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BNP-C3015A(ENG)
Introduction
Thank you for selecting the Mitsubishi spindle drive unit. This instruction manual describes the handling and caution points for using this AC spindle. Incorrect handling may lead to unforeseen accidents, so always read this instruction manual thoroughly to ensure correct usage. Make sure that this instruction manual is delivered to the end user. Always store this manual in a safe place. All specifications for the MDS-B/C1-SPT Series are described in this manual. However, each CNC may not be provided with all specifications, so refer to the specifications for the CNC on hand before starting use.
WARNING
Incorrect handling could lead to a hazardous situation and result in fatalities or serious injuries. When a dangerous situation may occur if handling is mistaken leading to medium or minor injuries, or physical damage.
CAUTION
the situation. In any case, important information that must be observed is described.
1) In this manual, the following items are generically called the "spindle amplifier". Spindle drive unit Power supply unit
Changes to terminal names The terminal names have been changed in two stages as shown below.
Before March 1995 R S T P N Ro So G Between April 1995 and March 1996 R/L1 S/L2 T/L3 L+/P L-/N L11/Ro L21/So G/ After April 1996 L1 L2 L3 L+ LL11 L21
Terminal name
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WARNING
Do not open the spindle amplifier's front cover or the spindle motor's terminal box cover while the power is ON or during operation. Failure to observe this could result in electric shocks. Do not turn the power ON with the spindle amplifier's front cover or spindle motor's terminal box cover removed. The high voltage terminals and charged sections will be exposed, and could result in electric shocks. Do not remove the front cover even when the power is OFF except for wiring work or periodic inspections. The spindle amplifier is charged and could result in electric shocks. Wait at least 10 minutes after turning the power OFF and LED on spindle amplifier turning OFF before starting wiring or inspections. Failure to observe this could lead to electric shocks. Ground the spindle motor and spindle amplifier with Class 3 or higher grounding. Wiring, maintenance, and inspection work must be done by a qualified technician. Wire the spindle motor and spindle amplifier after installation. Failure to observe this could result in electric shocks. Do not operate the spindle amplifier switches with wet hands. Failure to observe this could result in electric shocks.. Do not damage, apply forcible stress, place heavy items on the cables or get them caught. Failure to observe this could lead to electric shocks.
2. Fire prevention
CAUTION
Install the spindle motor, spindle amplifier, and regenerative resistor on non-combustible material. Direct installation on combustible material or near combustible materials could lead to fires. Shut off the power on the spindle amplifier's power side, if a fault occurs in the spindle amplifier. Fires could be caused if a large current continues to flow. When using the regenerative resistor, shut off the power with an error signal. The regenerative resistor could abnormally overheat and cause a fire due to a fault in the regenerative transistor, etc.
3. Injury prevention
CAUTION
Do not apply a voltage on each terminal other than that indicated in the Specification Manual or Instruction Manual. Failure to observe this item could lead to ruptures or damage, etc. Do not mistake the terminal connections. Failure to observe this item could lead to ruptures or damage, etc. Do not mistake the DC voltage polarity (+, -). Failure to observe this item could lead to ruptures or damage, etc. The spindle amplifier cooling fins, regenerative resistor and spindle motor, etc., will be hot during operation and for a short time after operation is stopped. Touching these sections could result in burns. iii
4. Various precautions Observe the following precautions. Incorrect handling of the unit could lead to faults, injuries and electric shocks, etc. (1) Transportation and installation
CAUTION
Correctly transport the product according to its mass. Use the spindle motor's suspension bolts only to transport the spindle motor. Do not transport the spindle motor when it is installed on the machine. Do not stack the spindle motors and spindle amplifiers above the indicated limit. Do not hold the cables, shaft or detector when transporting the spindle motor. Do not transport the spindle amplifier by holding the connected wires or cables. Do not hold the front cover, side covers or fins when transporting the spindle amplifier. The amplifier could drop or be damaged. Follow the instruction manual, and install the spindle motor and spindle amplifier at a place which can withstand the mass. Do not get on the spindle motor or spindle amplifier. Do not place heavy objects on the spindle motor or spindle amplifier. Always observe the indicated spindle motor and spindle amplifier installation direction. Provide the specified distance between the spindle amplifier and inner surface of the control panel and between other devices. Do not install or operate a spindle motor or spindle amplifier that is damaged or missing parts. Provide the specified distance between the spindle motor cooling fan's intake/outtake ports and other devices and between other machines' metal parts. Do not allow conductive matters such as screws or metal pieces, or combustible matters such as oil enter the spindle motor or spindle amplifier. The spindle motor and spindle amplifier are precision devices. Do not drop them or apply strong impacts. Store and use the spindle motor and spindle amplifier within the following environmental conditions. Conditions Spindle amplifier 0C to +55C (with no freezing) To follow separate specifications To follow separate specifications To follow separate specifications Spindle motor 0C to +40C (with no freezing) 80%RH or less (with no dew condensation) -15C to +70C
Environment Ambient temperature Ambient humidity Storage temperature Storage humidity Atmosphere Altitude Vibration
90% RH or less (with no dew condensation) Indoors (Where unit is not subject to direct sunlight) With no corrosive gas, combustible gas, oil mist or dust 1000m or less above sea level To follow separate specifications
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CAUTION
Securely fix the spindle motor onto the machine. Insufficient fixing may result in dislocation during operation. Always provide a cover, etc., on the shaft so that the spindle motor's rotating sections cannot be touched while the spindle motor is rotating. When coupling the spindle motor's shaft end to the machine's shaft, pulley or gears, etc., do not apply an impact on the spindle motor with a hammer, etc. Failure to observe this could result in bearing damage or detector faults. Do not apply a load exceeding the tolerable load onto the spindle motor shaft. Failure to observe this could result in bearing damage or shaft breakage. Consult with the Service Center or Service Station when storing the spindle motor or spindle amplifier for a long time. (2) Wiring
CAUTION
Correctly and securely perform the wiring. Failure to do so could lead to runaway of the spindle motor.
