Axor MAGNUM 400 Service Manual

AXOR Industries Service Manual Magnum400

TM

ver.2 rel.05/'15

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AXOR Industries Service Manual Magnum400

TM

ver.2 rel.05/'15

2

All rights reserved. Reproduction in whole or in part is prohibited without prior

written consent of the copyright owner. All specications are subject to change
without prior notication.

This manual has been carefully checked. However, Axor does not assume liability
for errors or inaccuracies.

THIS MANUAL CONTAINS A DESCRIPTION OF MAGNUM400TM

AND A GUIDELINES FOR THE DRIVE'S INSTALLATION;

FOR MORE DETAILS SEE ENCLOSURES ON THE CD PROVIDED WITH THE DRIVE.

USING THE DRIVE INCORRECTLY CAN INJURE PEOPLE OR DAMAGE THINGS.
FULLY RESPECT THE TECHNICAL DATA AND INDICATIONS ON CONNECTION

CONDITIONS.

Release Notes

ver.1 rel.12/'05

New paging.
Insert: Positioning and Homing Procedures.
Corrections.

ver.1 rel.09/'06

New paging.
Update chapters: "General Advices", "Installation", "Interfaces", "Di­agnostic", "Appendix".
Insert chapter: "7: Applications".
Insert Index.
Corrections.

ver.1 rel.03/'07

Update chapter: "5: Diagnostic".
New chapter reserved to Positioner and Homing procedure.
Update chapter "7: Applications": Reset Fault Function, Emergency
Function, Stop Functions.
Corrections.

ver.2 rel.09/'07 Manual reorganisation: rst base version.

ver.2 rel.02/'08

Regen resistance dimensions insertion.
Min/max dc bus voltege values insertion.
Brake circuit set point insertion.
Corrections.

ver.2 rel.12/'08

Corrections.
Figure pag.31 corrected.
Figure and note pag.39 corrected.
Note pag.40 corrected.
RS485 connection inserted.

ver.2 rel.01/'10 Note about regen resistance inserted.

ver.2 rel.09/'13 Correct note about resistor on RS485 interface.

ver.2 rel.04/'15 Update chapter: "5: Diagnostic".

ver.2 rel.05/'15 Corrections.

AXOR Industries Service Manual Magnum400

TM

ver.2 rel.05/'15

3

Summary

1) Description

1.1 Description 6

1.2 General view Magnum400 9

1.3 Technical Data 10

1.4 Mechanical Dimension 12

1.5 Product plate and Ordering Code 13

2) Installation

2.1 General Advices 16

2.2 Positioning 19

2.3 Environmental conditions 20

2.4 Cables 21

2.5 Connection to ground and earth 22

2.6 Note about cable shielding 23

2.7 Base installation procedure 24

2.8 Example of base connection 25

2.9 Supply connections 26

2.10 Motor power connection 27

2.11 Relè OK and regen resistance connections 28

2.12 Digital inputs connection 30

2.13 Digital outputs connections 31

2.14 Analog outputs connections 32

2.15 Analog inputs connections 33

2.16 Emulated encoder outputs connection 34

2.17 Pulse/Dir inputs connections 35

2.18 Feedback signals connections 37

2.19 Multidrop connection 39

2.20 Canbus connection 40

2.21 RS485 connection 41

2.22 Magnum400TM power up 42

2.23 Motor Test 43

3) Diagnostic

3.1 Display 46

3.2 Alarms 47

Index 50

Conformity 52

AXOR Industries Service Manual Magnum400

TM

ver.2 rel.05/'15

4

Enclosures to the manual

On the CD provided with the drive there are the following enclosures (in pdf):

• Operative Modes Manual

• Additional Features Manual

• Speeder One Interface

• Positioner Manual

• Display and Keypad Manual

• Alarms Manual

• ModBus Manual

• CanOpen Reference Manual

• Cables Manual

• Oscilloscope Manual

• Procedures Manual (available only on request)

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AXOR Industries Service Manual Magnum400

TM

ver.2 rel.05/'15

Chapter 1
Description

1.1 Description 6

1.2 General view Magnum400 9

1.3 Technical Data 10

1.4 Mechanical Dimension 12

1.5 Product plate and Ordering Code 13

1) Description

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AXOR Industries Service Manual Magnum400

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1.1 Description

OPERATIVE MODES

SPEED CONTROL

It is speed piloting utilising a digital reference or an
analogue reference (differential or common mode).

standard

TORQUE CONTROL

It is torque piloting utilising a digital reference or an
analogue reference. This function allows you to control the
current from the drive.

standard

POSITION CONTROL

The positioner can be managed via hardware (by using the
digital inputs) or via RS232 (by using the Axor's Speeder
One interface or another ModBus Master). It supports 32

programmable position proles; a single task or a sequence
of tasks are permitted.

