mitsubishi FR-SD Maintenance Manual

L-

USA-E99991-070-*

P

a

BCN-21374-52

1

!

r

SPINDLE DRIVE CONTROLLER

TYPE

FR-SD

MAINTENANCE MANUAL

c

‘leu

Translated from

r

publication effective July, 1982

Jananese

manual RCN

21.17641

CONTENTS

I-

-

CHAPTER I

1.1

1.2

1.3

CHAPTER II

2.1

2.2 AC Spindle Controller

2.3

CHAPTER

3.1

3.2 Turning on the power source

3.3

Scope of Maintenance Manual

Safety Provisions and Maintenance Personnel

Storage

AC Spindle Motor

Spindle Controller Composition

III

Preparation for Operation

Adjustment

GENERAL

SPECIFICATIONS

OPERATION AND ADJUSTMENT

. . . . .

9 9 9

10

3.4 Initial Operation

CHAPTER IV

4.1

4.2 Checking the Motor

CHAPTER V

5.1

5.2

5.3

5.4

CHAPTER VI

6.1 General

6.2 Checking before Regular Troubleshooting

Checkin&

Main Control Card FRS-SA2

Control Card FRS-GBl

Snubber Card FRS-SN

Optional Card

PERIODIC MAINTENANCE

the Controller Unit

CARD CHECKING AND ADJUSTMENT

TROUBLESHOOTING

. . . . .

11

12

15

15 16

17 18

18

19

c

-

l/2 -

6.3

I-

Indicator Lamp List

. . . . .

20

6.4

Typical Troubles

-6.5

Troubleshooting Practice for Each Trouble

CHAPTER VII

7.1

7.2

7.3

7.4

7.5

7.6

7.7

CHAPTER

8.1

Replacement of Each Control Card

Thyristor Module and Transistor Module

Diode

DCCT

Brushless

Cooling Fan

Bearing

TYPE FR-SD-2

.

11X

COMPONENT REPLACEMENT

Tacho-generator and Coupling

PARTS LIST

. . . . .

......

22

23

36 36 38

39

42

4.5

45

8.2

TYPE FR-SD-2A

8.3

TYPE FR-SD-2B

8.4

TYPE FR-SD-2T

......

50

56

61

- 2/2 -

CHAPTER I

I

GENERAL

1.1

1.2

Scope of

FR-SD Series is a line of regenerative type inverters used to

drive a machine tool spindle on the AC power source.

IhisMaint

to perform the periodic maintenance and troubleshooting.

To assure long life and trustworthy operation of the FR-SD

inverter, read the manual carefully and practice the periodic

maintenance and troubleshooting.

Safety Provisions and Maintenance Personnel

In order to assure safety in maintenance and adjustment,

the following cautions are very important.

-

Start-up,

,Maintenance

enance

Manual mainly describes the information necessary

maintenance and checking should be performed

Manual

.

c

by qualified electrician. Note that it is very hazard-

ous that unqualified persons handle the unit.

-

Remove ring, wrist watch, tie tack, and other metallic

objects from the body when the unit under live condition

4

a

is handled.

-

Electric shock is very dangerous, and may result in fatal

accident.

Carefully select and use testing apparatus because some

parts of the unit are at high voltage no matter whether

the power source is grounded or not.

When test appartus is applied to the unit,

should take care not to touch any grounded

testing person

object.

-l-

_

-

Usually, for high voltage is produced between the testing apparatus

case and the ground during the testing.

-

Do not wear loose working wears that may be involved into

a rotating body of the machine when you gains access to

the working machine in maintenance or setting up.

-

Do not load or unload a PC board (card) while the unit is

fed with the power source, or in operation, otherwise the

unit may be damaged.

-

Immediately after the power source is turned off, do not

testing apparatus case is not grounded and there-

1.3

touch the unit,

time taken for discharge of capacitor) and then start

the maintenance or adjustment.

Storage

When the unit is not immediately installed nor used, store

it in a clean, Since vapor and dust in the unit cause deterioration to the

insulated parts of the unit,

and dust.

When the unit is left out of use for any length of time, ma-

intain the unit under the ambient conditions same as those

while the unit is in operation.

but wait for at least one minute

dry environment at moderate temperature.

keep the unit away from vapor

It is recommended in

(

same

cases to use a space heater in the room where the unit

stored.

- 2-

is

CHAPTER II

SPECIFICATIONS

2.1

$

g-4

2:

30 min. rating

@a g:

50% ED rating

-0

(RPM)

: ’

$

Max. speed

Frame No.

