CONTENTS

l (1) SPECIFICATIONS ........................................ 1

(2) DRIVE SECTION BLOCK DIAGRAM ........................... 2

(3) CABLES ................................................ 4

1) CABLE CONNECTIONS FIGURE .......................... 4

2) CABLES ............................................ 5

(4) OUTLINE DRAWINGS ...................................... 8

1) TRANSISTOR AMPLIFIER .............................. 8

2) POWER UNIT ........................................ 9

(5) REPLACING AND HANDLING THE TRANSISTOR AMPLIFIER ....... 10

1) TRANSISTOR AMPLIFIER CONNECTIONS .................. 10

0
2) CHECKPOINTS BEFORE SWITCHING ON POWER ............. 12

3) CHECKPOINTS ....................................... 13

4) DESCRIPTION OF CHECK PINS ......................... 14

5) DESCRIPTION OF VRS ................................ 20

6) DESCRIPTION OF PLUGS .............................. 22

7) CONNECTOR AND CHECK PIN LAYOUT .................... 25

l 8) VR LAYOUT ......................................... 26

9) SETTING PLUG LAYOUT ............................... 27

(6) INSPECTION AND ADJUSTMENT METHODS ..................... 28

1) HOW TO MEASURE THE VOLTAGES AND CURRENTS .......... 28

2) TRANSISTOR AMPLIFIER INSPECTION ................... 31

3) POWER UNIT INSPECTION ............................. 36

e 4) POSITION LOOP OFFSET AND DROOP ADJUSTMENTS ........ 39

5) RESOLVER FEEDBACK ADJUSTMENT ...................... 41

6) MOUNTING THE DETECTOR ............................. 42

I
0
0 INTRODUCTION
This manual outlines the maintenance procedures for using the
MELDAS AC servo system. It details the methods involved in

8 replacing the transistor amplifiers as well as the inspection

locations and adjustments, and it should thus be read before
operating the AC servo system. Refer to the checkpoints before
switching on the power.
(1) SPECIFICATIONS
Item TRS50 TRS75 TRSl00 TRS150
Motor used HA40/80 HA100 HA200 HA300
8
Continuous output 20/30Arms 45Arms 66Arms 99Arms
current
Output torque (when 170/200 458 709 1036
used in combination kg.cm kg.cm kg.cm kg.cm
with amplifier)
0 Rated output voltage 155Vrms 155Vrms 155Vrms 155Vrms
Alarm circuits Fin overheating protection (FOH), power
unit alarm (PUAL), motor overloading
(MOH), TG over-speeding (TGOV), over-
current detection (OVC), instant over-
current protection (OCP), no-signal de-
l tection (NSG), instant power failure
compensation and under-voltage
compensation (LVAL).
Power supply 310V (DC) across P-N
(With AC 220V factory power supply)
0
Control loop Current loop (sine wave approximation,
PWM)/Speed loop
Control characteristics Speed control band: 500 rad/sec.
Speed control range: 1:10,000

-l-
 _
.;:

Hain circuitrv area

(2) DRIVE SECTION BLOCK DIAGRAM _ -
MTR U MTR V MTR W 1
1) BLOCK DIAGRAM OF TRANSISTOR AMPLIFIER
I - - - - -
(TYPE TRS)

AX14 card CON1

I -

I t I

From NC

rG. CH3 cH4

From other

To NC 1 ,-T.(i.
 (I, 0

-_

1
_TEll
2) BLOCK DIAGRAM OF POWER UNIT F12313
r 0 Pl

NFll MC11
Mcl2
- 4 P2-
3-phase - 1
AC200/220V
50/60Hz -
Since transformers are not THMl 1
included in the power unit,
the control unit and machine fl=@l
must be grounded. THM

Fll(lOh) 1
AC100

I
W
I Caoaci tor unit
(Woe CU)
Power u n i t

(tvoe APO) I’ -
ZPI
24V

: 1rHb1

. IYFB

I kLM
c 1

‘I?US E
 ( 3) CABLES
11 CABLE CONNECTIONS FIGURE D-10 e
1
Detector
q HAoo 1
D-10 \cE I
B-2@
# For NC higher
or
1oov * M4 C--'M4
0 n n nr .__,-13nn-nnn. B-24 0.2 d
U VW GlG2 -- , B-20 0.5 d
Set this t o tkhe Transformer 2
z 1 B-16 1.25d
factorv Dower ; -cov 8OOVA u - ‘rRSclC1
I
sunnlv.
I control sionalb ZP*-

I’ i-JB-243 or higher
. I
from CNA73
-,-(TO other amolifiers)
3-ohase TPA-2 to axis 5
I
I _ P -
lb
I 1
I I
I ADUOO i4 ,I. 1
I
J..v-1u
..
I I I
I 12P N
Notes

epp
I

I I (1) flake all the AC 100V cables B-20 or higher.

