Maintenance & Troubleshooting: Problem Isolation
Maintenance & Troubleshooting: Problem Isolation
Problem Isolation
If your system does not function as you expect it to operate, you must identify
and isolate the problem. When you accomplish this, you can effectively begin to
resolve and eradicate the problem.
The first step is to isolate each system component and ensure that each compo-
nent functions properly when it is run independently. You may have to dismantle
your system and put it back together piece by piece to detect the problem. If you
have additional units available, you may want to use them to replace existing
components in your system to help identify the source of the problem.
Determine if the problem is mechanical, electrical, or software-related. Can you
repeat or re-create the problem? Do not make quick rationalizations about the
problems. Random events may appear to be related, but they may not be contrib-
uting factors to your problem. Carefully investigate and decipher the events that
occur before the subsequent system problem.
You may be experiencing more than one problem. You must solve one problem at
a time. Document all testing and problem isolation procedures. You may need to
review and consult these notes later. This will also prevent you from duplicating
your testing efforts.
Once you have isolated the problem, take the necessary steps to resolve it. Refer
to the problem solutions contained in this chapter. If your system’s problem
persists, call Compumotor at 800-358-9070.
Encoder error— 3
Check encoder NO
cable connection
Correction
OK
Command input
Within Correction
specification
ranges
YES
Noise, poor connector
connection?
Correction
NO
Over Speed—1
Command input NO
correct?
YES
NO
Already tuned?
Excessive
YES
external force, applied
to motor's rotor?
Correction
NO
Power cable NO
connection OK?
OK
Correction
Correction
NO
Over voltage
Set test switch ON Over Current
LED Detail display
0001 0003
NO
Power supply
voltage, too high?
NO
Motor Cable
connection, OK?
YES
Load inertia, too much?
OK
NO
NO
Motor part, grounded?
YES
Operation duty, too high?
YES
Correction
NO Correction
Consult Compumotor
Power on again Consult Compumotor
Application Department Power on again
Application Department
Over load—C
YES
Motor's rotor, locked?
NO
Correction
YES
Operation duty
too high?
Power on again
Without specification
Driver ranges
installation
environment
Correction
Within specification
ranges
Although the heavier the deadweight, the greater the energy absorption, the lowest
limit is established by the following condition:
Deadweight weight > 1 kg
C R2
n = (R1+ R2) / R2
R1
ωs = 1/ (R1+ R2) C
nωs = 1/ R2 C
Phase [°]
90
-
+ 80
70
n
First Order Lag Filter Circuit
60
15
12
[dB] 50 7 10
fd1 fd2 8
6
ωs √ nωs nωs 40 5
4
30 3
20 2
10
0
0 2 4 6 8 10 12
[°] Gain [dB]
Relationship of Frequency
Ratio n, Phase, and Gain
Notch Filter
The notch filter circuit configuration is shown in the next figure. The notch filter
board is shown in the subsequent figure. This filter is effective for suppression of
high-Q resonances at 100 Hz and above. A switched capacitor filter is used for
the circuit, and the notch frequency and Q values can be set within a predeter-
mined range.
From a circuit configuration standpoint, dual types providing two stages for notch
frequency are typical, and in this case the first-order lag filter section is built into
this construction.
Jumper
Setting
20/80
30/120
40/160
{ Q1 Q2
IN -
+ - OUT
+
ØdB
-12dB
Q Value Q = fn / ∆f
Function
Transfer
Q1 Q2 ∆f 3dB
fn
Clock Monitor
Q Value Setting Notch Frequency Setting
Q1 Q2 F2
1.3 1.5 1.7 270Hz
fn2
1.1 1.9
F1
Adjustment Procedures
Since the offset voltage will change when the settings of pots Q1 and Q2 are
changed, you should adjust the offset adjustment pot (VR1) so that the voltage
difference between TP1 (VOUT) and TP3 (VIN) does not exceed 50mV. When taking
signals from
TP1, TP3, and TP6, be careful not to touch any other pins or parts of the pattern.
General Filter Specifications
Item Specification
System Dual switched-capacitor notch filter+ first-order lag filter
Dimensions(mm) $75 ~ 40 (board size)
Interface DM series: Directly installed on control board
DR series: Connected by 10-pin connector to control board
Power Supply ±15V, 50 mA
Resonance Tuning
The following is a procedure of suppressing resonance (vibration) in a Dynaserv
application without the use of FFT Analyzer or Oscilloscope. The purpose is to
adjust the Dynaserv for optimum tuning (high gain, stiffness, responsiveness) with
no resonance.
1. This procedure is done in the Position mode.
2. Set the Fc and I.lim to 3.
3. Set Test Switch to ON (up position).
4. On the Notch Filter board set Q1 and Q2 to 1.5 (mid position).
5. Increase the DC Gain until resonance occurs.
6. On the Notch Filter board adjust F1 to null (tune-out) the resonance. If resonance is
very close to the same frequency as the first, tune it out with the same pot (F1). If not
use F2 pot.
7. Repeat steps 5 and 6 until the DC Gain can no longer be increased without resonance.
8. Repeat steps 5, 6, and 7 adjusting F2 on the Notch Filter board.
9. Depending on the mechanical conditions of the application additional filtering may be
necessary. If resonance persists use the 1st Order Lag Filter (20/80, 30/120, 40/160)
jumpers. Use one of these jumpers to minimize resonance then repeat steps 5 - 8. (Go
to step 11).
10. Increase the DC Gain until resonance occurs, then try nulling it out with the 1st Order
1 1
KT J S
KF/V
The above figure illustrates the transfer function between torque (TRQ) and
velocity (VEL) when no resonance is present.
fc = KT • KF/V / 2π J
100
0
GAIN Frequency [Hz]
[dB]
20dB/dec
-90
Phase -180
[°]
30°
-270
The following tables contain the KF/V and KT values for DM and DR Series motors
respectively.
Motor Type: DM Series KF/V KT
[V/RAD/S] [Nm/V]
DM1050A 0.796 (5V/2 ) 3.92
A Type DM1100A 7.85
DM1150A 11.77
DM1200A 15.7
DM1015B 0.398 (5V/2 • 2) 1.97
B Type DM1030B 3.94
DM1045B 5.91
DM1060B 7.88