MTS Systems MPA-460 ANF3/8031 User manual

1
M P A - 4 6 0 A N F 3 / 8 0 3 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 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
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. MPA
amplifiers operate over ac voltage ranges 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 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 axis. Consideration for dissipation of
regenerative energy is included with internal shunt regulators.
The ANF3 Feedback Board is available as a means of providing multiple configuration and
extended features to the MPA Servo Amplifier.
The following features are available:
• 4-Pole, 6-Pole, 8-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
• Saves faults if Enable is used
• EPROM encoder selection
• Independent reference for all zero adjustments
• Lead Gain 16 choices for Cap
• 16 choices for Lag Network
• Overspeed shut down
• Interface to Indexer Board

4
Sizes
Model Continuous Amps Peak Amps
MPA-05-460 5 10
MPA-09-460 9 18
MPA-15-460 15 30
MPA-25-460 25 50
MPA-35-460 35 70
MPA-50-460 50 100
MPA-75-460 75 120
MPA-100-460 100 165
Features
• Efficient power conversion
• High frequency switching
• Resolver feedback
• Simulated encoder signals
• ±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
• Single or three-phase operation
• Simple one turn visual adjustments

5
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
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
Single or Three Phase
No Isolation Transformer Required
Output Characteristics
(All Models)
Quasi Trapezoid with Torque Linearization
Torque Ripple 5% Maximum
MPA-05-460:
Output:
Input:
5 amps continuous; 10 amps peak; peak ≤1 second
PWM frequency 15 kHz
Single phase; 6 amps continuous max
Three phase; 4 amps continuous max
DC Bus is AC line dependent
MPA-09-460:
Output:
Input:
9 amps continuous; 18 amps peak; peak ≤1 second
PWM frequency 15 kHz
Single phase, 9 amps continuous max
Three phase; 11 amps continuous max
DC Bus is AC line dependent

6
Parameter Specification
MPA-15-460:
Output:
Input:
15 amps continuous; 30 amps peak; peak ≤1 second
PWM frequency 15 kHz
Single phase; 18 amps continuous max
Three phase; 11 amps continuous max
DC Bus is AC line dependent
MPA-25-460:
Output:
Input
25 amps continuous; 50 amps peak; peak ≤1 second
PWM frequency 12 kHz
Single phase; 30 amps continuous max
Three phase; 20 amps continuous max
DC Bus is AC line dependent
MPA-35-460:
Output:
Input:
35 amps continuous; 70 amps peak; peak ≤1 second
PWM frequency 12 kHz
Single phase; 42 amps continuous max
Three phase; 26 amps continuous max
DC Bus is AC line dependent
MPA-50-460:
Output:
Input:
50 amps continuous; 100 amps peak; peak ≤1 second
PWM frequency 12 kHz
Single phase; 60 amps continuous max
Three phase; 40 amps continuous max
DC Bus is AC line dependent
MPA-75-460:
Output:
Input:
75 amps continuous; 120 amps peak; peak ≤1 second
PWM frequency 10 kHz
Three phase; 60 amps continuous max
DC Bus is AC line dependent
MPA-100-460:
Output:
Input:
100 amps continuous; 165 amps peak; peak ≤1 second
PWM frequency 10 kHz
Three phase; 80 amps continuous max
DC Bus 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)

7
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-05/09-460
MPA-15-460
MPA-25/35/50-460
MPA-75/100-460
12 lbs. max
14 lbs. max
20 lbs. max
45 lbs. max
Motor Inductance:
For all 460 volt products, the inductance line-to-line must be
no less than 4mH.
IND-100-.5mH
IND-25-460-2mH
One inductor in each line is typical. The turn ON times of the
power switches can cause catastrophic destruction of
motors. Inductors in RST of the motor leads limit the rise time
and preserve the motor. All 460 volt motors should have
inductors.

8
MPA-05/09/15/25/35/50-460 Mechanical Footprint
C
B
A
1.0
.31
N
O
T
E
13.6 14.6
FRONT VIEW
.5 RECOMMENDED
11.25
SIDE VIEW
Summary of Amplifier Dimensions
Model A (inches) B (inches) C (inches)
MPA-05/09/15-460 6.5 4.5 .53
MPA-25/35-460 8.5 6.5 .53
MPA-50-460 8.5 6.5 2.2
NOTE
If front cover is attached, additional
clearance of .2 should be allowed.

9
MPA-75/100-460 Mechanical Footprint
SIDE VIEW
1.64
11.63
.5 RECOMMENDED
15.2
5.5
5.5
13.6
14.6
3.15
.31
NOTE
FRONT VIEW
NOTE
If front cover is attached, additional
clearance of .2 should be allowed.

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Signal/Wiring Overview
LEAD
SIG
RESP
CUR
BAL
RESET
FEEDBACK
SHLD
SHLD
GND
GND
GND
GND
REF
COS
TS
SIN
I/O
GND
-AUX
+AUX
GND
-COM
+COM
CUR
VEL
GND
FLT
V/T
-LIM
+LIM
RES
CONTINUOUS
LIMIT
RESET
HI-BUS
MOTOR
FEEDBACK
AMPLIFIER
SHORTS
CURRENT
MARK
ENCODER
POWER

11
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
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 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.

12
ANF3 User Configuration Locations
NOTE
Never change DIP switches or jumpers
with power ON.

13
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 available. DIP switch S2 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 S2 with power
ON.
DIP SWITCH S2
S2 1 2 3 Motor Type
ON ON ON 8-POLE
OFF ON ON 6-POLE (default)
ON OFF ON 4-POLE
OFF OFF OFF BRUSH
All MTS Automation two-inch motors are 4-pole. The three-inch, four-inch, six-inch, and
eight-inch motors are 6-pole motors.
For brush motor operation, no resolver alignment is required and the R lead connects to
armature (+) and the T lead connects to armature (-). These connections will cause
clockwise rotation from the shaft end of the motor.

14
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 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 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.

15
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 .5 volts and logic 1 is typically between 3.3 and 4
volts.

16
S4 is provided as a means to determine the resolution of the simulated encoder signals.
The amplifier is configured form the factory to be 1024 lines.
S4 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.

17
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 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 is an input that determines the
amplifier mode, Velocity/Torque mode.
When the switch is open, the Velocity
mode is selected. When the switch is
closed, the Torque mode is selected.
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.

18
DIP switch S3 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 S2-4 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.
Sometimes the amplifiers Reset Input is used as an Enable Input by switching OFF S3-1.
The first input has to be switched ON (grounded) to enable the amplifier. With the input
OFF (ungrounded) the amplifier is in the reset condition. In the reset condition, the Reset
LED (red) is ON, fault conditions are reset, and the bridge power devices are disabled. If
an external controller uses a fault output to disable the amplifier by switching off the reset,
the fault that cause the fault conditions is reset. To preserve the fault status, the JP2
jumper can be moved to the left position. In this position, the fault LED's will clear when
the enable is switched ON.

19
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 5 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.

20
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.
The location of these adjustments is next to the I/O wiring.
FEEDBACK AND I/O CONTROL ASSEMBLY
LEAD
SIG
RESP
CUR
BAL
RESET
I/O
GND
-AUX
+AUX
GND
-COM
+COM
CUR
VEL
GND
FLT
V/T
-LIM
+LIM
RES
ENCODER
Outputs
Two diagnostic outputs are the dc voltage proportional to velocity and the dc output
proportional to current/torque. The nominal TAC gradient is determined by DIP switches
in a range of ±10 volts. The current gradient is 10 volts equal peak.