BNP-A8104-A

MELDAS DRIVE AMPLIFIER

MAINTENANCE MANUAL (II)

This Maintenance Manual covers the PU16, PU31 and PU71 power units as well as the
TRA31, TRA41 and TRA61 transistor amplifiers which are used for the MELDAS
numerical controller. Read through the instructions before use.

A MITSUBISHI
ELECTBtC
 BNP-A8104-A

MELDAS DRIVE AMPLIFIER

MAINTENANCE MANUAL (II)

This Maintenance Manual covers the PU16, PU31 and PU71 power units as well as the
TRA31, TRA41 and TRA61 transistor amplifiers which are used for the MELDAS ’
numerical controller. Read through the instructions before use.

TABLE OF CONTENTS -~---

1. FUNCTION ........__ . .........._ . ............ 1

2. OUTLINE DIMENSIONS.. ...................... 5

3. EXCHANGE METHOD AND HANDLING

FOR THE TRANSISTOR AMPLIFIER . . . . . . . . . . . . . . 9

4. POWER UNIT SETTING . . . . . . . . . . . . . . . . _ _ . ._ . . . 16

5. INSPECTION
(1) Servo System Alarm Transmission Route .......... 17
(2) Transistor Amplifier Inspection .................. 18
(3) Power Unit Inspection ......................... 23

MITSUBISHI
A ELECTRIC
 1. FUNCTION

The transistor amplifier amplifies the power by high frequency switching according to the pulse
width modulation method for the error voltage (command voltage) by comparing the position
detector output and the calculation result output from the logic card of the control unit in regard
to the movement command.

(I ) Drive Amplifier Composition

Transistor
amplifier r Power supply,
unit
1 3 phases , 200/210 v

Note: The capacitor unit may be added or not according to the load inertia (JL ) referred
to the motor shaft.

(2) Power Unit Types

Transformer 3 PH 2.3 KVAMTR

. Rectifier unit DLJ300

Capacitor unit cu150

Transformer 3 PH 3.8 KVAMTR

. Rectifier unit DU 300

Capacitor unit cu300

Transformer 3 PH 8.0 KVAMTR

. Rectifier unit DU700

Capacitor unit cu3ocl

I-
(3 ) Block Diagram for the Drive Part (Transistor Amplifier)

1 J’
(4) Cable Connection Diagram
To another
XIlplifipr
I
I_____,

- 'i I

-3-
Note 1: Connect cable DUC 1 to connector ZP3 of the primary axis of the transistor amplifier
from the rectifier unit (connection to the other axis amplifier is not required).
(Refer to transistor amplifier connection diagram, p. 9).
Note 2: The cable connecting PN of the rectifier unit and the @ and 0 terminals of the capac-
itor unit must be 250 mm, or less.
Note 3: The cable connecting PN of the rectifier unit and PN of the transistor amplifier TRAUO
must be 1,000 mm, or less.
Note 4: When above notes 2 and 3 cannot be observed, connect PN of the transistor amplifier
and @ 0 of the capacitor unit with wire of at least D-10 (max. 500 mm).
In this case, the connection length between the rectifier unit and the transistor ampli-
fier TRAO q is not specified.
Note 5 : Refer to the table below for the designated wire ratings:

-4-
 2. OUTLINE,DIMENSIONS

(I ) Transistor Amplifier
(2) Power Unit (PU16, PU3l,PU71)

Note:
The outline dimensions for power
unit PU16 m are the same as for
P U 3 1 m ,butCll andC12arenot
provided.

!FAP board I I

Power Unit Outline Diagram

(3 1 Transformer

Note :
M4 x 0.7 screws are used for all con-
nection terminals.

Iron core
Bottom
__-_ c l a m p

/connect the static electricity shield.

