Mitsubishi FREQROL-SFJ User manual

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LiC SPINDLE DRl.i/E
. . . .
t .,.
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-SFJ L
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P
MAINTENANCE -MANUAL
:
BNP-A282 l-02-A-E
ADVANCED AND EVER ADVANCING
n/lmJBlsHl ELEcTmc

-CO.NTENTS-
1.
GENERAL
1.1
Introduction
1.2
Safety during maitenance and troubleshooting
1.3
Storage
2. WIRING
2.1
External wiring
2.2
Parts arrangement
3. ADJUSTMENT
3.i
Preliminary check
3.2
Power feeding
3.3 FR-SFJ status display and parameter settings
. . . . .
1
. . . . .1
. . . . .1
. . . . .
2
. . . . .
3
. . . . .
3
. . . . .
10
. . . . .
12
. . . . .
12
. . . . . 13
. . . . . 15
3.3.1 (A) Status display and parameter setting
for ROM version A . . . . . 17
3.3.2 (B) Status display and parameter setting
for ROM versions after BO
3.4 Spindle control monitor on NC CRT dispaly
. . . .
when FR-SFJ is connected to M300 CNC
through bus line
3.5 Spindle control monitor on NC CRT display
. . . . when FR-SFJ is not connected to M300
CNC through bus line
3.6 Test operation
3.7 Adjustment of motor speed
3.8 Adjustment of oriented spindle stop function
3.9 Parameter list
4. CARD SETTINGS AND CHECK TERMINALS
4.1
Card SFJ-CA1
4.2
Card SF-ORJ
4.3 Card SF-TLJ
4.4 Card SF-DAJ
5. ADDITION AND REPLACEMENT OF COMPONENT
5.1 Addition of option card (SF-ORJ, SF-DAJ and
SF-TLJ)
5.2 Replacement of card
5.3 Replacement of ROM
5.4 Replacement of diode moduie and transistor
module
. . . . . 2C
. . . . .
26
. . . . . 29
. . . . .
32
. . . . . 32
. . . . .
34
. . . . .
42
. . . . .
50
. . . . .
50
. . . . .
55
. . . . .
56
. . . . .
57
. . . . . 58
. . . . . 58
. . . . . 59
. . . . . 60
. . . . .
61
5.5 Disassembly and assembly of SJ-J type AC spin-
dle motor
. . . . . 63
- 1/2-

6. INSTALLATICN OF ORIENTED SPINDLE STOP POSITION
DETECTOR
6.1 Magnesensor l-point oriented spindle stop
7. DISCHARGE RESISTOR UNIT
a. TROUBLESHOOTING
a.1
General information
,a.2
First step of troubleshooting
a.3 Second step of troubleshooting
8.4 Alarm and warning table
a.5 "Alarm/warning" display by LED readout
9. PERIODIC INSPECTION
9.1 Inspection of control equipment
9.2
Inspection of motor
9.3 Inspection of discharge resistor unit
10. PARTS LIST
. . . . . 72
. . . . .
72
. . . . . a2
. . . . .
a3
. . . . . a3
. . . . . a4
. . . . . 86
. . . . .
a9
. . . . .
94
. . . . 115
. . . . 115
. . . . 116
. . . .
ii8
. . . .
119
-2/2-

$1. GENERAL
1.1
Introduction
AC spindle drive unit, FR-SFJ series, is the inverter use,?
,-
to control a machine tool spindle drive AC motor.
It is capable of contro.lling widely ranged motor speeds ac-
curately and quietly.
Discharge resistors are connectec t-:
the drive unit to disperse regenerative energy for regenera-
tive braking of motor.
This manual mainly describes periodic maintenance and trou-
bleshooting which are very important to assure successful
use of your AC spindle drive.unit.
1.2
Safety during maitenance and troubleshooting
The maintenance and troubleshooting should be done with the
following safety consideration:
o The control system should be maintained and remedied by
qualified electrician.
o When a person who maintains or remedy the control system
must touch a part of control system under live condition,
he should take off finger ring, wristwatch, necktie pin,
and other metallic goods before starting the work.
o Electric shock may cause fatal accident.
When a circuit at high voltage must be checked, due care
should be taken to select appropriate test/inspection
equipment, tools, etc.
and to use them safetly (no matter
whether or not the circuit is grounded).
When a test equipment is applied to a part, component, or
circuit of the unit, operator should pay attention not to
touch a grounded part.
In general,
test equipment should not be grounded.
During test or measurement, it is likely that high voltage
is present across the test equipment and the ground.
When motor is run during adjustment or remedy, due care
should be taken in this respect.
o Person who carries out maintenance or remedy of rotative
machinery should not wear loosely (otherwise loose wear
- l-

