maxtune intelligent servo drive - pba systems

SYSTEMS

www.pbasystems.com.sg

I N T E L L I G E N T S E R V O D R I V E

QUICK START GUIDErevision 2.1

MaxTune Product Description

User Manual 1

Revision History

Document

Revision

Date Remarks

1.0 February

2012

Public Version

2.0 June 2012 Part number change. USB Functionality available

only on CANOpen models.

2.1 July 2012 Added diagrams

Hardware

Revision

Firmware

Revision

Software

Revision

Remarks

0.0.13

Important Notice

© 2012 PBA Systems Pte. Ltd

All rights reserved. No part of this work may be reproduced or transmitted in any form

or by any means without prior written permission of PBA Systems.

Disclaimer

The information in this manual was accurate and reliable at the time of its release. PBA

Systems Pte. Ltd reserves the right to change the specifications of the product

described in this manual without notice at any time.

Trademarks

All marks in this manual are the property of their respective owners.

Contact Information

PBA Systems Pte. Ltd

2 Woodlands Sector 1, Woodlands Spectrum 1,

#03-23, Singapore 738068

Tel: (+65) 6576 6767

Fax: (+65) 6576 6768

Website: http://www.PBASystems.com.sg/

Technical Support

If you need assistance with the installation and configuration of the MaxTune drive,

contact PBA Systems technical support: [email protected]

Customer Service

PBA Systems is committed to delivering quality customer service and support for all our

products. Our goal is to provide our customers with the information and resources so

that they are available, without delay, if and when they are needed. In order to serve in

the most effective way, we recommend that you contact your local sales representative

for order status and delivery information, product information and literature, and

application and field technical assistance. If you are unable to contact your local sales

representative for any reason, please use the most relevant of the contact details below:

http://www.pbasystems.com.sg/

http://www.pbasystems.com.sg/

mailto:[email protected]

Product Description MaxTune

2 User Manual

For technical support, contact: [email protected]

To order products, contact: [email protected]

For all other inquiries regarding MaxTune drives or other PBA Systems products, contact:

[email protected]

Part Number

For ordering the MaxTune, refer to the following diagram:

Ratings Units 2/6 4/12 6/25 8/25 11/39 14/39 16/33 18/39 28/67 33/67

Supply Voltage (120 VAC / 230

VAC)

1 Phase 1 Phase 1 Phase 3 Phase

1 Phase 3 Phase

1 Phase 3 Phase

1 Phase 3 Phase

N/A 3 Phase 3 Phase 3 Phase

Supply Voltage (400 VAC / 480

VAC)

N/A 3 Phase N/A 3 Phase N/A N/A 3 Phase N/A N/A 3 Phase

Continuous Current Apeak 2.1 4.2 6.3 8.4 11.3 14.1 16.9 18.3 28.2 33.9

Peak Current Apeak 6.3 12.7 25.4 25.4 39.5 39.5 33.9 39.5 67.8 67.8

Warranty

The warranty is valid for 30 months from the date of shipment and applies only if

material or workmanship is found to be defective. The warranty will be invalid if the

customer fails to install, operate or maintain the product in accordance with the

instructions in this user manual.




User Manual 3

During the warranty period, the owner must pay the cost of shipping the product to the

factory for repair, and PBA Systems will pay for shipping the repaired product to the

customer.

After the warranty period has expired, all shipping costs will be the responsibility of the

customer.

Before returning the product, the customer must first request a Return Materials

Authorization (RMA) number from PBA Systems by email to [email protected]



4 User Manual

Contents

1 Introduction .................................................................................................................................... 5 1.1 Documentation ....................................................................................................................... 5 1.2 Safety ..................................................................................................................................... 5

1.3 Standards Compliance ........................................................................................................... 6 1.4 Unpacking .............................................................................................................................. 7

2 Preparation ..................................................................................................................................... 8 2.1 Power Connectors .................................................................................................................. 8 2.2 Digital Connectors ................................................................................................................. 8

2.3 Connectors Pin-out diagrams ............................................................................................... 10 2.4 Computer System ................................................................................................................. 13

3 Hardware Installation ................................................................................................................... 14 3.1 Overview .............................................................................................................................. 14 3.2 Step by Step instructions ...................................................................................................... 14

4 Software Installation .................................................................................................................... 27


User Manual 5

1 Introduction

1.1 Documentation

1.1.1 About This Manual

This Quick Start Guide provides step by step instruction in setting up MaxTune. It is

divided into three parts:

1. Preparation: Encompass hardware that need to be ready before using

MaxTune. This step can be carried out without the MaxTune drive.

2. Hardware Setup: Connecting the connectors to the proper ports. There are

more details on the individual connections in this section.

3. Software Setup: Instructions to run through MaxLink Setup Wizard.

1.1.2 Documentation Set for MaxTune

This manual is part of a documentation set. The entire set consists of the following:

MaxTune Quick Start Guide. Basic setup and operation of the drive.

MaxTune User Manual. Hardware installation, configuration and operation.

MaxTune VarCom Reference Manual. Parameters and commands used to program

the MaxTune.

1.2 Safety

Only qualified persons may perform the installation procedures. You do not need to be

an expert in motion control to install and operate the drive system. However, you must

have a basic understanding of electronics, computers, mechanics, and safety practices.

The MaxTune utilizes hazardous

voltages.

Be sure the drive is properly grounded.

Before you install the MaxTune, review the safety instructions in this manual. Failure to

follow the safety instructions may result in personal injury or equipment damage.