I D-10
M5 I (2) Hake the length of wiring between the + and - of the

iI Pi
+

Icuoo
-

1
i
1
capacitor unit and P and N of the rectifier unitnotmore
than 258 mm.
I Caoacitor I (3) The zPL2 pin signals are given below:
I unit I 1 2 I 3
/ I
ALARM 1 +24V 1 RG (ground)
l- --J (4) Keep the detector cables and cables leading from the NC
Power unit
APUOO system as far away from the motor 0, V, W wiring as
possible.
 2) CABLES

Cable name Cable

Connector model
d
HR-20W5
HousinqURF-2OMOl
Contact BIRP-31112

0Cannon connector

a
CNA43-41
detector
cables
( f o r ARST)

a
Pousins MRP-20MOl
Contact MRP-Ml12

0Canno.n connector
Connector MS3103B20-29
Clamb MS3057-12A

detector
Y

f
 Cable name Cable
ZJ l-l
Connector model
oZJ1
Case bfR-2OW5
Housing MRP-20FOl
Contact MRP-FI12

oCAM1
Case: MRSBL of
MR-SBw
Housing bfRP-5OFO 1
Contact MRP -F 112
CA 19-n
CNA73-c
(cable for
control
signals)
between
NC unit
Ind amplifier

-60
 Cable name Cable

CNAS/CNAS 252-l/252-3 Connectar model

RSl oZJ2
* Case MR-2OW5
RS2
HousingMRP-20FOl
RCl Contact MRP -F112
RC2
ROl OCNA3-6
Case: MR-2BL OK
R02 UR-28W
CNA88-0 SG Housins MRP-2OFOl
Contact MRP-F112
(cable for
resolver
signal)

between NC
unit and
amolifier

CNAS/CNAS

CNA4/CNA6 ZJ2-2/ZJ2-4
l

Connector model
ZPIZ ZJ 5
u20-6 oZJ5
ALARM ,
+24v 2 0 ; 820-2 I O’
2 Housing 5258-034
ffiaL3 nzo-0 ’3
08
DUA- 1 COntaCt 5 16 7P BT

'Dower unit Wire mark

ontrol cable) oZPl2
Housing l-350355-9
L Contact 350019-2
8 I-
n- 8
(Pin no.) (Pin no.)

ZJ4
Connector model
ZJL
ALARU I RIO-6 oZJ4.ZJ5
+24V 2 n20-2 ’ 0: Housing 5258-034
R20-9
TRA-1 llc lo' ’ 08 COntaCt 5 16 7PBT
El 3

power unit
ontrol cable)
I
a
(Pin no.) (Pin no.)

-7-
(4) OUTLINE DRAWINGS

1) TRANSISTOR AMPLIFIER

Note 1: Fin-cooling fans are not provided

on the TRS50 or TRS75.

l
L
l

-8-
 l l e l l

2) POWER UNIT

T q
-.
-- I
Transformer Unit
Domestic Tl APU;;, 30, 70,
Control number specifications
plate \ Export APU 15-M, 30-M,
specifications T2 70-M, 72-M

max845
I
W
I

!
!

5 , 4 1 0 I_ ii0 !as(

Outline drawinq of power unit

(185) -
 0

(5) REPLACING AND HANDLING THE TRANSISTOR AMPLIFIER

1) TRANSISTOR AMPLIFIER CONNECTIOk- 0

AX04 .mo4
526 S26 S26
Ia E l El

0
Z J 3 Z P 2 ZP1 ZJ3 ZP2 ZPl
..

NC I
1 I 1 I I
control Position sicfnal
unit * cable
I

I
SDeed command

I
To axis
1 detector
cable

To axis
I

2 detector
To axis
3 detector
To DUA-1
Dower unit

Axis 1 amblifier Axis 2 amcilifiet Axis 3 amolifier

(Terminal block TEl is connected with the drive motor. The unit
proper can be mounted onto a rack with the two setscrews.)