might be involved into the running machine.
o DO NOT TURN OFF THE POWER IMMEDIATELY AFTER OPERATION IS
TERMINATED.
THE UNIT SHOULD BE HELD TURNED ON FOR AT
LEAST 10 MIN. FOR COOLING THE DISCHARGE RESISTOR UNIT
(BY COOLING FAN), AFTER THE OPERATION.
IF THE DRIVE UNIT IS TURNED OFF IMMEDIATELY AFTER THE
TERMINATION OF OPERATION, THE RESISTOR UNIT COOLING FAN
STOPS AND RESIDUAL HEAT, OF RESISTOR UNIT MIGHT CAUSE BURN-
ING OR DAMAGE TO OTHER COMPONENTS OF DRIVE UNIT.
o Do not touch the drive unit immediately after the opera-
tion is terminated (maintenance or remedy should be start-
ed in about 5 min. after the operation is terminated).
1.3 Storage
When your AC spindle drive unit is not used, store it in
clean and dry environment.
Note that humidity and dust entering into the control unit
may adversely affect insulation resistance of the drive unit.
When your, AC spindle drive unit is left out of operation for
any length of time, the same cautions should be taken.
It is recommended,
if the storage is humid, to use a heater
to keep the environment dry.
.
- 2 -

f-
c
92. WIRING
2.1
External wiring
2.1.1 Control system.where FR-SFJ is not connected
through bus line
a. Analog speed reference
signal
“““chins rc*dy” Input
FWd r”” command
R.3” run command
orlsnttd eplndl* atoP
commmd
I.“*-spewi qsllr select
“rdlum-specrl genr select
AUI . Input I
E
Yir:
AUX.
input 2
A C4I
I
“Up-to-speed” st.m.1
O”tpUt
Zero speed output
5111”“1
“rlcntation complete
( In-po~ltIorl) output
-
AUX. output 1
I
. 36
*“I. output 2
Is=_
RI
e 21
to M300
Nischarne r-es
- 3 -

b. Digital speed reference signal (option card SF-DAJ is used)
Basic system composition
F R - S F J - 2 -;;I; K - D
“VP-to-epee.9, OUrpUt aima,
“Zero speed” output signal
tJr,entstion ccmplett
(in-porrItIon~ signal
A”X. O”Ip”t I
A”X. output 2
speed meter
Lord rnCtCr
‘SF-DAJ”
Note 1:
This input port is used for speed
reference signal selection
between “analog” and “digital”.
For details, refer to paragraph
3.1.2 “Auxiliary input signals”
in the Standard Specifications.
- 4 -

f---
c
c
c. Control system equipped with oriented spindle stop func-
tion
A circuit illustrated below is added to the basic system.
(1) Magnesensor type oriented spindle stop (1 point) see-
cification (+ motor
speed feedback signal output)
(For spindle speed display/sync. feed
signal) .
f
_---
---
--
Option card
I
‘SF-DA 1’
OI-
'SF-OHJ'
.!.
_^
Maqnesensor
display/sync. feed signal
_____h To NC
(A.B,Z phases)
Pulse nu Number of pulses is
128/(reduction ratio).
detect
Magnesensor
(2) Encoder type oriented spindle stop (4096
cification,
equipped with index function
+_----_--_T_~
points) spe-
Option card
'SF-D41'
Oriented stop
position command
Speed display/sync. feed signal
e To NC
(1024P/rev
A.B.2 phases)
er detect signal
- 5 -

