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AC Servo School TextAC Servo Maintenance Course



Servo School Text AC

Servo Maintenance C

ourse (MELSER


AC Servo School TextAC Servo Maintenance Course (MELSERVO-J4)

Specifications subject to change without notice.

When exported from Japan, this manual does not require application to theMinistry of Economy, Trade and Industry for service transaction permission.




SH-030147ENG-A (1403) MEE

Safety Precautions

(Please read the precautions carefully before carrying out practical training.)

Read the relevant manuals and pay careful attention to safety when designing the system. When carrying out practical work, pay sufficient attention to the following points and handle the device properly.

[Practical training precautions]


Follow the instructions of the instructor. Do not remove the training machine module or change the wiring without prior consent.

Doing so may cause failure, malfunction, injury, or fire. Turn the power supply OFF before removing or installing a module.

Removing or installing while the power is ON may cause module failure or electric shock.

If the training machine emits an abnormal odor or an abnormal sound, press the "Power switch" or "Emergency switch" to stop the device.

When an error occurs, contact the instructor immediately.


To avoid electric shock, do not touch the terminal while the power is on. When opening a safety cover, make sure that the power supply is disconnected or

ensure sufficient safety before carrying out the work.

Safety Precautions


Table of Contents

1. Importance of Production Maintenance 1-1 1.1 Importance of Maintenance 1-1

1.2 Maintenance System 1-2

1.3 Maintenance Plan 1-3

1.4 Management of Maintenance Documents 1-4

1.5 Maintenance Record 1-4

1.6 Malfunction Modes 1-5

2. Understanding AC Servo Systems 2-1 2.1 Configuration of Training Machine 2-1

2.2 External Appearance and Name of Training Machine 2-3

2.2.1 External Appearance/Configuration of Training Machine 2-3

2.2.2 Configuration of Input/Output Operation Panel 2-4

2.3 Practical Training of MR-J4 Servo Amplifier 2-5

2.3.1 Speed Control 2-5

2.3.2 Position Control 2-17

2.4 AC Servo Setup Software 2-21

2.4.1 Setup Software (SW1DNC-MRC2-J) Startup Operation 2-24

2.4.2 Projects 2-27

2.4.3 Graph Display 2-31

2.4.4 Other Functions 2-45

3. Maintenance Countermeasures Design 3-1 3.1 Preliminary Actions for Implementing Maintenance Countermeasures 3-1

4. Preventive Maintenance 4-1 4.1 Necessity of Preventive Maintenance 4-1

4.2 Precautions for Maintenance and Inspection 4-1

4.3 Check Items 4-1


5. Corrective Maintenance 5-1 5.1 Troubleshooting 5-1

5.2 Troubleshooting Using Training Machine 5-1

5.2.1 Motor Does Not Rotate 5-1

5.2.2 E1 and AL. 50 Display 5-3

5.2.3 AL. 51 Display 5-6

5.2.4 AL. 52 Display 5-8

5.2.5 AL. 10 Display 5-11

5.2.6 AL. 52 Display 5-13

5.2.7 AL. 20 Display 5-13

5.2.8 AL. E9 Display 5-13

6. Maintenance for Improvement 6-1 6.1 Equipment Maintainability Improvement 6-1

7. Review of Equipment Environment 7-1 7.1 Noise Reduction Techniques 7-1

7.2 Leakage Current 7-5

7.3 Harmonics 7-7

7.3.1 Fundamental Harmonic and Harmonics 7-7

7.3.2 Characteristics of Rectification Circuits and Harmonic Occurrence 7-8

7.3.3 Harmonics Countermeasures 7-9

7.4 Operation after Installation 7-12

7.4.1 Startup Procedure 7-12

7.4.2 Installation 7-13

7.4.3 Wiring System and Sequence 7-27

7.4.4 Standard Connection Figure 7-36

7.4.5 Power-On 7-52

7.4.6 Parameters 7-56

7.4.7 Parameter Setting 7-78

7.4.8 External I/O Signals Check 7-81

7.4.9 Test Operation of Position Control Mode 7-83

7.4.10 Test Operation of Speed Control Mode 7-84

7.4.11 Test Operation of Torque Control Mode 7-85

7.4.12 Test Operation Mode 7-86


8. Life of AC Servo Parts 8-1 8.1 Part Replacement 8-1

8.1.1 Battery Replacement Procedure 8-2

8.1.2 Battery Mounting Procedure 8-3

8.1.3 Method for Battery Replacement by Turning the Control Circuit

Power Supply OFF 8-4


Appendix 1. Various Symbols Appendix-1

Appendix 2. AC Servo Fundamentals Appendix-2

Appendix 2.1 What is an AC Servo? Appendix-2

Appendix 2.2 AC Servo Positioning and Performance Appendix-2