Spindle amplifier
Do not install a condensing capacitor, surge absorber or radio noise filter on the output side of the spindle amplifier. Correctly connect the output side (terminals U, V, W). Failure to do so could lead to abnormal operation of the spindle motor. Do not directly connect a commercial power supply to the spindle motor. Doing so could lead to faults.
VIN (24VDC)
When using an inductive load such as a relay on the control output signal, always connect a diode in parallel to the load as a measure against noise. When using a capacitance load such as a lamp for the control output signal, always connect a protective resistor serially to the load as a measure against noise. Do not mistake the polarity of the noise (surge) absorption diode installed on the DC relay for the control output signal. The faulty signal will not be output and the spindle amplifier could fail. Do not connect or disconnect the cables connected to each connector or terminal while the power is ON. Securely tighten the cable connector fixing screw or fixing mechanism. Insufficient fixing could result in dislocation while the power is ON. If use of a shielded cable is indicated in the connection diagram for the signal wires connected to the spindle amplifier, always use a shielded cable, and always connect the shield to the connector clamp. Always separate the signal wires connected to the spindle motor and spindle amplifier from the drive wires and power wires. Always use wires and cables having a wire diameter, heat resistance and flexibility compatible with the system. Fix part of the cable connected to each spindle amplifier connector to part of the control panel so that connector is not pulled forward or vertically. Do not relay the speed detector or position detector cables. Failure to observe this could result in vibration, noise or positional deviation.
WARNING
When adjusting the drive unit with a personal computer, some parameters will be validated as soon as they are changed. Take special care when making adjustments while rotating the spindle, and take care not to approach body parts near the spindle. Failure to observe this could result in personal injury. When monitoring the state of the spindle or spindle motor with a personal computer, if the spindle motor's maximum speed is set to 33000r/min or more or if parameter SP257 is set to "0002", the spindle motor speed displayed on the personal computer will be half of the actual speed. Failure to note this could result in spindle damage.
CAUTION
Check each parameter before starting operation. Unpredictable movements could result depending on the machine. Do not make remarkable adjustments and changes as the operation could become unstable. (4) Usage methods
CAUTION
Install an external emergency stop circuit so that the operation can be stopped and power shut off immediately. Turn the power OFF immediately if any smoke, abnormal noise or odors are generated from the spindle motor or spindle amplifier. Only a qualified technician may disassemble or repair this product. Never make modifications. Connect a noise filter, etc., on the spindle amplifier power lead-in wire to reduce the effect of electromagnetic disturbances. Electronic devices used near the spindle amplifier could be affected by the electromagnetic disturbances. Use the spindle motor, spindle amplifier and regenerative resistor in the designated combination. Failure to observe this could result in fires or faults. After changing the parameters, maintenance or inspection, always carry out a trial operation before starting actual operation. Do not place hands or feet near the spindle during rotation. Use the power (input voltage, input frequency, tolerable sudden power failure time) under the power specification conditions given in the individual Specifications. Install a surge killer on coils for solenoid valves and contactors, etc., used near the spindle amplifier to prevent noise. Failure to do so could result in malfunctions. (5) Troubleshooting
CAUTION
If a hazardous situation could arise during a power failure or product fault, provide an external brake mechanism for holding purposes. Turn the power OFF if an alarm occurs. Never go near the machine after restoring the power after an instantaneous power failure, as the machine could start suddenly. (Design the machine so that personal safety can be ensured even if the machine starts suddenly.) vi
CAUTION
Back up the spindle amplifier parameters before starting maintenance or inspections. The capacity of the electrolytic capacitor will drop due to deterioration. To prevent secondary damage due to failures, replacing this part every five years when used under a normal environment is recommended. Contact the Service Center or Service Station for replacement. Never perform a megger test (insulation resistance measurement) on the spindle amplifier during inspections. (7) Disposal
CAUTION
Handle this product as general industrial waste. If heat radiating fins are exposed on the back of the spindle amplifier, a CFC substitute is in use. These models must not be handled as general industrial waste and must always be returned to the Service Center or Service Station. Do not disassemble the spindle motor or spindle amplifier. (8) General precautions
CAUTION
To explain the details, drawings given in this manual, etc., may show the unit with the cover or safety partition removed. Always install the cover or partitions at their original position before turning the spindle motor or spindle amplifier power ON, and operate as indicated in the manual, etc.
