Mitsubishi MELDAS TRS50 User manual

l
0
l
e
0
CONTENTS
(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
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
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
4)
POSITION LOOP OFFSET AND DROOP ADJUSTMENTS
........
39
5) RESOLVER FEEDBACK ADJUSTMENT
......................
41
6)
MOUNTING THE DETECTOR .............................
42
0
I

0
8
8
0
l
0
INTRODUCTION
This manual outlines the maintenance procedures for using the
MELDAS AC servo system. It details the methods involved in
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
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)
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-
tection (NSG), instant power failure
compensation and under-voltage
compensation (LVAL).
Power supply 310V (DC) across P-N
(With AC 220V factory power supply)
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-

_
.;:
(2) DRIVE SECTION BLOCK DIAGRAM
1)
BLOCK DIAGRAM OF TRANSISTOR AMPLIFIER
(TYPE TRS)
Hain circuitrv area
I-----
_-
MTR U
MTR V MTR W
1
AX14 card
I-
From NC
rG. CH3
cH4
From other
CON1
To NC 1 ,-T.(i.
I
t
I

(I,
0
2) BLOCK DIAGRAM OF POWER UNIT
-
3-phase -
AC200/220V
50/60Hz -
Since transformers are not
included in the power unit,
the control unit and machine
must be grounded.
I
W
I
NFll
MC11 Mcl2
THMl 1
fl=@l
THM
Power unit
(tvoe APO)
F12313
_TEll
r
0 Pl
4 P2-
24V
Fll(lOh) 1
I’ -
ZPI
AC100
rHb1
YFB
: 1
. I
I
c 1
‘I
kLM
?US E
1
-_
1
Caoaci tor unit
(Woe CU)

(
1
3)
1
CABLE CONNECTIONS FIGURE
D-10
e
1
Detector
q HAoo
1
D-10
\cE
I
B-2@
# For NC
or higher
1oov
*
M4
C--'M4
0nn
nr
B-24 0.2 d
--
k
Set this to the
factorv Dower ;
sunnlv.
I
Transformer
2
U VW GlG2
.__,-13nn-nnn.
,
B-20 0.5 d
-cov
8OOVA
z
u
- ‘rRSclC1
1 B-16 1.25d
I
control sionalb
ZP*-
I’
i-JB-243 or higher
. I
from CNA73
-,-(TO other amolifiers)
3-ohase
I
TPA-2 to axis 5
I
lb
I
CABLES
P
_ -
1
I
I
ADUOO
i4
I
I
I II
,I. 1
J.. . .
I
I
12P N
v-1u
Notes
I epp I
(1) flake all the AC 100V cables B-20 or higher.
I
D-10
Pi
I
(2) Hake the length of wiring between the + and - of the
M5
i
+ -
i
capacitor unit and P and N of the rectifier unitnotmore
I
Icuoo 1 1
than 258 mm.
I
Caoacitor
I
I
/
unit
I
l-
--J
(3) The zPL2 pin signals are given below:
1
I
2
I
3
ALARM 1 +24V 1 RG (ground)
(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
HR-20W5
HousinqURF-2OMOl
Contact BIRP-31112
0Cannon connector
CNA43-41
detector
cables
(for ARST)
Pousins MRP-20MOl
Contact MRP-Ml12
0Canno.n connector
Connector MS3103B20-29
Clamb MS3057-12A
detector
d
a
a
a
a
Y
f

Cable name Cable
ZJ l-l
Connector model
oZJ1
Case
bfR-2OW5
Housing MRP-20FOl
Contact MRP-FI12
CA 19-n
CNA73-c
(cable for
control
signals)
between
NC unit
Ind amplifier
oCAM1
Case: MRSBL
of
MR-SBw
Housing bfRP-5OFO 1
Contact MRP -F 112
-60

*
l
8
Cable name
CNA88-0
(cable for
resolver
signal)
Cable
CNAS/CNAS 252-l/252-3
Connectar model
RSl
oZJ2
RS2 Case
MR-2OW5
HousingMRP-20FOl
RCl Contact MRP
-F112
RC2
ROl
OCNA3-6
R02
Case: MR-2BL OK
UR-28W
SG
Housins MRP-2OFOl
Contact MRP-F112
between NC
unit and
amolifier
CNAS/CNAS
CNA4/CNA6 ZJ2-2/ZJ2-4
Connector model
ZPIZ
ZJ 5
L3
u20-6
3
oZJ5
ALARM ,
+24v 20 ;
820-2
I O’
2
Housing 5258-034
DUA- 1
ffia
nzo-0
’ 08
COntaCt 5 16 7P BT
'Dower unit
Wire mark
ontrol cable)
oZPl2
Housing l-350355-9
L
I-
Contact 350019-2
n-
8
(Pin no.)
(Pin no.)
Connector model
ZJ4 ZJL
ALARU I
El
RIO-6 oZJ4.ZJ5
+24V 2
n20-2
llc lo'
R20-9
’ 0:
Housing 5258-034
TRA-1
3
’ 08 COntaCt 5 16 7PBT
power unit
ontrol cable)
I
(Pin no.)
a
(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
I
W
I
!
!
5
Control number
plate \
2)
POWER UNIT
T
q
-.
-- I
410
,
Transformer Unit
Domestic
specifications
Tl APU;;,
30, 70,
Export
specifications
T2
APU 15-M, 30-M,
70-M, 72-M
max845
I_ ii0 !as( (185)
-
Outline drawinq of power unit