1.2.1 Safety Symbols

Safety symbols indicate a potential for personal injury or equipment damage if the

recommended precautions and safe operating practices are not followed.

The following safety-alert symbols are used on the drive and in the documentation:

Caution ISO 7000-0434 (2004-01)

Warning. Dangerous voltage. IEC 60417-5036 (2002-10)

Protective earth; protective ground IEC 60417–5019 (2006-08)

Caution, hot surface IEC 60417-5041 (2000-10)


6 User Manual

1.2.2 Safety Instructions

Read all available product documentation before assembling and commissioning.

Incorrect handling of this product may cause personal injury and/or damage to equipment.

Adhere strictly to the installation instructions and requirements.

All system components must be connected to ground. Electrical safety is provided

through a low-resistance earth ground connection. (Protective Class 1 according standard

EN/IEC 618005-1.)

This product contains static sensitive components that can be damaged by incorrect

handling. Avoid contact with high insulating materials (artificial fabrics, plastic film, etc.). Place

the product on a conductive surface. Ground yourself (discharge any possible static electricity

build-up) by touching an unpainted, metal, grounded surface.

Keep all covers and cabinet doors shut during operation. Otherwise, potential hazards

may cause personal injury and/or damage to equipment.

During operation the product has electrically charged components and hot surfaces. The

heat sink can reach temperatures of 90°C. Control and power cables can carry a high voltage,

even when the motor is not rotating.

To avoid electric arcing and hazards to personnel and electric contacts, never disconnect

or connect the product while the power source is energized.

After removing the power source from the equipment, wait at least 5 minutes before

touching or disconnecting sections of the equipment that normally carry electrical charges (e.g.,

capacitors, contacts, screwed connections). For safety, measure the electrical contact points

with a meter before touching the equipment. Wait until the voltage drops below 30 VAC before

handling components.

Provide a power mains disconnect device in according with local regulations.

Before testing and setting up, the manufacturer of the machine must generate a hazard

analysis for the machine, and take appropriate measures to ensure that unforeseen movements

cannot cause injury or damage to any person or property.

Since the drive meets IP20, the end user must select an enclosure that permits safe

operation of the drive. The enclosure must meet at least IP54 made of metal or material with

rating flammability of 5 VA.

Since the leakage current to PE is greater than 3.5 mA, compliance with IEC61800-5-1

requires that either the PE connection be doubled or a connecting cable with a cross-section

greater than10 mm² be used. Use the PE terminal and the PE connection screws to meet this

requirement.

Wiring of green color with or without one or more yellow stripes must not be used except

for protective bonding.

1.3 Standards Compliance

1.3.1 General Information

The MaxTune has been successfully tested and evaluated according to standards

IEC 61800-5-1. Conformance for UL 508C is in progress. This testing outlines the

minimum requirements for electrically operated power conversion equipment

(frequency converters and servo amplifiers), which are intended to eliminate the risk of

fire, electric shock, or injury to persons.

UL 508C references UL 840, which describes the achievement by design of air and

insulation creepage spacings for electrical equipment and printed circuit boards. The

MaxTune provides overload protection and current limit control.

http://ulstandardsinfonet.ul.com/scopes/scopes.asp?fn=0508C.html

http://ulstandardsinfonet.ul.com/scopes/scopes.asp?fn=0508C.html

http://ulstandardsinfonet.ul.com/scopes/scopes.asp?fn=0840.html

http://ulstandardsinfonet.ul.com/scopes/scopes.asp?fn=0840.html


User Manual 7

The drive is intended for operation in pollution level 2 environment.

The terminals on the controller are coded so they can easily be identified in the

instructions. The instructions identify the connections for the power supply, load,

control, and ground.

Integral solid state short circuit protection does not provide branch circuit protection.

Branch circuit protection must be provided in accordance with the National Electrical

Code and any additional local codes, or the equivalent.

1.3.2 CE Compliance

The MaxTune is designed to comply with the following European directives. Formal

certification is pending.

EC Directive 2004/108/EC

Electromagnetic Compatibility

Standard EN 61800-3 (2004)

LVD Directive 2006/95/EC

Electrical Safety: Low voltage directive

Standard IEC 61800-5-1 (2007)

1.4 Unpacking

The package contains the MaxTune drive only.

1. Open the package and remove all packing materials.

2. Check to ensure there is no visible damage to the MaxTune drive. If damage is detected,

notify the carrier immediately.


8 User Manual

2 Preparation

2.1 Power Connectors

Mating Connectors (provided)

P1, P2, P3, P4 and P5 for MT-11/39, MT-14/39 and MT-18/39

P1, P2, P3 for the rest

Wire for Connectors

Connector P1

All models : 26-28AWG

Connectors P2, P3 and P4

MT-2/6 and MT-4/12 : 18AWG

MT-6/25 and MT-8/25 : 16AWG

MT-11/39, MT-14/39 and MT-18/39 : 14AWG

Connector P5 (for MT-11/39, MT-14/39 and MT-18/39)

All models : 16AWG

Crimper for Connectors

Connector P1:

Molex Crimper 0638190000

Connectors P2, P3, P4, P5

JST Crimper YRF-1070

Note: If crimp extraction tool is needed, use JST extraction tool EJ JFAJ3

Others

Earth

M4 Ring or spade terminal

2.2 Digital Connectors

Mating Connectors

1. Connector C2 (Controller I/F)

Plug 3M 10136-3000PE and shell 3M 10336-52F0-008

2. Connector C3 (Machine I/F)


3. Connector C4 (Motor Feedback)


Wire for Connectors

Connectors C2 (Controller I/F), C3 (Machine I/F) and C4 (Machine Feedback)


