Document:

Chapter 4
Application
Absolute Encoder Setup and BatteryReplacement Application
Absolute Encoder Setup and Battery Replacement
This section describes the absolute encoder setup method and the battery replacementmethod.
4-1-1 Setup
Setup is required to set the amount of machine rotation to zero for trial operation of the Servomotor orwhen the absolute encoder has been left disconnected from the battery for more than two days. (This isbecause the voltage of the capacitor inside the absolute encoder will drop if a battery is not connectedfor more than two days, possibly interfering with the proper operation of internal elements.) H Setup Method
Perform the following procedure carefully. Mistakes may lead to errors in the setup.
1. Wire the Servo Driver, Servomotor, and encoder correctly if they are not already wired correctly.
3. Turn on power to the Servo Driver.
4. Turn ON the SEN signal (Cn1-5). When the SEN signal turns ON, 5 V will be supplied to the encoder.
5. Wait at least 3 minutes to allow time for the backup capacitor to be changed. An alarm will be gener- 6. Turn off power to the Servo Driver.
7. Short terminals 13 and 14 on the encoder connector to the motor for 1 to 2 seconds (see following 8. Remove the short between terminals 13 and 14.
9. Turn power on to the Servo Driver.
10. Turn ON the SEN signal. If no error occurs, the setup has been completed.
11. If an alarm (A.00) occurs, repeat this procedure from the beginning.
Note 1. When the CV500-MS221/421 or C200H-MC221 Motion Control Unit is connected, perform
the setup near the mechanical original.
Note 2. An error will occur is the absolute value data exceeds ±32,767 pulses when the
CV500-MS221/421 or C200H-MC221 Motion Control Unit is connected Application
4-1-2 Battery
H Lithium Battery
A battery must be used to back up the position data when power is not supplied to an absolute encoder.
Use one of the following batteries.
Manufacturer
Electrical
capacity
One battery/Servo DriverPredicted life: Approx. 10 years.
One battery/Servo DriverPredicted life: Approx. 10 years.
Note The battery voltage is not monitored internally when power is not supplied to the Servo Driver. Do
not let the voltage drop below 2.8 V. If required by the system for proper operation, install a voltagedrop detection circuit or monitor.
H Replacing the Battery
The following procedure can be used to replace the battery without loosing the encoder rotation amount
data.
1. Turn on power to the Servo Driver.
2. Turn ON the SEN signal and wait for 3 minutes for the capacitor inside the encoder to charge.
3. Turn off power to the Servo Driver.
The battery is connected between pins 28 and 29 of the Servo Drivers control I/O connector (CN1). + input for the backup battery (connect a 2.8 to 4.5-VDC battery).
– input for the backup battery (backup battery ground) Note 1. The encoder can be left without a battery for two days after the above step 2., above, is per-
Note 2. Do not short the + and – terminals when replacing the battery.
Note 3. When cutting the lead wires from the battery, cut them separately, never together. The termi-
nals will be shorted if the lead wires are cut at the same time, possibly causing sparks.
Note 4. Dispose of the used battery using the specified methods. Never incinerate or throw the bat-
Application
Using Displays
4-2-1 Display Functions
OMRON U-series AC Servomotors have unique servo software that enables quantita-tive monitoring in real time, on digital displays, of changes in a variety of characteristics.
Use these displays for checking the various characteristics during operation.
H Servo Driver Displays
There are two LED indicators on the Servo Driver itself. One is for the power supply and another is for
alarms.
Function
H Parameter Unit Displays
When a Parameter Unit is connected, monitoring can be conducted by means of a 5-digit 7-segment
LED.
Application
H Parameter Unit Key Functions
The contents displayed by the Parameter Unit can be changed by key operations.
Handy type
Mounted type
Function
R88A-PR02U
R88A-PR03U
Increments parameter numbers anddata values.
Decrements parameter numbers anddata values.
H Types of Modes
There are four types of modes for Parameter Unit displays. The functions in each mode are shown in the
following table.
Function
Bit display (indicating internal status via indicators):Power supply ON display, base block, speed conformity, rotation detection andcurrent limit detection, inputting speed command, inputting torque command Symbol display (indicating internal status via 3-digit 7-segment display:Base block, operating, forward rotation prohibited, reverse rotation prohibited, alarmdisplay System check: Jog operations, command offset automatic adjustment, alarm histo- ry data clear, command offset manual adjustment, motor parame-ters check, auto-tuning Setting and checking setup parametersSetting and checking user parameters Speed feedback, speed commands, torque commands, number of pulses from U-phase, electrical angle, internal status bit display Displays contents of alarms that have been previously generated (up to a maximum Application
H Changing the Mode
Use the MODE/SET Key to change from one mode to another.
