SERVO AMPLIFIER MAINTENANCE MANUAL (1st Edition) Pub.No.4017-E (EEA4-001-01) Jan.1995Cee RR eee ee reer | BE00-001-R1 P-(i) SAFETY GUIDELINES SAFETY GUIDELINES ‘The control device described in this manual uses a variety of electric parts and units. Before making connections between these parts and units or connecting the power source, read this manual carefully and strictly observe the folowing points to avoid accidental injury, malfunction or burning of units, and other trouble. (1). Before connecting or disconnecting a unit, shut off the power supply completely and discharge the charged parts in the unit. Failure to do this could result in injury due to electric shock, or unit malfunction or burning, (2) Before connecting the power supply to a unit, check the specifications of the power source. if the ‘source voltage does nat match the voltage to be supplied or the polarity is incorrect, units may malfunction or burn. (8) Connect the inputs and outputs to each unit correctly. Incorrect connection could cause Units to malfunction or burn (4) Be sure to connect the grounding of each unit, and the P.E. grounding cable, to the electrical cabinet. Failure to do this will result in injury in the event of a leak. (6) Be sure to connect an overcurrent protection device (breaker or fuse) in the power supply cables. Failure to do this could cause burning of cables or units, or the outbreak of fire, in the event of a short-circuit (6) When making the cables to connect the units, select wire sizes that are suitable for the application, Especially in the case of power cables, the selection must be made in accordance with the load current. If the cable capacity is insufficient for the application, the cables will overheat and this may cause them to burn or cause a fire, (7) The electrical cabinet, operation box, or other enclosure where the units are installed must have a water-proof and dust-proof construction. If it does not, injuries due to electric shock may be ‘caused, and units may malfunction or bur. (8) Always use the thermostats incorporated in the motors and units to protect these devices. If you do rot, the devices may burn or cause fires. The following warning indications are used importance, PAQINGz] : tncicates an imminent hazard which, ifnot avoided, will result in death or serious injury. AAWARNING) < !ecicates unsafe practices which, inet avoided, could result in death or serious Inu: this manual to draw attention to information of particular AXCAUTION Indicates unsafe practices which, if not avoided, could result in minor injuries or damage to NC unit or other equipment. Note: Indicates precautions relating to NC unit operations. This manual must be kept for future reference. The contents of the manual are subject to change due to product improvements.=! BEAO-007-A1 P-(i) ‘TABLE OF CONTENTS TABLE OF CONTENTS SECTION1 OUTLINE... 1. CONFIGURATION ... 2. CLASSIFICATION OF SERVO AMPLIFIERS SECTION2 MAINTENANCE AND INSPECTION ..........00ce000ceceese abet 1. INSPECTION DURING INSTALLATION ..... , 4 1-1. Installation Place 4 1-2. Environmental Requirements 4 1-3. Inspection of Source Voltage seeeavesy 5 2. PARTS ARRANGEMENT AND STRUCTURE OF SERVO AMPLIFIER 6 3. PROTECTION AND ERROR MONITORING FUNCTION ....-.+-s0+s0s00-e0ee = 12 3-1. Operation Status Indication . 2 3-2. Monitoring Function 4 3-3. Reset Function .. ei i Stein: 14 3-4, Arrangement of Status Indicating LEDs and Check Terminals 16 4, INSTRUMENTS AND PARTS USED FOR MAINTENANCE .. 16 SECTION 3 TROUBLESHOOTING ......... 1s idediasssapanayepes 7 1. CAUTIONS AT AN OCCURRENCE OF TROUBLES: 2 ”7 2. TROUBLESHOOTING TABLES .... 7 SECTION 4 SETTING AND ADJUSTMENT OF CONTROL BOARDS .. peered 23 SECTION 5 CHANGING THE CONTROL BOARDS AND UNITS 24 1. POWERUNIT 20 ...seecccseeee 24, 2. SVCIIBOARD ....... nite Dyiaaas selad teased 25 3, SEMICONDUCTOR DEVICES iu seaptsee 26 34. IGBT Module .. 3 - 28 3-2, Diode Module .. Lins, 26 28 3-3, Changing Semiconductor Devices ...... . 