User Manual 9

All models : 24-28AWG

Others

USB 2.0 A to Mini-B cable (for AF models)

4p4c plug and cable (for RS-232 communication)


10 User Manual

2.3 Connectors Pin-out diagrams


User Manual 11

1

2

3

4

1

2

1

2

3

4

5

1

19

2

20

3

21

4

22

5

23

6

24

7

25

8

26

9

27

10

28

11

29

12

30

13

31

14

32

15

33

16

34

17

35

18

36

Return user supplied 24 VDC

User supplied 24V

OUT 1

IN 2

IN 1

Equivalent encoder output A-

Equivalent encoder output A+

Equivalent encoder output B-

Equivalent encoder output B+

Equivalent encoder output Z-

Equivalent encoder output Z+

Ground

ANIN 1 +

ANIN 1 -

Direction in+/ Sec Encoder B+

Direction in-/ Sec Encoder B-

Ground

Pulse in+/ Sec Encoder A+

Pulse in-/ Sec Encoder A+

Ground

Ground

IN 3

IN 4

IN 5

IN 6

OUT 2

OUT 3

**AX4-

**AX4+

*ANIN 2 -

*ANIN 2 +

ANOUT

C2: MDR 36 Plug

C3: MDR 20 Plug

Controller I/F

Machine I/FFeedback

18

9

19

10

20

OUT 6

User supplied 24V


Fault Relay 1

Fault Relay 2

1

14

2

15

3

16

4

17

5

18

6

19

7

20

8

INC encoder A+ / Data+

INC encoder A- / Data-

INC encoder B+ / Clock+

INC encoder B- / Clock-

INC encoder Z+

INC encoder Z-

Hall U+

Hall V+

Hall W+

* 8V Supply

Resolver sine+

Resolver sine -

Resolver cosine +

Resolver cosine -

Resolver reference +

21

9

22

10

23

11

24

12

25

13

26

Resolver reference -

Sine encoder sine +

Sine encoder sine -

Sine encoder cosine +

Sine encoder cosine -

5V supply

Ground

Motor Temperature sensor


5V supply

Shield

C4: MDR 26 Plug

L1

L2

L3

L1C

L2C

AC Phase 1

AC Phase 2

AC Phase 3

Logic AC Phase 1

Logic AC Phase 2

P4: JST J300

AC Input

B1+

B2

DC BUS +

Regen BUS -

P3: JST J300

Regeneration

PE

U

V

W

Functional Ground

U Phase

V Phase

W Phase

P2: JST J300

Motor

1

2

3

4

24V STO

24V RTN

(JMP to #2)

(JMP to #1)

