Operating lnstructions# 039133 E
Electronic Frequency Converter
Type PCF 310
List of contents
1 Safety instructions
1.1 Warnings and symbols
2 Characteristics
2.1 Technical Data
2.2 Dimensions
3 Putting into operation
4 Conditions for use
4.1 Maintenance
5 Warranty
6 Remote control of the frequency
converter
7 Operating faults
7.1 Other possible faults
8 Spare Parts
Appendix
A Arrangement of the assernblies
B Control PCB
C Wiring diagram Output module
D Wiring diagram Smoothing unit
E Connection diagram HAN 6 I 2-ph.
F Connection diagram Harting EMC
/15P and 3-ph.
G Wiring of the output receptacle
1. Safety instructions
According to the provision of the EC
guideline on Machinery 89/392 EEC, version
91/368 EEC (or 93/44 with effect from 1 July
1994 onwards), commissioning of the
components is prohibited until conformity of
the complete operational machine in
accordance with the above guideline has
been established.
The frequency converter may only be used
for the designated application in an
industrial sphere.
The frequency converter can be
de-energised by pulling the mains plug.
The stop-button does not de-energise the
output.
Measurements and tests on the frequency
converter or opening of the units is only
allowable for authorised qualified
personnel.
Befor opening the unit it is essential to
disconnect the power plug and wait for at
least 4 minutes.
1.1 Warnings and Symbols lndication of effective spindie speed
with 3-character digital display. Load
The following signs and designations are used state of converter indicated by LED
in the manual to designate instructions of the strip.
particular importance.
Spindie speed is kept more or less
constant, even under Ioad .
I lmportant (refers to special
information on how to use the Signals to control the working feed rate
machine prohibitions directed supplied as standard.
towards preventing damage)
2.1 Technical data
Attention (refers to special
information on how to use the Standard input voltage: 230 V, single phase
machine I plant most efficiently) Permitted mains valtage variation: +6% I -10%
Line frequency: 50 Hz to 60 Hz
Danger (refers to orders and Maximum output voltage: 220 V
prohibitions designed prevent injury Maximum output frequency: 3000 Hz
or extensive damage) Maximum continuous output current: 10 A
Maximum ambient temperature: 40 oc
2 Characteristics Load power factor: 0.2 to 0.8

Static conversion with semi-conductor Dimensions:

switches, 2-phase or 3-phase,
frequency- proportional output voltage. 19" rack version:

Electronic overload protection, spindie Width of front panel: 483 mm

protected against overheating by Height of front panel: 132.5 mm
integrated PTC thermistor-actuated Depth: 292 mm (approx. 405 mm including
disconnecting device and automatic protruding hardware)
overcurrent trip. Weight: 1o kg

Output protected against Table-top housing version:

short-circuiting.
Width: 440 mm
Time-linear acceleration and Depth: 292 mm (approx. 395 mm including
deceleration action, electronic spindie protruding hardware)
braking. Height: approx. 145 mm (including rubber feet)
Weight: 9.5 kg

Load indicator
LED ..overtoad

1000 / min

Load Iim it .. signal

3~
.. 56 78

2
I 10
g
,-,-"'
IC - . -, [ID
I

u D
1
/~5678
Load change .. signal
2 g
I 10
411 1 10

rn rn oo
START STOP

LED over- LED ..fault .. Spindie start Spindie stop Mains switch
temperature (green) (red)
Installation When the buttans are released , the operating
mode is set automatical ly.
The converters are supplied pre-programmed The following text assumes that the " internal "
for the spindie being driven. However, before mode has been activated. Check mains data.
using, the operator should determine the Campare the specif ications on the spindie
operating mode, if applicable. name- plate with those of the converter.
Check for transit damage.
Piease read the operati ng instructions for t he
spindie and carry out the necessary
.& = Attention preparatory measures.

Before starting the converter Make all the necessary

the remote cantroll plug has electrical connections and
to be connected connect t he oil mist supply lhOim
PTC ' ' T""'"""'""
line, where appropriate .