29BEAO-010-R1 P-1 SECTION 1 OUTLINE SECTION1 OUTLINE This maintenance manual describes the maintenance and inspection procedure for BLII-D servo amplifier, 1 CONFIGURATION (Okuma AG servomotor system has the configuration as shown in Fig. 1-1. Position command information given from such as a part program is processed by the MAIN board 1 and given to the SVP board as the position command of individual axes. The SVP board executes position, motor speed, and torque control, and outputs the current command signals. ‘The current command signals are input to the servo amplifier where they are amplified, and then supplied to the BL-motor as power. ‘The position and motor speed information of the BL-motor is given to the SVP board from the position ‘encoder, incorporated in the BL-motor, as the feedback signal. Poston command (Current comman signal MAIN board 1 ‘SvP board ‘Servo amplifier Poston, motor speed, ‘anc torgue contol Position encoder Fig. BLmotor [7] Position, motor speed fecdback 4-1 AC Servomotor SystemBEAO-010-R1 P-2 SECTION 1 OUTLINE CLASSIFICATION OF SERVO AMPLIFIERS BLI-D series servo amplifiers are available in two types — 1-axis amplifier and 2-axis amplifier. The unit names determined based on the servo amplifier capacity so that unit identification can be made simply. For the relationship between the rated motor output and the servo amplifier capacity, refer to Table 1-1 “Combination of BL-motor and Servo Ampliiar. * taxis amplifier .... * 2-axis amplifier ... - BUDA BUILD kA Amplifier capacity (15 to 150) ~T— Ampltior capacity forthe second axis (18 to 75) Amplifier capacity for the first axis (15 to 75) ‘Aservo amplifiers configured from the control board (SVCII board) and the power unit as shown in Table 1-1 “Combination of Control Board and Power Unit" Table 1-1 Combination of Control Board and Pawer Unit Unit Type Power Unit Control Board ‘axis Amplifier BUTDI5A BLI-D15A PU SVCTI Board (-axis) BLI-D30A_ BLIL-D30A PU BLI-DSOA BLI-DS50A PU BLIED75A\ BLIFD75A PU BLI-D100A BLI-Di00A PU BLI-DI50A BLI-Di50A PU 2-axis Amplifier BLI-DI515A BLIFDiS15A PU ‘SVGII Board (@-axis) BLI-D3O15A BLIFD3O15A PU BLIF-D5O1SA BLI-D5075A PU BLIFD7515A BLIFD7515A PU BLI-D30304 BLT-D3030A PU BLI-D50308 BLIF-DS030A PU BLIL-D7530A BLI-D7530A PU BLT-D50508 BLIL-DS050A PU ‘BLI-D7550A BLILD7550A PU BLILD7575A BLI-D7575A PU Ail 2-axis amplifier. ON| : When using a 2-axis amplifier, the following restriction must be carefully observed. ‘The motor having a larger rated output must be connected to the first axis connector in the For example, when connecting 1.5 kW motor anda 4.0 kW tothe 2-axis amplifier, the 4.0 kW ‘motor having larger rated output must be connected to the first axis connector andthe 1.5 kW. motor having smaller rated output to the second axis connector. Itis not allowed to reverse. the connection of these motors at the 2-axis amplifier.BEA0-010-R1 P-3 SECTION 1 OUTLINE O1-R002HN-1a (g190-9001) Oz SLOeHN-Ta vostamma ost oeatozHn-7s| 08 0 09 (190-3001) 0e-S0PISWAIa yooLa-Ina oor Z-BLOrHNB| 09 o OF oe S0risWw18 oe-asziswe oz-asziswa (ze30-9001) | (0890-9001) | (2290-9001) | (ez90-9001) | (190-9001) Gia OSHA TE: vsesza-ine | vossza-ine | voesza-ine | vsisza-tma | vsza-1me se Oz-SLOZHW-1a| Oy % Sz on-aszsna oe-asesw18 oe-309sW718 (6290-9001) | (9290-9001) | (zz90-s001) | (zt90-9001) @b-SLOcHN-18 vososc-iria | voeosc-ma | vstosa-ma | vosaanie og ozaLoLHW7a| sz a st (szg0-9001) | (1290-9001) | (1190-9001) Oe S0ssW1d voroec-ina | vsioec-ina | woea-ina oe ZLSLOIHW78| go 91 8.0 of-301SW718 (oz90-8001) | (0190-9001) 08-302HW-14 vsisiains | vsia-ina st Oz-OLHN-I| 70 OF SL 08 08 sh Con sepi0) | fredeo (nw) 190490 (CON JOpIO) “duy epxe-g ‘duy spe-} | sdurysmyist | PALIN | JoroW pers ‘Aipedeg “duiy sixy puz |! Joyydury onteg pue Jojow-7g Jo UoWeUIqUIOD z-f oIGeLBEAO-011-R1 P-4 SECTION 2 MAINTENANCE AND INSPECTION, SECTION2 MAINTENANCE AND INSPECTION a INSPECTION DURING INSTALLATION 4-1. Installation Place For the requirements on the selection of servo amplifier installation place, refer to ‘Unit Installation Drawing” in "AC SERVOMOTOR SPECIFICATIONS MANUAL", 1-2. Environmental Requirements (8) Ambient Temperature = During operation Ambient temperature of unit 2 O°Cto 55°C ‘Ambient temperature of control cabinet: 0°C to 45°C ~ During transportation and storage Ambient temperature of unit 2 -20°C to 60°C (10) Humidity Under normal operation status: 75%RH max. For short