P1: Molex

STO

Safe Torque OFF

1

2

3

4

5

6

7

8

CANH

CANL

FGND

FGND

C5:RJ45

*CAN IN

*CAN OUT

1

2

3

4

Rx

GND ISO

TX

C7: 4p4c

RS232

1

2

3

4

5

6

7

8

CANH

CANL

FGND

FGND

Mating Connector type Crimp

Housing PN F32FSS-05V-KX

5x Crimp PN SF3F-71GF-P2.0

Mating Connector type Spring

PN 05JFAT-SBXGF-I





Not Available

Protective Ground

Terminal M4

PE





PN 04JFAT-SBXGF-I


Housing PN 436450400

4x Crimp PN 0430300001

C6:RJ45

*USB

C1: Mini-B

1

11

2

12

3

13

4

14

5

15

6

16

7

17

8

Sec encoder A+/ Pulse in+

Sec encoder A-/ Pulse in-

Sec encoder B+/ Direction in+

Sec encoder B-/ Direction in-

Secondary encoder Z+

Secondary encoder Z-

Secondary encoder 5V

Secondary encoder GND

IN 7

IN 8

IN 9

IN 10

IN 11

OUT 4

OUT 5

Mating Connector type Solder

3M solder Plug connector

PN 10126-3000PE

3M solder plug Junction shell

PN 10326-52F0-008



PN 10120-3000PE


PN 10320-52F0-008



PN 10136-3000PE


PN 10336-52F0-008

1 14

13 26

1 11

10 20

1 19

18 36

* Check ordering information

** Manufacturing setting

1

1

1

1

Daisy Chain

C8:0.1" IDC Female

NELTRON 4401-10SR OR

COXOC 304A-10PSAAA03

1

2

3

4

5

6

7

8

9

10

DC Shield

RXD

GND

TXD

GND

System Wiring

Pin AssignmentsMT-6/25 MT-8/25


12 User Manual

1

2

3

4

1

2

1

2

3

1

19

2

20

3

21

4

22

5

23

6

24

7

25

8

26

9

27

10

28

11

29

12

30

13

31

14

32

15

33

16

34

17

35

18

36


User supplied 24V

OUT 1

IN 2

IN 1

Equivalent encoder output A-

Equivalent encoder output A+

Equivalent encoder output B-

Equivalent encoder output B+

Equivalent encoder output Z-

Equivalent encoder output Z+

Ground

ANIN 1 +

ANIN 1 -

Direction in+/ Sec Encoder B+

Direction in-/ Sec Encoder B-

Ground

Pulse in+/ Sec Encoder A+

Pulse in-/ Sec Encoder A+

Ground

Ground

IN 3

IN 4

IN 5

IN 6

OUT 2

OUT 3

**AX4-

**AX4+

*ANIN 2 -

*ANIN 2 +

ANOUT

C2: MDR 36 Plug

C3: MDR 20 Plug

Controller I/F

Machine I/FFeedback

* Check ordering information

** Manufacturing setting

18

9

19

10

20

OUT 6

User supplied 24V


Fault Relay 1

Fault Relay 2

1

14

2

15

3

16

4

17

5

18

6

19

7

20

8

INC encoder A+ / Data+

INC encoder A- / Data-

INC encoder B+ / Clock+

INC encoder B- / Clock-

INC encoder Z+

INC encoder Z-

Hall U+

Hall V+

Hall W+

* 8V Supply

Resolver sine+

Resolver sine -

Resolver cosine +

Resolver cosine -

Resolver reference +

21

9

22

10

23

11

24

12

25

13

26

Resolver reference -

Sine encoder sine +

Sine encoder sine -

Sine encoder cosine +

Sine encoder cosine -

5V supply

Ground



5V supply

Shield

C4: MDR 26 Plug

L1

L2

L3

AC Phase 1

AC Phase 2

AC Phase 3

P4: JST J400

Main AC Input

B1+

B2

DC BUS +

Regen BUS -

P3: JST J400

Regeneration

PE

U

V

W

Functional Ground

U Phase

V Phase

W Phase

P2: JST J400

Motor

1

2

3

4

24V STO

24V RTN

(JMP to #2)

(JMP to #1)

P1: Molex

STO

Safe Torque OFF

1

2

3

4

5

6

7

8

CANH

CANL

FGND

FGND

C5:RJ45

*CAN IN*CAN OUT

1

2

3

4

Rx

GND ISO

TX

C7: 4p4c

RS232

1

2

3

4

5

6

7

8

CANH

CANL

FGND

FGND


Housing PN J43FSS-03V-KX

3x Crimp PN SJ4F-71GF-M3.0


Housing PN J42FSC-02V-KX


Protective Ground

Terminal M4

PE


Housing PN J43FSS-04V-KX



Housing PN 436450400

4x Crimp PN 0430300001

C6:RJ45

*USB

C1: Mini-B

1

11

2

12

3

13

4

14

5

15

6

16

7

17

8

Sec encoder A+/ Pulse in+

Sec encoder A-/ Pulse in-

Sec encoder B+/ Direction in+

Sec encoder B-/ Direction in-

Secondary encoder Z+

Secondary encoder Z-

Secondary encoder 5V

Secondary encoder GND

IN 7

IN 8

IN 9

IN 10

IN 11

OUT 4

OUT 5



PN 10126-3000PE


PN 10326-52F0-008



PN 10120-3000PE


PN 10320-52F0-008



PN 10136-3000PE


PN 10336-52F0-008

1 14

13 26

1 11

10 20

1 19

18 36

1

2

L1C

L2C

Logic AC Phase 1

Logic AC Phase 2

P5: JST J300

Logic powerAC Input




1

1

1

1

1

System Wiring

Pin AssignmentsMT-11/39 MT-14/39 MT18/39

Daisy Chain

C8:0.1" IDC Female

NELTRON 4401-10SR OR

COXOC 304A-10PSAAA03

1

2

3

4

5

6

7

8

9

10

DC Shield

RXD

GND

TXD

GND


User Manual 13

2.4 Computer System

The following computer system and software are required:

2GHz CPU

1MB RAM

1000 MB available on the hard drive (after MS .net Framework 4 is installed)

MaxLink, the graphical software interface for configuring and testing MaxTune servodrive.

Download from PBA’s website

Microsoft .Net Framework 4.0 (for details, refer to .NET Framework System

Requirements). If .Net 4 is not installed on the computer, MaxLink will guide you

through the installation, but will not install it automatically.


14 User Manual

3 Hardware Installation

3.1 Overview

Perform the following steps to install and setup a MaxTune system. The steps are

described in detail in the following pages (See figure below).

1. Mount the MaxTune.

2. Connect the motor to P2.

3. Connect safe torque off (STO) to P1, or use jumpers to bypass. Refer to Step 3.

Connect STO.

4. Connect regen resistor to pins B1+ and B2 on P3, if required.

5. Connect motor feedback to C4.

6. Connect Machine I/F to C3 and/or Controller I/F at C2.

7. Connect AC input voltage. Note: This interface varies among models. Refer to

Step 8. Connect AC Input Voltage.

8. Set the drive address using the rotary switches.

9. Connect the drive to the PC.

10. Power up the drive and the PC.

11. Install MaxLink software.

12. Using MaxLink, configure and test the drive.

3.2 Step by Step instructions

Step 1: Mount the MaxTune servodrive. Use the the following diagrams for the

dimension of the mounting holes.

Figure 3-1-MT-2/6-230, MT-4/12-230 Dimensions (in mm)

Note: MT-4/12-230 shown here; MT-2/6-230 does not have fan.


User Manual 15

Figure 3-2- MT-6/25-230, MT-8/25-230 Dimensions (in mm)

Figure 3-3- MT-11/39, MT-14/39, MT-18/39 Dimensions (in mm)

Step 2: Connect the motor phases to P2.

Figure 3-4- Motor Interface


16 User Manual

Pin Pin Label Function

1 PE Protective ground (motor housing)

2 U Motor Phase U

3 V Motor Phase V

4 W Motor Phase W

Table 3-1-Motor Interface

Step 3: Connect the STO

STO uses interface P1 on all MaxTune models.

Safe torque off (STO) is a safety function that prevents the drive from delivering power

to the motor, which can generate torque.

STO Enable and STO Return must be connected to enable MaxTune operation. The STO

Enable signal voltage must be 24 VDC.