(a) Insert all triangular wave setting plugs S26. Y

(b) The dither is not normally used. However, when it is used,
plugs Sll and S13 should be inserted.
(c) Connect the DUA-1 cable to ZP5 on the final axis. a
(d) Connect the TRA-lcable from ZP5 onthehead axis to ZP4 of

-lO-
d
 the next axis.

(e) Perform step (d) for each of the axes involved.

(f) Keep the S9 setting plug inserted for the head axis only;
remove the plugs for all other axes.

(9) How to insert the TRA-1 and DUA-1 cables

outside.
Notes:

a (1) Setting plugs and the adjustable variable resistors (VRs)

are located on the control card and they should be adjusted
when the unit is replaced.

(2) When check pins CHA, CHB, lB-6B and lE-6E are observed using
a synchroscope, do not connect the other check pins and
ground simultaneously.
(3) Ensurethatproper connection is made to P and N of the
transistor amplifier, and be sure to connect only after
confirming that there is no faulty or improper wiring.
(4) When the control loop is a closed loop, the ZP2 cable need
not be connected.

0 -ll-
 a

2) CHECKPOINTS BEFORE SWITCHING ON POWER

\ Item Checkpoint
1 P,N Check whether the power unit P/N, AC
connections 'transistor amplifier P/N and capacitor unit 9

P/N connections have been made properly.

2 Transformer The transformer tap selection (200/220V) is

tap made to the factory power supply. (800VA l

selection transformer)
.
3 Motor Check that the motor has been connected
connections properly:
Transistor U Motor armature U
amplifier pin V V
W W
GlG2 GlG2
(No polarity for Gl, G2) e
4 Loop polarity When the motor is rotating clockwise as
check viewed from the load side, check that a (-1
voltage is supplied to CHl. *

5 Setting plug, Check that the proper setting plug and VR

VR settings settings have been made.

-12-
 3) CHECKPOINTS

(11 Keep the detector mounted in the same position as when it

was shipped; moving it will cause the control modes to
undergo change.

(2) Do not touch the base amplifier at the top of the AX04 card
because of its high voltage.

(3) Under no circumstances should the power unit be touched

since the capacitor will be charged even if no power is

actually flowing the unitwhenthelampis on.

(D (4) The main circuitry area in the AC servo system is configured
without transformers and so the machine system and control
unit must be grounded.
a (5) Grounding
Since the OCP circuit is isolated from the other circuits,
do not connect the OCP ground (CHB) and the ground AG/LG of
the other circuits simultaneously with the synchroscope
ground.

0 -13-
4) DESCRIPTION OF CHECK PINS
Item Check Signal Function
pin
1 Control CH7 Servo ON Signal for checking servo ON/OFF.
signal signal Servo OFF when low; ON when high.
CHll Power Pin for checking whether +24V is being
unit con-
trol sig- supplied to power unit.
nal
CHlS I( 8,

2 Speed CHl TG feed- Pin for checking TG signal.

back
loop signal Output is 2V +/-10%/1000 rpm (ARST, ATT)
CH3 Speed Indicates error between speed command
loop
error signal and TG.
CH4 8, Compensation circuit output
CH5 Speed Check pin for when speed command is
command issued with VRl by toggle switch STl.
3 Current CH6 Current Current loop command signals serving
loop CH32 command as torque commands.
CH17 Current Current command (sine wave) of current
command loop phase U. Waveform is as below:
(phase V=Ei sinmt

U) Where Ei =CE6 voltage

rin wt = sine wave of 2 cycles per motor
revolution
Note: Output is 0V when Ei or sinwt = 0

-14-
 -
Item :heck Signal Function
pin
-
3 Curren' CH18 Current Indicates same as above for phase W.
command
loop (phase
CH19 Current Indicates phase U current feedback
feedbac signal.
phase U Note: Detection resistance differs ac-
cording to power unit. Output
voltage with 1A current differs
according to amplifier unit.

