Description
The CACR-02-TE1K is a legacy high-performance AC servo drive from Yaskawa’s M-Series (frequently associated with the Varispeed 626 or early Servopack families). This drive is designed to control high-torque, high-speed brushless AC motors used in heavy-duty CNC applications, metal forming, and precision manufacturing.
While it is a legacy component, it is highly valued in the aftermarket for maintaining vintage industrial equipment without requiring a full system retrofit.
Availability and Procurement
- Condition: Refurbished (Standardized Bench Testing) or New Surplus.
- Warranty: 12-month technical replacement warranty.
- Lead Time: Typically ships within 3–7 business days.
- Pricing: Subject to market supply for legacy Yaskawa power electronics; contact us for a formal quote.
Model Code Breakdown (CACR-02-TE1K)
- CACR: Servo Drive (Amplifier) Series.
- 02: Capacity/Current Code (corresponds to approx. 200W to 400W depending on the motor pairing).
- TE: Type/Revision code (Integrated electronics for specific control interfaces).
- 1: Supply Voltage (200-230 V AC).
- K: Design revision/Special features (Often signifies a specific interface or connector style).
Technical Specifications
The CACR-02-TE1K features a robust analog-based control architecture that offers high reliability in electrically noisy environments.
| Parameter | Specification |
| Input Power | 200–230 V AC (Single-phase or Three-phase) |
| Output Current | Approx. 2.0 A Continuous |
| Control Interface | Analog (+/- 10V Velocity/Torque Setpoint) |
| Feedback Type | Incremental Encoder (typically 1000–2500 pulses) |
| Cooling | Natural Convection (Heat sink) |
| Dimensions | Compact “book” style footprint |
| Protection | Overcurrent, Overvoltage, Undervoltage, Regeneration fault |
Core Functionality and System Role
The CACR-02-TE1K acts as the intermediary between the high-level CNC controller and the physical servo motor.
1. Precision Current Control
The drive uses a PWM (Pulse Width Modulation) inverter stage to generate a three-phase sine wave for the motor. By precisely controlling the current to the motor windings, it maintains constant torque even at low speeds, which is essential for smooth surface finishes in machining.
2. Analog Speed/Torque Command
This drive is typically operated in an analog velocity loop. The CNC controller sends an analog signal (usually +/- 10 V), where the voltage level corresponds to the desired motor speed. The drive’s internal logic compares this setpoint against the actual feedback from the motor’s encoder to correct for errors in real-time.
3. Error Monitoring
The CACR series is known for its extensive protection logic. It monitors for Regenerative Overvoltage, which occurs when a motor decelerates too quickly and pumps energy back into the drive. Internal resistors or external braking units are used to dissipate this energy.
Engineering Insights: Deployment and Maintenance
1. Potentiometer Adjustments (The “Tuning” Phase)
Unlike modern drives that use software parameters, the CACR-02-TE1K relies on Potentiometers (Pots) located on the front board for tuning.
- Best Practice: When replacing a drive, document the physical positions of the “Gain,” “Offset,” and “Current Limit” pots from the old unit. Fine-tuning these by hand is necessary to prevent machine oscillation (hunting) or sluggish response.
2. The Feedback Loop (Encoder Pins)
The drive relies on high-speed encoder pulses.
- Warning: If the encoder cable is damaged or improperly shielded, the drive will lose its orientation. On the CACR series, this often manifests as a “Runaway” condition where the motor spins to max speed instantly. Always use high-quality shielded twisted-pair cables for the encoder.
3. Capacitor Health
Because these drives are decades old, the Electrolytic Capacitors in the DC bus are the most likely failure point.
- Maintenance Tip: Look for “bulging” or leaking at the base of the large capacitors. If the drive has been unpowered for several years, “reforming” the capacitors with a variable AC voltage source (Variac) is highly recommended before applying full line power.
4. Heat Dissipation
The CACR-02-TE1K is fanless.
- Constraint: It relies on the thermal mass of the cabinet mounting plate. Ensure the mounting surface is clean and that there is no paint between the drive’s heat sink and the backplane of the cabinet to maximize heat transfer.
FAQ
Q: Can I use this drive with a modern Yaskawa Sigma-7 motor?
A: No. The CACR series is electrically and physically incompatible with the Sigma-5 or Sigma-7 encoder protocols. It is designed specifically for the older M-series motors.
Q: What does the “Alarm” LED mean?
A: A red Alarm LED usually indicates a fault. You must check the specific alarm code (usually displayed via a 7-segment display or specific LED combinations) in the service manual to determine if the fault is external (motor short) or internal (drive hardware failure).
Q: Is it possible to convert the analog interface to EtherCAT?
A: Only through the use of an external “Analog-to-EtherCAT” gateway or a motion controller that provides analog outputs while communicating over EtherCAT. The drive itself has no native digital bus capability.
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| Yaskawa CACR-02-TE1K |