Connect the STO interface.

Note: If the application does not require STO control, jumper pin 4 to pin 1, and pin 3

to pin 2, to bypass the STO.

Figure 3-5- STO Interface


1 24V STO Enable

2 GND STO Return

3 24V Return, provided by the drive for use with

emergency stop circuit

4 24V Supply, provided by the drive for use with

emergency stop circuit

Table 3-2-STO Interface

Step 4: Connect regen resistor to pins B1+ and B2 on P3, if required.

Regen uses interface P3 on all MaxTune models.

Note: On models MT-2/6 and MT-4/12, Regen and AC Input Voltage are combined

on one connector.

If the application requires a regeneration (regen) resistor, use the P3 interface.


User Manual 17

Connect the regen resistor between terminals B1+ and B2.

Figure 3-6- Regen Interface


1 B1+ DC bus +

2 B2 Regen bus -

Table 3-3-Regen Interface

Step 5: Connect the Motor Feedback to C4

Wire the motor feedback interface according to the type of feedback device to be used

in your application.

Pins 1, 2, 14 and 15 have dual functionality.

Pins 11 and 13 for 5V to the encoder are used in digital board revision 0. Pin 18 can be

used only in digital board revision 1 and later.

Pin 25 for the motor temperature sensor is connected internally in the drive to MaxTune

ground.

Unused pins must remain unwired.

1 14

13 26

Figure 3-7- Motor Feedback Interface


18 User Manual

Pin Function Pin Function

1 Incremental encoder A +

or SSI encoder data +

14 Incremental encoder A -

or SSI encoder data -

2 Incremental encoder B +

or SSI encoder clock +

15 Incremental encoder B -

or SSI encoder clock -

3 Incremental Encoder Z + 16 Incremental encoder Z -

4 Hall U + 17 Hall V+

5 Hall W + 18 8V supply (future use)

6 Resolver sine + 19 Resolver sine -

7 Resolver cosine + 20 Resolver cosine -

8 Resolver reference + 21 Resolver reference -

9 Sine encoder sine + 22 Sine encoder sine -

10 Sine encoder cosine + 23 Sine encoder cosine -

11 5V supply 24 Ground

12 Motor temperature sensor 25 Motor temperature sensor

13 5V supply 26 Shield

Table 3-4-Motor Feedback Interface

Wiring Guidelines

For incremental encoder with Halls, use pins 1, 14, 2, 15, 3, 16, 4, 17, 5, 18, 24

For resolver, use pins 6, 19, 7, 20, 8, 21

For sine encoder, use pins 9, 22, 10, 23, 11, 24

For sine encoder with Halls, use pins 9, 22, 10, 23, 11, 24, 4, 17, 5, 18

For EnDat 2.1 encoder, use pins 1, 14, 2, 15, 9, 22, 10, 23, 11, 24

Step 6: Connect Machine I/F to C3 and/or Controller I/F at C2.

If MaxTune has to be controlled using Analog Current, Analog Velocity or Stepper

Command such as Pulse and Direction; the Controller I/F needs to be connected. It also

contains digital I/O pins as well as analog output.


To preserve isolation of the digital I/Os, connect a 24 VDC source to pin 19. Connect

the return of the 24 VDC supply to pin 1, which functions as the ground path for the

outputs.

Note: The 24 VDC supply and return can be connected on either the Controller

interface (C2) or the Machine interface (C3), but it is not necessary to connect

it on both.


User Manual 19

1 19

18 36

Figure 3-8- Controller I/F Interface

Pin Function Description Pin Function Description

1 24 VDC

return

Return of the user-supplied

24 VDC

19 24 VDC User supplied 24V, for I/O

biasing

2 Digital

output 1

Opto-isolated

programmable digital

output. Read using OUT1

20 Digital

input 2

Opto-isolated

programmable digital input.

Read using IN2

3 Digital

input 1

Opto-isolated


Read using IN1

21 Reserved for future use

4 Equivalent

encoder

output A-

Low side of the equivalent

encoder output signal A

(RS422)

22 Equivalent

encoder

output A+

High side of the equivalent

encoder output signal A

(RS422)

5 Channel

B- out


encoder output signal B

(RS422)

23 Channel

B+ out


encoder output signal B

(RS422)

6 Channel

Z- out


encoder output index

(RS422)

24 Channel

Z+ out


encoder output index

(RS422)

7 Reserved for future use 25 Ground Digital ground

8 Analog

input 1+

High side of the differential

analog command input

(±10 VDC)

26 Analog

input 1-

Low side of the differential

analog command input

(±10 VDC)


20 User Manual


9 Direction

input+

High side of the direction

signal (RS422), or

High side of the master

encoder signal B, or

High side of the down

count signal

27 Direction

input-

Low side of the direction

signal (RS422), or

Low side of the master

encoder signal B, or

Low side of the down count

signal

10 Ground Digital ground 28 Pulse

input+

High side of the pulse signal

(RS422), or

High side of the master

encoder signal A, or

High side of the up count

signal

11 Pulse

input-

Low side of the pulse signal

(RS422), or

Low side of the master

encoder signal A, or

Low side of the up count

signal

29 Ground Digital ground

12 Reserved for future use 30 Reserved for future use

13 Ground Digital ground 31 Digital

input 3

Opto-isolated


Read using IN3

14 Digital

input 4

Opto-isolated


Read using IN4

32 Digital

input 5

Fast opto-isolated


Read using IN5

15 Digital

input 6

Fast opto-isolated


Read using IN6

33 Digital

output 2

Opto-isolated



16 Digital

output 3

Fast opto-isolated



34 Reserved for future use

17 Reserved for future use 35* Analog

input 2-

Low side of the second

differential analog input

(±10 VDC)

18* Analog

input 2+

High side of the second

differential analog input

(±10 VDC)

36 Analog

output

Analog output, referenced

to digital ground (0-10

VDC)

* Optional, see ordering information

Table 3-5-Controller I/F Interface

The Machine I/F can be used if more digital I/O or a secondary encoder is required.


