Thrust block fault finding (DS01042/D)

1. Introduction
This instruction sheet is intended as a fault-finding guide on the ThrustTube range of forcers. The mechanical
checks require that the thrust rod be removed to allow the internal forcer insulation to be inspected. In the
electrical tests listed measurements are made on the terminations and the hall effect circuit board on the side
of the thrust block. To obtain access to the measurement points described, undo the four M4 button head bolts
and remove the pocket cover plate. Alternatively the tests can be carried out at the drive amplifier end of the
thrust block cable. Refer to specific cable data sheets for cable colours and connections.
A Digital multimeter, oscilloscope and small tools are required to do the tests listed on this data sheet. All tests
except the Hall effect tests are made with the power disconnected.

2. Mechanical checks
2.1. Internal lining mechanical damage
ThrustTube series motors are lined with a Fluoroplastic sleeve.The Fluorplastic lining is clear plastic, and the
resin is a black matt finish. To inspect the internal lining of the thrust block the thrust rod must first be removed.
This is done using the following procedure.

The thrust rod contains very powerful magnets and caution must
be observed through out the disassembly and re-assembly process.

Fit packing material round the thrust rod to prevent it coming in contact with the bearing rail or any other
ferrous metal parts. Note which end the serial number is on the thrust rod, so that the thrust rod can be refitted
the same way round.

PACKING PACKING

Slacken the M10 clamping bolts in the thrust rod supports at either end of the assembly.

Slowly slide the thrust rod out of the assembly through the end thrust rod support, making sure that the thrust
rod is kept straight and no damage is caused to the inside lining of the thrust block. Also ensure that the gap
between the thrust rod and bearing rail is maintained by using the thrust block and the packing material as a
spacer to avoid the two becoming attracted.

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 The Thrust rod should then be stored in protective packing.

2.2. Overheating damage

Overheating of the forcer may result in the standard Fluroplastic lining becoming distorted. Over heating cannot
occur if the over temperature thermistor has been used by the control system to disable power to the forcer.
After overheating has occurred the insulation on the forcer coil windings normally fails and hence the electrical
resistance of the coils reduces.
When overheating occurs on motors there are normally no visual signs that overheating has taken place
unless very high temperatures have been reached. In these cases the coils can be seen to push out of the
motor ends and the resin lining becomes slightly raised.
In extreme cases of over heating the magnets in the thrust rod may be reduced in strength requiring the thrust
rod to be replaced. A basic check can be carried out by running a small terminal screw driver along the rod and
feeling the strength of the pull. If magnet failure is suspected contact your supplier.

2.3. Misaligned thrust rod damage

The thrust block should run concentric along the entire length of the thrust rod, so that at no point along it’s
travel does the block come in contact with the rod, should it touch the lining then damage may occur to the
inside lining of the motor can occur. Before this happens the thrust rod will become polished where the thrust
block lining is in contact with the rod.
Scratch marks can be seen on the inner lining of the thrust block and after a while the insulation on the coils
will become damaged and they will begin to short to the thrust rod and cause arc burn marks to the thrust rod.
Any arc marks on the thrust rod should be removed with a fine file as the edges of the arc mark are raised, and
will cause further damage to the lining of the thrust block. When arcing occurs this normally causes the
amplifier / control system to trip out and switch off power to the motor. Once the arc marks have been
smoothed then high temperature self adhesive insulating tape can be placed on the thrust rod and the system
run to confirm that it is operational.

Note : The tape must not be left on the thrust rod after the above test has been carried out. The
motor should be repaired or replaced.

2.4. Cable faults

Cable faults are caused mainly by poor installation. This is often because the cable is being flexed at less than
the minimum recommended bend radius or the cables are under tension in the drag chain pulling against over
tightened cable ties. Problems also occur when the cables are left free to flex at the motor cable gland entry
point with no cable management system or oil on the cables cause them to harden.

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3. Electrical checks
3.1. Coil resistance tests
During the following tests the thrust block should remain stationary relative to the thrust rod as any movement
will induce currents into the motor coils and cause fluctuations in the measurements obtained.
Motor Phase Connections
W (Blue)
Motor Thermistor V (Yellow)
Connections. U (Red)

Hall Board Connections Motor Cable Thermistor Wires, if it is required for them
to go down the motor cable instead of the Hall Cable.
NOTE: Only one set should be connected.