period (within 1 month): 959RH max. ‘There must be no condensation. (11) Vibration During operation: 0.5G max. (12) Ambient Atmosphere Must not be exposed to coolant, lubricating oil, chips, ete.BEAO-011-R1 P-5, SECTION 2 MAINTENANCE AND INSPECTION 1-3. Inspection of Source Voltage (1) (2) ‘Source Voltage Specification and Allowable Voltage Range + Specification The servo amplifier operates at three-phase, 200 V (for main circuit) and single-phase, 100 V (for control circuit). ~ Allowable range For main circuit : 180 to 220 V (ims) (49 to 62 Hz) For control circuit : 90 to 121 V (rms) Capacity of Power Source Since required power source capacity for the servo amplifier varies depending on the rated motor output, operation made, eto, it is necessary to measure input current by actually operating the system where actual loads are connected if the capacity must be found accurately. With machine tools, however, motors are rarely operated at the rated output. Taking this into consideration, required power can be roughly estimated using the following formula. Required power = (Rated motor output) x 0.32id BEAO-O11-R1 P-6 SECTION 2 MAINTENANCE AND INSPECTION. 2. PARTS ARRANGEMENT AND STRUCTURE OF SERVO AMPLIFIER Servo ampiifier is composed of the following parts: (1) Radiator plate (where devices are mounted) Power unit (2) Power board (3), SVCII board, ——————________ Control board Proteation cover (8) SVCT board Fesot switch Check terminal LD. WARNING CHARGE oratice LEE seine ® li) = LG tonasnrstte [| I LL G (LY yy er mcd ODOT Cine | nina, ir Fig. 2-1. Structure of Servo AmplifierBEAO-O11-R1 P-7 SECTION 2 MAINTENANCE AND INSPECTION. xB68 | XB58 XB2 XBS1 XEN pe ig EBL eeee ete ly iv ERE 2000 yeti TO14s cow 1006 080, \ YP age Fig. 2-2 SVCII board (1-Axis Amplifier) ‘Order No.: 1006-0600 ‘Order No, and version No, Reset switch Status indleatng LEDBEAO-O11-R1 P-8. SECTION 2 MAINTENANCE AND INSPECTION r i Le} 3 8 . 5 2 i 8 é : 3 8 i 8 xBe xB xBa2 7. 5 z 3 3 3 Fig. 2-8 SVCII board (2-Axis Amplifier) Order No.: 1006-0601BEAO-011-R1 P-8 SECTION 2 MAINTENANCE AND INSPECTION eax ax Tojsise) Busuee Wein df won, ‘oN ubIsION ue "ON 0p10) 9019 200010} jeune, Fig. 2-4 Power Board (For 1-Axis Amplifier, Excluding BLII-D150A)BEAO-011-R1 P-10 SECTION 2 MAINTENANCE AND INSPECTION NINEWIA sou0AM}19} 1891, s0}28u00 99u5 eH aa 50x 2otsiso1 Bujsuas wowing onan, ‘ON woIsION ue "ON 0B) Fig. 2-5 Power Board (For BLII-D150A)58 ap zg 52 gs 2 } id uw Z i mh Eg : 2 : Z : $ : so7oor01d a : wai FA a (oe puz) Abparatectdeettd i nsuser4 stein | J019601 ores 5 Pane, Ho] yy apacsekeeebeedergy gebicatei Re eends cs Es (se puz) nein een} 20412) are on ; a1 Bsus yuu s0uvHD ‘ pester) ShINIVAR : ' a Ta ‘ong * men [ a - 5001 eK sex vax i a on uolron edt wun pus 3610 Fig. 2-6 Power Board (For 2-Axis Amplifier)BEAO-O11-R1 P-12 SECTION 2 MAINTENANCE AND INSPECTION 31. PROTECTION AND ERROR MONITORING FUNCTION Operation Status Indication ‘The servo amplifier displays the operation status on the SVCIT board and power board by status indicating LEDs. Operating status display mode includes the run status, reset status, and malfunction status modes. In the malfunction status, the alarm message is displayed on the NC operation panel while the corresponding status indicating LED on the SVCII board sit. In this status, all motors are stopped. Table 2-1. Status Indicating LEDs and Display Mode - Display Mode Status Indicating LED SVCII board Power board Green Run status Yellow Reset status Red Malfunction status During chargeBEAO-O11-R1 P-13 SECTION 2 MAINTENANCE AND INSPECTION Table 2-2 Status Indicating LEDs and Indicated Status eee Description Location PON | Control power ON ‘Svol (green) | Power is being supplied to the SVCII board, peed OFF Servo amplifier operation disabled ‘svonr (yetlow) | The control circuits in the reset status due to an extemal input or occurrence | board ofan alarm. oc" Motor cable overcurrent svolr (red) | Overcurrent, exceeding 150% of the limit current value, is supplied to the motor. | board PCS* Inverter bridge cir ‘SvCII (Fed) | Overcurrent is supplied due to the following reasons: board + Short circuit in the inverter OC power supply due to a trouble of main circuit