Setpoi nt Display Mode I = lmportant
potentiomet er
The converter is equipped with a 5-pole
Left-hand
Iimit position
P lnt Interna! operating
elements monitari ng contact receptacle. Th e unit
manual operation w ill not function unless the receptacle is
connected to the system monitaring
circuit. lf several spi ndies are to be
Central posi tion PEXT External operating
driven with one converter, the PTC
elements (remote
control operation) therm ist ors, pressure-operated sw itches
and any other control contacts should
1. Switch off mains power. be connected in series. The total
resistance of the monitaring circuit must
2. Press the start and stop buttans not exceed 800 Q . When using an
simultaneously. Amphenol C 16-3 spindie connector, the
PTC thermistor is connected directly to
3. Whilst holding down the buttons , switch the frequency converter via pins 6 and
on themai ns power. 8, and 9. W hen a mon itaring contact
With the buttans pressed down , adjust receptacle is not in use, the supplied
th e set point potentiometer on the front jumper # 001 230 should be used.
panel, to the desired position (see
chart).

Interface to
machine control
(remote control Mains connector Cooling aircuttet Spindie receptacle
receptacle)

Monitaring contact
receptacle

Cooling air intet from betow

\
Alternative spindie connection
(band tl for units w ith 2 speed ranges)

- 3-
Set the speed to the lowest value. Switch on
the mains power. The converter will perform a
seif-test. Depending on the selected mode, the
display will either show "lnf' (internal) or "EXf'
(external) for a few seconds. lf the tachometer
is connected, the displaywill then briefly show
" tACH"; if no tachometer is detected, the
displaywill show "notA".
Press the start button. The spindie will
aceeierate to the minimum speed value within a
few seconds.
&= Attention
The maximum spindie speed must
never be exceeded , even with the
potentiometer set to maximum. ln
the event of irregularities, please
refer to the section entitled
" Operating faults".
Slowly turn up the setpoint
potentiometer on the front panel
(observing the start-up instructions for
the spindle).
Press the stop button ; the speed will
drop to zero in proportion to time.
&= Danger
Never restart the converter while the
spindie is decelerating, otherwise the
ball bearings may be damaged.
4 Conditions for use
lnstall the converter in such a way that cooling
air circulation is not impeded on any side. The
surrounding area should be kept as cool, clean
and dry as possible. lt is essential to protect
the converter against moisture, chips and direct
oil mist contaminants.
The built-in fan runs temperature-controlled,
but runs continously at any "Err ... " .
4.1 Maintenance
&= Danger
The frequency converter must
only be opened by authorised
qualified personnel.
The frequency converter is maintenance-free.
However, it is advisable to open the unit every
so often to clean it; the frequency of cleaning
will depend on the ambient conditions.
&= Danger
Before opening the unit, it is
essential to disconnect the power
plug and wait for at least 4 minutes
before tauehing any of the internal
components. This is the amount of
time required for the hazardous
live capacitors to become discharged.
5 Warranty
To the exclusion of other claims, we warranty
the products against any defects in material or
workmanship experienced during the first 6
months from the date of invoice.
Under this warranty, we undertake to repair or
replace free of charge any components which
are found by us to be defective, provided they
have not been misused, altered or carelessly
handled. Any complaints must be notified
immediately in writing. The defective units
must be sent unopened and carriage prepaid to
our factory or to one of our authorised service
stations; otherwise, our warranty Obligation
shall be invalidated.
The instructions included in the operating
instructions constitute an integral part of our
conditions of warranty. Failure to observe
these shall entitle us to decline responsibility
under this warranty.
Our warranty obligation is limited to the repair
or replacement of those components which are
verifiably defective, and does not extend to any
consequential damages, whether direct or
indirect, which may be caused by the defective
product. We reserve the right to make
structural changes to the product without prior
notice.
This warranty is exclusive and in lieu of all other
guarantees or warranties, whether written,
verbal or statutory.
6 Remote control of the frequency
converter
&= Attention
The electronic frequency converter
PCF 310 is provided with a remote
control socked as standard.
The interface with " 5" and " 6 " may
only be used in the operating mode
"PEXf'.
. 4
 component of the Ioad. Disregarding the
ii
~ l j l 4~ PCF310
Selpo~nl reached (aclno<e low) electrical Iosses in the windings and friction
g ;;I ~1 .e;1' lasses, this current is approximately equivalent
08::
_1 __ ,_ I -~~f-"' " i33V
H=
~
.'-.)--

ov to the actual torque produced in the spindle.

1
I
I
- -: =-
~'START
~ 5
approx3mAISV
\. . . /
(~ Pulses w llh 6 tJmes outpul
frequency or lachO pulses Consequently, the current measured in the
~l~
k /~lW,_~=====--~
spindie phases, which consists of inductive and
rCS:::J-~----- 7 +1 0V/mb20m A
resistive components, does not relate directly
~------~~
,-------~ 7,5V0100%
to the values shown on the LED strip or those
10 - relevant for portrayal of the effective Ioad
I8 signals.