(5)
REPLACING AND HANDLING THE TRANSISTOR AMPLIFIER
1)
TRANSISTOR AMPLIFIER CONNECTIOk-
526
Ia
AX04
S26
El
ZJ3 ZP2 ZP1
.mo4
S26
El
ZJ3 ZP2 ZPl
NC
I
1 I1I
I
control
Position sicfnal
unit *
cable
I
To DUA-1
Dower unit
I
SDeed command
cable
I
I
To axis
To axis To axis
1 detector 2 detector
3 detector
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.
(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.
(d) Connect the TRA-lcable from ZP5 onthehead axis to ZP4 of
Y
a
4
-lO-
d
0
9
0
0
. .
l

a
(e)
(f)
(9)
the next axis.
Perform step (d) for each of the axes involved.
Keep the S9 setting plug inserted for the head axis only;
remove the plugs for all other axes.
How to insert the TRA-1 and DUA-1 cables
Notes:
outside.
(1)
(2)
(3)
(4)
Setting plugs and the adjustable variable resistors (VRs)
are located on the control card and they should be adjusted
when the unit is replaced.
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.
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.
When the control loop is a closed loop, the ZP2 cable need
not be connected.
0
-ll-

\ Item Checkpoint
1 P,N
Check whether the power unit P/N, AC
connections 'transistor amplifier P/N and capacitor unit
P/N connections have been made properly.
2 Transformer The transformer tap selection
(200/220V) is
tap
made to the factory power supply.
(800VA
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)
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.
a
2)
CHECKPOINTS
BEFORE
SWITCHING ON
POWER
9
l
.
e
*
-12-

(D
a
l
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.
(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.
(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-

-
-
3
-
Item
Curren'
loop
:heck
pin
CH18
CH19
CH20
Signal
Current
command
(phase
Current
feedbac
phase U
Current
feedbac
phase W
Function
Indicates same as above for phase W.
Indicates phase U current feedback
signal.
Note:
Detection resistance differs ac-
cording to power unit. Output
voltage with 1A current differs
according to amplifier unit.
signal.
Phase is
Same Note applies as for CH19.
shifted 240 deg. from U.
Phase U
Phase W
l
-15-

Item
Check Signal
Function
pin
CH21 Base Signal which controls U phase transis-
ampli-
fier tors (upper transistors)
control
signal Top/bottom transistor shorting preven-
(phase U) tion period
nslln
Transistor
2V
0.7v
ON period
Transistor
OFF period
0
CH22 Base Signal which controls V phase transis-
ampli-
I
fier tors.
control
signal
(phase V)
CH23 Base Signal which controls W phase transis-
ampli-
fier tors.
control
signal
(phase W)
1
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
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
ground
l
a
a
a
4
-160

l
l
6
7
8
9
G
-
Item
Dither
Trian-
gular
wave
Resol-
ver
Clock
ovc
Check
pin
CH8
$2
CH9
CHl0
CH13
CH14
CH16
CH27
CH28
CH29
CH30
Signal
Dither
signal
Trian-
gular
wave-
form
Resolver
Eeedback
Resolver
Eeedback
Resolver
excita-
tion
Clock
signal
ovc
circuit
For checking dither signal
For adjusting amplitude of resolver
feedback.
Adjusted with VR10.
.%o [ 12fl VP_,
Signal produced by converting resolver
feedback signal into digital signal.
For checking resolver excitation
(4.5kHz)
For checking clock signal (18MHz)
Input signal of OVC circuit. Circuit is
activated when input voltage falls below
set value of OVC circuit.
c
-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-

8
8
-
Item
OCP
Check
pin
CHA
CHB Ground
Signal
OCP
input
Function
Input signal of OCP circuit.
Detection resistance differs according
to amplifier and so output per 1A also
varies.
Detection
TRSSO
RIA-5
0
TRS75
R II A - 7
5
TRSlOO
R 51 .I - 1
00
TRS 150 R
M A - 1
5 0
L
t
OCP circuit ground
T
t
I
3 1 mQ 0.031
V
20 mQ 0.020
V
125mQ 0.0125b
3 mQ’
0.008 V
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