Disconnect the three motor coil wires from the motor drive circuit, to eliminate the effect of the amplifier output
stage. The thrust block contains three sets of identical coils connected in star configuration. To check the
resistances of the coils measure phase to phase across each combination of the connecting wires and record
the resistance values measured. The resistance values measured should correspond to the values shown in
the following table for the motor type. The three values measured should all be matched to each other within
0.2 Ohms. If greater differences in values are measured this normally indicates a fault and the possibility that
overheating has occurred if the values are much lower than indicated on the table.

FORCER TYPE 3810 3808 3806 3804 2510 2508 2506 2504 Units
Nominal resistance (phase to phase) TB 21.41 17.13 12.85 8.56 15.04 12.03 9.02 6.02 Ohms
Nominal resistance (phase to phase) TBX 16.93 13.54 10.16 6.77 13.51 10.81 8.11 5.40 Ohms

The resistance values in the table above are given as a guide, actual resistance values measured may vary
due to temperature, Forcer cable resistance, internal lining type and updated specifications. Refer to motor
properties data sheets for more details of resistance values and other properties.
3.2. Coil isolation test
Measure the resistance between each of the phases and the earthing point screw on the thrust block body.
The resistance between the thrust block body and each phase should be greater than 100M ohm.

3.3. Thrust block earthing test

It is essential that the thrust block is earthed correctly. The earth wire is connected to the earth screw located
within the pocket next to the coil connections terminal block. Check the continuity between the earth on the
amplifier and the earth on the thrust block for a reading of less than 0.5 Ohms
3.4. Thermistor test
Three thermistors connected in series are fitted within the thrust block to detect the temperature of the coils in
each phase, once the temperature of the coils exceeds 100°C the resistance of the thermistor increases
sharply, which can be used to disable the drive amplifier to protect the motor. The thermistor is connected to
the raised terminal block inside the motor pocket. When the temperature of the thrust block is at a nominal
25°C the resistance of the thermistor should be between 150 and 350 Ohms if the motor is at the over
temperature point it would read >3000 Ohms
Measure the resistance between one motor phase and one thermistor termination. The resistance measured
should be greater than 100 M ohm.
Measure the resistance between the thrust block body and one thermistor termination. The resistance should
be greater than 100 M ohm.

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3.5. Analogue Hall effects tests
Analogue Hall effect circuit boards contain two Hall effect sensors. The Hall effect sensors are positioned in
different locations on the circuit board depending on the type of thrust block 25 or 38 range.
3.5.1. Oscilloscope Set-Up
Set the oscilloscope to a sensitivity of 2V per division versions with a time base of 20ms.
Zero the oscilloscope traces to the centre of the display.
Connect the oscilloscope ground to pin 6 (green 0v) of the 10-way Molex connector on the Hall effect PCB.
3.5.2. Check Hall 1 and Hall 2 signals
Connect channel 1 oscilloscope probe to pin 1 (blue) of the 10-way Molex connector on the Hall effect PCB or
to the blue cable at the amplifier end.
Connect channel 2 oscilloscope probe to pin 4 (violet) of the 10-way Molex connector on the Hall effect PCB or
to the blue cable at the amplifier end.

Apply power to the hall effect PCB but ensure that the motor coils supply is disabled.
Move the thrust block back and forth by hand and monitor the output on the oscilloscope and check that the
amplitude of the signals is the peak to peak value in the chart below centred around the zero point
corresponding to the version type. The two signals should be 120 degrees out of phase.

3.5.3. Checks using a digital multi-meter

if no oscilloscope is available to do the tests listed above, a multi-meter can be connected in turn to pins 1 to 4
while the forcer is moved very slowly back and forth by hand. The peaks of signals can then be checked and
the general trend of the sine waves monitored.

