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MT KONG ROSIE 7 Yar wines, 2. RAMICIENO I 72 9 av iRteehlcF— Siew TR IPL V ALERT B.ORT: FU TIF — yay, PE MMMM ATL a—ape, MOR MTR TE ES Yat be:Foreword This manual describes instructions as mentioned in the contents. For other items, when the drive unit is incorporated in a machine, follow the instructions of the machine. And when you purchased yaur drive unit and motor separately, be sure lo read the AC spindle motor manual and FRENICS000M3 technical manual together. Only proper use leads 10 full performance as expected. Wrong handling will cause malfunction, short service life, and faults. CONTENTS 1. Safely precautions 26 2. Receiving a7 3. Drive unit Views, 28 4. Checking and Setting of Operation Data 30 4-1 Functions of Digital Display and Push-button Swilches, 30 4-2 Function Selection and Operation Data Checking 31 4-3 Operation Data Setting 33 5, Maintenance and Inspection : 35 5-1 Precautions in Maintenance and Inspection 35 52. Daily Inspection 35 5-3 Periotical Inspection 35 5-4 Periodical Replacement of Parts 35 55 Meggering, 36 5-6 Main-Circuit DC Voltage Measurement 37 6. Troubleshooting 38 61 Protection Functions: 38 62. Display and Retrieval of Fault Contents 39 3 Retrieval af Fault Data 40 64 Diagnosis and Steps al Faull 4 7. Inspection List 4a 8. Standard Specifications 45 9. Block Diagram and Terminals .... 48 10. Function Table 47 1. Safety Precautions WARNING: Improper lifting practices can cause serious oF fatal injury. Lit only with adequate equipment and trained personel. Particular care must be taken to carry the unit by holding the main body, because holding the side covers or parts can cause damage or dropping. Wrong connection can result in the damage of the drive unit or personal injury. Connections must follow the instructions of the machine. Connect a molded-case circuit breaker (MCCB) on the power supply side to protect the unit from damage caused by power switching, overload on conductors, and a short-circuit current. If there is a fear of fault expansion or disaster occurrence such as fire, open the MCCB. immediately to stop power supply. Bo sure to ground the earth terminal E(@) for safety’s sake and to suppress radio noise. Do not service the equipment when power Is applied since this could result in electrical shock or burn. When you can not avoid live-wire work, for example, in the measurement of main-circult electric quantities, be fully careful with your work in addition to safety measures such as grounding of measuring instruments. It takes time for the smoothing capacitor to discharge after the power is turned off. Fot the sake of safoty, do not start work before you make sure with a tester of the like that the main-circuit DC voltage has dropped to a safe voltage after the charge lamp went out. When power supply to the drive unit is recovered from power cutting or power failure and when a protection function in operation is canceled by the RST switch, the drive unit can start outputting to restart the motor as long as the forward or reverse command remains ON. Sufficient care must be taken against danger when using a machine incorporating such connection. A cover is not provided in the front of this drive unit; therefore, be careful enough not to touch the live part. An optional front cover made of transparent acrylic resin Is available. You are recommended to buy and install it to prevent danger. Since the surface temperature of a braking resistor rises when a current flows in it, a cover or the like must be provided around it to prevent a human body from touching directly. CAUTION Never apply voltage exceeding the standard specifications. Excessive voltage will damage the drive unit. Environmental conditions for installation and transport must satisty the standard specifications. They have a great effect on performance end life. Explosion or fires may result from mounting the drive unit in hazardous area such as locations where inflammable or combustible vapor or dusts are present. The drive unit must be installed away from hazardous areas even if used with AC motors suitable for use in such locations. Meggering, if applied improperly, can damage the electronic components. Follow the instructions in 5-5 Meggering. When a drive unit protection function operates, examine the fault status following 6-2 Display and Retrieval of Fault Contents and 6-3 Retrieval of Fault Data, You are recommended to record this, data to make good use of it in the future maintenance and inspection of the system.TT FEE EEE eee oor 2. Receiving 8. Drive unit Views (1) Drive unit type: FRNOO1M3-21, FRNOO2M3-21, FRNOOSMS-21 WARNING Improper lifting practices can cause serious or fatal injury. Lift only with adequate equipment Frame (Cooling fin) Rectle diode and traind personel. Particular care must be