CH20 Current
feedbac signal. Same Note applies as for CH19.
phase W Phase is shifted 240 deg. from U.
Phase U Phase W

-15-
l
 Item Check Signal Function
pin
CH21 Base Signal which controls U phase transis- l
ampli-
fier tors (upper transistors)
control
signal Top/bottom transistor shorting preven-
(phase U) tion period

Transistor
2V 0.7v ON period
Transistor
0
OFF period nslln

CH22 Base Signal which controls V phase transis-

ampli-
fier tors.
control
I signal
(phase V)
CH23 Base Signal which controls W phase transis-
a
ampli-
fier tors.
control
signal
(phase W)
1 a
4 Position CH2 Error For checking speed command signal output
loop signal from NC system.
5 Power CH31 Analog Card AX04 analog ground
CH33 ground a
supply +12 +12v Card AX04 +12V power supply
-12 -12v Card AX04 -12V power supply
+5 +5v Card AX04 +5V power supply
LG Digital Card AX04 digital ground
4
ground

-160
l

Item Check Signal

pin
6 Dither CH8 Dither For checking dither signal
signal
$2
7 Trian- CH9 Trian-
gular CHl0 gular
wave CH13 wave-
CH14 form
8 Resol- CH16 Resolver For adjusting amplitude of resolver
ver Eeedback feedback. Adjusted with VR10.

.%o [ 12fl VP_,

CH27 Resolver Signal produced by converting resolver

Eeedback feedback signal into digital signal.
CH28 Resolver For checking resolver excitation
excita-
tion (4.5kHz)

l 9 Clock CH29 Clock For checking clock signal (18MHz)

signal
G ovc CH30 ovc Input signal of OVC circuit. Circuit is
circuit
activated when input voltage falls below
set value of OVC circuit.

-17-
Item Check Signal Function
pin
10 ovc This signal is produced by rectifying
the U, V, W phase current and by
converting the current from AC to DC. It
can be used to check the response of the
current loop at CH30.
Note: CH30 current must be used with ap-
propriate damping.

Insufficient Appropriate Excessive

damping damping damping
CH34 Load meter Used when measuring current at load
output meter output check pin.
signal Refer to voltage and current measurement
methods in (61-l) for output voltage.

-18-
 Item Check Signal Function
pin
8 OCP CHA OCP Input signal of OCP circuit.
input Detection resistance differs according
to amplifier and so output per 1A also
varies.
Detection T
TRSSO RIA-5 0 3 1 mQ 0.031 V
TRS75 R II A - 7 5 20 mQ 0.020 V
TRSlOO R 51 .I - 1 0 0 t 125mQ 0.0125b

CHB Ground
L
TRS 150
t
R MA- 1 5 0
I 3 mQ’ 0.008 V

OCP circuit ground

Care is required since this ground is
electrically insulated from AG/LG.
Therefore, connect the synchroscope
ground to AG, LG and CHB simultaneously.
-

8 -190
 l
5) DESCRIPTION OF VRS
Item VR Check Signal Function
P
1 Speed VRl CA: Speed VR for command when motor is driven
Q
loop command by speed command. Switch ST1 is
adjust- input switched from P to V for use.
ment VR3 Integral VR for adjusting integral compensa-
compen- tion of speed loop. Response is
I)

tion increased when rotated clockwise. .

VR9 For VR for servo rigidity which is in-
/

servo creased when rotated clockwise. Q

rigidity Servo system adjustments are usual-
ly done by VR3 and VR9.
2 Cur- VR4 CH6 Current VR for adjusting current limit of Q
rent clamp current loop. Limit is increased
loop setting when rotated clockwise.
VR5 Current VR for adjusting current loop gain. 0
VR6 loop gain Set VR5 and VR6 to same gradation.
setting These VRs should not be adjusted by
customer.
Q
3 Posi- VR2 Position VR for adjusting gain of position
tion loop gain loop.
loop setting
e

-2o- Q
 Item VR Check Signal Function
VR7 Offset VR for adjusting position loop off-
0
adjust- set. Position deviation is made
ment zero with this VR.
4 Resol- VR CH16 Amplitude VR for adjusting amplitude of sine
ver 10 adjust- waves fed back from resolver.
adjust- ment Adjust to 12 +/-lVp-p.
ments VR12 CH16 Amplitude VR for adjusting amplitude fluctua-
0
fluctua- tion of resolver feedback.
tion ad- Adjustment is made with motor
justment driven.
l VR16 CH27 Phase For adjusting phase of resolver
CH28 adjust- feedback with respect to resolver
ment excitation.
5 ovc VR15 VR for setting operating point of
adjust-
ment OVC circuit.
6 Dither VR8 CH6 Dither Dither is used to eliminate effects

l adjust- CH3l amplitude of sticking or slipping (dither =

ment adjust- 250Hz sine waves).
ment Normally VR is kept at MIN setting.
Note:
VRll, VR13, VR14 and VR16 are adjusted by Mitsubishi and should
not be touched by the customer.

