MTS Systems MPA-460 ACE-01 User manual

1
M P A - 4 6 0 A C E - 0 1 B R U S H L E S S S E R V O
A M P L I F I E R
Application
This manual is designed to help you install the MaxPlus™ 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 18 months from the original shipment by MTS Automation, or 12 months in service,
whichever comes first.
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
MPA Amplifiers represent a series of amplifiers that are high performance, reliable, and
efficient. The amplifiers are designed to be used with high performance brushless servo
motors. Extreme care has been taken to assure robust operation. Design consideration for
electrical transients have been implemented on the ac inputs and all I/O lines. The MPA 460-
100 series amplifiers operate over ac voltage ranges of 200 to 520 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 high power switching devices are
state of the art IGBT modules. The logic supplies are switch mode designs reducing
undesired heat. LED indicators for diagnostics are provided. Encoder simulated TTL
compatible differential quadrature outputs plus an index output are provided for external
pulse or position control. The amplifiers have inrush current protection to allow for normal
turn on. This is especially worthwhile for multiple axes. Consideration for dissipation of
regenerative energy is included with internal shunt regulators.
The ACE-1 (Analog Control Electronics) Control Board is available as a means of providing
multiple configuration and extended features to the MPA Servo Amplifier.
The following features are available:
• 6-Pole, 8-Pole, 12-Pole, and Brush Motor selection
• I/O logic level signal inversion
• 12 or 14 bit mode
• Internal or External TAC
• Four different TAC Filters
• 15 TAC Gradients per mode
• Latched fault display
• EPROM encoder selection
• Independent reference for all zero adjustments
• Lead Gain - 16 choices for Capacitor
• 16 choices for Lag Network
• Overspeed shut down

4
Sizes
Model Continuous Amps Peak Amps
MPA-100-460 100 165
MPA-100-230 100 165
Features
• Efficient power conversion
• High frequency switching
• Resolver feedback or Hall-effect commutation
• Simulated quadrature encoder signals (with resolver feedback)
• ±10 Vdc for maximum velocity or torque
• 24 volt I/O for ±LIMIT, RESET, VEL/TORQUE mode
• 2 differential analog channels (command and auxiliary)
• LED diagnostic indicators
• Motor and amplifier thermal protection
• AC, I/O and bridge transient suppression
• Totally self contained space efficient design
• Simple screw terminal interface
• AC inrush protection
• Three-phase operation
SpecificationsParameter 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
Auxiliary Input
Velocity Output
Current Output
Differential input 0 to ±10 Vdc(15 Vdc Max)
Differential input 0 to ±10 Vdc(15 Vdc Max)
1.5 volts per 1000 rpm (default)
±10 volts = ± Peak Current
24 Volt Logic:
Reset
+ Limit
- Limit
Velocity/Torque Select
Fault Output(Open Collector)
Overspeed
Fault Protection:
Continuous Current
Shorts(Stator)
Amplifier Temperature
Feedback Resolver Wiring
Motor Thermal
HI-BUS
Overspeed
Encoder Simulation:
TTL Differential Output Plus Index
Phase Quadrature
Line Count(select with DIP switch);
Standard - 250, 360, 400, 500, 720, 1000, 1024, 2000, and
4096
Electrical Characteristics:
Input Voltage
200 to 520 Vac
45 to 65 Hz
Three phase; 80 amps continuous maximum
No Isolation Transformer Required
Output Characteristics
(All Models)
Quasi Trapezoid with Torque Linearization
Torque Ripple 5% Maximum

5
Output: MPA-100-460
MPA-100-230
100 amps continuous; 165 amps peak; peak ≤5 seconds
PWM frequency 10 kHz
DC Bus and output voltage is AC line dependent
Motor/Amplifier Speed and Load
Relationship:
The motor's maximum speed is dependent on the bus
voltage and motor KE by the following relationships:
(AC Input)/(Motor KE Vrms) = Maximum no load speed.
Maximum no load speed * .75 = Maximum speed at
continuous full load.
Adjustments:
0 - Peak Current Limit(CL)
Response (RESP)
Auxiliary (AUX)
Signal (SIG)
Balance BAL)
Overspeed Shut Down
Speed/Torque Regulation
±5%
Max Speed 12000 rpm (12 bit) or 3000 rpm (14 bit)

6
Parameter Specification
Encoder Signals:
Resolution
Accuracy:
Resolver Cable Length:
15 foot
25 foot
50 foot
100 foot
250, 360, 400, 500, 720, 1000, 1024, 2000 and 4096 lines
Max. Error:
±20 minutes
±20 minutes
±30 minutes
±40 minutes
Weight:
MPA-100-460/230 75 lbs. max
Motor Inductance:
For all 460 volt products, the inductance line-to-line must be
no less than 1mH.
For all 230 volt products, the inductance line-to-line must be
no less than 500 µH.

