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Diagnostics/Troubleshooting

4-3

Instruction Manual

Malfunction Diagnosis

T

ABLE

4.1

MAX-430 System Problem Symptoms and Possible Causes

Symptoms

Possible Causes

Motor inoperative.

No AC power to the drive

Faulty wiring to motor

No ± 15 VDC at P2.

Power supply defective

± 15 VDC regulators defective

No voltage between MT+, MT- terminals.

INH clamp activated

Defective drive

Motor responds to commands only in one direction.

FAC or RAC clamp activated

Defective output stage or drive board

Voltage measured between motor terminals but
motor does not rotate.

Motor or load mechanically jammed

Motor brushes worn or improperly seated

Open motor winding

Motor runs only at a high constant speed.

Faulty wiring to the tachometer

Tachometer brushes worn or improperly seated

Open tachometer winding

Tachometer leads reversed

TACH gain fully CCW - See page 3-2.

Velocity Clamp jumpered - See page 2-12.

Bus Overvoltage

Shunt fuse (F1) blown

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Содержание MAX-430

Страница 1: ...PWM Servo Drive Instruction Manual Rockwell Automation Electro Craft 6950 Washington Avenue South Eden Prairie MN 55344 T H E R I G H T C O M P A N Y T H E R I G H T S O L U T I O N Click to Go Back to OEM Menu ...

Страница 2: ...h the construction and operation of this equipment and the hazards involved should install adjust operate or service this equipment Read and understand this manual and other applicable manuals in their entirety before proceeding Failure to observe this precaution could result in severe bodily injury or loss of life Intro WARNING The user must provide an external hardwired emergency stop circuit ou...

Страница 3: ... Power Connections 2 4 Auxiliary Logic Supply Power 2 8 Connecting The Motor 2 8 Logic Inputs and Outputs 2 8 Connecting Inputs 2 10 Velocity Command Signal VCS 2 10 Auxiliary Input 2 10 Inhibit INH 2 10 Forward and Reverse Amplifier Clamps FAC RAC 2 10 Internal Connections FAC RAC and INH 2 11 Velocity Clamp Torque Mode 2 12 External Current Limit Optional 2 12 Connecting Outputs 2 13 System Stat...

Страница 4: ...nostics Troubleshooting Monitoring Outputs 4 1 Motor Current Output MCO 0 10V 4 1 Motor Current Output MCO 10V 4 1 Motor Velocity Output MVO 4 1 Scheduled Maintenance 4 2 Checking and Replacing the Fuses 4 2 Malfunction Diagnosis 4 3 Light Emitting Diodes 4 4 Power LED Green 4 4 Test Outputs 4 5 CHAPTER 5 Specifications Inrush Currents 5 2 CHAPTER 6 Component Ordering Information CHAPTER 7 Referen...

Страница 5: ...pins 1 2 2 11 Sinking Opto s with External Power P8A pins 2 3 and P8 pins 2 3 2 12 SSO Open Collector Sourcing 2 13 SSO Open Collector Sinking 2 13 SSO Normally Closed Relay with Internal Power 2 14 SSO Normally Closed Relay using External Power with FAULT Condition Logic Level 1 2 14 SSO Normally Closed Relay using External Power with Drive READY Logic Level 1 2 14 Isolated Logic Interface Connec...

Страница 6: ...r Part Number 9077 0640 6 2 1 8 kVA Transformer Part Number 9077 0639 6 3 3 6 kVA Transformer Part Number 9077 0638 6 4 3 6 kVA Transformer Part Number 9077 0637 6 5 CHAPTER 7 Reference Drawings Outline Mounting and Adjustments Diagram 7 1 Simplified Circuit Diagram 7 2 APPENDIX A Differences from the MAX 400 ...

Страница 7: ...leshooting MAX 430 System Problem Symptoms and Possible Causes 4 3 LED Fault Conditions 4 4 CHAPTER 5 Specifications Performance Specifications 5 1 Electrical Specifications 5 1 Input Power Requirements 5 1 Physical Specifications 5 1 CHAPTER 6 Component Ordering Information Ordering PWM Servo Drive 6 1 Ordering Transformers 6 1 CHAPTER 7 Reference Drawings Listing of Drawings 7 1 APPENDIX A Diffe...

Страница 8: ...l Index page 4 4 page 4 5 page 2 4 page 2 8 page 2 4 page 2 8 page 2 4 page 2 8 page 2 4 page 2 8 page 3 3 page 4 5 page 2 10 page 2 10 page 2 10 page 2 13 page 2 13 page 2 12 page 2 10 page 2 10 page 2 10 page 2 12 page 2 12 page 2 15 page 2 15 page 2 15 page 2 15 page 2 15 page 2 12 ...