l -21-
6) DESCRIPTION OF PLUGS
Item Plug Function
1 Initial s4 Normally inserted for external emergency stop
settings uses. Removed when emergency stop is to be
operated externally.
s9 Set when supplying +24V to power unit.
S10 When removed for error correction, errors can
be corrected by NC with servo OFF.
S24 For alarm; high-level signal is output to NC
system when alarm state occurs.
S25 For alarm; low-level signal is output to NC
system when alarm state occurs.
Sl Inserted when resolver feedback polarity is
reverse of that of magnetic pole.
s2 For changeover of load meter output level,
usually used when plug is inserted.
s3 For changeover of load meter output level, and
the output increases when the plug is inserted
during set S2 is short-circuited.
2 Speed loop S6 Plug for short-circuiting capacitor in com-

operation pensation circuit

S12 Used when selecting non-linear gain. Gain is
reduced with plug inserted.
s21 Used when inserting non-linear circuit into
speed loop compensation circuit for
turret punch press.
s22 Plug for inserting high resistance at either
end of capacitor in compensation circuit.

-22-
0

Item Plug Function

S23 Plug to add capacitor in compensation circuit
l
3 Position s14 Insert plug when selecting 22 k.'2 input re-
loop sistor of operational amplifier.
s15 Insert plug when selecting 100 kR input re-
0
sistor of operational amplifier.
S16 Insert plug when selecting 200 kR input re-
sistor of operational amplifier.
l 4 Resolver S17 For adjusting resolver (for magnetic pole
position) feedback amplitude.
S18 For canceling resolver feedback no-signal

0 detection.
5 Closed loop S19 Used when exciting resolver from amplifier
S20 with closed-loop operation.

l 6 Dither Sll Used when dither signal is inserted into con-

circuit trol circuit for dither circuit connection.
S13 Used when oscillating dither circuit.
7 ovc S29 Used for OVC timer selection: timer time is
l
reduced by inserting plug.
8 Triangular S26 Used for triangular wave connection; normally
wave inserted for use; removed when making tri-
a
angular waves common between cards.

-23-
 Item Plug Function
9 TGOV S30 Used for switching TGOV level; 3000 rpm
specification applies when plug is inserted.
10 HA40 op- Ss Used for HA40; torque command falls by in-
eration serting plug.
S27 Used for selecting OCP operating level; plug
is inserted when HA40 is used.
S28 Used for selecting OVC comparison level; plug
is inserted when HA40 is used.

-24-
l
 7) CONNECTOR AND CHECK PIN LAYOUT

IB
0 1E II
2B
2E
aB
aE
IB
4E Current 1000 command siqnal
e A(0 phase)
/urrent 1000 command signal
(W ohase)
/utrent feedback signal
(II ohase)
Current feeflback sianal
(w ohase)
-Rare amolif ier control signal
(II ohase)
-Rase amolifier control sianal
OCP input+ (V 0hase)
OCRA
IBase l molifier control sional
OCP circuit- 0CHBaS27 (W Dhase)
.' gr0UXl lAnalog ground

l
OS26
ml
0
Digital ground
LG
SV Level meter outout
ZP6

Resolver excitation
0 Resolver feedback
/(dither siqnall
/Resolver feedback
-Powerunit control sisnal
7Trianqular wave output
-Dither s i g n a l
-Power unit control siqnal
0 -r ianqular wave outout
-Dither signal
-Servo ON signal
-Current command sisnal
-Soeed 1000 error

Q;t; !y;Lfrror
TC feedback signal
\ Analog ground
-60ed 1000 command inout

-25-
8) VR LAYOUT
Re-adjustment of these VRs is not necessary since they have
already been set to the specifications of the machine builder
when the unit was shipped from the manufacturing plant.