~ Feed control
K5 ~

~f-f-f-~ "
ln order to maximise chipremoval or monitor
K1 is closed when the spindie speed is zero
K2 closes when the set Ioad Iimit is exceeded the tool status, the frequency converter has an
K3 is closed in the event of a Ioad change
K4 is closed then the unit is oparational adjustable Ioad setting. Upon reaching the set
K5 is closed when the set speed is reached
Ioad Ievei, the converter sends a signal which
enables the controller to reduce the feed speed
in order to prevent overload tripping. The
signal to the controller is activated immediately
6.1 Funktion upon exceeding the set Ioad Iimit.
Approximately 3 seconds after reaching the
Start/stop Ioad Iimit, the spindie speed is reduced to zero
in order to protect the spindle. ln addition , a
A maintained-contact switch is connected to DC valtage which is approximately proportional
contacts 3 and 5. The "START" and " STOP" to the spindie torque is output at the connector
buttans on the front panel are inactivate. J14, which can be used to control the feed
rate. The magnitude of this valtage
Operating Ioad signals corresponds to the LED strip display on the
front panel of the frequency converter - in
Piease note that these signals can only be used other words, at full Ioad (100%), a valtage of
when one spindie is being operated on one 7.5 V is generated and 10 LEDs are illuminated.
frequency converter. The converter can be adjusted to the spindie
type used or the current machining operation
LED is illuminated when the "Ioad Iimit ..
using the " LOAD LIMIT" (I) potentiometer on
signal is triggered the front panel.
Load Iimit" potentio-
meter. Right-hand limit
position corresponds
Evaluating Ioad changes
to maximum Ioad
capacity of the conver-
ter (set in the tactory) With certain machine tools (particularly grinding
10 machines) , it is often desirable to indicate the
9
8 instant of contact between the workpiece and
7 the tool. Unlike conventional methods, which
34~5678
Potentiometer for ad- 6
justing the sensitivity of
5
utilise direct-contact vibration sensors, the
the ""Ioad change ..
signal. Right hand Iimit
2 9
4 PCF 310 evaluates minute torque changes in
position means that the 3
signal is triggered by 1 10 2
the spindle. ln th is way, it is possible to switch
maximum Ioad change
(set in the factory) ..di__".e 1 automatically from a faster feedrate to the
machining feed rate when the tool makes
LED is illuminated wh en
the "Ioad change signal
contact with the workpiece, thereby
is activated. considerably reducing idle grinding times and
minimising the cycle time of the machine,
particularily with coarse premachining
tolerances. The response sensitivity for contact
should be as high as possible, i.e. it should be
General just above the idle Ievei. As this is not constant
over a long period, only dynamic Ioad changes
Compared to the the effective current value are evaluated ; long-term changes, such as
(true RMS) in the spindie phases, which may those caused by temperature etc ., are
vary by less than 30% between idle and full disregarded. Sensitivity must be adapted to
Ioad operation, the PCF 310 evaluates the suit the circumstances using the trimming
current in the DC intermediate circuit, because potentiometer "16." . The signal is designed as
this is independent from the power factor of the a relay contact on connector J14. The contact
spindie (the inductive component is eliminated) is briefly closed in the event of a Ioad change.
and therefore only represents the resistive - 5-
"Speed reached" signal:
This signal should be used to enable the
machine feed. Transistor " 8 " or relay "K5" (cf.
page 3) is only activated if the spindie speed is
greater than or equal to the set speed. The
transistor is blocked by pressing the "STOP"
button , during the acceleration phase, when
the converter is switched oft, and in the event
of overload or some other fault.
''Zero speed " signal:
ln the case of spindies with automatic tool
change facilities, it is essential to ensure that
the tool change is not initiated whilst the
spindie is rotating. ln order to facilitate reliable
locking, the converter contains a relay whose
normally open contact is connected to pins 14
and 15 which can be used to trigger the tool
change sequence.
&= Attention
lf several spindies are
connected to one converter,
the tachometer must not be
connected. ln such cases,
the spindies are operated as
non-modulated asynchronaus
motors and the speed display
indicates the synchronaus speed .
There is no monitaring of the
spindie stop, and in this case,
the " zero speed" signal means
" converter frequency = 0" .
lf necessary, the automatic tool
change should be delayed, or
the spindie stop should be
registered externally.
Measuring spindie speed:
A suitable speed measuring device (frequency
counter) can be connected to contact 2 of
connector J14.
The transistor " A " (cf. page 3) supplies 6
pulses perspindie revolution with 2-pole
spindles. With 4-pole spindles, 12 pulses per
revolution are emitted. lf the tachometer is not
connected to the converter, a signal with 6
times the output frequency is high at contact 2.
Setting the speed:
External speed selection can be implemented
in two ways:
Method A
An external potentiometer (1 k/1 W PRECISE
part no. 006992) is connected to contacts 6, 7
and 8; the potentiometer on the front panel is
inactivate.
Method 8
A variable filtered DC valtage is applied to con-
tacts 3 and 6. The valtage required is 0 .. 10 V.
7 Operatingfaults
& = Attention
Measurements and tests on the
frequency converter is allowed to
be performed by authorised and
qualified personnel only.
Switching on the mains power produces no
response:
..,.. ls the mains valtage OK?
..,.. Are the miniature circuit-breakers at the
back switched on?
ls the pico fuse on the smoothing unit
OK?
The spindie speed fluctuates:
..,.. Are the plug connections of the
tachometer OK? ln particular, is the
shield connected correctly?
The shield must only be connected to
contact 3 of connector J13, or in the
case of spindies with an Amphenol
C 16-3 connector, to contact 7 of
connector J12. Under no circumstances
should it be connected to the housing or
PE conductor!
The speed display shows "00.0" but the
spindie is running :
..,.. ls the tachometer short-circuiting
(contacts 4 and 5 on connector J13 , or 5
and 9 on connector J12 in the case of
AMPHENOL C 16-3? As a check, Q
disconnect the tachometer and operate
the transformer without it. ln such a
case, the speed control system is
d isactivated.
Spindie speed too high or too low: ERR.8