(3) Z-phase controlled motor built-in encoder type ori-
ented spindle stop (4096 points) specification, equip-
ped with index function
Motor detector signal
_______----------
Option card
'iented spindle
'5 F-DA 1’
top position
ed display/sync. feed signal
Tmmand
SF-OKJ'
-----hTo NC
(128P/rev
A,B,Z phases)
-.
- 6 -

2.1.2 Control system where FR-SFJ is connected to M300 ,through
bus line (option card SF-TLJ is used) FR-SF
J -2 $K-T
a. Basic system composition
I QR I I
Poker supply
I
J
Connection is not
required for CON1
signal in usual
operation.
c
c
c
I/O signal assignment
CM300 series interface)
c
SRI jY251~Y2DI
CNI
____
A
‘< 1
‘< 2
,I
IVEIl
I
so
CNll7 ,
‘<2
!
le
7
:
'SF-TL.J'
Ot-
'SF-RSJ'
To CNlB of
final axis
MR-S servo
amplifier
Rev run Index
/Y255;Y2D5
ORC
lY256!Y2D6
BLS
c
*,.rm “on”
jXIC3 X243
ZS IXIC4/X244
us
lxlc5ix2451
ORA
/XlC61X246
J
- 7 -

b. Control system equipped with oriented spindle stop func-
tion
A circuit illustrated below is added to the basic system.
(1) Motor built-in encoder high-speed sync. TAP and magne-
sensor type oriented spindle stop (1 point) specifica-
tion
Opt
'S
ion card
Speed display/sync. feed signal
- To NC
(A.El.2 phases)
Number of pulses is 128/(reduction ratio).
Magnet
Detector
Magnesensor
(2) Encoder high-speed
sync.
TAP and multi-point (4096
points) oriented spindle stop specification, equipped
with 'index function
Option card Encoder detect signal
1024P/rev
Speed display/sync. feed signal
-To NC
(128P/rev
A,B.Z phases)
- 8 -

(3) Z-phase controlled motor built-in encoder high-speed
sync.
TAP and multi-point oriented spindle stop spe-
cification, equipped with index function
Option
‘SF-71card
A
- To
NC
(128P
‘/rev
A,B,
,Z phases)
feed signal
- 9 -

2.2 Parts arrangement
(1) SFJ-CA card and option
card
1
‘,’ ,,
,&
(2) Main board
L
f I’
\ -1
FR-SFJ-2- ::: K
fit 1 1 II1lA
SFI-CA card
FR-SFJ-2- :::K-R
SFJ-CA card
r
Option
CON1 CON2
In
n,
r
OP
II!
b
RI 0
6
04 ?
Et
MC2
01 6
O0
0 Cfl.
%f
-2 I-
-6 .3-
1
-10 12-
-” ,-
CON1 CON2
n
n
FR-SFJ-2- Ll K-D FR-SFJ-2-
i:IK-T
SFJ-CA card SFJ-CA card
option
0
@
w-1
Cl I
R2.2
t
0
CTV
IQ?
0
Option
Front panel
(namer
Ilate)
Option card
Card SFJ-CA z
CON1 CON2
nn
r
IP-PM power
- 10 -

c
c
c
c
FR-SFJ-Z-3.7K
0
“\ 0
:
3‘ !
0
KL’
0
1
l-l-
.c?
J
I
I ’
-L 4-
-Ii n-
-111 ,z-
-n ,-
FR-SFJ- -5.5K
- 11 -

$3. ADJUSTMENT
3.1 Preliminary check
Before turning on FR-SFJ, perform the following check:
(1) Is the external wiring in conformity with the relevant
wiring diagram?
(2) Are the motor and the drive unit grounded properly?
(3) Are all shielding wires terminated properly?
o Is each shield armour connected to the corresponding
terminal'?
o Is each shield armour not looped?
(4) Is any component or part not loose?
(5) Is any foreign matter is not involved in the drive unit?
(6) Is there any damage or defect on each,P.C. board?
(7) Do ROM No.
and jumper pin settings meet the order sheet?
- 12 -