7
MPA-100-460/230 Mechanical Footprint
AC POWER INPUT
A B C
MARK
+BUSSHUNT-BUSGND
D.C.BUS
RSTGND
MOTORPOWER
OUTPUT
T/S+
T/S-
-24V
+24V
AUX+
MOTOR
VELOCITY
SCALING
RESOLVER
COMP
VELOCITY
AMPLIFIER
RESET
HI-BUS
FDBK
LIMIT
+15V
BALANCE
RESOLVER
SIGNAL
TAC RET
LEAD
CURRENT
SIN
SIN GND
SHIELD
-15V
TAC
SHIELD
TS
GND
COS GND
GND
COS
GND
REF
INVERT
ENCODER
MODE
SHORTS
CONTINUOUS
MOTOR
SELECT
FLTINV
PWM MODE
RMS MODE
INPUT
GND
AUX-
GND
COM-
CUR
VEL
LIM+
V/T
LIM-
FLT
RES
ENCODER
POWER
RESET
MPA100-460
R
CURRENT

8
Control Interface and User Configuration Locations
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 used.
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, the amplifier is
disabled.
If this feature is not used, connect a short jumper wire between terminals 7 and 8.
MARK
AUX-
MOTOR
VELOCITY
SCALING
RESOLVER
COMP
VELOCITY
AMPLIFIER
RESET
HI-BUS
FDBK
LIMIT
+15V
BALANCE
RESPONCE
SIGNAL
TAC RET
LEAD
CURRENT
SIN
SIN GND
SHIELD
-15V
TAC
SHIELD
TS
GND
COS GND
GND
COS
GND
REF
INVERT
ENCODER
SW5
SHORTS
CONTINUOUS
MOTOR
SELECT
FLT INV
PWM MODE
RMS MODE
INPUT
GND
AUX+
GND
COM-
CUR
VEL
LIM+
V/T
LIM-
FLT
RES
ENCODER
POWER
RESET
MPA100-460
R
CURRENT
COM+
SW7
SW6
SW8
SW1
SW2
SW3
Disable drive before changing
DIP switch settings.
N O T E

9
Resolver Feedback Wiring
S
H
I
E
L
D
SHIELD
THERM GND
THERM SWITCH
SIN GND
SIN
COS GND
COS
REF GND
REF
10
9
8
7
6
5
4
3
2
1
REF
SIN
100%
Shielded
SIN/COS 0 TO 5 V
Maximum rms
Winding
Thermostat
Reference Frequency
2 kHz 20-25 VP-P

10
Motors and Commutation
The amplifier can commutate 6-pole, 8-pole, 12-pole, and brush motors in its standard
configuration and other factory options are available. DIP switch SW6 allows for
configuration changes and switches one through three determine the choice. Amplifiers are
shipped set for 6-pole operation. Never change the switch settings of SW6 with power ON.
DIP SWITCH SW6
SW6 1 2 Motor Type
ON ON 12-POLE
OFF ON 8-POLE
ON OFF 6-POLE (default)
OFF OFF BRUSH
SW6-3 selects the torque linearization mode. When the switch is on, a algorithm is invoked
to reduce the generation of torque ripple for 4 or 6 pole sinusoidally wound motors when
commutating with a trapezoidal output drive.
For brush motor operation, (SW6-1,2 off) no resolver alignment is required and the R lead
connects to armature (+) and the T lead connects to armature (-).
A positive command (+COM > -COM) will make the R lead positive with respect to the T
lead. These connections will cause clockwise rotation from the shaft end of the motor.

11
Diagnostic Indicators
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-color LED that can be either red or green as a function of load. Red indicates
positive torque and green indicates negative torque. The intensity increases with load.
There are eight faults that will disable the amplifier:
LED INDICATION
CONTINUOUS
If a load condition exists that causes the amplifier to
produce more than its continuous rating, this fault
occurs.
STATOR SHORTS
If stator shorts or most major wiring errors of the stator
occur, this fault occurs.
AMPLIFIER THERMAL
An 85°C thermostat is mounted to the amplifiers IGBT
heat sink. 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 or
OVERSPEED
If an excess thermal or adjustable overspeed condition
exists in the motor, this fault occurs.
HI-BUS
If excess DC voltage or a failure of the shunt circuit is
detected, this fault occurs.
RESET
During the first second of power up or if the reset input
is active, this LED will be ON.
LIMIT If either of the limit inputs are ON, this LED will be ON.
Power (GREEN)
If logic +5 Vdc is ON, then this LED is ON.

12
Simulated Encoder Signals
For external counting or position control, 9-pin D type female connector that has TTL
complimentary 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(default).
The above signals are TTL complimentary outputs from a DS26LS31 differential driver. The
logic 0 is typically between 0 and 0.5 volts and logic 1 is typically between 3.3 and 4.0 volts.