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Control panel
Electromagnetic contactor MC
Motor (servo/spindle)
(2) Environment Use the spindle drive within a Pollution Class 2 or less environment as stipulated in IEC664. Install the spindle drive in control panel having a structure (IP54) which does not permit the entry of water, oil, carbon or dust, etc. (3) Power supply (a) Use the spindle drive under the Overvoltage Category II conditions stipulated in IEC664. Install a reinforced isolating transformer complying with IEC or EN Standards at the power input section.
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(4) Grounding (a) To prevent electric shocks, always connect the spindle amplifier protective earth (PE) terminal (terminal with mark) to the protective earth (PE) on the control panel. (Always ground even when using an earth leakage breaker.) (b) When connecting the earthing wire to the protective earth (PE) terminal, do not tighten the wire terminals together. Always connect one wire to one terminal.
PE terminal
PE terminal
(5) Wiring (a) Always use crimp terminals with insulation tubes so that the wires connected to the spindle amplifier terminal block do not contact the neighboring terminals.
Crimp terminal
(6) Peripheral devices and options (a) Use no-fuse breakers and magnetic contacts which comply with EN/IEC Standards. (b) Select the wire size according to EN60204. (Refer to section (8.3 7).)
(7) Miscellaneous Refer to "EMC INSTALLATION GUIDELINES" for methods on complying with the EMC Directives.
ix
CONTENTS
I. MDS-B/C1-SPT Spindle System Configuration Section 1. Outline ................................................................................................................................. I-1 1.1 Features ...................................................................................................................... I-1 1.2 Precautions for use...................................................................................................... I-2 2. System Configuration .......................................................................................................... I-3 3. Unit Installation.................................................................................................................... I-7 4. Connection of Each Unit...................................................................................................... I-9 4.1 Layout of each unit .................................................................................................... I-10 4.2 Link bar specifications ............................................................................................... I-10 4.3 Precautions for installing multiple power supply units ............................................... I-12 4.4 Precautions when installing multiple spindle drive units to one power supply unit.... I-13 5. Connector and Cable Specifications ................................................................................. I-14 5.1 Half pitch connector and cable connection system ................................................... I-14 5.2 Cable details.............................................................................................................. I-15 5.2.1 SH21 cable (Semi-ordered part) [For B/C1-CV B/C1-SPT connection]........... I-15 5.2.2 Spindle control circuit cable list ........................................................................... I-16 5.2.3 Cable assembly procedure ................................................................................. I-21 6. Outline Drawing................................................................................................................. I-25 6.1 List of outlines............................................................................................................ I-25 6.2 Power supply unit ...................................................................................................... I-26 6.3 Spindle drive unit ....................................................................................................... I-27 6.4 AC reactor ................................................................................................................. I-28 6.5 Contactor ................................................................................................................... I-29 6.6 NFB ........................................................................................................................... I-29 7. Heating Value.................................................................................................................... I-30 8. Selection of Capacity......................................................................................................... I-31 8.1 Selection of the power supply unit (MDS-B/C1-CV) .................................................. I-31 8.2 Selection of the power supply capacity ..................................................................... I-31 8.3 Selection of wire size................................................................................................. I-32 8.4 Selection of AC reactor, contactor and NFB.............................................................. I-35
II. MDS-B/C1-CV Power Regeneration Type Power Supply Section 1. Power Supply Unit.............................................................................................................. II-1 1.1 Model configuration .................................................................................................... II-1 1.2 List of specifications ................................................................................................... II-2 1.3 Hardware and parameter setting ................................................................................ II-3 1.4 Status display ............................................................................................................. II-4 1.4.1 7-segment LED display ........................................................................................ II-4 1.4.2 Charge lamp......................................................................................................... II-4 1.5 List of alarms and warnings........................................................................................ II-5 1.6 Explanation of connectors and terminal block ............................................................ II-7 1.7 Functions added with MDS-B Series (Power supply external emergency stop function)...................................................... II-8 1.8 Main circuit connection ............................................................................................. II-10
III. MDS-B/C1-SPT Spindle Drive Unit System Section 1. Model, Configuration and Connection ............................................................................... III-1 1.1 Model configuration ................................................................................................... III-1 1.2 Configuration ............................................................................................................. III-2 1.2.1 Basic configuration (No additional specifications) ............................................... III-2 1.2.2 With orientation function...................................................................................... III-2 1.3 Device-to-device connections.................................................................................... III-4 2. Specifications .................................................................................................................... III-5 2.1 AC spindle motor and controller specifications.......................................................... III-5 2.2 Output characteristics................................................................................................ III-9 2.3 Outline dimension drawings .................................................................................... III-11 2.3.1 Motor ................................................................................................................. III-11 3. Status Display and Parameter Settings........................................................................... III-16 3.1 Status display with 7-segment LED......................................................................... III-17 3.2 Spindle parameters ................................................................................................. III-18 3.3 Spindle specification parameters screen................................................................. III-39 3.4 Spindle monitor screen............................................................................................ III-40 3.5 Control input signals ................................................................................................ III-41 3.6 Control output signals.............................................................................................. III-43 3.7 Meter outputs........................................................................................................... III-46 3.8 Output interface ....................................................................................................... III-48 4. Optional Specifications and Parts ................................................................................... III-49 4.1 Orientation specifications (optional) ........................................................................ III-49 4.1.1 1-point orientation using magnetic sensor ........................................................ III-49 4.1.2 4096-point orientation using encoder................................................................ III-57 4.1.3 4096-point orientation using motor built-in encoder .......................................... III-60 4.1.4 Operation of orientation..................................................................................... III-60 4.2 Synchronous tap function (option)........................................................................... III-63 4.2.1 Closed type synchronous tap............................................................................ III-63 4.2.2 Semi-closed type synchronous tap ................................................................... III-63 4.2.3 Operation of synchronous tap ........................................................................... III-63 4.3 C-axis control (optional)........................................................................................... III-64 4.3.1 When using encoder (OSE90K+1024 BKO-NC6336H01) ................................ III-64 4.3.2 When using built-in encoder (MBE90K) ............................................................ III-67 4.3.3 When using built-in encoder (MHE90K) ............................................................ III-67 4.4 Single parts (optionally supplied parts).................................................................... III-68 4.4.1 Power step-down transformer ........................................................................... III-68 4.4.2 Noise filter ......................................................................................................... III-70 4.5 Other optional specifications ................................................................................... III-72 4.6 Theoretical acceleration and deceleration times ..................................................... III-73
IV. Maintenance MDS-B/C1-SPT Spindle System Configuration Section 1. Starting up the System ...................................................................................................... IV-1 1.1 Startup procedures .................................................................................................... IV-1 1.2 Status display with 7-segment LED........................................................................... IV-2 2. Adding and Replacing Units and Parts.............................................................................. IV-3 2.1 Replacing the unit...................................................................................................... IV-3 2.2 Unit fan ...................................................................................................................... IV-6 3. Daily Maintenance............................................................................................................. IV-7 3.1 Maintenance tools ..................................................................................................... IV-7 3.2 Periodic inspections................................................................................................... IV-7 4. Maintenance Parts ............................................................................................................ IV-9 5. Selection of Leakage Breaker ......................................................................................... IV-10 6. Noise Filter ...................................................................................................................... IV-11
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V. Maintenance MDS-B-CVE/MDS-C1/CV Power Supply Section 1. Troubleshooting.................................................................................................................. V-1 1.1 Status display ............................................................................................................. V-1 1.2 Troubleshooting according to power supply alarm ..................................................... V-3 1.3 Power supply warning .............................................................................................. V-12
VI. Maintenance MDS-B/C1-SPT Spindle Drive Unit Section 1. Adjustment Procedures ..................................................................................................... VI-1 1.1 Starting up ................................................................................................................. VI-1 1.2 Confirming the speed loop......................................................................................... VI-1 1.2.2 Adjusting and confirming the motor (spindle) speed ........................................... VI-1 1.2.3 Adjusting the deceleration time ........................................................................... VI-2 1.3 Adjusting the orientation ............................................................................................ VI-2 1.3.1 Operation ............................................................................................................ VI-2 1.3.2 Operation sequence............................................................................................ VI-2 1.3.3 Encoder orientation/motor built-in encoder orientation stop position .................. VI-3 1.3.4 Diagram of orientation parameter relation........................................................... VI-4 1.3.5 Preparation for motor built-in encoder orientation adjustment ............................ VI-4 1.3.6 Preparation for encoder orientation adjustment .................................................. VI-5 1.3.7 Preparation for magnetic sensor orientation adjustment..................................... VI-6 1.3.8 Adjusting the orientation...................................................................................... VI-7 1.3.9 Adjusting the servo rigidity .................................................................................. VI-7 1.3.10 Delay/advance control and PI control................................................................ VI-8 1.3.11 Troubleshooting for orientation trouble ............................................................. VI-8 1.4 Adjusting the synchronous tap ................................................................................ VI-10 2. Troubleshooting............................................................................................................... VI-11 2.1 Introduction.............................................................................................................. VI-11 2.2 Step 1 ...................................................................................................................... VI-11 2.3 Step 2 ...................................................................................................................... VI-12 2.4 List of alarms and warnings..................................................................................... VI-15 2.5 Approach per phenomenon ..................................................................................... VI-16 2.5.1 Details when alarm or warning is displayed on the 7-segment display ............. VI-16 2.5.2 Details when alarm or warning is not displayed on 7-segment unit .................. VI-25 2.6 Periodic inspections................................................................................................. VI-28 2.6.1 Inspecting the control unit ................................................................................. VI-28 2.6.2 Inspecting the motor.......................................................................................... VI-28 3. Disassembling and Assembling the Motor ...................................................................... VI-29 3.1 Disassembling and assembling the SJ type AC spindle motor ............................... VI-29 3.2 Disassembling and assembling the SJ-N type AC spindle motor............................ VI-37 4. Handling the Orientation Detector ................................................................................... VI-46 4.1 Magnetic sensor type 1-point orientation................................................................. VI-46 4.1.1 Operation of magnet and sensor....................................................................... VI-46 4.1.2 Sequences, etc. ................................................................................................ VI-47 4.2 Encoder type 4096-point orientation........................................................................ VI-47 4.2.1 Configuration..................................................................................................... VI-47 4.2.2 Sequences, etc. ................................................................................................ VI-47 4.3 Motor built-in encoder type 4-96-point orientation ................................................... VI-47 4.3.1 Sequences, etc. ................................................................................................ VI-47
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Appendix 1 Parameter Setting List ..........................................................................................1 Appendix 2 Unit Conversion Table ..........................................................................................1 Appendix 3 Explanation of Large Capacity Spindle Unit Specifications ..................................1 1. Outline.................................................................................................................................1 2. List of units ..........................................................................................................................1 3. Selection of AC reactor (B-AL), contactor and NFB............................................................1 4. Outline of units ....................................................................................................................2 5. Panel cut dimension drawing ..............................................................................................3 6. Detailed outline drawing......................................................................................................4 7. Heating value ......................................................................................................................7 8. Selection of power capacity ................................................................................................7 9. Selecting of wire size ..........................................................................................................7 10. Drive unit connection screw size.......................................................................................8 11. Connection of Each Unit ...................................................................................................8 12. Restrictions .....................................................................................................................10 13. Parameters .....................................................................................................................11 14. Precautions .....................................................................................................................11
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1. Outline
1. Outline
1.1 Features
(1) High-speed serial communication with CNC A high-speed serial communication function, compatible with the Toshiba Machine CNC "TOSNUC 888.2" has been incorporated. (2) Compact and lightweight The volume, installation area and mass have been drastically reduced with the incorporation of high density mounted electronic parts IPM (Intelligent Power Module) and the high performance heat dissipation fin. (3) Standardization of dimensions Mounting in cabinets has been made easy by unifying the height and inner-panel depth dimensions of all power supply unit and spindle drive unit capacities. (4) Low heat generation The amount of heat generated has been greatly reduced by incorporating the IPM. (5) Separable units Separable converter sections and inverter sections allows the optimum unit matching the motor characteristics to be selected. Multiple inverters can be driven with one converter to handle multi-axis machines. (6) High-speed and precision processing A high-speed CPU has been mounted to improve the cutting performance and accuracy. (7) High-speed spindle orientation Smooth operations and minimum orientation times have been realized by using the high-speed orientation method which allows direct orientation from the maximum speed. (8) Simple parameter input All parameters can be input from the personal computer allowing startup and adjustments to be completed in a short time. (9) MDS-B/V1 Series features (a) European Safety Standard compliant This system is compatible with European Safety Standards (LVD Directives). (Refer to "Compliance with European EC Directives" for details.) (Note that the target models in the B/C1 Series are limited to the CV (power regeneration power supply) and SPT (spindle drive.) (b) Addition of power supply emergency stop input line When using the B/C1 Series, if the emergency stop hot line from the NC is disabled for any reason, the external contactor can be directly cut off with from the power supply. (This function is validated with the rotary switch and connected drive's parameter settings.)
I-1
1. Outline
I-2
2. System Configuration
2. System Configuration
WARNING
1. Wiring and inspection work must be done by a qualified technician. 2. Wait at least 10 minutes after turning the power OFF and LED on spindle amplifier turning OFF before starting wiring or inspections. Failure to observe this could lead to electric shocks. 3. Wire the spindle motor and spindle amplifier after installation. Failure to observe this could result in electric shocks. 4. Do not damage, apply forcible stress, place heavy items on the cables or get them caught. Failure to observe this could lead to electric shocks.
CAUTION
1. Correctly and securely perform the wiring. Failure to do so could lead to runaway of the spindle motor, or to injuries. 2. Do not mistake the names of the terminals for connecting the cables. Failure to observe this could result in rupture or faults. Spindle amplifier 3. Do not mistake the DC voltage polarity (+, -). Failure to observe this item could lead to ruptures or damage, etc. VIN 4. Do not mistake the polarity of the noise (surge) absorption (24VDC) diode installed on the DC relay for the control output signal. The faulty signal will not be output and the spindle amplifier could fail. Control output signal 5. Electronic devices used near the spindle amplifier could be affected by the electromagnetic disturbances. Connect a noise filter, etc., on the power lead-in wire to reduce the effect of electromagnetic disturbances. (Refer to III. Spindle drive unit section 4.4.2.) 6. Do not use a phase-advancing capacitor, surge killer or noise filter on the spindle motor's power wire. 7. If a spindle motor or spindle amplifier fails, cut off the power with the fault output. The regenerative resistor could abnormally overheat and ignite due to a fault in the regenerative transistor, etc. 8. Never modify the spindle motor or spindle amplifier. 9. Precautions for using MDS-B Series 1) The rush sequence of the power supply unit's MDS-B-CV-370 differs from other power supplies, so always install an external contactor. Do not share the contactor with other power supplies.
