Drives-AC Spindle Mitsubishi FR-SF | Repairs Precision Zone

Mitsubishi FR-SF AC Spindle Drive Repair Specialists

Here at Precision Zone, one of our specialties is the repair services of AC spindle drive units. One series that we often work on is the Mitsubishi FR-SF AC Spindle series.

One series of Mitsubishi’s AC spindle line is the FR-SF series. This series has quite a few options to abide to multiple application requirements. FR-SF series spindles can be set up to accept 200VAC or 460VAC input power and have output capacity ratings starting at 3.7kW and can go up to 45kW. There is a high power option, multiple option cards available, and two different mounting type’s available – intermediate panel mounting or panel inside mounting.

Option cards which are available will apply to different configurations. The SF-OR card can be used when an oriented spindle stop function is required – magnetic sensor orientation, encoder orientation, or Z-phase controlled orientation. SF-DA is an option card as well that is applicable when a digital speed input is being sent to the spindle drive. On top of these two, SF-TL cards are installed when the spindle unit needs to be bus-linked to M300 series controlled machines.

The top control board on the FR-SF spindle unit has six 7-segment displays grouped together allowing for easy parameter access, monitoring functions, as well as alarm codes which speed up and assist with troubleshooting when applicable.

When assessing the functionality of a drive, our repair team typically conducts a four-step check:

1. Visual Overview

2. Static Test

3. Checks Under Power

4. Alarm Codes Verification

This overview is Precision Zone’s basic troubleshooting process. Once our repair team starts on the job, we use specialized and customized testing fixtures, Huntron trackers, signal generators, oscilloscopes, milli and megaohm meters, as well as any other necessary tools we have available to assure quality repair work. Most importantly, every repair is fully tested in our custom-built simulators under load with a motor to replicate real-life working environment.

Precision Zone goes as far as using heating chambers and overnight dynamic testing, when applicable, to guarantee performance of the repaired product when it arrives back with the customer.

Repair Process for Mitsubishi FR-SF AC Spindle Drive Units

Visual Overview

When conducting a visual check, the technician inspects the drive for any mechanical damage to the drive itself and any printed circuit boards (PCB). The technician then proceeds to verify connections are tight and correct inside the drive and there are no loose screws, wires or debris. Additionally, the unit is checked for any burn marks on the components, PCBs or chassis. During the visual inspection, excessive dirt on cooling components is noted as well as the functionality of the heat sink.

Basic Static Check

Input Module Testing

If one is unfamiliar with working on these units, it is not recommended to perform the following tests as it does require opening the drive to access the DC bus. The input modules on these units can be tested by use of a digital multimeter with diode checking capabilities. Upon opening the hinged door, the R, S, and T terminals can be found on the inner portion of the magnetic contactor while the positive/negative bus bars along the DC bus capacitors can be used for positive and negative test points.

Positive Lead	Negative Lead	Reading
R	Positive Bus Bar	0.32V-0.44V
S	Positive Bus Bar	0.32V-0.44V
T	Positive Bus Bar	0.32V-0.44V
Negative Bus Bar	R	0.32V-0.44V
Negative Bus Bar	S	0.32V-0.44V
Negative Bus Bar	T	0.32V-0.44V

Output Module Testing

Using the same type of test as above, the output modules can be checked as well. Our technicians are also equipped with huntron devices further verify their integrity. Different sized modules are generally used based on the drive capacity meaning readings may vary between units. The important part is that all readings are within 10% of one another.

Positive Lead	Negative Lead	Reading
U	Positive Bus Bar	0.34V-0.39V
V	Positive Bus Bar	0.34V-0.39V
W	Positive Bus Bar	0.34V-0.39V
Negative Bus Bar	U	0.34V-0.39V
Negative Bus Bar	V	0.34V-0.39V
Negative Bus Bar	W	0.34V-0.39V

Mitsubishi FR-SF Spindle Drive Common Alarms

List of Alarms

Alarm Code	Description	Checks
AL. 10 Undervoltage	Main power supply voltage has dropped below a specific threshold – usually below 170VAC	Verify incoming voltage Check voltage between power supply pins ACDOWN an D05A, Normally +5V
AL.23 Excessive Speed Error	Discrepancy between command speed and current speed of motor	Verify motor load is within the proper range Encoder troubles, swap motor out with known working, when possible Failure of CPU1/2 or SE-101 board
AL.32 Inverter IOC	Excessive current has been detected flowing through the inverter section of drive unit	Check cables for poor insulation Perform megohm test on motor Use “Output Module Testing” test to verify modules Check for ground faults
AL.37 Parameter Error	Parameter value being checked is out of the permissible range	Disconnect all but incoming power cables, see if problem persists Verify parameter is properly set for current application If possible, switch control card out with known working one

For a full list of Mitsubishi spindle drive alarm troubleshooting, see manual below:

https://s3.amazonaws.com/Icarus/DOCUMENTS/Mitsubishi_Alarms_Faults_79.pdf

The list of alarms within the manual is a good starting point for troubleshooting Mitsubishi FR-SF spindle drives. If any additional troubleshooting assistance is needed for the FR-SF unit or any other product, Precision Zone offers free technical support. Feel free to contact us via phone or email to get in touch with our experienced technical support team.