taken to carry the unit by holding the main body, because holding the side covers or parts can cause damage or dropping. Mag. contactor (1) Drive units Check the description of the nameplates on the side covers fo see thal the delivered drive unit agrees ‘Smoothing capacitor with your order. Side cover (a) Right side contol PCB case cup Drive ui type 0 SR ees = Rated input AC voltage and U Control PCB 2o0e200=2a0\_ n/n QUAY 8 Sea tw anenceanse— |"! Connector or ntnaly connocted “SERAL— | SuSA32)R9n7=6H Moor rated output sg Full Electic Could saa wiring Manufacturers serial number INamertat| Fig. 2-1 Nameplate Ts 3 ° Drive unit type code designation RW 00s Ma 24 Ul CHARGE lamp Product type: FRENICS000 (b) Lett side Motor output (50%ED) | O01: 1.1 KW, 02:22 KW, 009: 3.7 KW, Contra PCB 005: 55kW, 0077.5 KW, O11: 11 KW, aaa Toraue smeplete caleuiating CPU 015: 15 kW, On SS KW, 018: 18.5 kW, 022: 22 kW, : Control CPU 030: 90 KW, 037 = 37 KW Digtal display Series name : Digital AC spindle drive system L acebaien Supply vollage 2: 200 V OH swiches Model No.: 1 Fig. 2-2 Nameplate position Connector (2) Accessories Control circuit ‘The standard accessories are a braking resistor(s) and a connector. Check the nameplates or the © @ ‘erie lypes marked on the product surlace with the Table 2-1 to make sure thal they match the drive unit you [sie citcut ordered Table 2-1 List of drive unit accessories: ' Tem Speciation Conirlciteuit terminals i Moir soneo | 11 | 22 | 37 | 55 | 758 | 1 | 15 | 5 | 2 | 30 | 37 Connector out tim) [oon [07 [is | 22 | a7 | 55 | 75 | 1 | 1 | 105 | 22 | co ictee ase Drive unit type FRNOD1 | FRNOO2 | FRNOOS| FRNOOS | FRNOO7 |FRNOT 1 | FRNO15 |FRNO1A | FRNOZ2 | FRNOSO| FRNOS7 ive unt yp maar | waar | Maat | Maar | wo-21 | wa-21 | wa-21 | wa-21 | 3-21 | wot | moot Contre! C8 ype | 08001 | Daoa2 | DBo08 | DBO0s | DBOVT | DBOTT | DO'S | DBOTE | DBO | DB0I0 | DB0I7 Braking [pe | gt | meat | Near | Nezt | Maer | wazi | Mazt | Mat | Mat | Maar | Meat | — Side cover low. a Le 2 ES RE Tel) 3 1 1 1 1 Main circuit terminals Connector ype, ay. [MRGALF (HONDA TSUSHIN KOGYO CO., LTD), 1 pe. Braking transistor Examine the articles for no damage due to transport such as a break, falling off of parts, and @ dent on the enclosure, Hf you find a doubtful or defective point, inform the agent you bought them. Peer menmiter (arate Cooling tn (Frame) Side cover Mounting adapter. < External cooling type > bow adapter f Nameplate Mounting adapter 4, Checking and Setting of Operation Data touch the live part. WARNING A cover Is not provided in the front of this drive unit; therefore, be careful enough not to Before pulling the drive system in operation, make sure thal data for parameters agree with the machine indications. Sel correct dala to parameters of which setting diflers from the indications. You can check or set dala with the digital display on the control printed circuit board (PCB) and the push-button switches. 4-1 Functions of Digital Display and Push-button Switches igital display Indicates a function code or selling’ operation data shown in the Function Table on pp.47, 48. ‘Mode switch + Selects an indication mode of function codes or setting! operation data ‘ON: Function codes OFF: Setting/operation data + This switch, when combined with UP or DOWN switch, gives function codes. To be switched on to input data ‘sel in the RAM into the memory {to update parameter data. Fo. |pispiy] £2 | oispiay ° e a a 1 t 8 5 2}elfe|e a{3]o]e¢ 4 y E & s|s|r |e [eae a eee ec 7 a L ‘ s|a|lolae ied |e | Ee pe Shilts a figure or code of setting/ vane} o Ju |e isplay dala as ilustraled below: nace] = | v |e ead oe Sy. [SET switch Ndapeb ST switch ‘In parameter mode To be switched on to change data indication into operation mode function indication. + In fault mode To be switched on to cancel operation after fault restoration. drive unit protection function in * LEDI shifts in order as above when LEDO shifts from F100: LED2, when LED shilts from F tod; and LEDS, when LED? shifts from F to 8. + Figures and cocies that are not designated to drive unit functions are skipped. * Data seiting is limited by the Upper limit of setting range. *Seiting of code 0 DOWN switch Shifts a figure or code of setting/ display data as illustrated below: Sbapab? + LED! shifts in order as above when LEDO shifts from 10 £: LED2, when LED1 shifts from 0 F; and LEDS, when LED2 shifts from 2 t0 F, + Figures and codes that are not designated to drive unit functions are skipped. * Data setting is limited by the upper limit of setting range. * Setting of code. =4-2 Function Selection and Operation Data Checking When power is supplied to the drive unit, the CPU FWDIREV/STOP Frequency command OFF adjust. pot. rev setal 0 a ee wes Til Hh Power. display wal 2a (a) Standby | woe LR Power. illuminates. LJolAlc} is (b) Power on so ae