YASKAWA Servopack CACR-SR Series User manual

HOW TO CHECK SERVOPACK:
Labels (models number)
1. Write down the model number of the drive. The model number starts
with CACR-SR*******
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2. Before turning off the power, check what numbers or letters appear on
the alarm display
Alarm display
3. Fault Codes
The fault code indicator is a LED display located on the control board.
There are eleven possible codes – 1-7, A, B, C, and F.
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Fault Codes
LED Detection Lighting Condition Probable Cause Corrective Action
Goes ON when power is supplied to the
control circuit. * Defective control circuit board (1PWB) Check 1PWB
Goes ON when power is supplied to the
main circuit and servo power is turned
ON.
* Defective current feedback circuit. * Check the PTM
* Defective main circuit transistor
module. * Check the current transformer DCCT.
* Check grounding
Over * MCCB does not trip * Motor Grounding.
1 Current Goes ON when power is supplied to the
main circuit and servo power is turned
ON.
* Defective motor grounding * Check the PTM.
* Defective main circuit transistor
module. * Check the grounding.
* MCCB does not trip
Goes ON when power is supplied to the
main circuit. * Defective main circuit transistor module. * Check the PTM.
Goes ON when the motor accelerates or
decelerates. * Incomplete (1PWB) VR8 adjustment. * Check 1PWB
Goes ON when power is supplied to the
control circuit. * Defective control circuit board (1PWB) * Check Thyristor.
Circuit
2 protector Goes ON when power is supplied to the
main circuit. * Defective main circuit Thyristor-diode module
tripped * MCCB trips.
Goes ON during operation. * Defective main circuit
Goes ON when power is supplied to the
control circuit. * Defective regenerative transistor. * Check Regen transistor and resistor.
Regenera- * Regenerative resistor disconnection.
3 tive Goes on approximately 0.5 to 1 second
after power is supplied to the main
circuit.
* No regenerative resistor connection
(SR60BB)
trouble
Goes ON when the motor accelerates or
decelerates. * Load inertia JI (GD^2) is too large. * Check the inertia of the machine with
the value converted to the motor shaft.
4 Over-
voltage * Defective regenerative circuit. * Check Regen transistor and resistor.
When the reference is input, the motor
runs fast and 5 goes on. * Motor connection error. * Correct motor connection.
5 Over- * Optical encoder connection error. * Check pulses in phases A, B, C, U, V,
and W on 2CN, and correct wiring.
speed * The reference input voltage is too large. * Decrease the reference input voltage.
6 Voltage Goes ON when power is supplied to the
main circuit. * Defective main circuit Thyristor-diode module. * Check the Thyristor.
drop
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LED Detection Lighting Condition Probable Cause Corrective Action
Goes ON when power is supplied to the
control circuit. * Defective control circuit board (1PWB). * Check 1PWB.
7 Overload Goes ON during operation. Operation with 105% to 130% or more of
the rated load. * Check and correct the load (may be overload)* When power to the control circuit is
turned OFF and then ON again, the
operation starts.
Goes ON during operation. Fan has stopped. Check the fan.
Heat * When power to the control circuit is
turned OFF and then ON again, 7 and A
goes ON again. When reset later, the
operation starts.
(where applicable)
A sink * Temperature around the servopack
exceeds 55 degrees Celsius. * Decrease the temperature below 55
overheat (the heat sink may be overheated)
The motor rotates, but the torque is
unavailable. When power to the control
circuit is turned OFF and them ON
again, the operation starts, but the
torque is still unavailable.
* Motor circuit error connection, such as
U-V, V-W, W-U, or single-phase
connection.
* Correct the connection.
Goes ON when power is supplied to the
control circuit. * Defective control circuit board (1PWB). * Check 1PWB.
b A/D error
CPU error Goes ON during operation. * Faulty internal elements. * Resume after reset operation.
* Defective internal elements. * Check servopack.
Goes ON when power is supplied to the
control circuit. * Defective control circuit board (1PWB). * Check 1PWB.
F Open
phase Goes ON when power is supplied to the
main circuit * Poor connection to 3-phase power supply. * Check 1PWB.
Goes ON when power is supplied to the
control circuit. * Defective control circuit board (1PWB). * Check 1PWB.