4-2-2 Status Display Mode
The status display mode is entered when powering up or by means of the MODE/SET Key. In the statusdisplay mode, Servo Driver status is displayed in two ways: bit data and symbols. These displays areshown in the following illustration.
H Bit Data Display Contents
Contents
Lit when Servo Driver power supply is ON.
Lit during base block (no power to motor); dimmed when servo is ON.
Lit when the motor rotation speed reaches the speed command value.
Lit when the motor rotation speed is equal to or greater than the rotation speed for motor rotation detection (Cn-0b).
Lit when a torque command is limited by the torque limit value (Cn-08, 09 orCn-18, 19 or the limit value from TREF.) Lit when a speed command input meets the rotation speed for motor rotationdetection (Cn-0b).
Lit when a torque command at least 10% of the rated torque is input.
Note The setting of bit no. 4 in setup parameter no. 1 (Cn-01) determines whether rotation detection or
current limit detection will be output.
Application
H Symbol Display Contents
Symbol display
Contents
4-2-3 Monitor Mode (Un-)
H Types of Monitoring
In monitor mode, six types of monitoring can be carried out.
Monitor no. Monitor contents
Explanation
Displays actual rotation speed of motor.
Displays command to speed loop. For analog speed con-trol, the command voltage is converted to r/min for display.
The command to the current loop is displayed as 100% ofthe rated torque. For torque control, the command voltageis converted to % for display.
The number of pulses from the U-phase edge is displayed Incremental encoder: Number of pulses per 1/4 turn dis-played as 2,048 pulses.
Absolute encoder: Number of pulses per 1/4 turn displayedas 1,024 pulses.
Displays the electrical angle of the motor.
Displays Servo Driver internal information as either lit or H Operation in Monitor Mode
In order to conduct monitoring, first go into monitor mode and then set the monitor number and press the
DATA Key. The items in parentheses in the following explanation indicate operations using the Handy-
type Parameter Unit.
1. Press the MODE/SET Key to go into monitor mode.
2. Using the Up and Down (and Right and Left) Keys, set the monitor number.
Application
3. Press the DATA Key to display the monitor data.
4. Press the DATA Key to return to the monitor number display.
5. Press the MODE/SET Key to move from monitor mode to alarm history display mode.
H Internal Status Bit Display (Un-05)
Internal status is displayed by 7-segment bit lighting. The bit number allocation is shown in the following
diagram.
Contents
Lit when in reverse rotation mode (when Cn-02 bit no. 0 = 1).
Lit when the motor rotation speed is equal to or greater than the rotation speedfor motor rotation detection (Cn-0b). Lit when a torque command is limited bythe torque limit value (Cn-08, 09 or Cn-18, 19 or the limit value from TREF.) Lit when the motor rotation speed reaches the speed command value.
Lit when the speed control loop is in P control.
Lit when forward rotation current limit / speed selection command 1 (CN1-11) isON.
Lit when reverse rotation current limit / speed selection command 2 (CN1-12) isON.
Encoder A phase (HA/LA/V/W Models: Lit when there is a signal; H/L Models:Not lit when there is a signal.) Encoder B phase (HA/LA/V/W Models: Lit when there is a signal; H/L Models:Not lit when there is a signal.) Encoder Z phase (HA/LA/V/W Models: Lit when there is a signal; H/L Models:Not lit when there is a signal.) Poll sensor U phase (Incremental encoder) Poll sensor V phase (Incremental encoder) Poll sensor W phase (Incremental encoder) MING/PLOCK Lit when CN1-15 is ON. (Input signal functions change according to parameterTVSEL/RDIR Lit when forward drive prohibit input is ON.
Lit when reverse drive prohibit input is ON.
Lit when the sensor ON input is ON (Absolute encoder) Application
4-2-4 Checking Servomotor Parameters (Cn-00 Set to 04)
Servomotor parameters can be checked when system check mode Cn-00 is set to “04.”Servomotor parameters are the Servomotor specifications that can be controlled by thatServo Driver. They are not the specifications of the Servomotor that is connected. Usethis to check whether the Servo Driver and Servomotor combination is suitable.
H Servomotor Parameter Checking Operation
The items in parentheses in the following explanation indicate operations using the Handy-type Param-
eter Unit.
1. Press the MODE/SET Key to switch to the settings mode.
2. Using the Up and Down Keys, set parameter number “00.” (System check mode) 3. Press the DATA Key to display the setting of Cn-00.
4. Using the Up and Down Keys, change the setting to “04.” (Servomotor parameter check) 5. Press the MODE/SET Key, and check the Servomotor parameters in order.