L LOVC setting
Current loop offset (W

lL
LCurrent loop offset NJ phase)
Current loop offset W phase)
Current loop gain (w phase)
-Current 1000 gain UJ phase)

vR12 VRlO VR16 vR2 VFU VFt3 VR3 VRS vR4

L Ls ervo
rigidity
Dither amplitude
adjustment
-Current loop compensation

11 L Position loop offset

L position gain
Phase adjustment
Resolver amplitude
adjustment
Resolver amplitude
fluctuation
I

LSpeed command input

-_ _I

-26-
a
l

9) SETTING PLUG LAYOUT

Re-adjustment of these plugs is not necessary since they have
l
already been set to the specifications of the machine builder
when the unit was shipped from the manufacturing plant.

l
S27: OCP level
selection
(inserted with
r - 1 I s26: For triangular
wave selection
HA4s only)

S28: ovc
l level selection
(inserted
s2: bad meter output
with HA40 only) , s3: Tar level selection

Sl: Switched according

to detector plug position
level selection
(inserted
l with 3000 rpau)
I

S14-Sl6r
Po8ition
gain adjus>
I
c S16
-L Sl7: Resolver amnolitude
adjustment
818: Plug to cancel
resolver no-signal detection
s15
l S13: For SlS/S29: Used to obtain
OUtDUt Of resolver excitation
dither
oscillation from amplifier
s12: - S18
Non-linear Used when insertins
gain adjustment - s12 non-linear circuit into
i comoensation circuJ+
Sll:
For dither I 522: Plua for shorting
0 comoensation circuit at hiuh
resistance
S23: Plus for addina
comoensation circuit caoacitor
p2KJy-- 824: Alarm (AL, high)
+iiv SupPlietl
to pornr unit I S25: Alarm (At, low)
I
86: Pluq for shorting
comoensation circuit caoacitor

I_ _ _ 'Sf: Torque limiter for HA/e

o-t in this direction.

\fvoPor external emergency
I
l

‘\ A r;ow shows insertion direction.

-27-
 0
(6) INSPECTION AND ADJUSTMENT METHODS

1) HOW TO MEASURE THE VOLTAGES AND CURRENTS

1. Motor voltage measurement
Since the voltage output from the transistor amplifier to the
motor is PWM-controlled, it appears in the form of pulsive
waveforms. The value of the voltage indicated may differ greatly
depending on the type of measuring instrument used. To measure, l
first attach the filter shown below and then use a rectifier-type
‘\

voltmeter. _.

Transistor
amolifier

i:Motor

(Waveform before filter attached) Walvefonn after filter has been at :tached)

-28-
 2. Motor current measurement

(i) Due to the reactance of the motor, the current is somewhat

smoothed from pulsive waveforms into sine waves. Therefore,
connect a moving-iron type of ammeter for measurement.

of ammeter
Transistor
amplifier V

l (ii) Besides the method outlined in (i), the motor current can be
measured by the voltage of CH34-AG on card AX04.
The output (DC output) is a result of 3-phase half-wave-

l rectifying the actual current. The table below shows the

relationship between the actual current and voltage.

The output voltage differs according to the amplifier and

the setting plug.
0 When S2 is open
Transistor amplifier. CH34 voltage V/Arms
TRS50 0.190V
l
TRS75 0.115V
TRSl00 0.085V
TRS150 0.057V
0 When S2 is shorted
Transistor amplifiel Setting CH34 voltage V/Arms
plug s3
TRS50 0 0.060U
0
0.024U
TRS75 0.015U
TRSl00 0.01lU
l
TRSl50 0.0072V
o denotes shorted.

l
 2) TRANSISTOR AMPLIFIER INSPECTION

a) Operating display lamps

DBL

‘cl
0

CRAB)

OLED5
24V

Lamp Function LED

l RDY (RAl) For checking NC READY status Lights with READY ON.
SVON (RA2) For checking whether servo is Lights with servo ON.
ON or OFF.
l DBL (RAB) For checking dynamic brake Lights when brake is
operation. OFF.
24V (LEDS) Lights when start signal is Lights when power is
is issued from NC system. ON.
b) Alarm displays

ALARM
l
0 LED 1

LED2
LED3 LED lights
LED4

-31-
l
The alarms are detailed below:
Instantaneous power failure compensation/under-voltage
compensation (LVAL)
The circuitry is protected when the supply voltage is
instantaneously cut off or when the voltage drops to an
abnormally low level.
Instantaneous overcurrent detection (OCP)
The transistors are protected when an overcurrent
momentarily flows to the transistors in the circuitry.
Overcurrent detection (OVC)
This protection circuit functions when an overcurrent has
flowed to main circuitry for more than a fixed period of
time. 0
Overspeed (TGOV)
The motor is protected when the motor speed exceeds its
rating due to a malfunction.
l
No-signal detection (NSG)
This alarm functions when the signals are no longer fed back
from the resolver to the transistor amplifier. (This is for
l
detecting the magnetic pole position.)