For converters with two speed ranges:
~ ls the jumper in the spindie connector
OK? (Contacts for range switching
" RANGE SW." jumpered at the spindie
with the highest speed?).
ERR.4
(Overtemperature within the frequency
converter)
Reset by switching oft the converter briefly.
Ambient temperature too high?
(Overload tripping caused by a short circuit or
very excessive Ioad)
Reset by switching oft the converter for a short
time:
~ ls the spindie being used with the
correct cable?
ls the spindie cable OK?
Are all terminals of the connector
securely tightened?
Are the windings of the spindie motor
OK (check by using an ohmmeter)?

Cooling air circulation OK?

~ = Attention
Excess Ioad?
Measurements and tests on the
ERR.5 frequency converter must only
be performed by authorised qualifie.
(Spindle overload by more than 10%)
Reset by pressing the " stop" button after
eliminating the cause of the fault.
7.1 Other possible faults
ERR.7
No output voltage:
(The monitaring contact is open, or the
resistance between contacts 1 and 2 on ~ ls the circuit-breaker at the rear of the
connector J13 is greater than 800 . unit switched on?
Acknowledge by pressing the "Stop" button ,
after eliminating the cause of the fault). ls themains valtage O.K.?

ls the spindie temperature OK

(thermistor)?
Are the flow volume and temperature of
the cooling fluid OK?
ls the air pressure adequate for oil-mist
lubrication, and does the oil quantity
comply with specifications?
ls the wiring of the monitaring contact
receptacle OK, and are the connectors
connected?
ls the ambient temperature too high?
(To check, contacts 1 and 2 in connector
J13 can be jumpered).
~= Attention
Spindie speed to low I to high:
Speed setpoint to low I to high .
~ Not correct adjusted for the
connected spind le.
Spindie speed fluctuates:
External speed setpoint not stabil and not
smoothed.
ERR.A
Converter is not correct adjusted.
ln this case please contact your
machine-builder or Precise directly.

For converters equipped

with the AMPHENOL C 16-3
receptacle, contacts 6 and 8 must
also be provisionally jumpered
for this purpose.