Rated torque

GD2

Weight

Allowable radial load

AC Spindle Motor

Standard Specifications

Continuous rating

Basic speed

(cont. rating) (kg-m)

(kg.m')

(kW) (kW) 5.5

(kWY

(RPM)

All2

0.08 0.12 0.22 0.25 0.35

(kg)

,70

150

3.7 5.5 7.5

5.5

2.4

7.5

1500

Note

6000

B112 ~132

3.57 4.87 7.15 9.74

80 110 120 140

200 300

11

1

11

15

15 18.5

15

18.5

1500

4500

c132

Cooling fan

Vibration

Noise level

Installation Vertical or horizontal

Overload capacity

f-

c

Ambient temperature Insulation class

Paint color Munsell N5.5

Accessories

Standard applied JIS C4004

Controller

Model: FR-SD-2-

Power capacity

Power supply

b

Note 1:For speeds over

(W)

(dB)(A)

(OC)

(kVA)

75

120% of 30min. rating, for lmin.

Brushless tacho-generator, overheat

detector

5.5K 7.5K

9 12

200/200- 230vi10%,

4,5OORPM,

the output is equal to the following

0 F

40

75

VlO

11K

17 23 28

15K

50/60H~+3%

80

18.5K

c

-3-

calculation result:

Rated output

x

4500

Speed RPM

Note 2:

When the line power source other than specified above is employed, use a suitable power

transformer.

.-

-4-

Standard Specifications (2)

Adapt the following specifications (basic speed: 1,lSOPRM) when a large gear reduction ratio is not available.

xContinuous

Q.f:

2:

30min. rating

rating

(kW) (kW)

c, a' 2:

50% ED rating

z

'Basic speed

8

Max. speed

-1

(kW)

(RPM)

Frame No.

Rated torque

(cont.

CD2

Weight

rating)

(kg-m)

(kg.m')

(kg)

Allowable radial load

Cooling fan

(W)

Vibration

Noise level

(dB)(A)

1

(kg)

1

3.7

5.5

B112

3.13

0.12

80

)

200 1

5.5

7.5

1,150

4,600

4.66

0.22

110 120

75

VlO

75

B132

7.5 11

11

6.35

0.25

300

11

15

Cl32

9.32

0.35 140

80

15

18.5

B160

12.7

0.65

220

I 2oo I

I

I I

I

Installation

Overload capacity

Ambient temperature

Insulation class

Paint color

Accessories

(OC)

Vertical or horizontal

I

120% of 30min. rating, for

I

o-

)

I

Munsell

40

F

N5.5

Brushless tacho-generator, overheat detector

I

lmin.

I I

Controller

f

Model:

Power

Power supply

FR-SD-2-

consumption

(kVA)

5.5K

9

7. SK

12 17

11K

200/200-23OV+lO%,

15K

23

50/60Hz_+3%

18.5K

28

-5-

2.2 AC Spindle Speed Controller

Specifications

Model

FR-SD-2-

Output capacity

I

"Output

il

cl

!Z

Power source capacity

I

z

Heat value

I

Weight

Main circuit

Control method

Braking method

Speed control range

Speed regulation

Speed control command

signal voltage

current

(kW)

(kVA)

(kg)

(A)

(WI

Pulsewidth modulation Slip control (Optimized V/F pattern con-

trol)

Regenerative braking

35 -

Below 0.2% of the max. speed (at load regulation ranging form 10 to 100%)

*lOV

6000 RPM

DC (Input impedance:

(PWM)

inverter

10Kohm)

Acceleration/deceleration control (Time constant at

Ambient temperature/

humidity

Environmental require- ments

Vibration

Standard applied

Cooling Air-cooling by fan

Slip regulation

-5

To be free from detrimental gas and dust

(JEM 1103, Grade

below 0.5G

I

IEC

I

-6-

50°C/below 85%

-

accel./decel.:0.5-10sec.

C)

Auxiliary functions

Function

(Signal)

Load meter siganl

Speed meter signal Speed meter

Zero speed signal

Speed arrival signal

Speed detect siganl

Application

Load meter

Interlock

Feedback to

NC equipment

Mechanical brake opera- tion

Clutch shifting

_

Remarks

Connected to single-swing

DC ammeter

Full scale: 150% of rated

load (adjustable within a range from 100% to 150%)

Connected to single-swing DC ammeter

Full scale: Max. speed

Contacts open when motor speed goes down below

SO*lOrpm.

Contacts close when speed is within *15% of the preset speed.

Contacts close if motor speed goes down below

500 rpm (adjustable from 50

to

ll!jOrpm).

Load detect

signal

Override

Prevention of stabbing of

too1

Override in

automatic eration

op-

Contacts close if slippage reaches near slip limit value (120% of output)

Can be set within a range from 50% to 120%.