Precision Zone Repair Benefits for Mitsubishi Spindle Drives

1. FREE evaluation by expert technician includes:

Visual Inspection

Static Check

Power Tests

2. FREE job estimate

3. 12 month warranty on our parts and labor

4. Flat Price

5. Exchange Option

6. Rush Service

Recently Repaired Products

FR-SF-2-11KP-C is an
Drives-AC Spindle manufactured by Mitsubishi
Discovered issues: Board Replacement Required, Multiple signs of previous repair, Parameter/Setting Adjustment
Drive Type: FR-SF AC Spindle Inverter
Power Supply: 200V
Output Capacity: 11kW
High Power Option: High power drive
Option Card: No Option Card Used (blank)
Panel Mount Type: Intermediate panel mount type
Options: None

FR-SF-2-15K-C is an
Drives-AC Spindle manufactured by Mitsubishi
Discovered issues: Bad Capacitor(s), Bad Cooling Fans, Bad Magnetic Contactor, Relay, Bad Power Board, Excessive Dirt/Debris, Leaky Capacitors (Open, Corroded Traces)
Drive Type: FR-SF AC Spindle Inverter
Power Supply: 200V
Output Capacity: 15kW
High Power Option: none
Option Card: No Option Card Used (blank)
Panel Mount Type: Intermediate panel mount type
Options: None

FR-SF-2-26K-BCG is an
Drives-AC Spindle manufactured by Mitsubishi
Discovered issues: Bad DCCT, Bad Gate Section/Board, Bad Output Transistors/SCRs
Drive Type: FR-SF AC Spindle Inverter
Power Supply: 200V
Output Capacity: 26kW
High Power Option: none
Option Card: SF-BS Card with Bus link
Panel Mount Type: Intermediate panel mount type
Options: Optional side mounting terminal covers

FR-SF-2-26KP-C is an
Drives-AC Spindle manufactured by Mitsubishi
Discovered issues: Bad Gate Section/Board, Bad Output Transistors/SCRs, Bad Power Board
Drive Type: FR-SF AC Spindle Inverter
Power Supply: 200V
Output Capacity: 26kW
High Power Option: High power drive
Option Card: No Option Card Used (blank)
Panel Mount Type: Intermediate panel mount type
Options: None

FR-SF-2-22K-CE is an
Drives-AC Spindle manufactured by Mitsubishi
Discovered issues: Bad Capacitor(s), Bad Circuit Board Component(s), Bad Cooling Fans, Bad Magnetic Contactor, Relay
Drive Type: FR-SF AC Spindle Inverter
Power Supply: 200V
Output Capacity: 22kW
High Power Option: none
Option Card: No Option Card Used (blank)
Panel Mount Type: Intermediate panel mount type
Options: Optional side and top mounting terminal covers

FR-SF-2-7.5K-BC is an
Drives-AC Spindle manufactured by Mitsubishi
Discovered issues: Bad Capacitor(s), Bad Cooling Fans, Bad Magnetic Contactor, Relay, Bad Power Board, Bad Power Section/Board, Excessive Dirt/Debris, Leaky Capacitors (Open, Corroded Traces), Missing parts/components
Drive Type: FR-SF AC Spindle Inverter
Power Supply: 200V
Output Capacity: 7.5kW
High Power Option: none
Option Card: SF-BS Card with Bus link
Panel Mount Type: Intermediate panel mount type
Options: None

FR-SF-2-26KP-RC is an
Drives-AC Spindle manufactured by Mitsubishi
Discovered issues: Bad Gate Section/Board, Bad Output Transistors/SCRs, Bad Power Board
Drive Type: FR-SF AC Spindle Inverter
Power Supply: 200V
Output Capacity: 26kW
High Power Option: High power drive
Option Card: SF-OR Card
Panel Mount Type: Intermediate panel mount type
Options: None