-32-
l
l

l
6 Power unit alarm (PUAL)
Power unit alarm display.
Refer to the section on INSPECTION OF POWER UNIT for further
0
details of the alarm.
7 Fin overheating (F.OH)
Protection is provided when an overcurrent flows to the
circuitry and the fin mounted on transistors overheats.
8 Motor overload (M.OH)
Protection is provided when motor is overloaded and it
l overheats.

c) REMEDIES FOR ALARMS

1) LVAL
l (1) Measure the AC 100V voltage of the amplifier terminal block
using a multimeter or synchroscope. Rating: 8%110V.
(2) When there is nothing unusual with the voltage, the trouble

l may be an instantaneous power failure. Check the AC 100V

and AC 200V wiring connections.
2) OCP
(1) Check using a multimeter whether the power transistors have
l
been damaged. Disconnect the wires and measure across the
collector and emitter of the transistors. When nothing is
wrong, the resistance is at infinity.
0

0 -33-
 l
(2) Check whether the connections inside the amplifier have been
made improperly and whether any screws are loose.

3) ovc
0
(1) Check whether a higher current than the rating is flowing to
the motor.
(2) Check that the AX04 card settings have been made properly.
4) TGOV l

(1) Check that the AX04 card settings have been made properly.
(2) Check that the TG voltage is 0V while the motor has stopped.

5) NSG l
(1) Use a synchroscope to measure whether the resolver feedback
voltage is 12V.
(2) When the voltage is BV, check the cables and connectors. l
(3) When the voltage is lower, useVRl0 to adjusttheCH16

voltage to 12Vp-p.
PUAL
6) l
(1) Check out the power unit.

(2) Refer to page 36 for the alarm displays

7) FOH
a
(1) Check that none of the amplifier's power transistors have
been damaged.

-34-
*
 (2) Check if any units other than the power transistors are
generating heat.

8) MOH
(1) Check whether the motor is generating heat and measure the
armature current. If the current is high, check whether the
proper motor has been selected.

(2) If the motor is not hot, disconnect Gland G2 on the ampli-

fier's terminal block and use a multimeter to check whether
power is still flowing or not. When everything is in order,
the resistance is zero.

0 -35-
3) POWER UNIT INSPECTION

1) Power onit operation status displays and alarm display lamps

(TR115A control card)

Name Lamp Description of display

)P- Pilot PLll Lights when DC voltage of rectifier unit is

srat- approx. 80V; off w h e n a p p r o x . 40-50V.

Do NOT touch since capacitor is still charged

PW. ON LED1 Lights when +24V is supplied by DUC-1 cable .J

(green) (ZP12 connector) from transistor amplifier.

Al- THM LED2 Lights when temperature of rectifier diode

arm (red) exceeds prescribed temperature.

sta- Alarm for all axes.

tus NFB LED3 Lights when no-fuse breaker of rectifier

(red) unit is tripped or when it goes O F F .

Alarm for all axes.

ALM LED4 When multi-tap transformer or RU unit is

installed, the RU unit will be an alarm or
(red) when transformer thermal is operated this
will be an alarm. Alarm for all axes.
FUSE LED5 Lights when the AClOOV fuse or the fuse in the
power unit output (P) breaks. Alarm for all
(red) axes.

-36-
l
 2) Description of power unit check pins
l
Check pin Signal Description of signal
CPl +24V DC +24V is output at same time as +24V is
supplied from NC system to amplifier. At
this time, LED1 (green) lights.
CP2 RG CPl-CP4 ground
CP3 AL Low-level signal (normally* open) when alarm
occurs inside power unit. At this time, one

of the lamps from LED2 to LED5 will light.

CP4 CR Signal which observes time constant of soft-
0 start circuit. Activates contactor sequence.