I-3
2. System Configuration
(1) Basic system configuration Spindle drive unit CN 1A 7 8 CN 5 6 MDS-B/C1-SPT MDS-B/C1-CV Power supply unit CN CN 4 4
NC (PC)
Link bar
Control power RS
MC1 U V W L1 L2 L3
ENC
Spindle motor
Contactor
AC reactor B-AL
200VAC IN
NFB 2
(Note 1) Always install the spindle drive unit next to the power supply unit. (Note 2) Wire the AC reactor to the front (NF side) of the contactor. (Note 3) Whether or not to install a contactor can be selected only for the MDS-C1-CV-300 and smaller capacities. For safety purposes, use the state with no contactor only when the system configuration ensures that problems can be avoided when trouble occurs. Set the rotary switch on the power supply unit according to whether the contactor is installed. Contactor installed : Rotary switch setting = 0 Contactor not installed : Rotary switch setting = 1 (Note 4) Always install the AC reactor. (The reactor is supplied from Mitsubishi.) (Note 5) Always install a surge killer on the contactor.
I-4
2. System Configuration
(2) List of units (a) MDS-B Series Power supply unit ..... DC power supply to drive unit/regenerative control
No. Model Capa- Mass city (kg) (kW) 3.7 5.5 7.5 11.0 15.0 18.5 22.0 26.0 30.0 37.0 5.0 5.0 5.0 8.5 10.5 10.5 12.5 12.5 12.5 12.5 Dimensions Correspondence to drive unit capacity (MDS-B-SPT) HWD (mm) Type 04 075 15 22 37 55 75 110 150 185 220 260 300 370 38060300 38060300 38060300 38090300 380120300 380120300 380150300 380150300 380150300 380150300 D1 B1 C1 A1
1 B-CVE-37 2 B-CVE-55 3 B-CVE-75 4 B-CVE-110 5 B-CVE-150 6 B-CVE-185 7 B-CVE-220 8 B-CVE-260 9 B-CVE-300 10 B-CVE-370
(b) MDS-C1 Series Power supply unit ..... DC power supply to drive unit/regenerative control
No. Model Capa- Mass city (kg) (kW) 3.7 5.5 7.5 11.0 15.0 18.5 22.0 26.0 30.0 37.0 5.0 5.0 5.0 8.5 10.5 10.5 12.5 12.5 12.5 12.5 Dimensions Correspondence to drive unit capacity (MDS-B-SPT) HWD (mm) Type 04 075 15 22 37 55 75 110 150 185 220 260 300 370 38060200 38060200 38060200 38090255 380120255 380120255 380150255 380150255 380150255 380150255 D2 B2 C2 A2
1 C1-CV-37 2 C1-CV-55 3 C1-CV-75 4 C1-CV-110 5 C1-CV-150 6 C1-CV-185 7 C1-CV-220 8 C1-CV-260 9 C1-CV-300 10 C1-CV-370
(Note 1) The power supply unit and spindle drive unit combination may differ from the above combinations. The power supply capacity is determined by the motor output, and the spindle drive unit capacity is determined by the motor characteristics. (Note 2) Refer to "Appendix 3 Explanation of Large Capacity Spindle Unit Specifications" for details on the MDS-B-CVE-450 and SPT-370, 450 and 550.
I-5
2. System Configuration
B1
C1
D1
W: 150
H: 380
H: 380
H: 380
H: 380
Outline type
A2
W: 60 (Fin section D: 120) D: 300 180
B2
C2
D2
W: 150
H: 380
H: 380
H: 380
H: 380
I-6
3. Unit Installation
3. Unit Installation
CAUTION
1. Correctly transport the product according to its mass. Failure to observe this could result in injury. 2. Do not stack the product above the indicated limit. 3. Install the product on non-combustible material. Installation directly on or near combustible materials could result in fires. 4. When installing, always observe this manual and install on a place which can withstand the mass. 5. Do not get on the product, or place heavy objects on it. Failure to observe this could result in injury. 6. Use the product within the designated environment conditions. 7. Do not allow conductive matters such as screws or metal pieces, or combustible matters such as oil enter the spindle amplifier. 8. Do not block the spindle amplifier's intake/outtake ports. Failure to observe this could result in faults. 9. The spindle amplifier is a precision device. Do not drop it or apply strong impacts. 10. Do not install or operate a spindle amplifier that is damaged or missing parts. 11. Consult with the Service Center or Service Station when storing the spindle amplifier for a long time. (1) Each unit is designed to be installed in a cabinet such as a power distribution box. Avoid installation in direct sunlight, near heat generating objects or outdoors. (2) The inner working environment (temperature, humidity, vibration, atmosphere) of the cabinet must be within the limits given in the "Specifications for each unit". The cabinet for the cutting machine must be a totally closed type cabinet. (3) Make considerations so that inspections and replacement during maintenance is easy. The space required around each unit's panel is shown in the outline dimension drawings. (4) Each unit generates some heat, so leave a space on the top and bottom when installing other equipment or parts. Refer to the outline drawing for the square hole dimensions. In this case, insert packing between the unit and power distribution box. Refer to the following installation examples for installing each unit.
