Mitsubishi D700 VFD User manual

MachMotion Version 1.0.2

MACHMOTION

Mitsubishi D700 VFD

Installation Guide

3/12/2012

Everything you need to know to

set

up your Mitsubishi VFD.

2 | P a g e

MachMotion

www.machmotion.com

14518 County Road 7240, Newburg, MO 65550

(573) 368-7399 • Fax (573) 341-2672

3 | P a g e

Overview __________________________________________________________________________ 4

Wiring ____________________________________________________________________________ 5

Control Cable ____________________________________________________________________________ 5

Enable Circuit ____________________________________________________________________________ 6

Spindle Motor ____________________________________________________________________________ 7

Brake Re i tor ____________________________________________________________________________ 8

Programming ______________________________________________________________________ 9

VFD Setup ________________________________________________________________________ 10

Standard Setup __________________________________________________________________________ 10

Auto Tuning _____________________________________________________________________________ 11

Brake Re i tor ___________________________________________________________________________ 11

Mach3 Setup ______________________________________________________________________ 1

Turning on Your Spindle _____________________________________________________________ 15

Calibrating Your Spindle_____________________________________________________________ 17

With Spindle Feedback __________________________________________________________________________ 18

Without Spindle Feedback _______________________________________________________________________ 18

Trouble Shooting __________________________________________________________________ 0

Alarm Li t ______________________________________________________________________________ 21

Warranty Information ______________________________________________________________ 3

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Overview

This installation manual is designed for Mitsubishi Variable Frequency Drives (VFDs) purchased from

MachMotion. It was written to interface VFDs with the Apollo I Breakout Board. It provides all the information

from wiring your VFD to troubleshooting it. Much of the wiring and many of the settings should already be

configured correctly for your spindle motor. However, all the information is provided in case you ever need to

disconnect or change something.

When the spindle is turned on inside Mach3, the Apollo I Breakout Board provides a 0-10V analog signal to the

VFD and turns on one of two relay contacts for clockwise and counterclockwise rotation. The VFD then scales

the analog signal to the maximum frequency of the spindle motor. For instance, if a spindle motor’s max

frequency is 60Hz, then 5V will give you 30Hz and 10V will give you 60Hz. The analog voltage is also scaled to the

max pulley speed inside Mach3. In the previous example, if the maximum pulley speed is 1000 RPM, then 500

RPM will make the VFD output 30Hz and 1000 RPM will make it output 60Hz.

If you purchased a drive enclosure from MachMotion, then all you have to do is set up your VFD parameters and

connect your spindle motor. Otherwise you will also have to wire up an enable circuit for your VFD.

We hope that this installation can be as quick and easy for you as possible. If you have any questions, please do

not hesitate to give us a call.

Sincerely,

The MachMotion Team

http://www.machmotion.com

14518 County Road 7240, Newburg, MO 65550

(573) 368-7399 • Fax (573) 341-2672

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Wirin

Control Cable

The VFD control cable is the Cat5 cable that runs from the breakout board to the Mitsubishi VFD. From the

factory it is already wired correctly to the VFD. Plug the cable into the RJ45 connector labeled Spindle Control on

the IO6 Breakout Board.

If for any reason you need to disconnect the control cable from the VFD, the wiring is shown below.

Figure 1 Control Cable

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Enable Circuit

To set up your VFD correctly, you only want power supplied to it while your control is enabled. Use the 24V

enable signal (24-EN) from the breakout board, a 24V relay, and a contactor as shown below. If you purchased a

drive enclosure, your enable circuit is already set up.

If your VFD is rated for your spindle motor (i.e. 3Hp VFD with a 3Hp motor), then anything above 3Hp must use 3

phase power. The blue dashed line in the diagram below shows the 3 phase wire.

Figure 2 Enable Circuit

When the machine is enabled, the 24-EN signal turns on. This turns on RC2 which then connects 230 VAC to the

coil of RC1. RC1 then turns on the power to the VFD. You can use the same enable circuit for your servo drives.