C Overrun
prevention The motor starts momentarily, then C
goes ON. * Motor connection error. * Check the motor connection.
* Optical encoder connection error. * Check and correct pulses in phases A,
B, C, U, V and W with 2CN.
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4. The power must be OFF in order to check out the servo chassis by
using a multi-meter.
5. Test Equipment
The basic tool used for troubleshooting a Yaskawa servo is:
Multimeter must be in
Diode Position
Digital Multimeter
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6. Main Circuit Test Procedure
This test procedure must be performed before replacing a servopack.
Test Procedure Checklist
Completed
Check RSTUVW on the terminal block.
Check the regen (regenerative) transistor.
Check the diode bridge # 1.
Check the diode bridge # 2.
Check the braking transistor.
Check the resistor module.
Check the thyristor module.
Check the cooling fan.
Check the Regen resistor.
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7.
Resistor Module
Braking Transistor
Thyristor ModuleCapacitor
Breaker
Regen Transistor
Power Transistor
Module - PTM
Diode Bridge # 1
Diode Bridge # 2
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8. Power the power OFF.
9. If breaker is tripped, do not reset and power on, check terminals.
Breaker
10. If breaker is blackened (burnt), need to replace servopack and check
contactor (power supply to the servopack), it may need to be replaced
too.
11. Terminal Block
Make sure the circuit breaker is ON for the following tests
R S T U V and Ware checked on the terminal block to give an initial
overview of what may be wrong with servo. Place the positive lead of the
meter onto the negative lead of capacitor . Check R, S, T, U, V, and Wwith
the negative lead of the meter. Then put the negative lead of the meter on the
positive lead of the capacitor and repeat. A table with the results is located
on the following page. If U, V, or Wreadings are bad, then their respective
parts on the PTM are bad and the PTM needs to be replaced. If the R, S, or
Treadings are bad, this implies that the thyristor is bad. Do not replace the
thyristor without checking. A digital multimeter is used to check the
terminal block.
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Note: Measured values (excluding 0L) vary with the power rating of the
servo. Check for consistency.
12.
Remove all wires from bottom of terminal strip (R-W)
13.
Set your multimeter to a diode symbol and measure as follows: (your
test leads form meter are the red and black)
Terminal strip
Red Black (V)
- R ≈.500
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14. Terminal Block
RST r tY3Y4UVW
15.
Terminal Block Check
Test Equipment – Digital Multimeter
Step #
Multimeter
Positive
Lead
Multimeter
Negative
Lead Expected Reading
(Diode Check)
1
Negative
capacitor
terminal
R, S, T Approximately 0.5 Volts must be
consistent with each other.
2
Negative
capacitor
terminal
U, V, W Approximately 0.4 Volts must be
consistent with each other.
3 R, S, T
Positive
capacitor
terminal
0L displayed
4 U, V, W
Positive
capacitor
terminal
Approximately 0.4 Volts must be
consistent with each other.
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16. Regen Transistor
When the servomotor is turned off, there is still a voltage present across
the main bus of the servo. The regen transistor acts as a switch with
closes when the servo is turned off to allow this voltage through to the
Y3 and Y4 terminals. Here it is dissipated across resistors 1 and 2. When
checking the regen transistor, you are making sure it hasn’t been shorted
across the emitter and collector.
Base
Collector
Emitter
17.
Regen Transistor Check
Test Equipment – Digital Multimeter
Step # Multimeter
Positive Lead Multimeter Negative Lead Expected Reading (Diode Check)
1 Base Collector
Approximately 0.5
Volts.
2 Emitter Collector
Approximately 0.4
Volts.
3 Emitter Base
Approximately 0.7
Volts.
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18. Diode Bridge #1
The diode bridge #1 is a component in the braking circuit. When the
servomotor is turned off, the continued spinning of the motor generates a
voltage across U, V, and W. The diode bridge directs the current from
this voltage to the braking resistor to be dissipated. This results in a
smooth braking of the motor.
Module Terminal 1
(+) Module Terminal 2
(-)
Module Terminal 3
19. Diode bridge #1 Check
Test Equipment – Digital Multimeter
Step # Multimeter Positive Lead Multimeter Negative Lead Expected Reading (Diode Check)
1
Negative
module
terminal
Module
terminal 1, 2, 3 Approximately 0.5 Volts must be
consistent with each other.