The Homing Procedure is implemented. It uses the signal
coming from the homing sensor and eventually the zero
signal of the encoder.

standard

ELECTRICAL AXIS

(GEARING)

It is possible to pilot the drive with the quadrature signals
of an emulated encoder from a Master drive or with the
quadrature signals of an incremental encoder from a Master
motor (Electrical Axis or Gearing).

standard

PULSE/DIRECTION

It is possible to connect the drive to a stepper-motor
controller, piloting it with the +/-Pulse and +/-Dir signals

(Pulse/Dir Mode).

standard

MULTIDROP RS232

It can work in Multidrop, where the rst drive, connected
via RS232 to the Master PC, is piloted with ModBus
communication, while the other drives are piloted with the
duplication of commands using the CanBus interface.

optional

RS485 INTERFACE

It is possible to communicate with two or more drives by
using the RS485 interface.

optional

CANBUS

It can be congured and controlled using CanBus. It
supports the following Can Open protocols:

• part of the DS301-V4.02

• part of the DSP402-V2.0

optional

Notes:

• The current controller is vectorial with sampling time of 62,5µs.
The velocity and position loop both work with sampling time of 250µs.

• The current commutation is sinusoidal.

FEEDBACK

ENCODER incremental encoder signals + hall signals standard

RESOLVER 2, 4, 6, 8 pole optional

The Magnum400

TM

is a digital drive capable of piloting both rotary AC brushless motors and linear

motors, up to 30Nm. It can be supplied by a 3-phase voltage equal to 400 or 480Vac.

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1.1 Description

DIGITAL INPUTS/OUTPUTS

9 DIGITAL INPUTS

They are programmable for: the limit switch, the holding
brake, the homing and positioning procedures, the emer­gency stop, the reset alarm, etc.

standard

2 programmable

DIGITAL OUTPUTS

They can be used to send messages from pre-programmed
functions of the drive.

standard

EMULATED ENCODER

OUTPUTS

There are 6 pins dedicated to emulated encoder with
different programmed ratios (1/2, 1/4, 1/8, 1/16, 1/32,
1/64, 1/128) between output pulse/rev and encoder/
resolver ones.

standard

ANALOG INPUTS/OUTPUTS

1 ANALOG

COMMON MODE

INPUT (TPRC)

It is used for controlling the current from the drive. standard

1 ANALOG

DIFFERENTIAL or

COMMON MODE

INPUTS (+/-Vref)

It is used for piloting the drive with an analogue speed
reference from an external controller.

standard

2 programmable

ANALOG OUTPUTS

They allow you to visualise by the oscilloscope some of the
drive’s measurement values (for example: the velocity, the
Iq current, etc.).

standard

GENERAL FEATURES

KEYPAD

Four buttons (UP-DW-MODE-SET) allow the manual

insertion of data without using a PC.

standard

DISPLAY

A display with 5 characters visualises: the inserted
values, the drive’s status, the alarms.

standard

SPEEDER ONE

SOFTWARE
INTERFACE

It allows you to set and manage all drive’s parameters by
using a PC connected to the drive.
The communication between the drive and PC is done by a
RS232 cable using the ModBUS protocol.

The software works on the following operating systems:
Windows 98, Windows 2000, Windows XP.

standard

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1.1 Description

HOLDING BRAKE

The drive has circuitry that allows the control of the elec­tromechanical brake integrated in the motor, which can

be used with motor not running, for blocking the motor's
axis.

The drive supplies the brake with +24Vdc. It can be exter-
nally managed by the user or automatically by the drive.

optional

EMI

FILTER

The drive is equipped with an integrated EMI anti-distur-

bance lter at the 3-phase power supply input and with

another EMI anti-disturbance lter at the auxiliary +24V

power supply input.

standard

REGEN CIRCUIT standard

EXPANSION CARDS

There is a slot for expansion card to implement additional
features.

optional

SAFETY

SAFETY

The converter is protected from short circuitry, the Max/Min

Voltage, the drive I

2

t , the Motor I2t , etc.
When there is an alarm the "Relè OK" contact opens and the
motor is stopped, or a message is visualised on the display
without compromising the system's functioning.

standard

BLACK-OUT

DYNAMIC BRAKE

FUNCTION

It stops the motor when there is a black-out. optional

EQUIPMENT

a drive serie Magnum400

TM

standard

terminals: M1, M2, M3, M4, M5

Service Manual

a CD-ROM with Speeder One software interface and all enclosures to service
manual

Motor inductance, 3x1.2mH, for cables over 20/25 meters in length

optional

an external braking resistor (500W or 1000W)

CBLS cable for motor feedback signal, encoder/resolver (meter multiple)

CBLS power cable for motors series SuperSAX;

motors series SuperSAX

All optional features have to be requested by using the proper ordering code (see "1.5 Product plate
and Ordering code").