Override can be reset by opening the circuit connected to controller terminals

"DEF"

c

-

7

-

2.3

I

Speed Controller Composition

The speed controller unit mainly consists of the following

seven components:

(1) Front panel

(2) Main control card, FRS-SA2

(3)

Control card,

(4)

Orient card, DL-FM (Option)

(5)

Snubber card, FRS-SN

(6) Converter

(7) Inverter

FRS-SA2 card

FRS-GBl

-

Converter partsc

I\

- 8 -

_

CHAPTER

I

ICI

OPERATION AND ADJUSTMENT

3.1

Preparation for Operation

When the controller is fed with the power source for the

first time,

power switch.

the

(1)

(2)

(3)

t.4 1

Is the wiring in conformity with the corresponding

wiring diagram?

Are the motor and control panel properly grounded?

Are all shielding wires properly connected?

-

Are they correctly connected to shielding wire ter-

minals?

-

Are shielding brades not looped?

Are all parts not

perform the following checking before turning on

damaged,

and securely fastened?

(5)

(6)

3.2

Turning on the power source

When the checking has been completed,

to the controller unit as follows:

(1)

(2)

(3)

Is there any wire

Do all PC boards

Set the breaker

Set the source frequency select switch

the front panel to the frequency of the available power

source.

Turn on the incoming power source and make sure the lamp

IPHASE SEQUENCE1

interchange the connection bewteen the two wires.

chip or foreign matter in the unit?

(

cards) present good appearance?

apply the power source

(CBl)

in the controller to OFF.

-FREQf

lights. If the lamp does not light,

on

-9-

(4)

Make sure no alarm lamp on the controller front panel

(5)

Set the breaker

Now the controller unit is ready for opration.

3.3

Adjustment

Although all potentiometers have been factory-adjusted,

readjust them to correct error that may be caused by connec-

tion with peripheral equipment.

lights.

(CBl)

in the controller unit to ON.

__

*Slip adjustment

%Speed

meter adjustment . . . . . . .

+Load meter adjustment

3.4 Initial operation

After directly connecting the controller unit to the motor,

start the initial operation for accommodation of the control-

ler system

If hunting

and verification of the operation.

or overshoot of motor speed occurs, adjust as

follows:

<IHunting

-%Overshoot

. . . . . . . . . . . .

. . . . . . . . . . .

. . . . . . . ..a....

VR7

VR6

. . . . . . .

VR3

Somewhat turn VR2 counter-clockwise.

Somewhat turn SW2 clockwise.

Then apply a load to the motor and start the regular opera-

tion to check the following:

-

Unusual sound

-

Foreign smell

-

Temperature rise on bearings

-

10

-

CHAPTER IV

Because it is imperative for long-lasting, trouble free operation

of the controller unit to perform trustworthy checking, be sure

to practice the periodic maintenance as follows:

PERIODIC MAINTENANCE

Warning:

Electric

shock may result in serious accident or death. Before starting the maintenance, do not fail to make sure the entire control system has been disconnected from the

line power source.

4.1 Checking the controller unit

,

r

Item Frequency

1.

Cooling fan Monthly

c

Checking

(1)

(2) Does the fan power-

(2) Does unusual sound

an the fan shaft Replace the

C

smoothly be turned by hand?

fully rotate?

not occur in bearings?

Remedy

fan.

c

a

2. Cleanliness and loosen- ble inter- retighten terminal screws and other ess of

screws

3.

Miniature

relay

At suita- Periodically clean each part and

val

Every months

3

clamping screws and nuts.

(1)

Are contacts not

worn out?

(2) Does the relay per-

mit the main circuit contactor to close and open sat-

isfactorily?

-

11

-

Replace the

relay.

Item

Frequency

Checking Remedy

4.

Wiring

4.2 Checking the motor

1.

Item

Noise,

vibra-

tion

Frequency Checking

At suita- ble inter- val

Monthly

Is any wire conductor in contact with the case or other metallic part?

I

Check if unusal sound or vib-

ration occurs.

If yes, checking:

(1) Are foundation and instal-

(2) Are the shafts accurately

perform the following

lation proper?

aligned?

Remedy

(3)

Is vibration not transmit-

ted from the coupled machine or device (load)?

(4)

Is bearing not damaged?

Is unusual sound not caused by bearing?

(5)

Is unusual vibration or

noise not caused by speed reduction gear, belt, or transmission system?

(6)

Is there any trouble asso-

ciated with controller unit?

(7)

Is there any trouble asso-

ciated with fan?

(8)

Check belt tension.

-

12

-

Item

Frequency

Checking

Remedy

Tempera- Monthly

2. ture usual? rise

c

Is temperature on bearings

(Usual temperature:

40°C over ambient tempera-

ture)

Is motor frame temperature usual?

