Prototrak Plus Retrofit with Mesa 7i77 & 5i25 cards

13 Mar 2017 20:18 #89546 by lakeweb
Hi Andy,
I'm going by that C3 is the high power cap and on his diagram I believe he is showing the back traces as dashed lines. In that case, the + of C3 goes to the red circle. And yea, there must be another to come from the rect-bridge, but not obvious. C1, and C2 are very small so probably the 40 volts he is measuring? And those were used for signal supplies, milliamps, not amps as R1 and R2 drop the high power in. Those would be unapplicable now.

Very hard to figure for sure without having hands on it.

That is why the light bulb and a 'DC' volt meter, you are looking for high voltage, high power. BTW, are you 120 or 240 volts for your typical plug? I'd guess it means your light bulb is 240 not 120 as I was assuming.
Best, Dan.
The following user(s) said Thank You: new2linux
13 Mar 2017 21:17 - 15 Mar 2017 17:49 #89551 by new2linux
Dan & andypugh thank you for your advise! Typical 120v plug. The dashed lines I had thought that it may be reading continuity back thru capacitor. I have tried to tease out the dotted line means or does, if on the ohm meter, is on R x 100 scale, testing continuity, if the meter is applied to the + of c3 to terminal and where "the dashed lines end or note 1" (to the left) the meter will fill and drop very small amount "hold steady"; if the meter were between the "left side" of c3 to terminal to the + of c3 to terminal, the meter will fill but will start to drift lower and lower, and the same when meter is between the "left side" of c3 to terminal and where the "the dashed lines end or note 1", again the meter will fill but drift down. I hope that helps. I will update diagram pic, please see the bottom (for notes) to leads for transformer and rectifier.

Many thanks!

Edit: Currently there is a separet transformer (provided by BigJohnT) for the 5v and the 24v connected to the TB1 (ground as marked) & TB2 (pin 1 and pin 8) on 7i77 card. The current configuration for TB5 "x" axes on terminals 3 & 4; "y" axes on terminals 7 & 8.

Edit 01: Attached a better pic of diagram, in addition each terminal has a number specific to it, with that said the test with voltmeter between the following terminals for power go like this:
40v=L2 & L3 or r2 & r3;
40v=L1 & L3 or r1 & r3;
75v=L1 & L2 or r1 & r2;
If testing resistance on R x 100 scale between the following terminals go like this:
The needle starts high but will fall it tested between C3+ & B2,L2,T2 & r2
The needle starts high but will fall it tested between C3b+ & B1,L1,T1 & r1
C3a does not seem to connect to anything.
By and large when testing resistance on the other terminals the reading is steady, some go 80% scale others go 55% scale, but firm, don't seem to drop very quickly. I will gladly test and retest and post results on the rest of PCB if that will help.
Many, many thanks for all the great help. If I am over my head (because you don't know what you don't know, so it's hard to know when to call it a day) I will still need to know the correct questions for the real electrician.

many thanks!!

Edit02: This link is most helpful, "analog drive configuration &setup notes"

Many thanks!!
Last Edit: 15 Mar 2017 17:49 by new2linux. Reason: additional info; updated diagram:02 to add link
16 Mar 2017 17:33 - 23 Mar 2017 12:26 #89758 by new2linux
Many, many thanks to all that have help with this project!
And special thanks to the following: andypugh, Todd Zuercher, lakeweb, PCW, tommylight, and bevins for there invaluable assistance!!

As for the power supply, upon study of old and how the new AMC amps work my thinking is to try the (P2 location on amp) pins: 3, 4 & 5. My thinking (I know, some of you think, this may not turn out good) is to follow the diagram and testing I have shown in prior post.
40v=L2 & L3 or r2 & r3;
40v=L1 & L3 or r1 & r3;
75v=L1 & L2 or r1 & r2;
So if you reference the r1&r2;L1&L2 to the diagram you will see the why. The big foot print of copper on near and far sides of PCB just seem to be uniform in appearance, to be placed on pin 3 or 4 and pin 5 goes to r3&L3. Both r3&L3 (if you follow diagram) go to #1 on transformer, and neither have any reference to note 1 or 2 on diagram. There is a reference to the DIP switches a way to set max current, test mode and tuning procedure, but the 4.1.6 is 1st.

I have been reading & pondering, it appears the 1st requirement to preform Current Limiting Procedure. If this is not the way to approach please say so:
My servos are rated at 1/3 horsepower at 75vDC (max output of transformer,as tested) so:
1/3hp x 746 watts=248.66
248.66/75=3.32 amps (if you do the math using 80vdc=3.11 Amps.)

The following is from this link page 46 (pdf 53/73)

4.1.6 Current Limiting Procedure (there is 2nd part if required)
Before operating a drive, the current output of the drive must be limited based on motor and
system current limitations. Depending on the drive model, ADVANCED Motion Controls’ analog
servo drives feature a number of different current limiting methods. However, the procedure
for setting the current limit will essentially be the same for each drive. Consult the drive
datasheet to see what current limiting options are available on a specific drive.
The current limiting steps should be taken with no power applied to the drive.
1. The following two options may be used separately or in conjunction with each other to
reduce the current limits. Keep in mind that any current reductions enacted by the use of
an external resistor will come secondary to DIP switch settings.
— If available, position any current scaling or current limit ratio DIP switches to the
desired position (see “Potentiometer Function Details” on page 43).
— If available, use an external resistor connected to the Continuous Current Limiting Pin
based on the values given on the drive datasheet (see “Continuous Current Limit Pin”
on page 41).

I will be working this and moving thru setup. Using this link as well for setup.

Many thanks for all the help!!

Edit: To clarify for next person, the DC voltage out of PCB (bridge retrifier) as per prior diagram, goes like this:
38vdc=L3 or r3 to ground
0vdc=L2 or r2 to ground
75vdc=L1 or r1 to ground
So at the amplifier (each is very specific, as to the setup) make shore to have on hand the most current manual, to your application and follow closely to it. I have several steps to go.
Last Edit: 23 Mar 2017 12:26 by new2linux. Reason: spelling, clairify
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