Mitsubishi D700 VFD Installation

 

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Overview

When the spindle is turned on inside the controller software, the 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 set inside of Mach. 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. 

Wiring

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 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.JPG

Figure 1 Control Cable

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.JPG

 

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.

 

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.JPG

Figure 3 Spindle Motor

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 and often times from MachMotion.

Motor (Hp)

Resistance (Ohms)

Continuous Power (W)

Mitsubishi 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

20

18

400

FR-ABR-15K

If there is jumper across the PR and PX terminals of the VFD, remote it. (not all models will have a PX terminal).

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

 

Figure-4-Brake-Resistor.JPG

 

Figure 4 Brake Resistor

Note: Each VFD model is slightly different. Just make sure that you connect the resistor to the correct terminals (PR, P/+).

Programming

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-User-Interface.JPG

 

Figure 5 VFD User 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 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, Er2, Er3, or Er4 error, make sure to put the VFD in PU mode before changing the parameters!

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 Poles / 120

Standard Setup

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

Parameter #

Description

Default

73

Analog Input Selection

10

74

Input Filter Constant

6

 

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

Parameter #

Description

Standard

Range

1†

Maximum Frequency (If less than 120 Hz)

Max Motor Frequency

0-120Hz

2

 Minimum Frequency

0

0-120Hz

3

Base Frequency (Continuous)

-set to whatever actual spindle frequency is.

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

19

Base Frequency Voltage

Motor Voltage

 

20

Accel / Decel Reference Frequency

Max Motor Frequency

1-400Hz

72

PWM Frequency Selection

10

0-15

125†

Maximum Frequency

Max Motor Frequency

0-400Hz

158

Load Meter Analog Output (AM Terminal)

17

 

180*

Orient Start Input (RL Terminal)

22

 

190

Zero Speed Output (RUN Terminal)

100

 

192

Fault Output (IPF Terminal)

99

 

193*

Orient Complete Output (OL Terminal)

127

 

197

Up to Speed Output (SO Terminal)

1

 

All the frequency parameters (1 or 18, 3, 20, 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.

Parameter 72 may also have to be adjusted depending on how your VFD sounds. If it is very noisy or if it sounds like it is grinding, you can try changing this anywhere from 0 to 15.

If you get a regenerative error, you can lengthen the deceleration time (parameter 8).

* not applicable for the D700 model

Should be set according to actual spindle motor frequency. However, P125 can be increased to get a faster spindle speed. Depending on the frequency P1 or P18 may need to be set as well. Start with P125 and test. If desired results are not achieved, then adjust P1 (for up to 120) or P18 (for over 120). SEE WARNING BELOW

WARNING: running a motor at a higher frequency than designed for can result in motor failure. Consult the manual, manufacturer, or qualified personnel for details. MachMotion does not recommend running a motor at a higher frequency than the motor is designed for and is not responsible for any damage as a result from modifying the parameters to do so.

Auto Tuning

If your spindle is not working well, you may need to use auto tuning. Most systems will not need this.

Parameter #

Description

Standard

Range

71

Applied Motor

13

0,1,3,13,23,40,43,50,53

80

Motor Capacity

Rated Motor kW

0.1-7.5kW


If you do not have a Mitsubishi spindle motor, just set parameter 71 to 13. Otherwise enter the motor code into the parameter.

To auto tune your VFD, follow the instructions below.

  1. Set parameter 96 to 11.
  2. Press the Mode button until the MON LED turns on.
  3. Press the Run You should see 12 in the display while the spindle motor runs. If the auto tuning is successful, you will see the display change to 13.
  4. Press the Stop/Reset

Auto tuning should now be complete. Make sure to exit PU mode! If your spindle is still not running well, please call MachMotion at 573-368-7399 or Contact Mitsubishi Support directly, at 847-478-2100.

Brake Resistor

For a brake resistor, you must set up two other parameters.

Parameter #

Description

Standard

Range

30

Regenerative Function

1

1

70

Special Regenerative Brake Duty

15

0-30%

 

You will have to experiment with the regenerative brake duty. If you get a regenerative error (E.OV1 through E.OV3), then the duty is set too high. If your spindle does not stop fast enough, then the duty is too low.

Clear Parameters

If you are uncertain if the current parameters in the VFD are correct or if you just want to begin with default values, follow the procedure below to clear all the parameters.