Страница 9: ...uxiliary power input main power will dissipate immediately on power down However if there is no power being supplied to the auxiliary power input main power must dissipate through a resistor and it will take at least 60 seconds before the voltage is at a safe level Introduction to the MAX 430 The SystemFunctionalDiagram oftheElectro CraftMAX 430driveisshownonthefollowing page MAX 430 series drives...

Страница 10: ...such that a controller provides an analog voltage signal proportional to the desired motor torque Refer to the System Functional Diagram shown below The MAX 430 drive contains circuitry for protection of both motor and drive from effects of various overload and short circuit conditions The command signal to the power drive can be monitored at the ICMD output The MAX 430 is a 16 kHz pulse width mod...

Страница 11: ...ard and Reverse Amplifier Clamps FAC RAC on page 2 10 Intro CAUTION If replacing a MAX 400 with a MAX 430 refer to Appendix A Differences from the MAX 400 for a list of changes to be aware of TABLE 2 1 Inputs and Outputs with Jumpers P6 through P9A Jumper Pins Position Operation Page P6 1 2 FAC ILIMIT Current reduced to 5 of peak current in the forward direction when FAC is clamped 2 10 2 3 FAC DI...

Страница 12: ...king 2 12 P9 P9A 1 2 SSO Relay System Status Output is controlled by a relay 2 13 2 3 SSO Open Collector System Status Output is controlled by an open collector transistor 2 13 Intro FIGURE 2 1 Jumper Locations TABLE 2 1 Inputs and Outputs with Jumpers P6 through P9A continued Jumper Pins Position Operation Page NOTE Figure depicts factory jumper settings Refer to the Internal Connections FAC RAC ...

Страница 13: ...r and you are unsure of the exact speed and torque in your application Look at the speed torque curve for your drive motor combi nation as shown in the Electro Craft catalog and use the values for the worst case continuous speed and torque Transformer single phase KVA rating Sum of each motor s average output power x 2 0 KVA Selecta transformer that can provide enough voltage for theapplication Th...

Страница 14: ... Refer to Transformer Sizing on page 2 3 Alternatively the MAX 430 may be supplied with 30 120 VDC ThegroundingconnectionforACandDCpower chassisandmotormustbeconnectedasshown in the following wiring diagrams Intro CAUTION All TB1 terminals must be tightened to 9 lb in All wiring must be a minimum of 60 C insulation rating Intro FIGURE 2 2 115 VAC Input Power Motor Wiring ...

Страница 15: ...rom each drive should terminate at the trans former terminals as shown on the drawing When powering more than one drive it is recommended but not required that individual secondaries of a transformer be used so that the power inputs of the drives are completely isolated Intro FIGURE 2 3 230 VAC Input Power Motor Wiring Intro FIGURE 2 4 30 120 VDC Input Power Motor Wiring ...

Страница 16: ...2 6 Installation P N 0013 1025 001 Rev F Intro FIGURE 2 5 Multiple Axis Power Wiring Individual Secondaries Recommended Method ...

Страница 17: ...Installation 2 7 Instruction Manual Intro FIGURE 2 6 Multiple Axis Power Wiring One Secondary Alternative Method ...

Страница 18: ...viewed from the shaft end of the motor Likewise there will be counterclockwise rotation when a negative voltage is applied to VCS To reverse direction while keeping the voltage polarity on VCS and VCS the same both motor leads andtachometer leads need to be reversed To reduce the effect of radiated electrical noise it is suggested that the motor leads and the supply leads be run as twisted pair sh...

Страница 19: ...Proper shielding is recommended The shield may be connected to common P1 pin 4 or to common on controller end of wire The connections shown are with factory default jumper settings See Internal Connec tions FAC RAC and INH on page 2 11 for details on connections for other jumper set tings ...

Страница 20: ...is also used to reset the System Status Output SSO fault circuit The INHibit input must be activated to clear the SSO fault Connection P1 pin 8 Refer to Internal Connections FAC RAC and INH on page 2 11 Forward and Reverse Amplifier Clamps FAC RAC Function The forward amplifier clamp FAC and reverse amplifier clamp RAC are directional clamps that will operate in one of two ways depending on the po...