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AXOR Industries Service Manual Magnum400

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1.2 General view Magnum400

Display and KeyPad

(J1 Connector)

Encoder or Resolver

signals

(M5 Connector)

Motor, brake and

braking circuit

connections

(M3 Connector)

Auxiliary power

supply +24Vdc

(M4 Connector)

Main supply

(J5 Connector)

RS232 comunication

(M2 Connector)

Analog and Digital

Inputs/Outputs

(J3-J4 Connectors)

Can BUS or

RS485 comunication

(M1 Connector)

Encoder emulation,

Pulse/Dir signals

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1.3 Technical Data

Nominal Data

Nominal Voltage Vac

Three phase: 3x480Vac +10% max, 3x400Vac -10%, 50/60Hz

(Single phase permetted for setup only)

Min/Max dc bus

voltage

Vdc

400Vac 480Vac

400Vdc min ÷ 800Vdc max 500Vdc min ÷ 870Vdc max

Auxiliary power

supply

(for back up)

Vdc +24Vdc (0%, +15%) - 1Adc (3Adc with brake)

Size 1,5/3 3,5/7 7/14 10/20 14/28 20/40

Nominal Current Arms 1,5 3,5 7 10 14 20

Peak current for

5 sec.

Arms 3 7 14 20 28 40

Dissipation at

nominal current

W 30 42 56 88 165 195

Dissipation with

output stage

disabled

W 20

PWM output

frequency

kHz 8

Control signals

Optoisolated digital inputs +24Vdc - 7mA (PLC compatible)

Optoisolated digital outputs +24Vdc - 50mA (PLC compatible)

Analog programmable outputs ±10V (±5%)

A common mode analog input (TPRC) ±10V max, 10kOhm input resistance

A differential or common analog input

(+/-Vref)

±10V max, 40kOhm input resistance

Pulse/Dir digital inputs +5V, optoisolated, max. frequency 250kHz

Emulated encoder outputs

V

OH

=2.5V min - IOH=-20mA

VOL=0.5V max - IOL=20mA

Braking Resistance

Internal Resistance

200W - 66Ohm size: 1.5/3, 3.5/7, 7/14

200W - 33Ohm size: 10/20, 14/28, 20/40.

External Resistance

500W - 66Ohm size: 1.5/3, 3.5/7, 7/14.

500W - 33Ohm size: 10/20, 14/28, 20/40.

1000W - 33Ohm +33Ohm 500W size: 1.5/3, 3.5/7, 7/14.

1000W - 66Ohm // 66Ohm 500W size: 10/20, 14/28, 20/40.

Set point values

400Vac 480Vac

695Vdc min ÷ 735Vdc max 815Vdc min ÷ 845Vdc max

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Motor encoder inputs

Encoder supply

+5V @ 220mA (±5%)

Differential encoder inputs

line receiver

AM26LS33

Differential hall signal inputs

line receiver

AM26LS33

Encoder max. frequency

250kHz

External Protections (fuses or similar)

Size 1,5/3 and 3,5/7 7/14 and 10/20 14/28 and 20/40

Power supply (F

2

) 6A T(Time Lag) 10A T 20A T

Auxiliary power

supply (F

3

)

6A T

External braking

resistor (F

4

)

4A F(Fast) 6A F 6A F

1.3 Technical Data

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AXOR Industries Service Manual Magnum400

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1.4 Mechanical Dimension

Dimension in: [mm]

UP

MODE DWN SET

A

A

B

B

73,5

270

247

284

223

33

UP

MODE DWN SET

NOTE:
The M1 and M2 connectors are located
under the plastic cover.
To open it, push the cover on the
borders (see A), move it down and
remove it (see B).

Mechanical specications

External dimensions mm 284 x 223 x 73,5

Size 1,5/3 3,5/7 7/14 10/20 14/28 20/40

Weight Kg 4,2 4,6

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AXOR Industries Service Manual Magnum400

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1.5 Product plate and Ordering Code

On the side of each Magnum400TM there is a product plate like the following:

To order a digital drive serie Magnum400

TM

refer to this ordering code:

Nominal and peak
output current (in
Ampere RMS)

Power

supply

Protection

rating

Environmental

temperature

range

"Cod" is an internal production
code. Use this number for any
enquires.

