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

Mitsubishi FR-SF-2-18.5KP-C image FR-SF-2-18.5KP-C is an
Drives-AC Spindle manufactured by Mitsubishi
Discovered issues: Bad Circuit Board Component(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: High power drive
Option Card: No Option Card Used (blank)
Panel Mount Type: Intermediate panel mount type
Options: None

Mitsubishi FR-SF-2-18.5KP-BCG image FR-SF-2-18.5KP-BCG is an
Drives-AC Spindle manufactured by Mitsubishi
Discovered issues: Passed Testing - Highly Recommend Recondition
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

Mitsubishi FR-SF-2-37K-BCG image FR-SF-2-37K-BCG is an
Drives-AC Spindle manufactured by Mitsubishi
Discovered issues: Bad Circuit Board Component(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: SF-BS Card with Bus link
Panel Mount Type: Intermediate panel mount type
Options: Optional side mounting terminal covers

Mitsubishi FR-SF-2-22K-CE image FR-SF-2-22K-CE is an
Drives-AC Spindle manufactured by Mitsubishi
Discovered issues: 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: 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

Mitsubishi FR-SF-2-26K image FR-SF-2-26K is an
Drives-AC Spindle manufactured by Mitsubishi
Discovered issues: Bad Circuit Board Component(s), Bad Cooling Fans, Bad Fuse, Bad Magnetic Contactor, Relay, 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

Mitsubishi FR-SF-2-45K-BCG image FR-SF-2-45K-BCG is an
Drives-AC Spindle manufactured by Mitsubishi
Discovered issues: Bad Circuit Board Component(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-BS Card with Bus link
Panel Mount Type: Intermediate panel mount type
Options: Optional side mounting terminal covers

Mitsubishi FR-SF-2-11KP-RC image FR-SF-2-11KP-RC is an
Drives-AC Spindle manufactured by Mitsubishi
Discovered issues: Bad Output Transistors/SCRs
Drive Type: FR-SF AC Spindle Inverter
Power Supply: 200V
Output Capacity: 11kW
High Power Option: High power drive
Option Card: SF-OR Card
Panel Mount Type: Intermediate panel mount type
Options: None

Mitsubishi FR-SF-2-26K-BCE image FR-SF-2-26K-BCE is an
Drives-AC Spindle manufactured by Mitsubishi
Discovered issues: 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: 26kW
High Power Option: none
Option Card: SF-BS Card with Bus link
Panel Mount Type: Intermediate panel mount type
Options: Optional side and top mounting terminal covers

Mitsubishi FR-SF-2-11KP-TC image FR-SF-2-11KP-TC is an
Drives-AC Spindle manufactured by Mitsubishi
Discovered issues: Bad Output Transistors/SCRs
Drive Type: FR-SF AC Spindle Inverter
Power Supply: 200V
Output Capacity: 11kW
High Power Option: High power drive
Option Card: SF-TL Card
Panel Mount Type: Intermediate panel mount type
Options: None

Mitsubishi FR-SF-2-26KP-C image FR-SF-2-26KP-C is an
Drives-AC Spindle manufactured by Mitsubishi
Discovered issues: Bad Cooling Fans, Bad Gate Section/Board, Bad Power Board, Excessive Dirt/Debris, Leaky Capacitors (Open, Corroded Traces), Bad Output Transistors/SCRs
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

Mitsubishi FR-SF-2-7.5K-BC image FR-SF-2-7.5K-BC is an
Drives-AC Spindle manufactured by Mitsubishi
Discovered issues: Bad Circuit Board Component(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: 7.5kW
High Power Option: none
Option Card: SF-BS Card with Bus link
Panel Mount Type: Intermediate panel mount type
Options: None

Mitsubishi FR-SF-2-7.5KP-BC image FR-SF-2-7.5KP-BC is an
Drives-AC Spindle manufactured by Mitsubishi
Discovered issues: Bad Circuit Board Component(s), Bad Cooling Fans, Bad Gate Section/Board, Bad Magnetic Contactor, Relay, Bad Output Transistors/SCRs, Bad Power Board, Bad Power Section/Board, Bad Precharge Resistor, Leaky Capacitors (Open, Corroded Traces)
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

Mitsubishi FR-SF-2-18.5K-TC image FR-SF-2-18.5K-TC is an
Drives-AC Spindle manufactured by Mitsubishi
Discovered issues: Bad Circuit Board Component(s), Bad Cooling Fans, Bad Magnetic Contactor, Relay, Bad Main Switch, 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: SF-TL Card
Panel Mount Type: Intermediate panel mount type
Options: None

Mitsubishi FR-SF-2-11KP-C image FR-SF-2-11KP-C is an
Drives-AC Spindle manufactured by Mitsubishi
Discovered issues: Bad Circuit Board Component(s), Bad Cooling Fans, Bad Magnetic Contactor, Relay, Bad Output Transistors/SCRs, 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: No Option Card Used (blank)
Panel Mount Type: Intermediate panel mount type
Options: None