0 -37-
3) Power unit card

_ __ _ _ _ __ __ _ 0

1 ZPll !2 loI
CPI 2 a 4

- 0
N 0
- 0

0000 0
w2 w 3 w4 LED5 Wl
THM NFB AL!4 FUSE AN-ON
l
Control card (TR-115)

-38-
 4) POSITION LOOP OFFSET AND DROOP ADJUSTMENTS
l
Item Adjustment Remarks
Dffset 1 Display screen 5 with ALARM/DIAGNOSIS
adjust- control at NC side. (With MQ)
.;
aent 2 Check that NC READY signal appears.
3 Adjust VR7 on AC transistor ampli-
fier and set POSITION DROOP to +/-2.
Droop 1 Display screen 5 with ALARM/DIAGNOSIS
adjust- control at NC side.
ment 2 Check that detector being used and
name of detector on screen tally.
3 Check that TAU and LINEAR ZONE are
correct.
4 Calculate position droop from formula
below: Feedrate (mm/min) x 1 x 2
60 gain

Feedrate is Fl000 (approx. 100 rpm

motor speed)
5 Feed axis 1 so that position droop is Remember that
made (+) and use VR2 on AC transistor this differs
amplifier to adjust to position droop from machine's
in (4). (+)(-I direc-
tions.
Item I
Adjustment P emarks a
6 Feed other axes so that position droo
is made (+) and adjust to within +/-1%
of droop adjusted in (51.. s

l
 4) POSITION LOOP OFFSET AND DROOP ADJUSTMENTS
l
Item Adjustment Remarks
Offset 1 Display screen 5 with ALARM/DIAGNOSIS
adjust- c.ontrol at NC side. (With MQ)
.?
ment 2 Check that NC READY signal appears.

3 Adjust VR7 on AC transistor ampli-

fier and set POSITION DROOP to +/-2.
Droop 1 Display screen 5 with ALARM/DIAGNOSIS
adjust- control at NC side.
--;
_ .: nent 2 Check that detector being used and
l name of detector on screen tally.
3 Check that TAU and LINEAR ZONE are
correct.

l 4 Calculate position droop from formula

below: Feedrate (mm/min) x 1 x 2
60 gain
Feedrate is Fl000 (approx. 100 rpm
motor speed)
5 Feed axis 1 so that position droop is Remember that
made (+I and use VR2 on AC transistor this differs
0 amplifier to adjust to position droop from machine's
in (4). (+I (-1 direc-
tions.

‘.

0 -390
 ,
Item Adjustment Remarks 0
6 Feed other axes so that position droop
is made (+) and adjust to within +/-1%
of droop adjusted in (S),.

--.
,
0

l
 5) RESOLVER FEEDBACK ADJUSTMENT
Item Adjustment Remarks
Feed- 1 Measure check pin TPl on GX96 card
back using synchroscope. (M-LB, MB) PI
*=
voltage 2 Voltage should range from 8Vp-p to p3
I
check 13vp-p. Short-circuit S5 if higher 00
%I
than 13Vp-p.
Ampli- 1 Obtain highest and lowest points of
tude waveform at check pin TPl, set volt-
fluctua- age range to 0.2V/DIV and set time
0 tion base to 0.1-0.2 sec/DIV. c'
*?I
adjust- 2 Drive machine at 3-4 m/min and ad- e

ment just VRl and VR2 so that amplitude

l fluctuation is made less than 40

mVp-p.
(GX96 card) ~llrl rrll rl rlrl l l l l J~J~~
3 To set voltage range to Q.ZV/DIV, use
synchroscope ADD and shift with both
channels 1 and 2.

-41-
6) MOUNTING THE DETECTOR
The motor's magnetic pole position (magnet position) must be
detected in the AC servo system. Therefore, the detector is
mounted differently from that in a DC servo system. The method
. . 3. &':'
is shown below.

1) Detector mounting surface

Fig. 1 Motor detector mounting surface
4-n5 x Q.R, 7.S rleoth
Mark-off 1 ine I /
Rev

2) Detector
(With bellows)
Fig. 2 Detector (with bellows)
Positionins marks

Rlonqated hole

c Key groove
$
O-ring S75
installation
----__- ",fkF'"'

3) Installation (when sensor is installed in

direction A)

-Y
HA m o t o r
’
Sensor
Note
When the sensor is Installed in directions B, C or D,
the sensor connector moves accordingly to positions B,
C or D as shown in the above diagram.

-42-
 4) Installation method
l (1) Install the O-ring (S75) to the
sensor flange.
(2) Install an M4 hexagonal bolt with
hole to the coupling.
(3) Align the motor shaft key with key
groove in the sensor bellows
(4) Align the sensor positioning mark
with the motor mark off line.
(5) Install the sensor to the motor
(using M5xO.8 screws).
(6) Tighten the screw on the key groove
to secure the key so that it cannot
move.
0 (7) Insert the sensor rubber plug
Note: The bellows should not be detached from the detector
since the positions ofthesetwoparts standin a precise

0 relationship.

-43-
0