de- vices or control circuit ~ Grounding fault inside the motor ov Power circuit overvoltage svoml (red) | inverter DC voltage is abnormally high. board uv Power circuit iow voltage ‘Svor (4) | inverter DC vottage is abnormally low, board ROH Regenerative resistor overheat svonr (ed) | Regenerative resistor is overheated due to the following reasons: board ~ Continuous current flow tothe regenerative resistor due toa trouble in the control circuit. ~ Excessive regenerative energy BOH Power board overheat Sven (22) | Power board is overheated. bored! Loss ‘Abnormal voltage of power supply for control clrcult svoit (Fe) | Voltage of the power supply for control circuit exceeds the safe operating range, | board WARNING ‘Main power ON Power CHARGE gq) | Power supply to tho main circuits ON. hoard: Note: Anasterisk represents axis number, tstaxis. : 2nd axis : *=2 While the WARNING CHARGE LED is lit it indicates that high voltage is applied to the ‘components in the servo amplifier. If you touch a component in the servo amplifier in such, status, you might be injured due to electric shock, ‘When changing change a board or unit, turn off the circuit protector and make sure that this LED is turned off before attempting the required work.BEAO-O11-R1 P-14 SECTION 2 MAINTENANCE AND INSPECTION 3-2. Monitoring Function Itis possible to check the motor speed and torque of BL-motor using the check terminals on the SVCIT board. (Check Terminal 5 Note Description Output Rating VEL1 Itis possible to monitor the motor speed (for the | = 10 V/a:3750 min” {rpm} ‘1st axis) by measuring the voltage between check terminals [COM] and [VEL 1] with an oscilloscope. TO1 {tis possible to monitor the torque command (for the 1st axis) by measuring the voltage between check terminals [COM] and [TO 1] with an oscillo- scope. 10 Vi{torque limit) * Torque limit varies depend- ing on motor type. VEL 2 Itis possible to monitor the motor speed (for the 2nd axis) by measuring the voltage between check terminals [COM] and [VEL 2] with an oscil- loscope. Note: _ Only for the 2-axis control board £10 W/23750 mir! (pm) To2 itis possible to monitor the torque command (for the 2nd axis) by measuring the voltage between check terminals [COM] and [TO 2] with an oscilo- 10 Viftorque limit) * Torque limit varies depending on motor type. scope. Note: Only for the 2-axis contro! board 6 Power source of 5 V for control circuit Note: Only for the t-axis control board COM Ground for control circuit 3-3. Reset Function ‘The servo amplifier can be forcibly placed in the reset status using an internal switch. Use this function when ‘checking a trouble. ‘The status indicating LED OP is lit when the servo amplifier is reset, DIP Switch Name Description Output Rating Swit Servo reset switch for the 1st axis Reset when the switch is ON. ‘SWt-2 ‘Servo reset switch for the 1st axis, Reset when the switch is ON. Note: Valid only tor 2-axis control boardBEAO-O11-R1 P15 SECTION 2 MAINTENANCE AND INSPECTION 3-4, Arrangement of Status Indicating LEDs and Check Terminals (1) SVCII Board (for 1-axis amplifier) = | —1 9 ot Sei | Lh ag a = Ee al awe ee © «.comte0 (Oa ® see Red LED (1 t= SS oslo Cres ps — - = COOCOOOOMOOOOO®OO® VEL’ TOs VEL2 TO2 COM PON OP OCM Ocs OV WW ROM BOH LOSS OCS GCM OF © ---crmte0 - Yolow LED © @ vs Rests XEVE (Check terminala BEAO-011-R1 P16 SECTION 2 MAINTENANCE AND INSPECTION INSTRUMENTS AND PARTS USED FOR MAINTENANCE Instruments used for maintenance are indicated in Table 2-1. ‘Table 2-1 Maintenance instruments. Name Specifications Use AG voltmeter 300V For measuring power supply voltage Analog circuit tester Market product For checking resistance Philips screwdriver Medium, small Components parts used in the BLII-D servo amplifier and those necessary for maintenance are indicated in Table 2-2. ‘Table 2-2 Maintenance Parts for BLII-D Servo Amplifier “Amplifier Capacity N y ‘Okuma Part N sa ne me ran’ [18 [30 | 50 | 75 | 100] 150 TGBT module | BMBISOFA-050 Eaas-722087 [O | O 380A 600 V (Fuji) ‘MBISOFA-060 4448-72-08 o ‘e 50 A 600 V (Ful) 2 6MBI75FA-O60 E4443 722-089 oO 2 75 A 800 V (Ful) g ‘MBITOOFA-060 EAA4S-TEE-043 o 3 100 A 600 V (Ful) = EMBIT5OFA-060 E4445-722-040 150 A 600 V (Fuji) Diode module | 6RIS0E-080 Eeria7ezo01 |O|O;OlOlo 50 A 800 V (Ful)BEAO-012-R1 P-17 SECTION 3 TROUBLESHOOTING SECTION3 TROUBLESHOOTING CAUTIONS AT AN OCCURRENCE OF TROUBLES After an occurrence of a trouble indicated in 2. “TROUBLESHOOTING TABLES" below, if it becomes necessary to change the boards or uns, follow the steps indicated below before beginning the necessary work. ~ Tum off the power. ~ Tum off the circuit protector in the servo amplifier. ~ Make sure that the WARNING CHARGE LED is OFF. dal While the WARNING CHARGE LED is lit, it indicates that high voltage is applied to the components in the servo amplifier. If you attempt changing of a board or unit, you might be injured due to electric shock or the unit might be damaged, 2. TROUBLESHOOTING TABLES. (1). Status Indicating LED PON is not Lit Status Indicating LED LOSS is Lit Failure Factor ‘Check Measure ‘Abnormally high orlow | Check ifthe voltages applied to the input | Adjust the input voltages. source voltage terminals R, S, and T of servo amplifier are_| to values within the within the allowable range: 180 to 220V AC. | allowable range. Fuse (HMS.2A) is Check if the fuse mounted on SVCIT board | Replace the fuse. blown, is blown Imperfect insertion of | Check ifthe interboard connectors are Insert propery. the connectors XB5 __| securely inserted into the connectors on the (86) on the PC board. | SVCIT board, Power is not supplied — |(1) Remove the blue connector cover. Replace the power unit. ro the power unit to the SVCII board. (2) With the power ON, check ifthe voltage ‘across the 6th and 10th pins of the connector XB6 on the SVCII board is 200V AC using a voltmeter. Fallure of the SVCII_—_| Check ifall the above checking items are | Replace the SVCII board | normal board. PUNE] < Hich votage is applied tothe SVCTT board, Use utmost care winen measuring supply voltage to this board to protect yourself from electrical shock.BEA0-012-R1 P-18 SECTIONS TROUBLESHOOTING (2) Status Indicating LED OCMis Lit Failure Factor Check Measure Contact failure between the motor cables and the terminal base Check if the terminal screws are securely | tightened, Tighten securely. Disconnection, Remove the motor cables from servo Replace the motor the SVCTI board is replaced. interphase short-circuit, | amplifier and the motor to check them for _| cables. ground fault of the motor | continuity. ables Failure of the BL-motor | After removing the motor cables from the | Replace the motor. ‘motor, measure the insulation between the ‘motor terminals and the frame using a megger. Imperfect connection of | Check the connector. Properly connect. the connector XBt Defective SVP boar Check if allthe above checking items are | Replace the SVP board. the NC unit normal. Failure of the SVC. | Check ifall the above checking items are | Replace the SVCII board normal. board. Fallure of the power unit | Check ifthe OCM lamp lights up even after | Replace the power unit.BEA0012-R1 P-19 SECTION 3 TROUBLESHOOTING (8) Status Indicating LED OCS is Lit Failure Factor Check Measure Failure ofthe SVCIT_ | See Table $-1. See Table 3+. board or the power unit Interphase short-circuit | Remove the motor cables from servo Replace the motor ofthe motor cables | amplifier and the motor to check them for__| cables. continuity Failure of the BL-motor | After removing the motor cables from the _| Replace the motor. ‘motor, measure the insulation between the ‘motor terminals and the frame using a megger. Table 8-1 Method of Checking SVCII Board and Power Unit on Occurrence of OCS Process Contents, 1__ [Tum OFF the power. 