is equivalent to an open
collector NPN transistor whose emitter is connected to GND.
The READY Output (option only) can be turned on or off by the computer interface option.

12
Simulated Encoder Option
TB2
1
7
TB1
1
18
T
O
P
V
I
E
W
ENC01.PCB
DB9 FEMALE
CONNECTOR
MARK LED
The ENC01.PCB plugs into the drive mating connector and is held in position with two #6-32
screws. 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.

13
Simulated Encoder Connector
9
-
P
I
N
D
B
9
F
E
M
A
L
E
9 8 7 6
5 4 3 2 1 PIN 1 = A\ PIN 6 = A
PIN 2 = B PIN 7 = B\
PIN 3 = M PIN 8 = M\
PIN 4 = GND PIN 9 = GND
PIN 5 = SHIELD
The phase relationship of channels A, B and M 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
(default).
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.
SW1 is provided as a means to determine the resolution of the simulated encoder signals.
SW1 1 2 3 4 LINES 12 BIT 14 BIT MARK
ON ON ON ON 2000 NO YES YES
OFF ON ON ON 500 YES YES YES
ON OFF ON ON 400 YES YES YES
(Default) OFF OFF ON ON 1024 YES YES YES
ON ON OFF ON 250 YES YES YES
OFF ON OFF ON 1000 YES YES YES
ON OFF OFF ON 720 YES YES YES
OFF OFF OFF ON 360 YES YES YES
OFF OFF OFF OFF 4096 NO YES NO
The normal factory configuration of 2-Channel quadrature provides for output resolution of 12
bits or 4096 counts per revolution. There is no mark signal when 4096 is selected. The 4096
selection is only possible in the 14-bit mode of operation. The 2000 line choice is only valid in
the normal 14-bit mode.
The maximum tracking rate of the amplifier is determined by the resolver to digital converter,
the motors KE, and the TAC gradient.

14
Bus Voltage Limit
The motors maximum no load speed is limited by its KE. The simple guideline is to divide the
KE into the AC input voltage.
AC Input
-------------- = MAX no load speed
KE Motor
This maximum speed must be derated by .75 at full load.
TAC Gradient Limit
If the drive is being used in the velocity mode, the TAC gradient, as determined by the R-D
converter resolution jumpers, would limit speed.
JP1 JP2 Mode TAC Gradient
IN OUT 14-bit 3.0 ± .3 Vdc Per 1000 rpm
OUT IN 12-bit .75 ± .075 Vdc per 100 rpm
Amplifier saturation occurs at 10 Vdc command. The speed limitations are:
10 / 3 = 3,333 rpm in 14-bit Mode
10 / .75 = 13,333 rpm in 12-bit Mode
14 Bit/12 Bit Jumper
JP1
JP2
NOTE
Do not move jumpers with power ON.
Resolver to Digital Converter Limit
If the drive was being used in the torque mode, bus voltage and the tracking rate of the R-D
Converter would be the speed limitations.
6,000 rpm in 14-Bit Mode
18,000 rpm in 12-Bit Mode

15
Analog Input and Adjustments
There is one analog input channel for command. This has differential inputs and is summed
with a TAC feedback differential amplifier that controls velocity if the Velocity Mode is selected.
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.
If the input for VEL/TORQUE is active and a torque mode is chosen, voltages applied to the
COMMAND ± inputs control motor current. The SIG pot can now be used to adjust the
amount. Normal operation in this mode assumes that 10 volts is peak current and 5 volts is
the continuous current rating of the amplifier.
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 startup to adjust the CUR pot to its full CCW position
and increase it slowly CW to assure normal operation.
During startup 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.
Once connected to loads, the crispness of motion (step response) and stability can be
optimized with the RESP pot. Full CW is maximum response.
NOTE
The BAL and RESP pots apply only to
operation in the Velocity Mode; the CUR and
SIG pots apply to both modes.
(
9
)
C
O
M
M
A
N
D
+
(10) COMMAND –
(11) GND

16
AC Input and Internal Protection
A branch circuit disconnect must be provided in front of the drive.
Model Single Phase
MPA-03 SL 5 amps
MPA-06 SL 10 amps
AC power wiring must be consistent with any local codes, national electric codes, and be able
to withstand the voltage current ratings applied.
A GND terminal is supplied and should be connected to earth ground.
DC Bus
The drive has two AC Input fuses on the circuit board as a means of protection from
catastrophic failures. These fuses are substantially larger than needed. In the event that
these fuses become defective, the amplifier must be repaired by a factory technician.

17
Stator Wiring
The locked rotor stator current is equal to the drive's continuous rating, and for either low
speed or locked rotor conditions, the stator must withstand this continuous rating.
Model Locked Rotor
MPA-03 SL 3 amps
MPA-06 SL 6 amps
It is acceptable and recommended that four conductor shielded cable be used.
TB2
1
7
1
2
3
4
4
5
6
7
SHIELD
T
S
R
GND
GND
L2
L1
FRAME
MOTOR
A GND connection is supplied as a means to ground the motor frame to earth ground.
If shielded cable is not used, it is recommended that the RST and GND wires be twisted.
NOTE
If the resolver feedback wiring is to be run
adjacent to the RST motor wiring, the motor
wiring should be 100% shielded (foil and
braid).
This manual suits for next models
1
Table of contents
Other MTS Systems Amplifier manuals