wee TLR ae * ssf} "is | Gn) } O° | (©) Ready for selection | wo rev va wes LL OW Dt iz Indicates prove asi aged ce 08 | {d) Selection start Fig. 4-1. Preparation for function selection on the control PCB starts reading intemal data, It takes about 2 seconds and the digital display indicates LaAld. After 2 seconds, the display indicates an output frequency value (displays 0.0 during stoppage). The CHARGE lamp (LD1) on the same PCB illuminates, Now operation for selecting a function can be started, © The digital display always indicates output frequency of the drive unit Example: Output frequency is 0 during stoppage; indication is 0.0. @ Switch on the MODE, and the aigital display indicates the function code of daia being indicated, Example: When an output frequency value is indicated, function code C21 for output frequency is indicated. Switch off the MODE when you do not select another function, ‘The display indicates a function code for about 5 seconds after the MODE is switched on, and after that, i automatically indicates data (an output frequency value), When the MODE is switched off after an on- slate exceeds § seconds, data is indicated immediately @ When you select another function, switch on the UP or DOWN while keeping the MODE on. e Selecting order of functions + MODE + UP ‘A function is selected in the downward order of the functions described in the Function Table. F009 folowed by £00! + MODE + DOWN A function is seleéted in the upward order of the functions described in the Function Table. £881 is folowed by F25 + The fault mode F80! to FEES can be selected only when a drive unit protection function operates. NOTE Note that when POOP: set data protection is set at ~ (data setting abled), if you switch on UP or DOWN before MODE while a parameter ‘mode function is indicated, the set daa will be changed. This step is the same as the ‘operation in Section 4-3 (page 33) Digital display Aya uu] + MODE at @ Yes From p. 33, 34 TInIAIy Hala a ‘Selected code, Function P code F code passed No function Yes change aller MODE, > — seling Yes ToP. 34 No Back fo C code. function preceding current P code ® Yes W Tor. 33 ® When the display indicates a selected function code, switch off UP or DOWN, and then MODE. The displayindicates the data of the selected function Example: Shows that the maximum frequency has been set 10 100.0 Haz, NOTE Note that when 20°: set data protection is set at - (daia set abled), if you switeh off MODE before UP or DOWN while @ parameter mode function is solected, the set data wil be changed. This step is the same as the operation in Section 4-3 (page 33). Data indication time differs according to @ salocted function code + When an operation mode (C cade) {function is selected, the display continues {o indicate the data till another function is selected, + When a parameter mode (P code) function ora faull mode (F code) function is selected, the display indicates the selected function data about 5 seconds aller MODE is switched off, I automaticaly shifts to an output frequency value in 6 seconds. @ For the setting or changing of a parameter mode function data, reler to Section 4-3 (page 33). © While parameter mode (P code) function data is indicated, the operation mode (C code) function that had monitored before this P code function was selected can be selected by the following operation.® Switch on the AST while P code function data is indicated (about 5 seconds). The display indicates the C code function that had monitored before the P code function was 7] selected Ho Note that while a function code (P code) is indicated, RST ES e3! { switching can not shift indication to a C code function. @ Ma Example: Before a P code function was selected, COD'! CS output voltage set value had monitored. T D When the RST is switched otf, the C code function data is sos indicated. Even ifthe RST is kept on, the display will shift Cjo|e {0 data indication after certain seconds. The dala indication continues fll a next function is selected, Example: The output voltage set value is 220 V. No. (es QD) om 4-3 Operation Data Setting © Stop the drive unit culput. During operation, data can be set to certain functions, but not to almost all the functions, For details, refer to the Function Table (pages 47 and 48). @ Select the PA9P: protection of set data, and check for protection active or inactive. Data indication - : Data setting abled. a : Data setting disabled. When - is indicated, you can set data. When a is indicated, change the indication to - following the instructions below and then set data, ® Select a required function following the steps in Section 4-2, and get data on display. @® Switch on UP or DOWN to change data on the digital display. Adjust excess or deficiency to a setting value by repeating ON/OFF of UP or DOWN. Example: The maximum frequency setting