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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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)

Negative

capacitor

terminal

R, S, T Approximately 0.5 Volts must be

consistent with each other.

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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