Страница 21: ... 2 10 Sinking Opto s with Internal Power P8A pins 2 3 and P8 pins 1 2 Active High To enable the drive or to release the forward or reverse amplifier clamps hold input at high volt age P1 7 Switch Status Closed OK Open Clamped Opto 3 3k 1 0k 15V Unregulated 15V P1 7 INHIBIT P1 8 FAC P1 9 or RAC P1 10 15V COM Active High To enable the drive or to release the forward or reverse amplifier clamps hold ...

Страница 22: ... ILIM potentiometer is fully clockwise the exact degree of reduction is a function of the internal current limit See Figure 2 7 on page 2 9 Connection P2 pins 5 and 6 Intro FIGURE 2 11 Sinking Opto s with External Power P8A pins 2 3 and P8 pins 2 3 Resistance Reduction of Peak Current 330 Ω approximately 25 of peak current 1 2 kΩ approximately 50 of peak current 3 3 kΩ approximately 75 of peak cur...

Страница 23: ... the figure SSO Normally Closed Relay with Internal Power the logic levels are the opposite of the open collector logic levels Refer to Figure 2 1 If there is a fault one of the red LEDs on the drive turns on to indicate which fault has occurred See Light Emitting Diodes on page 4 4 Connection P1 pins 5 and 6 Refer to the following diagrams TIP The open collector configuration cannot be used with ...

Страница 24: ...ally Closed Relay using External Power with Drive READY Logic Level 1 15VDC MAX 430 SERVO DRIVE 7 6 ON OK CUSTOMER 15 VDC CONTROLLER 4 P1 SSO 15VDC COM 5 FAULT Open Relay 1 2 3 P9A 1 2 3 P9 MAX 430 SERVO DRIVE 6 ON OK CUSTOMER SSO CONTROLLER 5 P1 SSO FAULT Open Relay 22 28 VDC COM 22 28 VDC 1 2 3 P9A 1 2 3 P9 MAX 430 SERVO DRIVE 5 ON FAULT CUSTOMER SSO CONTROLLER 6 P1 SSO FAULT Open Relay 22 28 VD...

Страница 25: ... Output MVO Function The motor velocity output MVO signal is an analog voltage signal which is proportional to the actual instantaneous motor speed The scaling of this signal and the tolerance is dependent on the voltage constant of the tachometer in use This output is not affected by the TACH gain potentiometer See Tach Gain TACH on page 3 3 In the standard drive motor connection this voltage is ...

Страница 26: ...verse amplifier clamps can be wired as limit switches Intro FIGURE 2 17 Isolated Logic Interface Connections Intro FIGURE 2 18 Limit Switch Wiring 1 The connections shown are with jumpers in factory default settings See Internal Connec tions FAC RAC and INH on page 2 11 for details on connections for other jumper set tings ...

Страница 27: ...rive to run in torque mode The following diagram shows a suggested method for using the 15 volts on P2 pins 9 and 10 as a voltage source for the VCS input With positive voltage at VCS with respect to VCS there will be torque in the CW direction With negative voltage at VCS there will be torque in the CCW direction The velocity clamp must be jumpered Tachometer feedback should not be used when in t...

Страница 28: ...en the two drives Two MAX 430 drives can also be wired for a torque sharing application The wiring is the same as below except the voltage to the second drive is supplied from the MCO output on P2 pin 7 instead of the MVO output The velocity clamps must be jumpered on both drives Tachometer feedback should not be used when in torque mode current mode Intro FIGURE 2 22 Torque Control Intro FIGURE 2...

Страница 29: ...ge for the application This can be determined by looking at the maximum speed of the application and the voltage constant KE of the motor selected 6 Check that the incoming AC or DC voltage is correct Do not apply more than 85 VAC or 120 VDC to TB1 pins 6 and 7 Verify fusing per wiring diagrams in AC and DC Power Connections on page 2 4 7 Install drive Refer to Mounting on page 2 3 8 Replace cover...

Страница 30: ...rrent with no external current limit resistor The average current limit will always be 50 of the peak current limit 11 Turn the COMP control CW until the motor shaft starts to oscillate then turn back suffi ciently to stop the oscillation 12 Remove power from the drive and use either of the following methods to apply a veloc ity command voltage signal to the drive a Connect a potentiometer to the ...

Страница 31: ...nt with no external current limit resistor 8 turns CW approximately 70 peak current with no external current limit resistor 16 turns CW 100 peak current with no external current limit resistor The average current limit will always be 50 of the peak current limit Balance Control BAL With the drive enabled the motor should not rotate when the drive is receiving a zero VCS signal but it may move slow...