2 Module
terminal 1, 2, 3
Positive module
terminal Approximately 0.5 Volts must be
consistent with each other.
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20. Diode Bridge #2
Diode bridges are used to rectify voltage wave patterns. In this case, the
input voltage is the three phase AC voltage RST. In order for this voltage
to be useful to the PTM, it must first be converted to a DC voltage
pattern. The diode bridge #2 further rectifies the voltage out of the
Thyristor into DC voltage, which is then sent to the power transistor
module.
2 2, 3
3
1
1
21.
Diode Bridge #2 Check
Test Equipment – Digital Multimeter
Step #
Multimeter
Positive
Lead
Multimeter
Negative
Lead Expected Reading (Diode
Check)
1 Terminal (2) Terminal (1) Approximately 0.5 Volts must be
consistent with terminal (2).
2 Terminal (3) Terminal (1) Approximately 0.5 Volts must be
consistent with terminal (3).
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22. Braking Transistor
The braking transistor is actually a triac. A triac acts like a diode except
that it can conduct in both directions. The braking transistor rectifies and
provides a return path through the braking resistor for the UVW voltage
from Diode Bridge #1.
T1
T2
Gate
23. Braking Transistor Check
Test Equipment – Digital Multimeter
! Multimeter must be in Ω(Ohm) Position !
Step # Multimeter
Positive Lead Multimeter Negative Lead Expected Reading (Ohm Check)
1 Gate T2
Approximately
1.65 M Ω.
2 T2 T1
Approximately
1.65 M Ω.
3 T1 Gate
Approximately
50-90 Ohm.
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24. Resistor Module
The braking resistor is primarily used to dissipate the current created by
the voltage which is generated by the spinning servomotor after the servo
has been shut off. Usually this resistor needs to be replaced if it is
cracked or physically damaged in a similar way.
1 Divider Resistor
P1
32
2 Braking Resistor
25. Resistor Module Check
Test equipment – Digital Multimeter
! Multimeter must be set to 200k ohm and 200 ohm !
Step # Multimeter
Position Multimeter Positive Lead Multimeter Negative Lead
1
Divider 200k Ω(Ohm)
Resistor
(P) module
terminal
Module terminal
(1)
2
Braking 200 Ω(Ohm)
Resistor
Module terminal
(3)
Module terminal
(2)
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26. Thyristor Module
The Thyristor module is composed of both diodes and silicon-controlled
rectifiers. The Thyristor is the main component which contributes to the
conversion of the AC input voltage to the DC voltage used to power the
servomotor.
P N
27. Thyristor Module Check
Test Equipment – Digital Multimeter
! Multimeter must be in Diode position !
The Thyristor module is checked using the connector end of its
wiring harness. Make sure you check the wires corresponding to the
Thyristor module (i.e. gray and green)
Step # Multimeter Positive Lead Multimeter Negative Lead
Expected
Reading (Diode
Check)
1 R, S, T P OL
2 N R, S, T 0.5
R, S, T
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28. Cooling Fan
Only the SB 60 and BB 20+ units have a cooling fan that blows air across
the heat sink on the back of the unit. If the cooling fan is not working
properly, the servo will trip on an overheat fault. Visually check the cooling
fan to make sure it turns freely. If there is no physical evidence that the fan
is bad, the motor can be checked with an ohmmeter. Using an ohmmeter,
measure across the fan motor terminals. If the measured value is 0 ohms, we
can conclude that the motor is shorted, or if the measured value is infinite
ohms, we can conclude that the motor is burned open. If the fan is not
working, then replace the fan.
29. Regen Resistor Check
On some of the BB models only, the Regen resistor is found underneath the
heat sink. If the resistor is in metal case, it should be checked to ensure that
there isn’t leakage from the lead to the metal casing. Excluding SB models,
the value of the Regen resistor is measured at terminals Y3 and Y4. The
Regen resistor is external on the SB models.
Model:
BB, BZ Resistance
3 100
5 100
7 100
10 50
15 50
20 25
30 12.5
44 12.5
If you find that these readings are different than what you
measure call us, you may need to replace the servopack.
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