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Spindle Motor

Connect your spindle motor to the terminals labeled U, V, and W as shown below. If your spindle moves the

wrong direction when you turn it on, just swap any two of the spindle motor wires.

Figure 3 Spindle Motor

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Brake Resistor

If you want a brake on your spindle, you will need a brake resistor. Use the table below to locate the correct

resistor size. You can order them directly from Mitsubishi.

Motor (Hp)

Re i tance (Ohm ) Continuou Power (W) Mit ubi hi Part #

1/2 200 60 FR-ABR-0.4K

1 100 80 FR-ABR-0.75K

2 & 3 60 120 FR-ABR-2.2K

5 40 155 FR-ABR-3.7K

7 1/2 25 185 FR-ABR-5.5K

10 20 340 FR-ABR-7.5K

If you have a brake resistor, connect it between PR and P/+ on the VFD.

Figure 4 Brake Re i tor

Note: Each VFD model is slightly different. Just make sure that you connect the resistor to the correct terminals

(PR, P +).

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Pro rammin

To setup your VFD, you will have to learn how to program it. The VFD user interface consists of a small screen, 5

buttons, a few status LEDs, and a scroll wheel as shown below.

Figure 5 VFD U er Interface

To change any settings you must enter PU mode. Press the PU/EXT button once and the LED by PU should light

up. When you are finished changing the settings, you must put the VFD back into EXT mode by pressing PU/EXT

again. If the LED by EXT is not on, then the VFD will not work.

You can setup parameters by following the procedure below:

1. Make sure the VFD is in PU mode (LED by PU is on). If not press the PU/EXT button to turn it on.

2. Press the Mode button until you see “P 0”. This is parameter 0.

3. Use the scroll wheel to go to your parameter number (P18 for example).

4. Press the Set button once. The current value of the parameter should display.

5. Change the value by using the scroll wheel.

6. Press the Set button again. The screen will start to flash between the parameter and the value.

7. Repeat steps 3 to 6 until all your parameters are set up correctly.

8. Put the VFD back into EXT mode by pressing the PU/EXT button. Make sure that the LED near EXT is on.

9. Cycle the power to the VFD. Make sure to wait until the VFD completely turns off before repowering it.

Now you should be ready to run the VFD.

Note: If you see an Er1, Er , Er3, or Er4 error, make sure to put the VFD in PU mode before changing the

parameters!

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VFD Setup

To setup your VFD you will need to know your spindle motor’s frequency. It is also helpful to know the

maximum current that your spindle motor should ever draw. You should be able to find both values on the

motor’s nameplate.

If you cannot locate the motor’s frequency, the name plate should tell you how many poles there are on the

motor. Using the motor’s maximum RPM and its number of poles, you can calculate the frequency with the

formula below.

Frequency = Max RPM * Number of Pole / 120

You are now ready to setup your VFD.

Standard Setup

Your VFD comes pre-programmed from MachMotion. The following parameters should never be changed.

Parameter # De cription Default

73 Analog Input Selection 10

74 Input Filter Constant 6

You may, however, have to change the following parameters.

Parameter # De cription Standard Range

1 Maximum Frequency (If less than 120 Hz) Max Motor Frequency 0-120Hz

2 Minimum Frequency 0 0-120Hz

3 Frequency Motor Frequency 0-400Hz

7 Acceleration Time 1-3 0-3600 Sec

8 Deceleration Time 1-3 0-3600 Sec

9 Max Motor Current Rated VFD Current 0-500

18 Maximum Frequency (If greater than 120 Hz) Max Motor Frequency 120-400Hz

72 PWM Frequency Selection 10 0-15

125 Maximum Frequency Max Motor Frequency 0-400Hz

All the frequency parameters (1 or 18, 3, and 125) will be the same value unless your maximum frequency is

different from the frequency on the spindle motor’s nameplate. Only set parameter 1 if your max spindle

frequency is less than 120 Hz. Only set parameter 18 if your max spindle frequency is greater than 120Hz.

If your spindle motor does not mention a minimum frequency, leave parameter 2 at zero. Also, if you cannot

find your max motor current, just set parameter 9 to the rated VFD current.

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