2 | Turn OFF the circuit protector and make sure that the WARNING CHARGE LED is OFF. 3 | Remove the SVCII board and check ifthe interboard connectors are securely engaged with the XB connectors 4 to 6 on the power unit Ensure that they are fixed together. Pressly Intorboard connector Connector on power unit 4 __|Cheok the IGBT module. (See Section 5, 9-1. “IGBT Module”) 5 __ [install the SVC boar 6__| Make a trial run to check if he OCS lamp lights up. 7__ [Ifthe lamp lights up again, replace the SVCII board and make a trial run 2 _|ifthe lamp still ights up, replace the power unit [Al 2 While the WARNING CHARGE LED is it, it indicates that high voltage is applied to the ‘components in the servo amplifier. If you touch a component in the servo amplifier in such status, you might be injured due to electric shock.ad BEAO-012-R1 P-20 SECTION 3 TROUBLESHOOTING (4) Status Indicating LED OV is Lit Failure Factor Check Measure ‘Abnormally high source | Check ifthe voltages applied to the input | Adjust the input voltages voltage terminals R, S, and T of servo amplifier are _|to values within the within the allowable range: 180 to 220V AC, | allowable range, Loose screws on power |(1) Tum OFF the power. | Tighten the screws cable terminals securely. (@) Check ifthe power cable terminals are securely fixed with the screws. circuit {rouble in regenerative | After taking actions according to the steps in | See Table 3-2. Table 3-2, check if the OV lamp stil lights up. Table 3-2 Method of Checking SVCII Board and Power Unit on Occurrence of OV Process Contents 1 [Tum OFF the power. 2 | Tum OFF the circuit protector and make sure that the WARNING CHARGE LED is OFF, 3 | Remove the SVCTI board and check if the interboard connectors are securely engaged with the XB connectors 4 to 6 on the power unit. 4 | Check if the terminals VH and TRC for connecting the regenerative resistance are seourely tightened. 5 | Check the IGBT module for regenerative circuit. (See Section 5, 3-1 *IGBT Module’) 6 _| install the SVCII board. 7___|Make a trial run to check if the OV lamp lights up. 8 _| Ifthe lamp lights up again, replace the SVCTI board and make a trial run. 8 __| Ifthe lamp stil ights up, replace the power unit, LA WARRING ! While the WARNING CHARGE LED is lit, it indicates that high voltage is applied to the ‘components in the servo amplifier. If you touch a component in the servo amplifier in such status, you might be injured due to electric shock.BEAO-012-R1 P-21 SECTION 8 TROUBLESHOOTING (6) Status Indicating LED UV is Lit (6) Failure Factor Check Measure ‘Abnormally low source voltage ‘Check if the voltages applied to the input terminals R, 8, and T of servo amplifier are within the allowable range. ‘Adjust the input voltages to values within the allowable range. No input voltage to one Check the input voltages. Check the power module ‘of the three phases cables. Circuit protector is, Check the circuit protector. Tum ON the circuit tumed OFF. protector. Loose sorews on IGBT | Check the screws. Tighten them securely. Failure of |GBT module Check the IGBT module. Replace the IGBT (See Section 5, 3-1 “IGBT Module") module. Imperfect insertion of | Check ifthe interboard connectors are Insert properly the interboard ‘Securely inserted into the connectors on the ‘connectors ‘SVCII board. Failure of power unit | Check ifallthe above checking items are | Replace the power unit. normal. Fallure of SVCII board | Check if the UV lamp lights up even atter__ | Replace the SVCIT replacement of power unit board. Status Indicating LED BOH is Lit Failure Factor Check Measure ‘Motor overload Check the overload rate with the load display. Review the operation program. Imperfect insertion of | Check ifthe interboard connectors are Insert properly, the interboard securely inserted into the connectors on the connectors SVCII board, Failure of SVCIT board | Check if all the above checking items are _| Replace the SVCIT normal. board. Failure of power unit Check if the BOH lamp lights up even after replacement of SVCII board, Replace the power unit.BEAO-012-R1 P-22 SECTIONS TROUBLESHOOTING (7) Status Indicating LED ROH is Lit display. Failure Factor Check Measure Failure of regenerative | Check the regenerative IGBT module. Replace the IGBT IGaT (See Section 5, 3-1 IGBT Module”) module, Imperfect insertion of | Check if the interboard connectors are Insert properly. the interboard securely inserted into the connectors on the [connectors SVCII board. Motor overload Check the overload rate with the load Review the operation program. Loose screws for fixing regenerative resistance ‘Check the serews on the terminals THR and COM. Tighten them securely. Failure of SVCUI board | Check if all the above checking items are _| Replace the SVCII normal. board, Fallure of power unit | Check