value is 125 Hz NOTES The drive unit will be operated by data inaicated on the digital display even if you fail to switch on the SET. It is designed to be operated by input data in the RAM. The SET is lo be switched on to update the memory. Methods of returning data on display to the previous one (stored in the memory) are as follows: @ To retum data to the previous one by switching on the UP or OWN. © To turn off the power once. © To select and set P228: resetting standard setting data. Note that this fonetion retums data to the one set by the drive unit factory before shipping (See the List of Functions). Jn the case that you purchased your drive combined with a machine, follow the instructions of the machine, ve SO 7 ! ® w SO i i own Oz TG ]q] daa Tickers 7 i <>, Yes Spas attr UP) > own OF 's data set ting over? select A223 NOTE When you selected a function that does not allow setting or changing data, itis not possible to change data on the digital display by switching on the UP or DOWN. The drive unit can not be subjected to a trouble by this operation. @ The display indicates data about 5 seconds after the UP or DOWN is switched off. The data tickers, Switch on the SET to update the memory. The display automatically shifts to aulput frequency value in 5 seconds. To update the memary after output frequency is on cisplay, select the function code again, check the data and switch an the SET within 5 seconds. © When selting more than one data, you can use the P229: blanket. parameter setting, to dispense with selling each for a function. You can select and sel the F229 al any time uring a data setting process, and can sel the whole dala thal were set around the time of F229 setting at a time by switching on the SET as ‘mentioned in, @ When you switch on the SET, the indication on the digital display goes ‘out and memory updating starts, Then switch off the SET. i in a ea aac ore ® TPEE ee i a (Memory updated) 7 IG] outa a) oi NOTE The switching off of ihe SET alter output frequency value appeared will have no effect on the drive writ and motor; however, make a rule of switching i off when the indication goss out. ® When the memory is updated, the set dala is indicated again. In about 5 seconds, an output frequency value will be indicated. @® To make setting each for a function without setting the A228, repeat the sleps to this point for each.5. Maintenance and Inspection WARNING Do not service the equipment when power is applied since this could result in electrical shock or burn. When you can not avoid live-wire work, for example, in the measurement of ‘main-circult electric quantities, be fully careful with your work in addition to safety measures such as grounding of measuring instruments, The drive unit is composed of many parts and it can nol bring its performance into full play unless those aris operate properly, Proper maintenace and inspection is necessary in order to prevent drive unit trouble from occurring and to continue its reliable operation for a long lime. For the inspection items and methods, see Section 7. Inspection List on page 44 5-1 Precautions in Maintenance and Inspection WARNINGS Turn off the power without fail before you will touch the drive unit. Make the worker himself check the power ON/OFF and forbid power operation by others who are not in charge. The smoothing capacitor remains charged for some time after the power is turned off, Start ‘work after CHARGE lamp LD1 on the control PCB is off and the main-circuit DC voltage measured with a tester is as low as safe voltage. CAUTION Hold the housing, not the cable, to pull out the connectors. Be careful not to insert them into wrong positions. 5-2 Daily Inspection © The fundamentals of daily inspection is to check for abnormal noise, unusual smell or visual abnormally from outside during operation. ® When you find an abnormality, investigate the location and extent immediately @ Check the contents of the abnormalily and judge whether operation can be continued of nol. I nat, stop the equipment immediately and remove the cause of the abnormality. 5-8 Periodical Inspection Turn off the power. Check the places thal can be inspected only when aperation is sloped, and check places and parts thal require periodical inspection. If you find an abnormal place or part, remave the cause of the abnormality or replace the part 5-4 Periodical Replacement of Parts Though the service life of drive unit parts depends an the working environment and operation time of the unit, the life expectancy of electrolytic capacitors is about 5 years and thal af cooling fans, about 3 years when they are operated continuously within the allowable limits of the standard specificalions. You are recommended particularly to replace these paris belare a trouble occurs. © 5-5 Meggering CAUTION Carry out meggering in accordance with