The "Part. No" gives others descrip­tive codes about the drive and the
settings.

TYPE: MAGNUM-400-7/14-RX-S-D-1000-EC-EC-RD
ADJ: 7/14A 3000 Rpm Enc
Data 20/09/2004 Ord: 0981/2004 Cod. 93759999

M400 - 20/40 - RXX - S - RO - 0 0 0 0 0 X - 00 - Sxxx

Dumping size:
RXX = Internal standard resistor
R5 = 500W external resisor (opt)

66Ω (for 1.5/3 to 7/14)
33Ω (for 10/20 to 20/40)
R10 = 1000W external resistor (opt)
33Ω + 33Ω da 500W (for 1.5/3 to 7/14)
66Ω // 66Ω da 500W (for 10/20 to 20/40)

Size: 1.5/3, 3.5/7, 7/14, 14/28, 20/40

Drive Model

Protection:
S = Standard
T = Tropicalized

Feedback:
RO = Resolver
EC = Commutation encoder
ER = Encoder or Resolver (both)

Expansion cards:
00 = Not present (std)

Additional features:

0 0 0 0 0 X

CBMD: CanBus + Multidrop Interface

1= Present (opt)
0= Not Present (std)

Not in use

Not in use

RXDB: Black Out Dynamic Brake

1= Present (opt)
0= Not Present (std)

R485: RS485 Interface

1= Present (opt)
0= Not Present (std)

Specic number presence (opt):

S xxx

001÷999=specic number

HBD: Holding Brake Drive

1= Present (opt)
0= Not Present (std)

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AXOR Industries Service Manual Magnum400

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AXOR Industries Service Manual Magnum400

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Chapter 2
Installation

2) Installation

2.1 General Advices 16

2.2 Positioning 19

2.3 Environmental conditions 20

2.4 Cables 21

2.5 Connection to ground and earth 22

2.6 Note about cable shielding 23

2.7 Base installation procedure 24

2.8 Example of base connection 25

2.9 Supply connections 26

2.10 Motor power connection 27

2.11 Relè OK and regen resistance connections 28

2.12 Digital inputs connection 30

2.13 Digital outputs connections 31

2.14 Analog outputs connections 32

2.15 Analog inputs connections 33

2.16 Emulated encoder outputs connection 34

2.17 Pulse/Dir inputs connections 35

2.18 Feedback signals connections 37

2.19 Multidrop connection 39

2.20 Canbus connection 40

2.21 RS485 connection 41

2.22 Magnum400TM power up 42

2.23 Motor Test 43

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AXOR Industries Service Manual Magnum400

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2.1 General Advices

During the transport of the drive respect the following indications:

• the transport must be made by qualied personnel;

• avoid shocks;

• the temperature range must be between -25°C and +55°C;

• the max. humidity must be 95% (without condensation);

• The converters contains elements which are sensitive to electrostatic discharges. These elements

can be damaged by careless manipulation.
Discharge static electricity from your body before touching the converter.

Avoid contact with material that insulates well (synthetic bres, lms of plastic material and so

forth).

• we suggest to check the motor condition at its arrival to survey eventual damages.

Transport

The unused drives must be storage in an environment having the following characteristics:

• temperature from -25°C to +55°C;

• max. relative humidity 95% (without condensation);

• max. time with the drive powered off (without supply connections):

 drive having a power supply ≥ 220VAC  1 year
 drive having a power supply ≤ 145VAC (200VDC)  2 years

After this time, before enable the drive, it is necessary activate the capacitors following this procedure:
remove all electrical connections, then supply the input terminals of the supply with the main voltage
(three phase or single phase) for 30 minutes.
In details:

- for the drive having a power supply equal to 380VAC: power it by using a single phase (or three
phase) supply equal to 220VAC;

- for the drive having a power supply equal to 220VAC: power it by using a single phase (or three
phase) supply equal to 110÷130VAC.

In order to avoid this procedure, we suggest to power on the drive with its rated voltage for 30 minutes,
before the max. time is reached.

Storage

The drives does not need maintenance.
Otherwise:

• if the casing is dirty: clean it with isopropanol or similar;

• if the drive is dirty: the cleaning is reserved to the producer;

• if the fans are dirty: clean them by using a dry brush.

Maintenance

The disposal should be carried out by a certied company.

Disposal