ithe ROH lamp lights up even after _| Replace the power unit. replacement of SVCII board. (8) Circuit Protector Trips Failure Factor ‘Check Measure [Wrong wiring of output | Check them for wiring Correct the wiring, terminals (U, V, W, E) Interphase short-circuit of motor cables Remove the motor cables from servo amplifier drive unit to check them for continuity Replace the motor cables. Failure of IGBT module Check the IGBT module. Replace the IGBT normal, (See Section 5, 8-1 “IGBT Module”) module, Defective diode module | Check the diode module. Replace the diode (See Section 5, 3-1 “IGBT Module”.) | module, Failure of power unit | Check if all the above checking items are _| Replace the power unit. Failure of SVCII board Check if the circuit protector trips even after replacement of power unit Replace the SVCIT board. (9) WARNING CHARGE LED is not Turned Off in Response to Turning Off of Circuit Protector Failure Factor Check Measure Failure of power unit After leaving the unit for about 30 minutes, make sure that the LED is OFF. Then, replace the power unitBEA0-013-R1 P.23 SECTION 4 SETTING AND ADJUSTMENT OF CONTROL BOARDS SECTION4 SETTING AND ADJUSTMENT OF CONTROL BOARDS Since all information necessary to drive the servo amplifier is supplied from the NC unit, no special setting is, required for the control boards.BEAO-014-R1 P-24 SECTION § CHANGING THE CONTROL BOARDS AND UNITS SECTION5 CHANGING THE CONTROL BOARDS AND UNITS POWER UNIT After following the instruction given in Section 3, 2. "TROUBLESHOOTING TABLES’ it it becomes necessary to change the power unit, follow the procedure indicated below. Procedure: (1) 2 @) (a) ©) (6) m7 8) (9) ‘Turn OFF the main breaker in the control cabinet. ‘Turn OFF the circuit protector and make sure that the WARNING CHARGE LED is turned off. Remove the power cables and motor cables. Remove the power unit from the control cabinet. Check the order number of the new power unit. It must be the same number as the one labeled on the removed power unit to be changed, Mount the new power unit in the control cabinet. Connect the power cables and motor cables. Turn ON the circuit protector. ‘Tum ON the main breaker in the control cabinet and carry out test operation. While the WARNING CHARGE LED is lt, it indicates that high voltage is applied to the ‘components in the servo amplifier. If you attempt changing of a board or unit, you might be injured due to electric shock or the unit might be damaged.BEA0-014-R1 P-25 SECTION 5 CHANGING THE CONTROL BOARDS AND UNITS 2. SVCII BOARD After following the instruction given in Section 3, 2. “TROUBLESHOOTING TABLES", if it becomes necessary to change the SVCII board, follow the procedure indicated below. Procedure: (1) Turn OFF the main breaker in the control cabinet. (2) Turn OFF the circuit protector and make sure that the WARNING CHARGE LED is tured off, (8) Remove the protection cover. (4) Check the order number of the new SVCII board. It must be the same number as the one labeled cn the removed SVCII board to be changed. (5) Install new SVCII board and mount the protection cover. (8) Tum ON the circuit protector. (7) Tum ON the main breaker in the control cabinet and carry out test operation. [AAWARNING) : We the WARNING CHARGE LED isi, it indicates that high voltage is applied to the ‘components in the servo amplifier. If you attempt changing of a board or unit, you might be injured due to electric shock or the unit might be damaged.BEA0-014-R1 P-26 SECTION 5 CHANGING THE CONTROL BOARDS AND UNITS SEMICONDUCTOR DEVICES After following the instruction given in Section 3, 2. “TROUBLESHOOTING TABLES’, if it becomes necessary to change the semiconductor devices, follow the procedure indicated below. IGBT Module Procedure: a) (2) (3) (4) (8) 6) 7) (3) (9), Remove the power unit from the control cabinet. ‘To remove the power unit from the control cabinet, follow steps (1) to (4) in 1. “POWER UNIT. Remove the protection cover. Remove the SVCII board, Remove the power board. Measure the resistance across the terminals with a multi-meter. ‘Arrangement of terminals and internal equivalent circuit of the IGBT module are shown in Figs. 5-1 and 5-2. The terminal names of one