40
160
40
Filter Intake
Front
Rear
Example 1.
Leave space for air flow when the power distribution box is at the rear of the machine.
Example 2.
When the outdoor air cooling section is to protrude from the power distribution box, make sure that cutting chips, etc., do not enter the outtake section.
I-7
3. Unit Installation
CAUTION
1. Do not hold the front cover when transporting the spindle amplifier. The amplifier could drop and cause injury. 2. Always observe the installation direction. Failure to do so could result in faults. 3. Provide the specified distance between the spindle amplifier and inner surface of the control panel and between other devices. Failure to do so could result in faults. Note 1. Note 2. Note 3. Note 4. When installing in a poor environment (factory with high levels of oil mist), install a filter at the intake section of the partition showed with the dashed line in Example 2 above. Make sure that cutting chips from the drill, etc., do not enter the spindle amplifier when assembling the control panel. Provide means so that oil, water and cutting chips, etc., do not enter the spindle amplifier from the control panel clearances or the ceiling fan. When using the product in a place with high levels of harmful gases or dust, protect the spindle amplifier with air purging (feed in clean air from outside so that the pressure in the storage panel is higher than outside to prevent the entry of harmful gases or dust).
(5) Installation of cooling fan Each unit (excluding types without fins) is individually provided with a cooling fan (FAN1 shown below). However, when using the totally closed type unit installation method and the box structure in which cutting oil and dust, etc., easily enters the unit's fan and fin section (a structure where the fan may stop easily due to the working environment), the user should add a fan at the FAN2 position shown on the right. Carry out forced cooling with the velocity set to 2m/sec or more. Also take the serviceability into consideration in this case.
Inside box
Outside box
Wind direction
FAN1 (mounted on unit as standard) FAN2 (Additionally installed by user) * Install a finger guard for safety.
Due to the structure, heat will tend to accumulate on the top of each unit. Thus, install a fan in the power distribution box to mix the heat at the top of each unit. (Inside box) Wind direction
FAN3 (Additionally installed by user) Velocity 2m/sec or higher * Install a finger guard for safety.
Power supply
Spindle drive
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NC (PC)
CNS20
Note 1. Starting with production in April 1995, a grounding bar has been attached to each unit before shipment. Connect the grounding wire as shown below, and do not tighten the grounding wires together.
For B/C1-SPT
CN9 CN4 CN9
U VW
For B/C1-CV
L1 L2 L3
CN6
CN5
CN6
U V W
U WV
Note 2. If the unit may malfunction since devices (contactor, magnetic brakes, relay) that generate high levels of noise are installed near the power supply unit and drive unit, install a surge killer on the noise generating device, so as to suppress the noise.
CN7
CN8
(Magnetic sensor)
(Contactor)
MC
A/BAL (AC reactor) (Encoder) (Spindle motor) T 3 S 200VAC R 200 to 230VAC 60Hz
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(Front) (2) When installing two spindle drives (a) When the total spindle drive output is 37kW or less Spindle Power Spindle drive supply drive Link bar
(Front) (b) When the total spindle drive output exceeds 37kW Spindle Power Spindle Power drive supply drive supply (1) (1) (2) (2)
(Front)
Link bar
(Note 1) Install each unit next to each other (vertical direction is not acceptable) with a 3cm or less clearance between each unit. Note that this does not apply to the spindle drives (2) and power supply units (1) shown in (b) of section (2). (Note 2) When using section (2) (b), install an ACL (A/B-AL) on each power supply unit.
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An outline connection diagram is shown below for reference. (1) Outline connection drawing
SPT B/C1-CV
(Note) Mount the terminal cover after wiring as shown on the left. The terminal cover differs for each unit width. Refer to section "8.3 Selection of wire size".
N RO SO
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C N 1A 1B 9 5 6 7 8
C N 4
C N 1A 1B 9 5 6 7 8
C N 4
Contactor NFB1
Fig. 1 1) Connecting the L+, L-, L11 and L21 link bars Connect the L+ and L- link bars independently with A/B-CV (No. 1) and A/B-CV (No. 2) as shown above. Make sure that both A/B-CV link bars are not short-circuited and connected. Note that the L11 and L21 link bars can be connected together. 2) Connecting and selecting NFB1, contactor and AC reactor The NFB1 and contactor can be shared as shown above. Note that when using the B-CV-370, the rush circuit and contactor operation sequence differ, so the contactor must be installed independently. (The contactor cannot be shared.) Damage will result if the contactor is omitted, or if it shared with the other power supplies. The AC reactors must be installed separately for the A/B-CV (No. 1) and (No. 2). 3) Connecting the MC1 terminal (A/B-CV) When sharing the contactor as shown above, connect the terminal (MC1) for exciting the contactor coil to one of the A/B-CV connections. Set the A/B-CV rotary switch to which MC1 is connected to "0", and set the other switch to "1".
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4.4 Precautions when installing multiple spindle drive units to one power supply unit
The methods for installing two spindle drive units to one power supply unit are explained here as an example.