FR-SF-2-26K is an
Drives-AC Spindle manufactured by Mitsubishi
Discovered issues: Bad Cooling Fans, Bad Gate Section/Board, Bad Magnetic Contactor, Relay, Bad Output Transistors/SCRs, Bad Power Board, Excessive Dirt/Debris, Leaky Capacitors (Open, Corroded Traces)
Drive Type: FR-SF AC Spindle Inverter
Power Supply: 200V
Output Capacity: 26kW
High Power Option: none
Option Card: No Option Card Used (blank)
Panel Mount Type: Panel inside mount type (blank)
Options: None

FR-SF-2-11KP-BC is an
Drives-AC Spindle manufactured by Mitsubishi
Discovered issues: Bad Capacitor(s), Bad Cooling Fans, Bad Magnetic Contactor, Relay, Bad Power Board, Bad Power Section/Board, Excessive Dirt/Debris, Leaky Capacitors (Open, Corroded Traces)
Drive Type: FR-SF AC Spindle Inverter
Power Supply: 200V
Output Capacity: 11kW
High Power Option: High power drive
Option Card: SF-BS Card with Bus link
Panel Mount Type: Intermediate panel mount type
Options: None

FR-SF-2-18.5KP-BCG is an
Drives-AC Spindle manufactured by Mitsubishi
Discovered issues: Bad Capacitor(s), Bad Control Section/Board, Bad Cooling Fans, Bad Gate Section/Board, Bad Magnetic Contactor, Relay, Bad Output Transistors/SCRs, Bad Power Board, Excessive Dirt/Debris, Leaky Capacitors (Open, Corroded Traces)
Drive Type: FR-SF AC Spindle Inverter
Power Supply: 200V
Output Capacity: 18.5kW
High Power Option: High power drive
Option Card: SF-BS Card with Bus link
Panel Mount Type: Intermediate panel mount type
Options: Optional side mounting terminal covers

FR-SF-2-37K-BCG is an
Drives-AC Spindle manufactured by Mitsubishi
Discovered issues: Bad Capacitor(s), Bad Cooling Fans, Bad Gate Section/Board, Bad Magnetic Contactor, Relay, Bad Power Board, Excessive Dirt/Debris, Leaky Capacitors (Open, Corroded Traces)
Drive Type: FR-SF AC Spindle Inverter
Power Supply: 200V
Output Capacity: 37kW
High Power Option: none
Option Card: SF-BS Card with Bus link
Panel Mount Type: Intermediate panel mount type
Options: Optional side mounting terminal covers

FR-SF-2-11K-BC is an
Drives-AC Spindle manufactured by Mitsubishi
Discovered issues: Bad Capacitor(s), Bad Cooling Fans, Bad Magnetic Contactor, Relay, Bad Power Board, Excessive Dirt/Debris, Leaky Capacitors (Open, Corroded Traces), Wrong/corrupted parameters
Drive Type: FR-SF AC Spindle Inverter
Power Supply: 200V
Output Capacity: 11kW
High Power Option: none
Option Card: SF-BS Card with Bus link
Panel Mount Type: Intermediate panel mount type
Options: None

FR-SF-2-26K-TCE is an
Drives-AC Spindle manufactured by Mitsubishi
Discovered issues: Bad Capacitor(s), Bad Cooling Fans, Bad Gate Section/Board, Bad Magnetic Contactor, Relay, Bad Power Board, Board Replacement Required, Excessive Dirt/Debris, Leaky Capacitors (Open, Corroded Traces)
Drive Type: FR-SF AC Spindle Inverter
Power Supply: 200V
Output Capacity: 26kW
High Power Option: none
Option Card: SF-TL Card
Panel Mount Type: Intermediate panel mount type
Options: Optional side and top mounting terminal covers

FR-SF-2-37K is an
Drives-AC Spindle manufactured by Mitsubishi
Discovered issues: Bad Capacitor(s), Bad Cooling Fans, Bad Gate Section/Board, Bad Magnetic Contactor, Relay, Bad Output Transistors/SCRs, Bad Power Board, Excessive Dirt/Debris, Leaky Capacitors (Open, Corroded Traces)
Drive Type: FR-SF AC Spindle Inverter
Power Supply: 200V
Output Capacity: 37kW
High Power Option: none
Option Card: No Option Card Used (blank)
Panel Mount Type: Panel inside mount type (blank)
Options: None

FR-SF-2-15K-BCG is an
Drives-AC Spindle manufactured by Mitsubishi
Discovered issues: Bad Gate Section/Board, Bad Output Transistors/SCRs
Drive Type: FR-SF AC Spindle Inverter
Power Supply: 200V
Output Capacity: 15kW
High Power Option: none
Option Card: SF-BS Card with Bus link
Panel Mount Type: Intermediate panel mount type
Options: Optional side mounting terminal covers