6. Press the MODE/SET Key to display special specifications in hexadecimal.
7. Press the MODE/SET Key to return to the data display for the system check mode.
H Parameter Display Contents
D Servomotor Parameters
Application
D Special Specifications
User specifications number (hexadecimal display) Using the Monitor Output
The Servo Drive outputs a monitor voltage proportional to the Servomotor rotationspeed and current from the monitor output connector (CN4) on the top of the Servo Driv-er. This output can be used to install a meter in the control panel or to enable more pre-cise gain adjustments.
H Analog Monitor Output Specifications
D Monitor Output Terminals (Top of the Servo Driver)
Application
D Monitor Output Circuit
D Monitor Output Specifications
With 0 V as center, voltage output at 0.5 V/(1000 r/min) ratio. Forward rotation: (–) volt-age; reverse rotation: (+) voltage Output accuracy: approximately ±10% With 0 V as center, voltage output at 0.5 V/(rated torque) ratio. Forward acceleration:(–) voltage; reverse acceleration: (+) voltage Output accuracy: approximately ±10% Application
Protective and Diagnostic Functions
4-4-1 Alarm Displays and Alarm Code Outputs
The Servo Driver has the error detection functions shown below. When an error is de-tected, the alarm output (ALM ) and the alarm code output (AL01-03) are output, the Ser-vo Driver’s internal power drive circuit is turned off, and the alarm is displayed.
H Alarm Table
Alarm code
Error detection func-
Detection contents
solute value data when the SEN signalis input.
The checksum for the parametersread from the EEP-ROM does notmatch.
Overcurrent or overheating detected.
Main circuit DC voltage exceeded theallowable value (410 VDC or more).
Detected at reverse limit characteris-tics when the output torque ex-ceeds120% of the rated torque. (HA/LA/V/W Models) Detected at reverse limit characteris-tics when 135% of the rated torquewas exceeded. (H/L Models) Detected at reverse limit characteris-tics for 120% to 135% of the ratedtorque. (H/L Models) of feedback pulses for 1 revolution.
dropped. (This error is always giventhe first time the encoder is used.) higher for a 5-V power supply input.
from the A/D converter within a fixedtime.
Application
Alarm code
Error detection func-
Detection contents
Connector not properly connected.
Encoder not properly wired.
Momentary power fail- The power supply was re-started with-ure alarm power supply was turned on. (It nolonger exists in the alarm history.) Note 1. A.00 and A.80 to A.85 are detected only for absolute encoders.
Note 2. “---” means indefinite.
4-4-2 Alarm Output
This section describes the timing of alarm outputs when power is turned on and whenalarms occur. The method used to clear alarms is also described.
H Timing Chart
Application
H Alarm Output Circuit
Output specifications: 30 VDC, 50 mA max.
Normal: H Clearing Alarms
• Any of the following methods can be used to clear alarms: Turn ON the alarm reset signal (RESET).
Toggle the power supply.
Press the Reset Key on the Parameter Unit.
Overcurrent alarms (A.10), however, cannot be cleared by toggling the power supply.
• Operation will start as soon as the alarm is cleared if the alarm is cleared while the Run command (RUN) is ON, possibly creating a dangerous situation. Turn OFF the Run command before clearingalarms. Take adequate safety precautions if an alarm is going to be cleared while the Run command isON or when the Servo Always ON (Cn-01, bit 0 set to 1) is used.
Application
4-4-3 Overload Characteristics (Electron Thermal
Characteristics)
An overload protection function (electron thermal) is built into the Servo Driver to protectagainst Servo Driver or Servomotor overload. If an overload (A.70 to A.72) does occur,first clear the cause of the error and then wait at least one minute for the Servomotortemperature to drop before turning on the power again. If the power is turned on againtoo soon, the Servomotor coil may be damaged.
H Overload Characteristic Graph
The characteristic between the load ratio and the electronic thermal operating time is shown in the fol-
lowing graph.
Note 1. The load ratio is calculated in relation to the Servomotor’s rated current.
Note 2. For example, if a current three times the rated motor current is applied continuously, and over-
load will be detected in approximately 3 s.
Application
4-4-4 Alarm History Display Mode
The Servo Driver stores the history of the 10 most recent alarms that have been gener-ated. The alarm history can be displayed by going into the alarm history display modeand using the Up and Down Keys.
To clear the alarm history, set the system check mode to “02” and press the MODE/SETKey.
H Displaying the Alarm History
1. Confirm that the initial display is shown (–. bb).
2. Press the MODE/SET Key to go to the alarm history display mode.
3. Use the Up and Down Keys to go up and down through the error occurrence numbers and display the corresponding alarm history data. (The larger the error occurrence number, the less recent thealarm is.) H Clearing Alarm History Data
Alarm history data initialization is executed in the system check mode. The items in parentheses in the
following explanation indicate operations using the Handy-type Parameter Unit.