Appendix 2.3 AC Servo Mechanism Appendix-7

Appendix 2.3.1 Block Diagram of Servo Amplifier and Operating

Principles Appendix-7

Appendix 2.3.2 Characteristics of AC Servo Motor and Operating

Principles Appendix-11

Appendix 2.3.3 Encoder Functions and Operating Principles Appendix-13

Appendix 3. Positioning Control by AC Servo Appendix-16

Appendix 3.1 Positioning Method and Stopping Accuracy Appendix-16

Appendix 3.1.1 Positioning Types Appendix-16

Appendix 3.1.2 Positioning Control and Stopping Accuracy with the

Speed Control Method Appendix-16

Appendix 3.1.3 Position Control Method Types Appendix-19

Appendix 3.2 Fundamentals of Positioning Control by AC Servo Appendix-20

Appendix 3.2.1 Position Detection and Number of Pulses per Motor

Rotation Appendix-20

Appendix 3.2.2 Position Servo Concepts Appendix-20

Appendix 3.3 Positioning Accuracy Appendix-21

Appendix 3.3.1 Machine Feed Length per Pulse Appendix-21

Appendix 3.3.2 Overall Machine Accuracy and Electrical Side

Accuracy Appendix-22

Appendix 3.4 Motor Speed for Machine High Speed Appendix-23

Appendix 3.5 Command Pulse Appendix-24

Appendix 3.5.1 Electronic Gear Functions Appendix-24

Appendix 3.5.2 Maximum Input Pulse Frequency Appendix-30

Appendix 3.6 Speed Pattern and Stop Settling Time Appendix-31

Appendix 3.6.1 Speed Pattern and Droop Pulse Behavior Appendix-31

Appendix 3.6.2 Stop Settling Time ts Appendix-32


Appendix 3.7 Relationship between Machine System and Response

Level Setting Appendix-33

Appendix 3.7.1 Response Level Setting Appendix-33

Appendix 4. Positioning Controller Appendix-34

Appendix 4.1 Setting Data of Positioning Controller Appendix-34

Appendix 4.1.1 Basic Parameters/Detailed Parameters Appendix-34

Appendix 4.1.2 Home Position Return Basic Parameters/Home

Position Return Detailed Parameters Appendix-35

Appendix 4.1.3 Positioning Data Appendix-36

Appendix 5. Functions and Operations of MELSERVO-J4 Appendix-38

Appendix 5.1 Function List Appendix-38

Appendix 5.2 Configuration with Peripheral Equipment Appendix-40

Appendix 6. Terminology Appendix-42

Appendix 7. QD75D1N Setting Values (Training Machine) Appendix-51

Appendix 8. Servo Amplifier Inspection Request Appendix-58



1. Importance of Production Maintenance


If the production system stops due to a malfunction or power failure, a loss proportional to the stop time occurs. Therefore, it is necessary to design the equipment system so as to prevent [Stopping due to malfunction] or [Stopping due to power failure]. Even if the production system stops, the important issue is how the system will be quickly restored. Therefore, organization with maintenance staff is established in each factory to improve the operation rate of the production system.

1.1 Importance of Maintenance The latest production systems are advancing in terms of machinery mechatronics and system complexity, as well as the black-boxing of remarkably sophisticated equipment. As such, the relative maintenance level is decreasing and it is becoming difficult to improve the availability of the system. Therefore, "highly reliable products" and an "increased level of maintenance technology" are strongly required.

Standard production system

Mechatronics of machineryand equipment

Black boxing of the equipment

Highly reliable product application

Complicated and highly-developedproduction system

Decrease in relativemaintenance level

Increasing the level ofmaintenance technology

Realization of highly reliableproduction system

1. Importance of Production Maintenance


1.2 Maintenance System In order to achieve a highly reliable production system, it is important to have an established maintenance system in place. The following shows an outline of a maintenance system.

When developing new machinery, give due consideration tomaintenance countermeasures at the designing stage.

Preventive maintenance of the machinery is carried out if themachinery is prone to financial losses or serious disasters due tofailures or accidents, and if it is beneficial to carry out preventivemaintenance of such machinery. Also perform maintenance actionsfor predictable failures and


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