3.2 Power feeding
3.2.1
Turning on the power
Immediately after the FR-SFJ is turned on, see the ?-seg-
.ment LED readout at the center of front panel to check
conditions:
(1) For FR-SFJ connected to M300 through bus 1
.ne
3 4-AC200/220 ON
1
I
1
+ NC power is turned on.
I 1
1
1
Normal operation
1
NC power is turned off.
Wait for turning on NC power
Initial data communica-
tion with NC (momentary
display)
Initial data communication
complete
Wait for "ready ON".
Wait for turning on NC
Alarm code is
displayed in
case of failure.
- 13 -

(2) For FR-SFJ not connected to M300
I_ 3 #-A C200~220 0 N
1
1
Normal operation
1
Power is turned off.
Alarm code is
displayed in
case of failure.
- 14 -

3.3 FR-SFJ status display and parameter settings
c
c
Operation status is displayed by the 7-segment LED readout
on card SFJ-CA1 and parameters can be set by DIP switches.
Status display and parameter settings depend on ROM version
of card SFJ-CA1 card.
For ROM version A@ . . . . .
(A) 3. 3. 1
For ROM version BO and thereafter . . . . (B) 3. 3. 1
When FR-SFJ is connected to M300 CNC through bus line, sta-
tus can be displayed and parameter can be set on the NC CRT.
(For details,
refer to 3.5.)
DIP switch settings and functions
Since DIP switch settings must be changed only when test op-
eration is required, they should not be changed during normal
operation.
Mode
DIP switch setting
Function
/ (0:
Set position)
1 I
1 j
i Normal operation
; g@$ !
I ,
I
I_i_ _--_._ -.._- _-._._... .__!_-_-_-_- ._-_.._ -_ __.__-__ ___. ___ _. __ _
2 i
1 2 3
[ Spindle parameters displayed by NC
/ CRT are ignored.
,
ON !o/
I
I
;
I ,-
j ‘A j c ]
When FR-SFJ is connected to M300 CNC,
the spindle parameters set and dis-
I
I
played on the CNC side are ignored
!
and the parameters set on the FR-SFJ
side are used.
I
!
-.--. .--__ _.. ._ _. . ._
3 !
1 2 3
I Setting prohibited (for manufacturer's
1 test operation)
_._._
4
__ __-
-~_--.-. -.- ._-_--_ .._ &_ _.... -.
1
2 3
Setting prohibited (for manufacturer's
c
- 15 -

M
-
-
-
-
ode
DIP switch setting
(
3: Set position)
Function
1 2 3
6
1 2 3
7
I 1
ON; ,
i3lC!
I’
v!
I’JI ’
j j
Initialization of parameters
The standard values (manufacturer's)
are set for all parameters.
User should not use this setting.
9
4
Meter test mode
c
931
Speed meter/load meter output
I
;
(for ROM versions after BO)
- 16 -

3.3.1 (A)
Status display and parameter setting for ROM version 1
(1) Readout and switches
I
I
I
I I
I
I
L ADRESSJ
- D A T .A-
clr13~ 4n
!dODE
Ii P DOWN SET
"Motor speed", "alar::"
and
"parameter seLting"
are displayed.
I-
1
Display
MODE:
Display mode can c?
selected between
ADDRESS and DATA.
UP
: Value displayed in
ADDRESS and DATA
can be incremented.
DOWN: Value displayed in
ADDRESS and DATA
can be decremented.
SET :
Data set for para-
meter can be stcred.
1) The display modes include "motor speed" display, "alarm"
display, and "parameter setting", as described in Table
2) After turning on the power, "motor speed" is displayed
unless alarm occurs.
3) In case of alarm, alarm code is displayed.
c
c
c
Table 1
Display modes and information for ROM version I'.\ I'
Display mode
Display example and information
Motor speed
o Motor speed (rpm) is dispiay-
display
mi
ed in DATA section with 4-
digit numerals.
ADD DAT.A'
o Display in ADD section is in-
significant.
oIn this example, motor speed
is 5,OOOrpm.
Alarm dis-
o In case of alarm, alarm No.
play
\
/
\/
and alarm code are displayed
'RI;-! ~ ‘,:I 31 .
in DATA section with 2-digit
J/L ~numerals (for details, refer
1,-
L
to APPENDIX 1).
/
\
/
\
o Display in ADD section is in-
They flicker.
significant.
o This example shows occurrence
of
"excess error".
- 17 -