13
SW8 is provided as a means to determine the resolution of the simulated encoder signals.
The default factory configuration is 1024 lines.
SW8 1 2 3 4 Lines
ON ON ON ON 2000 (14-bit only)
OFF ON ON ON 500
ON OFF ON ON 400
OFF OFF ON ON 1024 (default)
ON ON OFF ON 250
OFF ON OFF ON 1000
ON OFF OFF ON 720
OFF OFF OFF ON 360
OFF OFF OFF OFF 4096 (14-bit only)
The normal factory configuration of 2-Channel quadrature provides for output resolution of
12 bits or 4096 counts per revolution.
The maximum tracking rate of the amplifier is limited by the resolution selection of the R-D
Converter of 12-bit or 14-bit. This also affects the line choices.

14
I/O Wiring and Descriptions
The amplifier has four inputs and one output. These inputs and output 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 RESET, + LIMIT, - LIMIT, or VEL/TORQUE, the amplifier is
enabled and normal operation will occur in a velocity mode. The inputs are activated by
connecting them with a switch closure or open-collector pull-down to any of the provided
GND terminals.
I/O Wiring Example
LEAD
SIG
RESP
CUR
BAL
RESET
I/O
GND
-AUX
+AUX
GND
-COM
+COM
CUR
VEL
GND
FLT
V/T
-LIM
+LIM
RES
ENCODER
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.
NOTE
The V/T input determines the amplifier outer
loop mode, Velocity vs. Torque.
When the switch is open, the Velocity mode
is selected. When the switch is closed, the
Torque mode is selected.

15
As the polarity of the inputs may vary depending on the application, a DIP switch is provided
to allow for an inversion of the function.
DIP switch SW7 switches 1, 2, 3, and 4, are used for this purpose.
Input Switch Number Factory Setting
RESET 1 ON
+ LIMIT 2 ON
– LIMIT 3 ON
VEL/TORQUE 4 OFF
By setting switch 2 to the OFF position, the operation of the + LIMIT would change to be
closed to run in a plus direction. This reversing characteristic is true for all four switches.
There is a FAULT output. This is equivalent to an open collector NPN transistor with its
emitter connected to GND. This transistor can sink 2 amps and it can withstand 110 volts dc
when OFF. When a fault occurs, this output turns ON. This output can also have its polarity
inverted by switching the fourth switch on DIP switch S2. Once this is done, this output will
be ON if no fault exists. This output would now be thought of as a READY output instead of
a FAULT output. The normal fault operation occurs with SW6-4 ON.
The purpose of inversion of this output is to allow for direct connection to fail safe brakes or
other brake interlock circuits. This transistor can sink two amps, and it can withstand 110
volts DC when OFF.
If this inverted output is used, consideration for the Power-Up Reset Input may be required.
For example, during power-up a reset would disable faults. This same reset may then
defeat the desired operation of the brake. With no faults and an inverted output selected,
the brake output would be ON but power would not be applied to the motor. If the JR1
shorting pin is installed then a Reset/Disable condition is allowed to keep the output ON
even though there is no fault.

16
Analog Inputs, Outputs and Adjustments
Inputs
There are two analog input channels; one for command and one for auxiliary. Both of these
channels are differential inputs and both are summed with a TAC feedback differential
amplifier that controls velocity.
LEAD
SIG
RESP
CUR
BAL
RESET
I/O
GND
-AUX
+AUX
GND
-COM
+COM
CUR
VEL
GND
FLT
V/T
-LIM
+LIM
RES
ENCODER
}
}
ANALOG INPUT
WIRING EXAMPLE
GND
– AUX SIGNAL
+ AUX SIGNAL
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 operation of the AUXILIARY ± inputs is the same as the COMMAND inputs. The normal
purpose of the AUXILIARY inputs is to provide a second summing voltage to compensate/modify
normal COMMAND voltage.
If the input for VEL/TORQUE is active and a torque mode is chosen then voltages applied to the
COMMAND ± inputs control motor current. The SIG pot can now be used to adjust the current.
Normal operation in this mode assumes that 10 volts represents peak current and 6 volts
represents 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 start-up to adjust the CUR pot to its full CCW position
and increase it slowly CW to assure normal operation.