JPH9KV.\\ffR-L G701250 3 2 5 , 2 1 0 150 1 7 0 ’ 1 6 0 , 96’2401260:250 60’160 TS503;;r

Transformer Outline Diagram

-6.
 I fl5 +
t-
S11ppoI-t
angle - I_
m
.I.

c 11

.I.
c
-3

c 13

Pb,
c 14

-t
.I.
LTI.
-

f “SFour oval-shapey
h o l e s 7 x IO

(for rack i n s t a l l a t i o n )
Note :
The unit is normally installed on the floor
but it can also be installed on a rack by
adding a support angle. In this case, order the
support angle separately. The dimensions
marked by %- are the dimensions for rack
installation. (The additional support angle is
shown by a dotted line.)
DU30+CUl5 DU30tCU30 DU70+CU30

(for floor installation )

Capacitor/Rectifier Unit Outline Diagram
 (5) Rectifier Unit (DU30, DU70)

Note :
DU70A and DU30A have the same
outline dimensions. but the internal
installation parts differ slightly.
,55 (max. dimension)
I
25 130
t
110 M
_j

Rectifier Unit Outline Diagram

(6) Capacitor Unit (CU 15, CU30)

2 elongated holes

1. By changing the installation

position of the support angle,
floor as well as rack installation

The dimensions marked by l

indicate rack installation.
(The support angle for rack
installation is shown by dotted

2. CU 15 has the same external

dimensions as CU30 m , but
4 oval-shaped
C 1 1 and C 12 are not provided.
holes 7 x 10
(for rack installation)

Capacitor Unit Outline Diagram

-8-
 3. EXCHANGE METHOD AND HANDLING
FOR THE TRANSISTOR AMPLIFIER
(1) Connecting the Transistor Amplifier
[The terminal board CON23 is connected to the drive motor.
To power unit
The unit body is installed to the rack by 2 set screws.]

DUC-,I NC control unit

cable t

TR2 3rl

TRC- 1
cable

CON23 CON23

Axis 1 Amplifier TRC- 1 cable

(Primary Axis) Axis 3 Amplifier
Axis 2 Amplifier

Each control card (TR23 0) has two short-circuit bars on T.A.W. and DTHR of the setting
plug (23). Remove these two short-circuit bars from all axes except one.
By doing this, the triangular waves and dither frequency on each axis will be made uniform.
REF: [In the above diagram, the short-circuit bars are shown in place on Axis 1 only, but
exactly the same results will be obtained by leaving the bars in place on Axis 2, and removing
them from Axes 1 and 3.1
Connect the TRC-1 cable as shown in the above diagram as follows:
1. Connect ZP3 (DUC-I cable) to the primary axis.
2. Using the TRC-1 cable connect TCP 17 - 2 0 (upper connectors) of the primary axis to
TCP 2 l- 24 (lower connectors) of the other axis.
3. Perform above operation #2 in accordance with the number of axes used.
4. Remove the PW.U of the 23 setting plug on all but the last axis.

-9-
@ If you use old style amplifiers together with new, take the following precautions:
1. Remove PW.U of the 23 setting plug. (If it is left in, a short will occur between +24V
and ground .>
2. At this time, connect the DUC-I cable attached to ZP3 to the old style amplifier.
(If it is connected to the new amplifier, the +24V electrical current will not be supplied
to the power unit .)
(In this case, even during an Alarm, the current will not drop.)

@ Insertion method for cable TRC 1

Cable TRCm- I

Insert to pins 17 to 20 or 2 1 to 24 respectively

e connector No. 17 (TCP! 7) of the printed
Insert so that this circuit board (card TR-3)
projection faces (insertion to either side is possible).
toward\ the outside.
Printed circuit board

4
Edge of the printed
circuit board

The shaded part is the insertion 1

place for cable TRC- 1.

Note:
As the control card (TR23) has setting plugs and adjustment volumes. setting must be exe-
cuted in case of card exchange.
(2) Handling Precautions
@ Earth (E) and GND
a . TR23n - 3 1 As there are three types of earth, take care that the different
TR 230 - 41 card : earth signals are not connected simultaneously to the earth
TR 330 - 61 of the synchroscope.

Correspondence between earth and check pins

Signal check pin number / Corresponding earth terminal
!~ --___-_t ~~ ~~~~~_.____.~~
Group 1 ‘I’(’ I’ 1 -‘I’(: I’ 3 6 / ‘I’ (: P 2 7 -T C I’ 2 9

Group :! 1’~: I’ .1 ( T (: P R ) TCPRCTCPA)

I Group 3 / ‘I’(: I’ (:
I T C I’ I) I

b. TR 340card: As the earth differs for each check pin, execute synchroscope confirma-
tion separately for each channel.
Simultaneous observation of 2 channels is not possible (this can cause defects).