  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”.
  3. Rotate the scroll wheel until “Pr.CL” and “(ALLC)” appear.
  4. Press the Set button once. The initial value “0” should appear.
  5. Change the value to “1” by using the scroll wheel.
  6. Press the Set button again. The screen will start to flash between “Pr.CL”, “(ALLC)”, and “1”.
  7. Put the VFD back into EXT mode by pressing the PU/EXT Make sure that the LED near EXT is on.
  8. Cycle the power to the VFD. Make sure to wait until the VFD completely turns off before repowering it.

Now you must setup all the standard values as shown in Standard Setup section.

Test Run

You can test your spindle motor directly from your VFD. Follow the sequence below.

  1. Press PU/EXT to put the VFD into PU mode (make sure the PU LED is on).
  2. Press the Mode button until the MON LED turns on.
  3. Turn the wheel to set your frequency and press Set. The screen will flash between F and your frequency.
  4. Press Run and the motor should begin moving.
  5. Press Stop/Reset to stop the motor.

If it seems to be running well, you can continue below with the controller setup. Make sure to exit PU mode!

Mach4 and Mach4 Setup

Note: For Mach4, the following ideas apply, but you need to select the Configure -> Mach… menu options, then select the Spindle tab to enter the RPM info.

With your spindle wired and programmed, it is time to set up Mach4.  You must enter in your maximum RPM for the spindle motor so Mach4 knows how to scale the analog voltage output. If you have different gears, you can set up multiple maximum speeds. Mach4 uses a different pulley for each different speed configuration. For example, one pulley could be set to 75 to 300 RPM for a low speed (at 300 RPM the control will output 10V). A medium speed pulley could go from 300 to 1200 RPM and high speed pulley could run from 1200 to 2400 RPM.

To change your pulleys, go to Config -> Spindle Pulleys. The Pulley Selection window will appear as shown in Figure 7.

    Figure-6-Spindle-Pulleys.JPG     

Figure 6 Spindle Pulleys                                                                                        

Figure-7-Pulley-Speed-Setup.JPG

 

Figure 7 Pulley Speed Setup

Use the drop down menu titled Current Pulley to select the pulley you want to update. Enter in your maximum and minimum speeds for each pulley. Then select the pulley you want to load and press OK.

You can also change pulleys by using M41-M45. The macros can be used to just change pulleys in Mach4, or you could use them to automatically change gears on your machine. Outputs 12-16 are configured to shift between gears 1 and 5. To shift your machine into neutral, run M40. Open up the macros with the VB Script Editor for more details.

Mach4 should now be set up correctly.

 

 

Turning on Your Spindle

Note: For Mach4, you can set the speed in the Speed text box and use the Spindle FWD and Spindle REV buttons in the Machine tab.

To turn on your spindle, begin by setting up your spindle speed. Navigate to Prog Run and click on the Spindle S: user input. Enter your speed and press Send as shown in Figure 8.

Figure-8-Setting-up-Spindle-Speed.JPG

Figure 8 Setting up Spindle Speed

Control the spindle by pressing the FWD and REV buttons. Pressing the button again turns the spindle back off.

  Figure-10-Spindle-Buttons.JPG                    

Figure 10 Spindle Buttons

Note: If you don’t have the MachMotion screen set, turn on the spindle by pressing the button Spindle CW F5. When the button is flashing, the spindle should be on.

Figure-11-Spindle-Speed.JPG

Figure 11 Spindle Speed

You can also control the spindle by using M-codes. As a reference use the table below.

M-Code

Function

M3

Clockwise

M4

Counter/Clockwise

M5

Stop

 

Test your spindle by commanding it to go half of the pulley’s maximum speed. If it is working correctly, your VFD will be running at close to half of the maximum frequency. Next command it to move the pulley’s maximum speed. Your VFD should now be running at the maximum frequency. If the frequency is very far off, check your calculations and make sure that the VFD was programmed correctly. If it still is not correct, you may have to calibrate your spindle.

If your VFD is not turning on or if it has a fault, see the trouble shooting section below.

Calibrating Your Spindle

For most Mach4 systems you can completely skip this section. If your Breakout Board is not outputting the correct analog voltage, you can calibrate your spindle by using the procedure below.

There are two different methods to use depending on if you know the spindle speed or not. It is simpler to calibrate your spindle if you know the speed.

Begin by finding the current velocity of your spindle. On the top menu bar select Config, then Motor Tuning. You should see the Motor Tuning and Setup window as shown below.