To preserve isolation of the digital I/Os, connect a 24 VDC source to pin 9. Connect the

return of the 24 VDC supply to pin 19, which functions as the ground path for the

outputs.


User Manual 21

Note: The 24 VDC supply and return can be connected on either the Controller

interface (C2) or the Machine interface (C3), but it is not necessary to connect

it to both.

1 11

10 20

Figure 3-9- Machine I/O Interface


22 User Manual


1 Secondary

encoder A+

High side of the

secondary encoder input

signal A (RS422), or

High side of the pulse

signal

11 Secondary

encoder A-

Low side of the secondary

encoder input signal A

(RS422), or

Low side of the pulse

signal

2 Secondary

encoder B+

High side of the

Secondary encoder input

signal B (RS422), or

High side of the direction

signal

12 Secondary

encoder B-


encoder input signal B

(RS422), or

Low side of the direction

signal

3 Secondary

encoder Z+

High side of the

secondary encoder input

index (RS422)

13 Secondary

encoder Z-


encoder input index

(RS422)

4 Secondary

encoder 5V

5 VDC supply for the

secondary encoder

14 Secondary

encoder

ground

Ground of the 5 VDC

supply for the secondary

encoder.

5 Digital

input 7

Opto-isolated


input. Read using IN7

15 Digital

input 8

Opto-isolated



6 Digital

input 9

Opto-isolated



16 Digital

input 10

Opto-isolated



7 Digital

input 11

Fast opto-isolated



17 Digital

output 4

Opto-isolated



8 Digital

output 5

Opto-isolated



18 Digital

output 6

Fast opto-isolated



9 24 VDC User supplied 24V, for I/O

biasing

19 24 VDC

return

Return of the user-

supplied 24 VDC

10 Fault relay 1 Terminal 1 of the dry

contact fault relay

20 Fault relay 2 Terminal 2 of the dry

contact fault relay

Table 3-6-Machine I/F Interface

Step 7: Connect AC input voltage. Note: This interface varies among models.

Note: The AC Input interfaces and connectors vary among MaxTune models.

MT-2/6 and MT-4/12: One connector for bus power and logic power uses interface P3.

MT-8/25: One connector for bus power and logic power uses interface P4.

MT-18/39: Two connectors – a connector for bus power uses interface P4, and another

connector for logic power uses interface P5.

Make the following connections:

1. Connect L1, L2 and L3 (for bus power).

If the main voltage is from a single-phase source, connect line and neutral to L1 and L2.


User Manual 23

If the main voltage is from a three-phase source, connect the phases to L1, L2 and L3.

1. Connect the AC input voltage ground wire to the PE terminal, located on the MaxTune

front panel. Use an M4 ring or spade terminal.

2. Connect L1C and L2C (for logic power).

If the main voltage is from a single-phase source, connect line and neutral to L1C and

L2C.

If the main voltage is from a three-phase source, connect any two phases to L1C and

L2C.

Make sure the main voltage rating matches the drive specification.

Applying incorrect voltage may cause drive failure.

Make sure that the AC supply for the main power input (L1 and L2), and

the logic power input (L1C and L2C) are from the same AC phase input.

Do not apply power until all hardware connections are complete.

Note: On models MT-2/6 and MT-4/12, Regen and AC Input Voltage are combined on

one connector. Since these models support only single-phase AC, they do not

have a L3 terminal for bus power.

MT-2/6

MT-4/12 Pin Pin Label Function

P3 3 L1 AC Phase 1

4 L2 AC Phase 2

5 L1C Logic AC Phase 1

6 LC2 Logic AC Neutral

MT-6/25

MT-8/25 Pin Pin Label Function

P4 1 L1 AC Phase 1

2 L2 AC Phase 2

3 L3 AC Phase 3

4 L1C Logic AC Phase 1


MT-11/39

MT-14/39

MT-18/39


P4 1 L1 AC Phase 1

2 L2 AC Phase 2

3 L3 AC Phase 3

P5 1 L1C Logic AC Phase 1


Table 3-7-AC Input Voltage


24 User Manual

Item MT-2/6, MT-4/12

Manufacturer JST J300

Housing and 6-pin crimp

(includes Regen)

F32FSS-06V-KX and

SF3F-71GF-P2.0

Spring terminal 06JFAT-SBXGF-I

Wire Gauge 16 AWG

MT-6/25, MT-8/25


Housing and 5-pin crimp F32FSS-05V-KX and SF3F71-GF-P2.0

Spring terminal 05JFAT-SBXGF-I

Wire Gauge 14–16 AWG

MT-11/39, MT-14/39, MT-18/39


Housing and 3-pin crimp F32FSS-03V-KX and SJ4F-71GF-M3.0

Spring terminal Not available

Wire Gauge 14 AWG


Housing and 2-pin crimp F32FSS-02V-KX and SF3F-71GF-P2.0

Spring terminal Not available

Wire Gauge 16 AWG

Table 3-8- AC Input Voltage Interface Mating Connector

Step 7: Set the drive address using the rotary switches.