- 7-
 Control PCB

Smoothing unit

Figure 7 Arrangement of the assernblies

To output module

To monitaring cantact

Ta smoothlng unit

To remote cantrot {
receptacle

Figure 8 Control PCB

Temperature sensor To centrat PCB

To outpul modute

10pper resistor
1ly with air-
aring spindles)

Ta smoothing unit

Figure 10 Smoothing unit

Figure 9 Output module

-8-
 Mains plug

,--------+--~~ IJ
Li!
11

Spindie power cable -

Hart ing HAN GE plug

~--------.==+---l~~~ut Pl--!1 white I-J3- - - - - - - -,

lr-+--+---:?)<:----'o""ut""n'ud!.t-...--JP= '"'"L --1- ~,- !_Y _ -<LJ4 Output 1
rr==---- ~ :.<1 mtn ..t P" <> '"" LJS module I
(f J. _g ~ M,-!--1--~utpu! ~ -""=' ':"' -'- t - --<i-J6
" ' -1-;_;:_vioe;ole"--- I
tzi ~ Q ~ 2 -~ @.! P ROT.r:><>nlt l\l r ~---- ----- '
~
w _ ;f3 RANGE SW. Optional
~ f-- ~ ------- --:
1
_ J3 RANGE SW.Ootional -
1
Spindie
J12 I I
~~-------~ I I

Pressure switch
: Co ntrol 1

-~} \ ~1 l
Jumper plug
# 001230
' ---c:=-~
'---- t-- J 13 TH ERMISTOR i PCB
14- --+1--+'Y'-ii--;___ _ __ -l-----+-t+-~ _Shield I I

i. ...
=~
- 5;
1- ~.<1
'-----tl-+;,s._,____ _-+---+-Y----;s_J
~ Tachometer
P C F31 - - -- -- - - - .J 1
1

Lubricati on unit

Monitaring contact _

Figure 11 Two- phase spindie connection HAN 6E

r - - -..,
Tachometer Thermistor Motor

I-
TP ;:-
L T .J
( ... _.;- J ,- Outer shield
.,-+---J.- - Intermediate
shield
r 1--_;_- Inner shield

Ju mper
I~ Q)

if 1%'
Q)
::: required Q)
Ol
c
c
:::
0
c
Q) _Q r , ~ Ol
~ -
~ ~ Qj 1 2 3
0 .0 ..2' >. I I \ I
r o3o8o7()s 5 4 o10 1 o9 i;r 1 2 3 64-651 r .if- i
L - -
- Einsatz B - - ..JL
Einsatz A
- - ..Jl.- _J

Figure 12 Three-phase spindie connection Harting EMV I 15 P

-9-
 Connection to output module

Spindie Connector J3 white J4 grey J5 red J6 violet Range PE

switching conductor
(optional) (green/
yellow)

3-phase Harting HAN 6E Pin 1 Pin 2 Pin 4 N/A Pin 3 + 6 PE

(standard wiring)

3-phase Harting HAN 6E Pin 1 Pin 2 Pin 3 N/A N/A PE

(PCB industry)

2-phase Harting HAN 6E Pin 1 Pin 2 Pin 4 Pin 5 Pin 3 + 6 PE

3-phase Amphenol C 16-3 Pin 1 Pin 2 Pin 3 N/A Pin11+12 PE

2-phase Amphenol C 16-3 Pin 1 Pin 2 Pin 3 Pin 4 + 10 Pin11+1 2 PE

2-phase AMP-CPC (USA) Pin 11 Pin 8 Pin 1 Pin 3 N/A Pin 13

2-phase Amphenol C 16-3 Pin 1 Pin 2 Pin 4 Pin 5 PE

Table 2 Wiring of the output receptacle

- 10 -
 440

145

Spare parts for the PCF 310

Description Catalogue-number

Potentiometer knob # 002121

Output module for ball bearing spindies # 001554

Output module for air bearing spindies # 001555

Smoothing un it # 001553
Rectifier unit P 102 W # 002117
Mai ns switch # 003995
Circuit-Breaker 1 GA - 1-pol. # 001557
Micro fuse 0 ,63 A time-lage type # 001221
Control PCB # 001552

When ordering spare parts, please always specify the serial number
of the frequency converter.

Ihr Partner in der Nhe: Precise Przisionsspindeln GmbH

precise For sales and support contact:

Pour une information
complete, contactez:
Am Wallgraben 2 D-42799 Leichlingen
Postfach 14 61 D-42785 Leichlingen
Telefon: (02 175) 9 71 0
Telefax: (02 175) 9 71 99, 9 71 97
w
The Precise Corporation (")
(")

37 15 Blue River Avenue i

0
P 0 Box 085000 OJ
Racine, Wisconsin 53408-5000, U.S.A. 8l
Telephone (414) 6 32 61 73
())
Telefax: (414) 6 32 67 30 N