Correspondence between earth and check pins

I Signal check pin number Corresponding earth terminal

I (;roup 1 Hl I E 1 I

Group 2 13 2 E: 2

Group 3 n3 Ic 3

Group 4 n4 E: 4

@ Pay sufficient attention to the wiring of P and N of the transistor amplifier and connect
after confirmation to avoid wiring errors.

-II-
 (3) General View of Circuit Board (control card TR23)
Alarm reset button SW

Relay operation indicator

Check
Pin Position loop gain adjustment
T C I’ 1 VR2 (GAIN)

Speed loop command button SW

Zero point adjustment VR7
(OFFSET)
Speed loop command VRI (V.IN)

Dither amplitude adjustment

T(’ 1’ 8 VRll (DT.L)
Speed loop compensation VR3
TC‘l’9 (COMP)
Dither frequency adjustment
VRIO (DT.F)
Low gain adjustment VR14
(L.L.C)

S$eed loop gain adjustment VR9

(F.W.G.)
Current loop compensation
adjustment VR1.5 (C.C.)
Current clamp VR4 (CSET)

\tt16 u 1
Dead band adjustment
VR16 (L.S)

T(‘l’2 5
?
TCt’28 terlock adjustment VR13
- TCI’37 (IN-L) -
TCl’29

T(‘P4 0
2
Interlock adjustment VR12

Thermal adjustment VR6 (THM)

TR2 31 II Alarm indicator lamp

Electrical current value and speed
- lamp

-12-
(4) Setting by Setting Plugs
As this setting has been set at the time of shipment according to the specifications of the machine
manufacturer, no change is required.
, Set in this direction.

‘Arrow indicating the insertion direction

Setting according to the type of speed

feedback TG (for TG feedback selection)

Setting according to the type of detector gear

box (for position loop gain adjustment)

23

AL. L
L s ‘I- Setting to standard (O), and setting only one
EH. (‘S of multiple axes (A)
c. IL (’
T. A. W
I’T t1 H

24

H A setting which is normally not set

El
0
0
0
0

%5
0 0 I RI'1

Ed
0
0
0
0
0
0
1 Nl)Z
c-511’
fl. L. G
Setting in accordance with control loop
characteristics

- 1 3
 Transistor amplifier and motor
Z6
correspondence.

I
0 0 5 OA
Setting in accordance with
0 0 7 5A
armature current
0 0 75/100A

%7 TRNI
HD80

=Ia
0
aA HDIOO
0 HWO

0 Setting in accordance with

El+
0

0 0 17A type of motor

0 0 (For Electronic thermal
0 current value setting)

H ; ] 30.4 HD2OQ
0 ~.
HO300
~1~
0 0 Spare HDtOt 3 @I,.0 14A
HDIOO ttD201
HD3OI
4 0.0 17A
TK.461
ItDlOt-13 2 ea.3 j 24A
HD2W ItD3OIH.12
za 0
HD3Cil
0

El
0 1OOOrpm TRAP, HD3OIH-I3 0 0.s.d 36A
0 0 1500rpm
Setting ^ in accordance
. with _,
0 0 2OOOrpm type ot tachometer generator r*“rc)27u”ing ’ 0
0 0 2v and maximum rpm utilized SOA CD

0 0 3v 17 L?!
17 _ 6
1OOA a
30 (a,

%9 MIN 0

50A
;=_ @a
0 0

H
27 (Z7.No ,

0 0 7 5A Setting in accordance with Nu,c, HDIOI how, HD30,., 2 (,K”, rpm ,pc )

0 0 1004 abnormal current detection level

%I0

El
0 0
0 0 Level meter (LED 2) switching setting
0 0

Zll
Removed when brake unit is added.
a HKK
(Normally refers to the setting plug)

-14-
(5) Setting by Volume
violume
No. Name Function Setrmg
-
Speed loop Motor speed command at the time of l Applies when V.IN (Z 4-l) setting plug
command speed loop operation. is inserted. The motor can be turned by
1 volume pushing V.CHECK
Lo\
I
Clockwise
runnmg of l This volume normally IS set to 5.
the motor (Do not touch this volume when a motor
is installed on the machine.)
- - --I
1 PosItIon
Adjustment of the position loop As this volume has been adjusted before
gain shipment. do not change its settmg.