The MaxTune has two 10-position rotary switches, accessible from the front of the unit.

The switches are used to set the drive address. When there is more than one drive on a

daisy-chain or CANbus network, each drive must have a unique address to enable its

identification on the network.

Use the two rotary switches to set the drive address for both CAN and serial

communication.

For Ethernet-based motion buses, the switch has no functional use for either the drive

or the network. It can be used at the application level to identify specific drives on a

network.

Each switch has 10 positions:

The upper switch positions are set as tens: 10, 20, 30 … 90

The lower switch positions are set as ones: 0, 1, 2 … 9

Note: If two or more drives are connected to the network, address 0 cannot be used.

A singular drive may have the address 0.


User Manual 25

Figure 3-10- Drive Address Rotary Switches

Step 8: Connect the drive to the PC.

To connect the drive to the host computer, use either one of the following interfaces:

USB port. The interface is labeled C1 on all MaxTune models. Use a USB 2.0 A to Mini-B

cable.

Figure 3-11- USB Port

The first time the drive is connected to the host computer on the USB port,

Windows will detect the device and display a Found New Hardware wizard.

RS232 port. The interface is labeled C7 on all MaxTune models.

Use a 4p4c plug.


26 User Manual

Figure 3-12- RS232 Port


1 RX Receive

2 GND ISO Ground

3 TX Transmit

4 Unused

Table 3-9- RS232 Interface


User Manual 27

4 Software Installation

Step 1: Install MaxLink software.

Using the provided installation file, install MaxLink software on the host computer.

When installation is complete, start MaxLink from the Windows Start menu or the

shortcut on your desktop.

Step 2: Power up the drive and the PC.

After completing the hardware connections, turn on power to the drive.

Note: If logic and bus AC supplies are separate, it is recommended that logic AC be

turned on before bus AC.

The first time the drive is connected to the host computer on the USB port, Windows

detects the device and displays a Found New Hardware wizard.

Browse to and select the Drivers folder. The path will vary, depending on the

computer’s operating system and the location selected for software installation; for

example:

\Program Files (x86)\PBA\MaxLink\Drivers

\Program Files\PBA\MaxLink\Drivers

Look at the 7-segment display on the MaxTune front panel.

Upon initial power up, the status display shows a flashing e, indicating a Parameter

Memory Checksum Failure. This fault will be cleared once the drive is configured

and the parameters are saved in the drive’s non-volatile memory.

Figure 4-1- 7-Segment Display


28 User Manual

Step 3: Launch Maxlink and Connect to the MaxTune Servodrive.

From the MaxLink navigation sidebar, click Connection.

The Connection screen is now displayed in the task area.

Figure 4-2- Connection Screen

To connect to the drive, use either of the following options:

Auto Connection. Click Search & Connect.

The software searches all COM ports on the host computer to locate the port to

which a drive is connected.

Once the software identifies the port, it searches for all drives that may be daisy-

chained to the port. Since this search can take a long time, the Limit Address

option allows you to define the number of addresses, from 0-99 to be searched. By

default, the limit is set to 5 addresses.

The names and addresses of all drives found will be listed under IDs to connect.

Manual Connection. Set the COM port, the baud (data transfer) rate, and the address,

and Click Connect.

If you are using a USB connection, check the Windows Device Manager to see

which COM port is mapped to the Servo Drive USB device.

The port address can be any value, from 0 to 99. The value you enter must match

the drive address defined by the rotary switches (set during installation).

Step 4: Click on Digital IOs and make sure none of the inputs are set to “Remote

enable”. If there is, set it to “Idle”. This will make it possible to switch on the drive

using just software enable.


User Manual 29

Figure 4-3- Disable Remote Enable

Step 5: Click on “Setup Wizard” and enter the name of the axis which MaxTune is

controlling. In this example, we name it “XAXIS”. Click “Next”.


30 User Manual

Figure 4-4-Setup Wizard, Entering Drive Name

Step 6: Select “PBA Motors” for the Family dropdown box.

Figure 4-5-Choose Motor Family

Step 7: Choose the appropriate model number of the motor under the Model dropdown

box. Be careful to choose the right winding connection (ie. “S” for series or “P” for

parallel). This is crucial for the tuning of the current loop.

Figure 4-6-Choose Motor Model


User Manual 31

Step 8: Choose the correct encoder resolution. In this example, we are using a 1

micron incremental encoder.

Step 9: Place the motor in the middle of the track and click on the verify button. The

motor will move.

Figure 4-7-Choose Motor Resolution


32 User Manual

Step 10: A dialog box will prompt that phasing is successful. Click “Yes” and “Next”.

Figure 4-8-Phasing for Motor Commutation

Step 11: Select the preset values for the application velocity limit and peak current

limit or select the “User Defined” radio button and key in value. Remember to input a

number considerably higher than the required values, especially for the current limit. In

this example, the peak current limit is set to the motor peak current which is 9.2A.

Figure 4-9-Set Motor Velocity and Peak Current Limit


User Manual 33

Step 12: Click on the “Negative” or “Positive” button and observe if there’s motion. If

there isn’t, increase the value of the “% of Motor Continuous Current” incrementally to

a point the motor moves.

Figure 4-10-Checking which direction is positive

Step 13: Choose the desired direction to be defined as “positive” and “negative” by

checking or unchecking the “Inverse Direction” checkbox. Click “Approve Direction” and

then next.

Figure 4-11-Inverse Direction if required and Approve Direction


34 User Manual

Step 14: Click on “Save to Drive” and “Save to File” to back up the configuration.