Страница 32: ...nction generator to the VCS and VCS inputs P1 pins 1 and 2 and connect the oscilloscope to the tachometer signal Set the function generator for a frequency of 0 5 Hz with an amplitude of 0 5 volts square wave VCS Gain Setting Turn the VCS gain potentiometer CW until a 0 5 volt tachometer signal is observed on the oscilloscope Make adjustments as required to obtain optimum system response as shown ...

Страница 33: ...Applying Power for the First Time 3 5 Instruction Manual Intro FIGURE 3 1 System Response to a Step VCS Input ...

Страница 34: ...starts to rotate 11 Apply zero volts to VCS Or jumper P1 pins 1 and 2 12 Adjust the BALance potentiometer CW until the motor shaft remains stationary 13 The COMP potentiometer should remain fully CW 14 Set the ILIM relative to motor peak current a 4 turns CW approximately 50 peak current with no external current limit resis tor b 8 turns CW approximately 70 peak current with no external current li...

Страница 35: ... to the motor The VCS adjustment scales the output to the level set by the potentiometer as shown in the figure below Scaling changes the Volts to Amps resolution of the drive It is not necessary to have tachometer feedback when used in the torque mode current mode Jumper P2 pin 1 to P2 pin 2 Intro FIGURE 3 2 VCS Torque Mode Scaling Examples 30 15 16 VCS turns 8 2 0 30 15 16 VCS turns 8 2 0 ILIM 5...

Страница 36: ...3 8 Applying Power for the First Time P N 0013 1025 001 Rev F ...

Страница 37: ...l is 10 volts 30 0 amps 10 See Figure 2 17 on page 2 16 Connection P2 pin 7 signal P2 pin 4 or pin 6 reference Motor Velocity Output MVO Function The motor velocity output MVO signal is an analog voltage signal which is proportional to the actual instantaneous motor speed The scaling of this signal and the tolerance is dependent on the voltage constant of the tachometer in use This output is not a...

Страница 38: ...is persistently high or low change transformer taps as necessary Checking and Replacing the Fuses The DC Bus shunt fuse F2 and the 24 VDC Auxiliary Power Input fuse F1 are located on the power amplifier board of the MAX 430 To check and or replace either fuse 1 Measure voltages at TB1 pin 6 and pin 7 and at TB1 pin 9 and pin 10 to insure incoming power is OFF Make sure that the green READY LED is ...

Страница 39: ...ve drive Motor responds to commands only in one direction FAC or RAC clamp activated Defective output stage or drive board Voltage measured between motor terminals but motor does not rotate Motor or load mechanically jammed Motor brushes worn or improperly seated Open motor winding Motor runs only at a high constant speed Faulty wiring to the tachometer Tachometer brushes worn or improperly seated...

Страница 40: ...oximate length of time that current exceeding average current can be drawn through the drive before the drive faults TABLE 4 2 LED Fault Conditions Fault LEDs Red Condition O Current This LED will turn on due to three conditions 1 Short circuit overcurrent 2 Excessive average current see figure below 3 FAC or RAC in an invalid state 0 9mA opto source sink current 1 4mA O Volt Bus overvoltage above...

Страница 41: ...e scaling of this signal is approximately 1 75 volts 30 amps This output should be used for trouble shooting purposes only Note The scaling of this output is differ ent than the MCOs at P2 pins 3 and 7 Motor Velocity Output MVO The motor velocity output signal is an ana log voltage signal which is proportional to the actual instantaneous motor speed In the standard amplifier motor connection this ...

Страница 42: ...4 6 Diagnostics Troubleshooting P N 0013 1025 001 Rev F ...

Страница 43: ...Impedance 10V 30 A 10 Motor Current Output Monitor Absolute 1 kΩ Output Impedance 0 10V 30 A 10 SSO Open Collector Voltage 40 VDC Max SSO Open Collector Sink Current 50 mA Max SSO Relay Voltage 50 VDC Max SSO Relay Current 500 mA Max FAC RAC INHIBIT Opto Sink Current each 15 mA 10 FAC RAC INHIBIT Opto Source Current each 15 mA 10 FAC RAC INHIBIT Opto Input Leakage Current 100 µA Max Bus Overvoltag...

Страница 44: ...mary and secondary taps of the transformer Length 7 30 in 185 mm Weight 6 6 lbs 2 90 kg Ambient Temperature Operating Storage Shipping Relative Humidity 32 to 122 F 0 to 50 C 40 to 158 F 40 to 70 C 5 to 95 non condensing Intro FIGURE 5 1 Inrush Current Measurements TABLE 5 4 Physical Specifications t ms t ms Primary Inrush Current Secondary Inrush Current Note The measurements reflect the typical ...