Mitsubishi FR-SF-4-18.5KP-TG image FR-SF-4-18.5KP-TG is an
Drives-AC Spindle manufactured by Mitsubishi
Discovered issues: Bad Cooling Fans, Bad Magnetic Contactor, Relay, Bad Power Board, Bad Power Section/Board, Leaky Capacitors (Open, Corroded Traces)
Drive Type: FR-SF AC Spindle Inverter
Power Supply: 400V
Output Capacity: 18.5kW
High Power Option: High power drive
Option Card: SF-TL Card
Panel Mount Type: Panel inside mount type (blank)
Options: Optional side mounting terminal covers

Mitsubishi FR-SF-2-22K-R image FR-SF-2-22K-R is an
Drives-AC Spindle manufactured by Mitsubishi
Discovered issues: Bad Circuit Board Component(s), Bad Cooling Fans, Bad Gate Section/Board, Bad Magnetic Contactor, Relay, Bad Power Board, Excessive Dirt/Debris, Leaky Capacitors (Open, Corroded Traces), May Require Board Replacement
Drive Type: FR-SF AC Spindle Inverter
Power Supply: 200V
Output Capacity: 22kW
High Power Option: none
Option Card: SF-OR Card
Panel Mount Type: Panel inside mount type (blank)
Options: None

Mitsubishi FR-SF-2-18.5KP-TCG image FR-SF-2-18.5KP-TCG is an
Drives-AC Spindle manufactured by Mitsubishi
Discovered issues: Bad Cooling Fans, Bad Magnetic Contactor, Relay, 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-TL Card
Panel Mount Type: Intermediate panel mount type
Options: Optional side mounting terminal covers

Mitsubishi FR-SF-2-11KP-DC image FR-SF-2-11KP-DC is an
Drives-AC Spindle manufactured by Mitsubishi
Discovered issues: 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: SF-DA Card with digital speed input
Panel Mount Type: Intermediate panel mount type
Options: None

Mitsubishi FR-SF-2-11K image FR-SF-2-11K is an
Drives-AC Spindle manufactured by Mitsubishi
Discovered issues: Bad Circuit Board Component(s), Bad Control Section/Board, 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: 11kW
High Power Option: none
Option Card: No Option Card Used (blank)
Panel Mount Type: Panel inside mount type (blank)
Options: None

Mitsubishi FR-SF-2-18.5KP-TC image FR-SF-2-18.5KP-TC is an
Drives-AC Spindle manufactured by Mitsubishi
Discovered issues: Bad Cooling Fans, Bad Magnetic Contactor, Relay, 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-TL Card
Panel Mount Type: Intermediate panel mount type
Options: None

Mitsubishi FR-SF-2-18.5K-BCG image FR-SF-2-18.5K-BCG is an
Drives-AC Spindle manufactured by Mitsubishi
Discovered issues: Bad Circuit Board Component(s), Bad Cooling Fans, Bad Gate Section/Board, Bad Magnetic Contactor, Relay, Excessive Dirt/Debris, Leaky Capacitors (Open, Corroded Traces), No Display
Drive Type: FR-SF AC Spindle Inverter
Power Supply: 200V
Output Capacity: 18.5kW
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

Mitsubishi FR-SF-2-26K-BCG image FR-SF-2-26K-BCG is an
Drives-AC Spindle manufactured by Mitsubishi
Discovered issues: Bad Power Board, Not Repairable Recommend Replacement
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

Mitsubishi FR-SF-2-7.5K image FR-SF-2-7.5K is an
Drives-AC Spindle manufactured by Mitsubishi
Discovered issues: Bad Cooling Fans, Bad Magnetic Contactor, Relay, Excessive Dirt/Debris, Leaky Capacitors (Open, Corroded Traces)
Drive Type: FR-SF AC Spindle Inverter
Power Supply: 200V
Output Capacity: 7.5kW
High Power Option: none
Option Card: No Option Card Used (blank)
Panel Mount Type: Panel inside mount type (blank)
Options: None

Mitsubishi FR-SF-2-18.5K-RC image FR-SF-2-18.5K-RC is an
Drives-AC Spindle manufactured by Mitsubishi
Discovered issues: Bad Circuit Board Component(s), Bad Cooling Fans, Bad Gate Section/Board, Bad Magnetic Contactor, Relay, Bad Power Section/Board, Excessive Dirt/Debris, Passed Testing - Highly Recommend Recondition, Leaky Capacitors (Open, Corroded Traces), Physical Damage to the Circuit Board/s
Drive Type: FR-SF AC Spindle Inverter
Power Supply: 200V
Output Capacity: 18.5kW
High Power Option: none
Option Card: SF-OR Card
Panel Mount Type: Intermediate panel mount type
Options: None