MaxTune is now phased and current loop has been tuned. Operation in “Serial Current”

and “Analog Current” modes are now possible. If operating in position command (for

example pulse and direction), click next.

Figure 4-12-Saving to Drive and File

Step 15: This steps checks the inertia of the motor. Move the motor to the middle of

the track and click “Start” followed by “Ok” on the dialog box.

Figure 4-13-Load Estimation

The value of the estimated payload will be shown. Click “OK” and the next. If this step

fails to estimate the payload, select “Known Load Inertia” and enter the value of the

payload and click “Start”.


User Manual 35

Figure 4-14-Load Estimation Results

Step 16: This step will tune the motor’s position loop. Move the motor to the middle of

the track. Ensure that the “Distance (encoder counts)” is possible with the stroke of the

motor and the “Speed (mm/s)” is not too fast for the machine. If they are acceptable,

don’t change these values otherwise edit them as required. Click “Start” and the motor

will begin the auto tuning process. Once finished, click next.

Figure 4-15-Start Gain Optimization of the Position Loop


36 User Manual

Figure 4-16-Motor will Move and best Gains Chosen

Step 17: This step checks the performance of the auto tuned gains. Click on “Move and

Plot” to invoke a point to point motion and check the response on the graph on the

right hand side. Adjust the “NL Adaptive Gain Scale Factor” to adjust the how much

overall gain to apply. Fine tuning can be done later.

Figure 4-17-Adjust Gain Scale Factor to Achieve desired Profile

Step 18: Click on “Save to Drive” and “Save to File” to back up the configuration. The

motor has now been phased and tuned in both the current and position loop. It is

possible to control to motor in Analog Current, Pulse and Direction and serial position


User Manual 37

(standalone or CANOpen). It is unable to run in Analog Velocity mode since the non-

linear control structure omits the velocity loop. To use analog velocity control, the

velocity and position loop needs to be controlled by conventional PID and tuned. This

step won’t be covered in this guide. Click next.

Figure 4-18-Save to Drive and File

Step 19: The scope screen is used to fine tune the motor. Click on “Parameter Table”

tab to access the gains.

Figure 4-19-Scope Window

Click on the icon below to both record and move the motor. Adjust the parameters as

required until the desired response is achieved.


38 User Manual

Figure 4-20-Fine Tuning Gains

Step 20: Set encoder simulation output. This will simulate an incremental encoder AB

Phase output on the Controller I/F connector that will copy the main encoder feedback.

The resolution of this output can be defined.

In most application, the simulated encoder output that is needed would be a copy of

the main encoder, including its resolution. Copy the “Lines Per Revolution” value from

the “Encoder” section to “Resolution” in the “Encoder Simulation” section. Set the

“Mode” dropdown box to Enabled.

Connect this encoder simulation output on the Controller I/F connector to the motion

control card to provide it with position feedback.


User Manual 39

Figure 4-21-Setting Encoder Simulation

Step 21a: To set to Analog Current Mode, go to “Motion” and under operation mode,

select “3 - Analog Current”. In Analog Current mode (OPMODE 3), only the MaxTune’s

current loop is active, and the drive responds to a command from the primary analog

input, connected at pins 8 and 26 of the Controller I/F connector.

Figure 4-22-Setting drive to Analog Current Mode


40 User Manual

Enter the Current Scaling to match with the application peak current. For example, if

the peak current is 9.2A, set it to 0.92 A/V. Since the command is for a range of +/-

10V, it is able to move the motor for a current range of -9.2A to 9.2A.

Analog Offset The DC voltage offset on the analog input. Refer to

VarCom ANIN1OFFSET.

Deadband The deadband range of the analog input. This is useful for

preventing the drive from responding to voltage noise

near the zero point of the analog input. Refer to VarCom

ANIN1DB.

Filter This value is a low-pass filter applied to the analog input.

This is useful for filtering high frequency noise from the

input, or for limiting the rate of change of that signal.

Refer to VarCom ANIN1LPFHZ.

Analog Input The voltage at the analog input. Read only. Refer to

VarCom ANIN1.

Current Scaling When the first analog input is used as the command for

the current loop, it is important to set the scaling, that is,

the ratio of the analog input voltage to the command that

the drive interprets. Refer to VarCom ANINISCALE.

Current

Command

The resulting Current command. Refer to VarCom ICMD.

Actual Values Shows the actual values of motor current, motor velocity

and motor position.

Click “Save” on the header bar once done.

Step 21b: To move in pulse and direction, go to “Motion” and under operation mode,

select “4-Position Gear Mode”.

First choose the input for the pulse and direction signal. It can be either from the

Controller I\F (C2) or Machine I\F (C3). Check the “Pulse and Direction (P&D)” radio

button.

Under Gear Filter Mode section, select “0-Transparent(no filter)” on the dropdown box.

If noise cause lost count in the pulses, this can be set later.

In the Ratio section, enter 1 for both multiplier and divider. For external resolution,

enter 4 times the lines per revolution of the encoder (if the encoder is an incremental

4X AB Phase).

Each pulse for the encoder quadrature signal consists of 4 counts. However each pulse

of the Pulse and Direction signal consist of only 1 count. As such the lines per

revolution for the encoder is 15000 and the lines per revolution for the gear input is

15000 X 4 = 60000


User Manual 41

Figure 4-23-Example Values for Operating in Pulse and Direction Mode

Click “Save” on the header bar once done.

Step 22: MaxTune has now been tuned and ready to be controlled by the motion control card.

maxtune intelligent servo drive - pba systems

Documents