17
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.
Once connected to loads, the crispness of motion (step response) and stability can be optimized with
the RESP and LEAD pots. Full CW is maximum response and full CCW is minimum LEAD.
Outputs
Two diagnostic outputs are provided: A dc voltage proportional to velocity and a dc output
proportional to current/torque. The nominal TAC gradient is determined by DIP switches within a
range of ±10 volts. The current gradient is 10 volts equal peak.
LEAD
SIG
RESP
CUR
BAL
RESET
I/O
GND
-AUX
+AUX
GND
-COM
+COM
CUR
VEL
GND
FLT
V/T
-LIM
+LIM
RES
ENCODER

18
The analog input channels employ differential input amplifiers to allow controllers that have
true differential output drivers to use a three wire connection that excludes potential ground
loops. When a true differential command is used, the command or auxiliary input is based
on 5 volts maximum input on each side of the differential input, and the analog ground from
the external controller must be connected to the amplifiers GND connection. A +5 volt
connection to the COM+ terminal and a -5 volt connection to the COM- terminal creates a
net +10 command voltage. This equal and opposite, or balanced, input defines true
differential operation and is recommended for optimum command signal fidelity, especially in
a noisy or demanding environment. An analog GND connection is still required to maintain a
nominally zero common mode voltage between the controller and the drive. 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.
2
3
–
+1
2
3
–
+1
COMMAND
TYPICAL EXTERNAL CONTROLLER
WITH DIFFERENTIAL DRIVERS
AMPLIFIER I/O AND
ANALOG INPUTS
GND
–
+
GND
COM–
COM+
2
3
–
+1
CMD
The most typical input to the command and auxiliary inputs is a simple two wire interface
consisting of a command voltage with respect to a GND. The GND potential must be
connected to the 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.
2
3
–
+1
COMMAND
MOST COMMON EXTERNAL CONTROLLER
WITH SINGLE ENDED DRIVER
AMPLIFIER I/O AND
ANALOG INPUTS
GND
–
+
GND
COM–
COM+
2
3
–
+1
CMD

19
R-D Converter Resolution
SW2 is used to set the resolution of the resolver to digital converter. The amplifier is
configured from the factory for 12-bit mode.
SW2 1 2 3 4 5 6 7 8 Mode
ON OFF ON OFF ON OFF ON OFF 12-bit (default)
OFF ON OFF ON OFF ON OFF ON 14-bit
The motor speed and TAC gradients are affected by these settings.
Mode Maximum Speed
12-bit 12000 rpm
14-bit 3000 rpm
TAC Compensation
SW3 is used to alter the TAC gradient characteristics when the amplifier is used as a
velocity control. SW3 switches 1-4 are used to set the TAC gradient value that is multiplied
by the base value. The base value is expressed in volts per KRPM and is 0.85 volts in the
12-bit mode and 2.0 volts in the 14-bit mode. The four switches represent a binary multiplier
with switch one being the most significant bit. The switches value exists when the switch is
open (OFF). At least one switch should be open – a multiplier of zero is not allowed.
In actual practice, the best setting for the TAC gradient is the highest possible TAC gain for
the application. Amplifier saturation is based on 10 volts of either signal or TAC. With the
TAC gradient switches set at default (SW3 1-4 = ON ON OFF OFF) saturation will occur at
10 / (3 * .85) = 3.922 KRPM in 12-bit mode. The motor’s KE value and the amplifier DC bus
voltage (a function of AC line voltage) will also limit the maximum speed.
The amplifiers SIG pot controls the amount of command voltage and velocity from the
external controller. The best performance will occur when the CMD pot is turned almost full
CW and the TAC gradient is increased to reduce the desired maximum speed so that a 10
volt command equals the maximum RPM.
As TAC gain is increased, the effects of TAC ripple are also increased. It may then be
necessary to increase the amount of filtering of the TAC signal. SW3 switches 5-6 are
provided to increase filtering. Each switch adds additional filtering.
Increased TAC gain effects the performance of the amplifier based on the amount of load on
the motor. When this occurs, it may be necessary to alter the TC network associated with
the velocity loop. This is controlled by SW1 switches 4-7.
In some applications, the amplifiers performance can be improved with the used of an
external TAC signal. SW3 switches 7-8 determine where the TAC signal is derived from.
SW3 7 8 TAC Signal
OFF ON R-D converter
ON OFF External brushless TAC
When using the external brushless TAC, the signal must come from the resolver interface
connector. The assembly must have a 14 pin instead of a 10 pin strip connector, and the
motor must have a tachometer. The TAC gradient multiplier is determined by the external
tachometer’s TAC gradient per thousand RPM.

20
DIP Switch SW3 - Velocity Signal Processing
–
+
12
3
EXTERNAL BRUSHLESS
TAC
INTERNAL RESOLVER
TAC SW3
R139
R138 13K
13K
1
2
3
4
5
6
7
8 9
10
11
12
13
14
15
16
C109
.022M
C92
.047M
C93
.1M
R137
51K
51K
R159
R158
100K
R157
200K
R156
390K
VEL
TP23
U39A
LM358
R154
R155
200K
REF– 3
2
1 REF+
R
A
8
50K
10K
CCW