3.6. ‘A4’ Hall Option Connection details

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 Pin number Function
1 +Hall 1
2 No connection
3 No connection
4 +Hall 2
5 +5V
6 0V
7 No connection
8 Forcer over temperature thermistor
9 Forcer over temperature thermistor
10 No connection

PIN 10

PIN 1

MOLEX CONNECTOR

Plan View

3.7. Digital Hall effects tests

The digital Hall effect boards contain three Hall effect devices with differential output circuits. The output of
each device changes as the thrust block is moved along the thrust rod and a magnetic transition is detected.
The Hall effect sensors are positioned in different locations on the circuit board depending on the type of motor
block 25 or 38 range.

3.7.1. Oscilloscope set up

a) Set the oscilloscope to a sensitivity of 2V per division for both channels and a time base of 20ms.
b) Zero the oscilloscope traces to the centre of the display.
c) Connect the oscilloscope ground to pin 6 (green 0v) of the 10-way Molex connector on the Hall effect pcb.

3.7.2. Check A and B positive outputs

Connect channel 1 oscilloscope probe to the hall effect output pin to be monitored on the 10-way Molex
connector on the Hall effect pcb.

Apply power to the Hall effect pcb but ensure that the motor coils supply is disabled. Move the thrust
block back and forth by hand and monitor the output on the oscilloscope and check that the signal switches
between 5v dc and 0v as the motor is moved.
Repeat for each of the six outputs.

3.7.3. Checks using a digital multi-meter

If no oscilloscope is available to do the tests listed above, a multi-meter can be connected in turn to each
output pin in turn while the forcer is moved very slowly back and forth by hand. The transitions of the signals
can then be monitored.

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 Pin Number Function
1 +Hall 3
2 +Hall 1
3 -Hall 3
4 +Hall 2
5 +V
6 0V
7 -Hall 1
8 Forcer over temperature thermistor
9 Forcer over temperature thermistor
10 -Hall 2

PIN 10

MOLEX CONNECTOR

PIN 1

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4. Re-assembly
4.1. Thrust rod
Slide the thrust block to the end of travel that the thrust rod is to be fitted from. Ensure that the thrust rod is
refitted with the serial number at the same end as originally supplied.

Leaving some of the protective packing in place on the thrust rod, gently push the rod through the thrust rod
support.

Push the thrust rod through the thrust block taking care not to damage the inside lining of the thrust block.
Then use the thrust block as a spacer to keep the thrust rod separated from the bearing rail, by moving the
thrust block along with the thrust rod as well as using packing material to maintain separation.

Slide the rod until it is fitted into both thrust rod supports flush at each end. Then rotate it till the serial number
is the correct way up and horizontal.

Secure the thrust rod in each support by tightening the M10 fixing bolts to 50Nm Torque setting.

4.2. Thrust rod adjustment

The thrust rod should not require adjustment on shorter module lengths as the dowel pins allow the thrust rod
supports to be relocated to their original set up positions. Move the thrust block along the entire length of travel
and check for concentricity with the thrust rod.
Note the direction in which the rod is coming closer to the inner bore of the thrust block.

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 On longer assemblies with alignment rings adjustment may be necessary to overcome slight sag in the
thrust rod. For more detailed instructions and diagrams see data sheet DS01006.

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5. Check list / Fax back form

Fax to +44 1268 293344

Attn
From
Company
Phone number
Fax number
E-mail support@copleymotion.co.uk
Date

Forcer details :
Test Result
Forcer type
Forcer serial number
Internal mechanical damage
Internal overheating

Resistance tests :
Phase U to phase V resistance Ohms
Phase V to phase W resistance Ohms
Phase W to phase U resistance Ohms
Phase W, U, V To forcer body resistance Ohms
Forcer earth to drive amplifier resistance Ohms
Thermistor resistance Ohms
Thermistor to forcer body resistance Ohms
Thermistor to phase W, U, V resistance Ohms

Hall effect results :

Analogue Hall effect signal A V pk to pk
Analogue Hall effect signal /A V pk to pk
Analogue Hall effect signal B V pk to pk
Analogue Hall effect signal /B V pk to pk
Digital Hall effect signal1 V
Digital Hall effect signal /1 V
Digital Hall effect signal 2 V
Digital Hall effect signal /2 V
Digital Hall effect signal 3 V
Digital Hall effect signal /3 V

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