1. Confirm that the initial display is shown (–. bb).
2. Press the MODE/SET Key to enter the settings mode.
3. Using the Up and Down Keys, set parameter number “00.” (System check mode) 4. Press the DATA Key to display the setting of Cn-00.
5. Using the Up and Down Keys, set the parameter to “02.” (Alarm history clear) 6. Press the MODE/SET Key to clear the alarm history data.
7. Press the DATA Key to return to the settings mode.
Application
Troubleshooting
When an error occurs, check the error contents by means of the operating status andalarm display, investigate the cause and apply the appropriate countermeasures.
H Error Diagnosis by Means of Operating Status
Probable cause
Items to check
Countermeasures
being used, set Cn-01 bitnos. 2 and 3 to “1.” Application
Probable cause
Items to check
Countermeasures
shaft and the mechanicalsystem, or there are loadtorque fluctuations accord-ing to how the pulley gearsare engaging.
• Use auto-tuning.
• Adjust the gain manually.
ambient temperature around ture to 40°C or lower. (Usethe Servomotor is no higher foreign objects in the mov-able parts, or whether thereis any damage, deforma-tion, or looseness.
Application
H Error Diagnosis by Means of Alarm Display (Parameter Unit)
Alarm dis-
Error content
Condition when error oc-
Probable cause
Countermeasures
Operate from a Handy-typeParameter Unit.
resistance at the Servo-motor itself. If there isshort-circuiting, replacethe Servomotor.
tance. If the coil are dam-aged, replace the Servo-motor.
waiting for a time, operationresumes.
Application
Alarm dis-
Error content
Condition when error oc-
Probable cause
Countermeasures
be 85 to 127 VAC when100 VAC is specified.
be 85 to 127 VAC when100 VAC is specified.
the machine, and reducethe gravity torque.
be 170 to 253 VAC when200 VAC is specified.
be 85 to 127 VAC when100 VAC is specified.
Application
Alarm dis-
Error content
Condition when error oc-
Probable cause
Countermeasures
Turn OFF the SEN signal,reset the alarm, and thenturn ON the SEN signal.
Incremental encoder: 0Absolute encoder: 1 and then perform the abso-lute encoder setup.
Incremental encoder: 0Absolute encoder: 1 Incremental encoder: 0Absolute encoder: 1 Application
Alarm dis-
Error content
Condition when error oc-
Probable cause
Countermeasures
Incremental encoder: 0Absolute encoder: 1 • The power supply was re- • Set Cn-01 bit no. 5 to “1” alarm when the power isrestored after a momen-tary power failure.
Application
Periodic Maintenance
! WARNING
Do not attempt to disassemble, repair, or modify any Units. Any attempt to do so mayresult in malfunction, fire, or electric shock.
! Caution
Resume operation only after transferring to the new Unit the contents of the datarequired for operation. Not doing so may result in an unexpected operation.
Servo Motors and Drives contain many components and will operate properly only wheneach of the individual components is operating properly. Some of the electrical and me-chanical components require maintenance depending on application conditions. In or-der to ensure proper long-term operation of Servo Motors and Drivers, periodic inspec-tion and part replacement is required according to the life of the components.
The periodic maintenance cycle depends on the installation environment and application conditions ofthe Servo Motor or Driver. Recommended maintenance times are listed below for Servo Motors andDrivers. Use these are reference in determining actual maintenance schedules.
H Servo Motors
Ambient motor operating temperature of 40_C, within allowable shaft load,rated operation (rated torque and r/m), installed as described in operationmanual.
• The radial loads during operation (rotation) on timing pulleys and other components contacting belts is twice the still load. Consult with the belt and pulley manufacturers and adjust designs and system set-tings so that the allowable shaft load is not exceeded even during operation. If a motor is used under ashaft load exceeding the allowable limit, the motor shaft can break, the bearings can burn out, andother problems can occur.
H Servo Driver and Regeneration Units
Ambient driver (regeneration unit) operating temperature of 55_C, rated op-eration (rated torque), installed as described in operation manual.
• The life of aluminum analytical capacitors is greatly affected by the ambient operating temperature.
Generally speaking, an increase of 10_C in the ambient operating temperature will reduce capacitorlife by 50%. We recommend that ambient operating temperature be lowered and the power supplytime be reduced as much as possible to lengthen the maintenance times for Servo Drivers and Regen-eration Units.
• It is recommended that the Servo Driver and Regeneration Unit be inspected at five-year intervals if they are used under conditions worse than the above or not used over a long time of time. Contact yourOMRON representative for inspection and the necessity of any component replacement.

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