Figure-12-Motor-Tuning-and-Setup.JPG

Figure 12 Motor Tuning and Setup

On the right column titled Axis Selection, press the Spindle button. The spindle parameters will be loaded. Now record the Velocity value located on the bottom right of the window. See the figure below.

 Figure-13-Spindle-Velocity-Value.JPG

Figure 13 Spindle Velocity Value

In Figure 13 the spindle’s current velocity is 1575.

With Spindle Feedback

If you have spindle feedback or a tachometer, you can use the shorter method to calibrate your spindle. Simply find the values shown below.

 

Current Velocity
Use the velocity value found above from the Motor Tuning and Setup window.

Commanded RPM
Enter in a spindle speed as shown above. Then turn the spindle on.

Actual RPM
Record the actual speed either using a tachometer or another method of spindle feedback.

 

Now plug these values into this formula:

New Velocity = Current Velocity*(Commanded RPM / Actual RPM)

Your new velocity value should be fairly close to 1575. If not, check your calculation again.

With your new velocity calculation, go to the Motor Tuning and Setup window by selecting Config, then Motor Tuning. Press the Spindle button and enter in your new velocity. Press SAVE AXIS SETTINGS before pressing OK. Your spindle should now be calibrated.

 

Without Spindle Feedback

If you do not have a method to calculate your spindle speed, you can calibrate your spindle by using the frequency of your variable frequency drive (VFD). However, you need to find the five different values as shown below.

Current Velocity
Use the velocity value found above from the Motor Tuning and Setup window.

Pulley Max
Go to Config on the main menu bar, then select Spindle Pulleys… You will see the following window:

 

Figure-14-Max-Pulley-Speed.JPG

Figure 14 Max Pulley Speed

Your current pulley will be selected. Your Max Speed value is your pulley max needed for the spindle calibration.

Max VFD Hz
The maximum motor frequency is your Max VFD Hz (assuming your VFD is set up as shown above).

Commanded RPM
Enter in a spindle speed as shown above. Then turn the spindle on.

Actual Hz
Your VFD should display the current frequency in Hz, which is the Actual Hz value.

With the above information, you are ready to calculate your new velocity. Use the formula below:

New Velocity = Current Velocity*(Max VFD Hz *Commanded RPM/Pulley Max)/Actual Hz.

Your new velocity value should be fairly close to 1575. If not, check your calculation again.

Now go to the Motor Tuning and Setup window by selecting Config, then Motor Tuning. Press the Spindle button and enter in your new velocity. Press SAVE AXIS SETTINGS before pressing OK. Your spindle should now be calibrated.

Trouble Shooting

If your spindle is not turning on, follow the procedure below.

  1. Check the REV and FWD LEDs on the Breakout Board.
    1. Neither REV nor FWD ever come on:
      1. Make sure your spindle is enabled (Config->Ports and Pins->Motor Outputs).
      2. Set the spindle’s Step Pin# to 1 and the Step Port# to 2 (Config->Ports and Pins->Motor Outputs).
  • Enable outputs 1 and 2, set both Port#’s to 2 and the Pin#’s to 14 and 16 respectively (Config->Ports and Pins->Output Signals).
  1. Make sure the check box Disable Spindle Relays is unchecked and that the Clockwise Output # is 1 and the Counterclockwise Output # is 2. Also, select the check box PWM Control and set the PWM Base Freq. to 100 (Config->Ports and Pins->Spindle Setup).
  1. REV and/or FWD do work
    1. Set the spindle speed to the maximum pulley speed.
    2. Check the 0-10V on 0-10 terminal on the Apollo Breakout Board with a voltmeter. You should read 10V.
  • Check your wiring.

Alarm List

If your VFD has an alarm, use the lists below to figure out what to do.

Mitsubishi-D700-Alarm-List.JPG 

 Mitsubishi-D700-Fault-List.JPG

Warranty Information

MachMotion warranty policy is subject to change. Updated information is available at our website:
https://machmotion.com/warranty

 

The MachMotion Team
http://www.machmotion.com
14518 County Road 7240, Newburg, MO 65550
(573) 368-7399 • Fax (573) 341-2672

 

 

 


Revision #16
Created Mon, Oct 23, 2017 8:40 AM by Aaron
Updated Mon, Jul 29, 2019 3:55 PM by Dan