If not,

ing checking:

(1) Is cooling fan running

(2) Is cooling air stream

(3) Does load not abruptly

perform the follow-

as usual?

not obstructed by foreign matter (between frame and cover)?

+lO°C -

Clean.

increase?

(4) Is there any trouble

with the controller?

3. Insula- Every 6 Check if insulation resist-

tion months resist-

ante

ante unusally decreases.

To check, motor from the controller and measure resistance across the entire circuit and the ground using a megger. (R be over

If the resistance is below

1

Mohm,

disconnect the

SOOV

esistance should

1Mohm)

clean the motor in-

Refer to

TROUBLESHOOTING.

terior and dry. (To dry the

-

13

-

Item

I

Frequency

Checking

Remedy

4. Cooling

fan

Weekly Monthly

motor, place it in a drying

oven at a temperature

below Check if cooling fan runs

properly, sound or vibration occurs.

disassemble and

90°C.

and if unusal

I

-

14

-

CHAPTER V

CARD CHECKING AND ADJUSTMENT

t125 tip.

(

I1

53

t153

Note:

5.1

Main Control Card FSR-SA2

CHl

CH2

CH3

CH4

CH5

low. pin

up. pin

CH7

All

control cards are factory-adjusted at shipping. User should not change the settings of variable resistors used in the cards.

Fig. 5.1 shows the main control card FRS-SA2.

, lines shown in

measured at

I=]

I]

is shown in

and

r-1

are insulated.

II,

and that measured at

In the figure

Wave form

4

Cbr,r,,t

i3

detect

-l2sv/roo%

frequency

output

m

current

1

c

a-

c

CH31, 32,

ä

Reference sine

wave

--sv~

CH41

'

Transistor base

CHlG

. . . . .

CHl9

CH26

33

siganl

output

frequency

_ 46

signal

. . . . .TG feedback:

. . . . .

1

Fig. 5.1 Card FRS-SA2

Current detect signal:

+lOV/CII

Speed command signal: -lOV/CW max. speed,

-2.5V/lOO%

max. speed, -lOV/C.CW max. speed

current

+lOV/C.CW

CH12

max. speed

-

15

-

5.2 Control Card

Voltage wave form measured at each common of the card FRS-GBl

FRS-GBl

CHl&CHl9

warning:

The terminal board circuit voltage.

tric

shock.

TB102

Carefully handle it avoiding

of this card is at the main

elec-

CIll CH3 cn4

CHS

CH6

Modulation pulse

*

Both ends of R130,

134,

135, 136, 140,

hz-L!V

-0

- Ia-w

TB102-

This its wa on

ignal is for driving the main transistor and

s

ve form is not measuredat

eat

h both sides of R 130, 134, 135, 136, 140 and

Fig. 5.2 Card

FRS-GBl

NOl,

but

measured

'CH22

y-1

+2.5V/DC220V

\

,cHll

/

;yJ;er,voltage

-5V/DC220V

141.

1

-

16

-

5.3 Snubber Card FRS-SN

This card has the snubber circuit with thyristor on the con-

verter side,

Warning:

The terminals of this card areatthe main circuit voltage. Carefully handle the card avoiding electric shock.

5.4 Optional Cards

Optional cards are available for special specification.

For details of optional cards,

ruction manual.

Orient Card, DL-FM . . . . .

1)

2) Orient Card, DL-AE

and requires no adjustment.

refer to the respective inst-

BCN-21374-S2

. . . . .

BCN-18564-S2

c

-

17

-

CHAMPTER VI TROUBLESHOOTING

6.1

General

If any trouble occurs with the controller unit, it is re-

commended to perform the preliminary checking instructed

below before the regular troubleshooting.

The preliminary checking will be very helpful when you con-

sult manufacturer's service personnel.

Preliminary checking in case of trouble

1.

Does any alarm lamp that indicates occurrence of trouble

light? If yes,

2.

Is any fuse brown out?

Is recurrence of the same trouble possible?

3.

Are ambient and unit interior temperatures proper?

4.

Does the trouble occur during acceleration, or decelera-

5*

tion,

What is the speed when the trouble occurs?

6.

Is there any difference between CW operation and C.CW op-

eration?

Did momentary power interruption not occur?

7.

8.

Does the same trouble occurs under a specific operation

or command?

or steady state operation?

identify the lamp.

If yes, identify the fuse.

9.

10.

11.

What is the frequency on that trouble? (Does the same

trouble occur frequently or rarely?)

Did the trouble occur when load is engaged, or disengaged?

Has any unit part been replaced or remedied before the

the touble?

-

18

-

mitsubishi FR-SD Maintenance Manual

Specifications and Main Features

Frequently Asked Questions

User Manual