FR-SF-2-7.5KP-BC is an
Drives-AC Spindle manufactured by Mitsubishi
Discovered issues: Bad Gate Section/Board, Bad Output Transistors/SCRs
Drive Type: FR-SF AC Spindle Inverter
Power Supply: 200V
Output Capacity: 7.5kW
High Power Option: High power drive
Option Card: SF-BS Card with Bus link
Panel Mount Type: Intermediate panel mount type
Options: None

FR-SF-2-11KP-DC is an
Drives-AC Spindle manufactured by Mitsubishi
Discovered issues: Bad Capacitor(s), Bad Cooling Fans, Bad Gate Section/Board, Bad Magnetic Contactor, Relay, Bad Output Transistors/SCRs, Bad Power Board, Excessive Dirt/Debris, Leaky Capacitors (Open, Corroded Traces)
Drive Type: FR-SF AC Spindle Inverter
Power Supply: 200V
Output Capacity: 11kW
High Power Option: High power drive
Option Card: SF-DA Card with digital speed input
Panel Mount Type: Intermediate panel mount type
Options: None

FR-SF-2-45K-TC is an
Drives-AC Spindle manufactured by Mitsubishi
Discovered issues: Bad Capacitor(s), Bad Cooling Fans, Bad Gate Section/Board, Bad Magnetic Contactor, Relay, Bad Output Transistors/SCRs, Bad Power Board, Excessive Dirt/Debris, Leaky Capacitors (Open, Corroded Traces)
Drive Type: FR-SF AC Spindle Inverter
Power Supply: 200V
Output Capacity: 45kW
High Power Option: none
Option Card: SF-TL Card
Panel Mount Type: Intermediate panel mount type
Options: None

FR-SF-2-22K is an
Drives-AC Spindle manufactured by Mitsubishi
Discovered issues: Bad Capacitor(s), Bad Cooling Fans, Bad Gate Section/Board, Bad Magnetic Contactor, Relay, Bad Power Board, Excessive Dirt/Debris, Leaky Capacitors (Open, Corroded Traces)
Drive Type: FR-SF AC Spindle Inverter
Power Supply: 200V
Output Capacity: 22kW
High Power Option: none
Option Card: No Option Card Used (blank)
Panel Mount Type: Panel inside mount type (blank)
Options: None

FR-SF-2-11K is an
Drives-AC Spindle manufactured by Mitsubishi
Discovered issues: Bad Control Section/Board
Drive Type: FR-SF AC Spindle Inverter
Power Supply: 200V
Output Capacity: 11kW
High Power Option: none
Option Card: No Option Card Used (blank)
Panel Mount Type: Panel inside mount type (blank)
Options: None

FR-SF-2-45K is an
Drives-AC Spindle manufactured by Mitsubishi
Discovered issues: Bad Capacitor(s), Bad Cooling Fans, Bad Gate Section/Board, Bad Magnetic Contactor, Relay, Bad Output Transistors/SCRs, Bad Power Board, Excessive Dirt/Debris, Leaky Capacitors (Open, Corroded Traces)
Drive Type: FR-SF AC Spindle Inverter
Power Supply: 200V
Output Capacity: 45kW
High Power Option: none
Option Card: No Option Card Used (blank)
Panel Mount Type: Panel inside mount type (blank)
Options: None

FR-SF-2-18.5K is an
Drives-AC Spindle manufactured by Mitsubishi
Discovered issues: Bad Capacitor(s), Bad Cooling Fans, Bad Magnetic Contactor, Relay, Bad Power Board, Excessive Dirt/Debris, Leaky Capacitors (Open, Corroded Traces)
Drive Type: FR-SF AC Spindle Inverter
Power Supply: 200V
Output Capacity: 18.5kW
High Power Option: none
Option Card: No Option Card Used (blank)
Panel Mount Type: Panel inside mount type (blank)
Options: None

FR-SF-2-11KP is an
Drives-AC Spindle manufactured by Mitsubishi
Discovered issues: Bad Capacitor(s), Bad Cooling Fans, Bad Gate Section/Board, Bad Magnetic Contactor, Relay, Bad Output Transistors/SCRs, Bad Power Board, Excessive Dirt/Debris
Drive Type: FR-SF AC Spindle Inverter
Power Supply: 200V
Output Capacity: 11kW
High Power Option: High power drive
Option Card: No Option Card Used (blank)
Panel Mount Type: Panel inside mount type (blank)
Options: None

FR-SF-2-22K-T is an
Drives-AC Spindle manufactured by Mitsubishi
Discovered issues: Bad Magnetic Contactor, Relay
Drive Type: FR-SF AC Spindle Inverter
Power Supply: 200V
Output Capacity: 22kW
High Power Option: none
Option Card: SF-TL Card
Panel Mount Type: Panel inside mount type (blank)
Options: None