Adjustment of system response and ’ l Turn in stability direction (counter-

pensation volume stability. clockwise) when there are severe vibra-
Turning the volume has the following tions on the machine side.
results. l When the movement tends to overshoot,
Clockwise turning: The response is turn in direction of improved response
3 i improved, but stability (clockwise).
decreases. (Turning should be executed in steps of
Counterclockwise turning: The re- one half graduation. Large changes can
sponse decreases, but stability cause huntmg.)
is improved.

1 Current clamp Maximum current flowing to motor is Setting to the specified current value has
’ volume regulated by the amplifier been executed at the time of shipment.
4 Do not change the setting of this volume,
T It A 6 1 ...... 9 0 A
1’ R A 4 1 ...... 6 5 4 as this may cause transistor damage.
T R :\ 3 1 ...... 4 5 .A

-__
~Thermal Setting is executed according to the -rhc settings for each motor are shown
~setting rated current of the used motor. below.
volume This volume specifies the ratio in HOlO,
regard to the setting position at TnnrWor Former M~d,wn WC6 27 QAl”l~
setting plug 27. .mpi,hrr Y”” 1°C”” Y”S P,n.iwtan, Y”lq
6 Hwc “[YI

TP.A.I HDlcc HD’OI

HD3ca-~~ ___, _ 0 @ JOA

TRAW~-- I_~
, i tlDIOIHI3 0 p &;.cu 3t.A
hum, L7 z,tL”*

: NOl., HDm stwn m101 12 ,laNrpm qx ,

-15
 >lume
Name
No. ~ Function Setting
___-
7 Zero Volume for fine adjustment of the by turning the volume so that the
point ~droop near zero with a position loop droop with the operation panel of the NC
adjustment 1 established. side set to “POD” becomes close to zero.
volume ~(Readjust when the machine moves
at the time of NC power supply ON.)
~_ ~~__t----_ tm -~~~~-~___- -- ~~~~
9 Speed loop gain ~Volume in regard to servo rigidity. Control system and detection system
adjustment Turning of the volume has the follow- response have been adjusted at the
volume ing results. ttme of shipment.
Turning in clockwise direction:
Servo rigidity is increased, but
excessive turning causes instability.
~ Turning in counterclockwise direction:

Adjustment of the dither amplitude.

This has been adjusted at the time of

shipping; do not change the volume gradua-
tions.
~-- 1 _
Interlock adjust- Perform interlock adjustment on transis- This has been adjusted at the time of
13
ment volume tors 3 and 4. shipping; do not change the volume gradua-
tions.

Low gain adjust- Perform servo rigidity adjustment at low Servo rigidity (stability) in all speed
14 speed.
ment volume ranges can be adjusted with VR9, but when
you want to increase servo rigidity at low
speed, turn in direction of CW. If it is turned
too much, VR9 identical stability will be
lost, and the motor axis will vibrate.
- __~~ __~ ~~_
Current loop Adjust the current loop response. Normally. set on graduation 5.
15
compensation
adjustment
volume ~ .~
1nsensitivity-band Adjust the current insensitivity band. This has been adjusted at the time of
16 range adjustment shipping; do not change volume graduations.
volume

4. POWER UNIT SETTING

Setting is executed by the short-circuit bar for the tap change over for 200/220 V AC of the
transformer unit according to the input voltage.
( For 220V ) ( For 200V )
200 V 27ov 200 v ‘37 I
0

-16-
 1’
n . .
alarm transmissiOn route (With 3 axis control)
,__.... ^ . ..
- -
F _ _Servo
_ _ _ _system
_ -------_-_---__---__-_--__---------- Lz---__- __ -
I
r
I FIN
I c
I 0. II.
I
t I
1 Transistor amplifier TRA3 1 q /TRA41 o/TRA6 lo % I’3
I
,
1 (jxis I servo system) I
__-_------__-__----_-_-_-_-_____------- 1 _-i I