Страница 45: ...Littelfuse 225001 0020 1354 209 Terminal Block Mating Connector 10 position quantity 1 2 connectors per drive TABLE 6 2 Ordering Transformers Part Number Description 9077 0640 0 65 kVA single phase transformer See Figure 6 1 9077 0639 1 8 kVA single phase transformer See Figure 6 2 9077 0638 3 6 kVA single phase transformer See Figure 6 3 9077 0637 3 6 kVA single phase transformer See Figure 6 4 ...

Страница 46: ...6 2 Component Ordering Information P N 0013 1025 001 Rev F Intro FIGURE 6 1 0 625 kVA Transformer Part Number 9077 0640 ...

Страница 47: ...Component Ordering Information 6 3 Instruction Manual Intro FIGURE 6 2 1 8 kVA Transformer Part Number 9077 0639 ...

Страница 48: ...6 4 Component Ordering Information P N 0013 1025 001 Rev F Intro FIGURE 6 3 3 6 kVA Transformer Part Number 9077 0638 ...

Страница 49: ...Component Ordering Information 6 5 Instruction Manual Intro FIGURE 6 4 3 6 kVA Transformer Part Number 9077 0637 ...

Страница 50: ...6 6 Component Ordering Information P N 0013 1025 001 Rev F ...

Страница 51: ...Drawings TABLE 7 1 Listing of Drawings Drawing Number Description 9077 0674 Simplified Circuit Diagram See Figure 7 2 9077 0675 Outline Mounting and Adjustments Diagram See Figure 7 1 Intro FIGURE 7 1 Outline Mounting and Adjustments Diagram ...

Страница 52: ...7 2 Reference Drawings P N 0013 1025 001 Rev F Intro FIGURE 7 2 Simplified Circuit Diagram ...

Страница 53: ...en average current is exceeded for the permitted time period in the MAX 430 the amplifier shuts down and the Overcurrent fault LED turns on Motor Current Output The MCO output P2 pin 7 on the MAX 430 is scaled so that 10 Volts equals 30 Amperes of motor current The MAX 400 scaled 1 5 Volts at 30 Amperes The higher Voltage results in more accurate current readings Multi Axis Power Wiring Multiple M...

Страница 54: ...A 2 Differences from the MAX 400 P N 0013 1025 001 Rev F ...

Страница 55: ...quirements 5 1 Input Power Motor Wiring 2 4 Inputs 2 10 Auxiliary Input 2 10 FAC 2 10 Inhibit 2 10 RAC 2 10 VCS 2 10 Inrush Currents 5 2 Installation 2 1 Internal Adjustments 2 1 Internal Connections 2 11 Internal Opto Power 2 1 J Jumper Locations 2 3 Jumpers 2 1 L LED Indicators 4 4 Limit Switch Wiring 2 16 Logic Inputs and Outputs 2 8 M Maintenance 4 2 Malfunction Diagnosis 4 3 MAX 400 to MAX 43...

Страница 56: ...pto s 2 1 2 2 2 11 2 12 Sourcing Opto s 2 1 2 2 2 11 Spare Parts 6 1 Specifications 5 1 SSO 2 1 2 13 SSO Open Collector 2 2 SSO Relay 2 2 Support Help 5 System Response to a Step VCS Input 3 5 System Status Output 2 1 2 13 T TACH 3 3 Tach Gain 3 3 Technical Assistance Help 5 Test Outputs 4 5 Torque Control 2 18 Torque Mode 1 2 2 12 2 18 3 7 Transformers 2 4 2 5 2 6 2 7 6 1 Troubleshooting 4 1 V VC...

Страница 57: ..._______________ _________________________________________________________________________________________________ _________________________________________________________________________________________________ _________________________________________________________________________________________________ __________________________________________________________________________________________...

Страница 58: ...Help 4 Documentation Improvement Form P N 0013 1025 001 Rev F Second Fold Tape First Fold ...

Страница 59: ...tfactorybasedsupportstaffbyphonebetween 7 30 AM and 5 00 PM CST Monday through Friday at 1 800 328 3983 The applications engi neers can assist you with programming difficulties as well as ideas for how to approach your automation task Should your problem require on site assistance field service is available The applications engineers can also be reached via fax at 1 612 942 3636 The fax machine is...

Страница 60: ...PWM Servo Drive Rockwell Automation Electro Craft 6950 Washington Avenue South Eden Prairie MN 55344 612 942 3600 main 612 942 3636 fax 800 328 3983 technical support P N 0013 1025 001 Rev F Instruction Manual ...

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