the following instructions. Note that wrong application may cause drive unit damage. (1) Main circuits Use a 250 V DC meager. Do not use a 500 V OC megger because a leakage current due to the vollage characleristics of the surge suppressor connected on the power supply side may cause incorrect indications. ® Remove the external connections from all the drive unit terminals (including control circuit terminals). Connect all the main circuit terminals Contro! PCB Conta Ereut {ermnais Connector fish Hee VAM with a common wire as shown in Fig. 5-1 = Iwfelolel erout ® Carry aut meggering oniy between the main a PREleT era circuit common wire and earth terminal E(G). Never apply meggering to control circuits and) others, FAI @ The drive unit is normal when the megger an beueee indicates more than 5MiQ Fig. 5-1 Meggering connection (2) Control circuits Remove the exlernal connections from control circuit terminals and carry out noncantinuity-to-earth test. Use a high-resistance-range tester. Never use a megger. (3) Precautions in the tests of external main and control circuits When you apply dielectric test or meggering to external circuits, detach all the external connections at the drive unit terminals so thal test voltage can nol be impressed on the unit,5-8 Measurement of Main Circuit DC Voltage Measuring terminals are the main circuil terminal P for positive (+) and the signal check terminal OGN on the control PCB for negative (—). Use a lester or the lke WARNING Take the utmost care that the voltage during current carrying sometimes exceeds 310 V. CHARGE _— Signal check Tarp ie) terminal DCN | : LI ee pe Hee ones Fig. §-2 Rough sketch of the control printed circuit board © 6. Troubleshooting 6-1 Protection Funotions WARNINGS ‘A cover is not provided in the front of this drive unit: therefore, be careful enough not to touch the live part. If there is a fear of fault expansion or disaster occurrence such as fire, open the MCCB Immediately to stop power supply. ‘The drive unit has protection functions as shown in Tables 6-11 and 6-12. The operation of a protection function in Table 6-12 (lault occurrence) cuts off the power transistor base current and the drive unit stops: output immediately 10 protect the unit and motor. Then the motor runs free and the indication ofthe digital isplay on the drive unit automaticaly shifts to the indication of the contents (type) of a faut. The contents ‘and dala of more than one faull can be relrieved by operating the push-button switches on the control PCB, ‘Aller you switch on the RST to cancel the operating protection function, you can not select or retrieve the functions (FED! to F6DS ) for the contents of faults and operation status al fault. Therefore, you are recommended to record these data. ‘Table 6-11 Protection functions (1) Function Description Stall Increases acceleration time automatically to suppress overcurrent al rapicl acceleration so that prevention [overcurrent trip can be prevented. Similarly, increases deceleration time automatically to suppress Svercurrentiovervoliage at rapid deceleration so thal overcurrenl/overvollage trip can be prevented. Current | Suppresses overcurrent by aur own method when the drive unit output current reaches the current limiting limiting level. Instataneous | Running continues about 15 ms alter the power fails under a continuous rated load, power failure | (Under a lighter load. running time is longer.) Input surge | Protects the drive unit from § kV standard impulse voltage that comes in from the main circuit power supply Table 6-12 Protection functions (II) Function [Display] Description Under. LU [When the main-circuit OC vollage drops below the undervoltage level, the drive unit stops vollage ‘oulput immediately and holds a trip condition. protection | When a power failure is s0 long tat control power fails, the function is automatically reset. al \ ee ee COvenoliage | oi’ | When the main-circuil DC volage reaches the overvottage protection level, he drive unit protection slops output immediately. ‘Overcurrent | of |When the drive unit autput current reaches the overcurrent protection level, the unit stops protection oulput immediately. Overload | off | when the drive unit operation exceeds the overload capacity (inverse-lime characterisic), the unit stops output immediately, Motor ‘2 |When the temperature detection thermistor bull in the motor detects the overload level, the overload drive unit stops oulput immadiately to protect the motor surely from burnout due to overload. inverter cofff | When the drive unit cooling fins is overheated or unil temperature is too high. the unit stops ceverheating ‘output immediately External ‘oN2 | When an extemal alarm signal, such as from the thermal relay for braking resistor overheat faults election, Inputs, the driva unit stops outpul immediately