-Cable DUC-I--------
IJB 0. II. I<’ ZI’12
-(A
1. c 1
Power unit PU 16o/PU3 1 q /PU7 1

( ~-__----------__-- ________ --- _____ ---___

,’
I I
’ i 0. c:. I’.
I
i
1
I Transistor amplifier TRA3 1 q /TRA4 1 o/TRA6 1 I
1 (Axis 2 servo system)
L----_-----_----------- -----------------_
I
I I
r --------------__----- ------------_a__

I I

i 1 Transistor amplifier TRA3 1 q /TRA41 o/TRA61 I

I i I
‘, (Axis 3 servo system)
L,-------~--------- -----------a------_ --------_ i I’ NC logic circuits
- - _---

(NOTE 1): When the axis 1 transistor amplifier’s ZP3 and the power unit’s ZPI 2 are connected (by cable DUC-I).
(2) Transistor Amplifier Inspection

e Transistor amplifier indicator lamps (control card TR 23 0)

1) Relay Indicator Lamps

SVOlu tU)y NIW I)Rl, t’. Ot~‘t

LEI)l

FUNCTION

Lights when servo is ON. Goes out when servo is OFF.

Lights when NC READY. Goes out with READY OFF.
Lights when NC Power is ON and Goes out when there is an alarm.
conditions are normal.
1
Lights when dynamic brake signal is ON. Goes out when conditions return to ~
normal.
Lights when POWER OFF signal is ON. Goes out when conditions return to
normal.
-_-I .

2) Alarm Indicator Lamps

r_ NAME
C. LMT
FUNCTION mm7
Lights when current limiter circuit operates.
Normally, does not light. (However; may
1
~
light during sudden changes in use.)
_.
TR. D Lights under NC NOT READY condition
and motor is overrun.
M. OH Lights when motor overheats and the motor
case exceeds a specified temperature (95°C). 1
When the temperature drops below a speci- ~
Bed temperature (70°C) the motor can be
returned to READY condition by NC reset. ~
~--~ 1
F. OH Light when cooling fin temperature exceeds ~
set temperature (80°C). When the tempera- ~
ture drops below a specified temperature
(S’C), the motor can be returned to
READY condition by the NC reset.
TG. 0 Lights when the motor turns at a higher
speed than the set rpm .
0. c. P. Lights when higher than the designated
electrical current flows into the transistor
amplifier. When this indicator lights, it
cannot be released without first turning
power OFF and pushing the amplifier reset
switch.
M. OL Lights when motor is in condition of con- ~
tinuous overload. When this indicator lights, ~
the alarm can be released either by de-
creasing the NC power, or after releasing the ,
motor from the overloaded condition, by
pushing the amplifier reset switch.
L

-18-
3) Electrical current value indicators and speed indicators (LED 2. These indicators, during
driving indicate electrical current value and speed, and during alarm conditions they indicate
the particular alarm condition .)

ZlO
LM. C
] Set only one or the other
LM. ‘Ix
MGN
Electrical current value
indicator Speed indicator
50.4/l OOA - 2 0 0 0 r p 111
~2012/40A~ t 800rpm)

25A/50A lOOOrp,nr
(1011/20A) ( 4 0 0 r pm )

0 - 0

BY indicating the LM.C of setting plug Z 10, the shaded (slanting lines) portion of the above
diagram becomes a level meter for the electrical current value indicator.
. With TR4l/TR61, if the shaded portion is entirely lit, it corresponds to approximately
lOOA.
. With TR3 1, if the shaded portion is entirely lit, it corresponds to approximately 50A.

By indicating both the LM.C and the MGN of setting plug ZlO.
. With TR41/TR61, if the shaded portion is entirely lit, it corresponds to approximately
40A.
. With TR31, if the shaded portion is entirely lit, it corresponds to approximately 20A.

By indicating the LM.TG of setting plug ZlO, the shaded (slanting lines) portion of the
above diagram becomes a level meter for the speed indicator.
. By indicating LM.TG, if the shaded portion is entirely lit, it corresponds to approxi-
mately 2000 rpm .
. By indicating LM.TG and MGN, if the shaded portion is entirely lit, it corresponds
to approximately 800 r p m

-19-