NC(PC) MDS-B/C1-SPT(No.1) MDS-A/B-CV MDS-B/C1-SPT(No.2)
C N 1A 1B 9 5 6 7 8
C N 4
C N 4 C N 9 MC1
C N 1A 1B 9 5 6 7 8
C N 4
MC
Contactor
NFB1
Fig. 2 1) Connecting B-CVE/C1-CV and B/C1-SPT Connect B-CVE/C1-CV CN4 and B/C1-SPT (No. 1) CN4 to B-CVE/C1-CV CN9 and B/C1-SPT (No. 2) CN4. If B/C1-SPT for three or more axes is connected, leave CN4 for B/C1-SPT (No. 3) and following open. Note that the A/B-CV can be controlled (READY ON/OFF, alarm display, etc.) only with the spindle drive unit connected to A/B-CV CN4. Make sure that the machine ready input turns ON and OFF simultaneously for all spindle drive units. Do not allow the signal to turn ON and OFF for only one spindle drive unit. When turning the machine relay input OFF during an emergency stop, always output the zero speed signal with all spindle drive units before turning the signal OFF. If an alarm occurs in one of the spindle drive units, turn OFF the machine ready input OFF for all spindle drive units. When connecting three or more spindle drive units, install the large-capacity drive units on both sides of the power supply unit.
2) 3) 4) 5)
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5. Connectioor
CN1A 7 8
CN4
CN4 9
Detector
Cable name
SH21 cable
Connector name Recommended connector Cable materials on controller on cable side (Maker) (Maker) side (Maker) 10220-L8A9VE Shell (Crimp type): 10320-3210-000 (3M) UL2789 AWG28 (3M) (DDK) Plug (Pressure welding type): 10120-6000EL (3M) 10PVV-SB AWG2810P (3M)
Press machine unit (with gage block) : 3794-1000 Locator plate : 3795-1A Platen : 3795-2A Cutting unit : 3795-3A Fixture unit : 3796-1A Fixture unit : 3796-2A Fixture unit : 3796-5A Fixture block : 3796-3A Cable clamp : 3796-4
CNP5 cable
Same as above
Same as above
(1) Controller side Plug (soldered-type): 10120-3000VE (3M) Shell (soldered-type): 10320-52F0-008 (3M) (2) Detector side Connector: AMP-350720-1 (AMP) Pin: AMP-350689-1 (AMP) (1) Controller side Same as above (2) Detector side (a) Magnetic sensor TRC116-12A10-7F10.5 (Tajimi Musen) (b) Encoder MS3106A20-29S (Canon) (1) Controller side Same as above
Same as above
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5. Connectioor
3M 3M 3M
103 11 1
101
102
101 103
12
10 350 (Standard)
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5. Connectioor
No.
Application
Motor temperature switch signal (1) Motor speed detection signal CN5 CNP5 cable
Spindle drive unit (Shell) 10320-52F0-008 (Plug) 10120-3000VE 3M Spindle drive unit
CN6
Tajimi Musen Twisted pair batch shield cable 0.2SQ Maximum diameter 11mm MS3106A20-29S Encoder
CN6
(Shell) CNP6A 10320-52F0-008 (Plug) cable 10120-3000VE 3M Spindle drive unit (Connector) 54306-2611 (Clamp) 54331-0261 MOLEX Spindle drive unit (Shell) 10320-52F0-008 (Plug) 10120-3000VE 3M
DDK Batch vinyl shield cable NC (PC) 0.2SQ x 20-core Maximum diameter 11mm
(4) Communication
CN1A CN7
No ordered part
NC (PC)
CN9A
CN9A cable
No ordered part
CN9A
Twisted pair shield cable 0.3SQ Personal computer RS232C Maximum diameter 11mm connector
(7)
CN9A
CN9B cable
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No ordered part
Motor (connector) Motor (lead wire terminal) Maximum diameter 11mm (Connector) AMP-350720-1 (Pin) AMP-350689-1 Japan Amplifier Magnetic sensor Twisted pair batch shield cable drive unit 0.2SQ Twisted pair batch shield cable 0.2SQ
5. Connectioor
(Note 1) The connector shell on the spindle drive unit is the 3M "10320-52F0-008", but this is a shell with a one-touch locking mechanism that does not require screw locking. When ordering the cables from Mitsubishi, this shell will be used. However, if the cable is to be manufactured by the user, the shell "10320-52A0-008" (3M) with the screw lock mechanism can be used instead of the above shell. (Note 2) Keep the length of the cables, excluding the CN9B cable to 30m or less. (The CN9B cable must be 3m or less.) (Note 3) Do not relay the CNP5, CNP6M or CNP6A cables. Malfunctions could occur due to noise from the motor drive wire or other cables. (Orientation position could dislocate, vibration could occur, etc.) If the cable must be relayed, keep the peeled shield section as short as possible (3cm or less), and separate the cable from the other drive wires and cables. Mitsubishi will not be held liable for any problems that should occur as a result of a relayed cable. The customer is responsible for providing measures against noise.
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5. Connectioor