device in the IGBT module are shown in Fig. 5-3. Check the measured resistance by referringto the equivalent circuit in Fig. 5-1 and make sure that tis within the normalrange siven in the oriteria table (Table 5-1). if measured resistance is abnormal, change the IGBT module. For the procedure usad to change the IGBT module, refer to the procedure given in $-3."Changing ‘Semiconductor Devices”. If measured resistance is correct, or after changing the IGBT module, install the power board. install the board by tightening the screws securely. {Install the SVCII board and mount the protection cover. Mount the power unit to the control cabinet, then follow steps 7), 8), and 9) in 5-1 “Power Unit". C|[e-0)) CLI ‘inet type Gina ype Fig. 5-1 IGBT Module Terminal LayoutBEA0-014-91 P-27 SECTION § CHANGING THE CONTROL BOARDS AND UNITS c 6 = ‘inet typo Fig. 5:2 Equivalent Circut of IGBT Module c et e Fig. 5-3 Terminal Names of One Device on IGBT Module Table 5-1 IGBT Terminals Normal Range | Abnormal Range Multimeter Terminal Terminal a int Tint Sint () Side O Side Several tens to | Several tens to several hundreds | several hundreds e e of kilo-ohms of ohms, Rane See Note 1. E c 2 See Note 2. | Several hundreds of ohms or less c 6 oe Several thousands of ohms or less G c © ‘Several thousands of ohms or less. g E cy ‘Several thousands of ohms or less. E 6 2 Several thousands of ohms or less Note 1: Measure the resistance with the multimeter measuring range set to "x 1” Note 2: In order to obiain correct measurements, short the circuit between G and E. AXCAUTION] : Pay attention not to directly touch the IGBT module terminals by hand. Since the IGBT module is MOS device, it is susceptible to static electricity. Do not use @ megger when checking the IGBT module, Otherwise, itis damaged.BEAO-014-R1_P-28 SECTION 5 CHANGING THE CONTROL BOARDS AND UNITS 3-2. Diode Module Procedure: (1) Follow steps (1) to (4) in 3-1. GBT Module”. (2) Measure the resistance across the terminals with @ multi-meter. ‘Arrangement of terminals and internal equivalent circuit of the diode module are shown in Figs. 5-4 and 5-5. The terminal names of one device in the diode module are shown in Fig. 5-6. Check the measured resistance by referringto the equivalent circuit in Fig. 5-4 and make sure thatitis within the normal range given in the criteria table (5-2). (8) If measured resistance is abnormal, change the diode module. For the procedure used to change the diode module, refer to the procedure given in 8-8 “Changing ‘Semiconductor Devices”. (4). If measured resistance is correct, of after changing the IGBT module, install the power board Install the board by tightening the screws securely. (6) Install the SVCII board and mount the protection cover. (6) Mount the power unit to the control cabinet, then follow steps (7), (8), and (9) in 5-1 "Power Unit”, = = = + t lo O} OI! es Fig, 5-4 Terminal Arrangement Fig. §-5 Equivalent Circuit of Diode Module of Diode Module Kk A Fig. 5-6 Terminal Names of One Device on Diode Module Table 5-2 Criteria Diode Module Terminals T Multimeter Terminal | Multimeter Terminal Normal Range ‘Abnormal Range (+) Side (©) Side A K eS Several hundreds of ohms or less K A Several tens to several = hundreds of ohmsBEA0-014-A1 P-29/E SECTION 5 CHANGING THE CONTROL BOARDS AND UNITS 3-3. Changing Semiconductor Devices The procedure to be followed when changing semiconductor devices is given in Table 5-3 Table 5-3 Semiconductor Device Changing Procedure Process Contents, Remarks 1, [Remove the module fixing sorews to dis mount the module. 2 [Apply silicone compound (THERMAL ‘The compound will increase adherence of GREASE 800-1: CASTALL INC.) tothe _| the module to the mounting face, and so back of a new module. the module will be cooled better. 3 __ Install the new module and fix with the Make sure that the module is placed in cor screws. rect orientation. CAUTION Pay attention not to directly touch the IGBT module terminals by hand, Since the IGBT module is MOS device, it is susceptible to static electricity.REVISION HISTORY Manual Name: SERVO AMPLIFIER MAINTENANCE MANUAL Manual No. : 4017-E (EEA4-001-O%+) [_Eaition Date Revision (01) January ‘95 First edition