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FIT-36 SERVICE rev1.2doc
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1. avoidance 300 to 800 01 400 400 operation level ce ce e e e e 71 Terminal 2 frequency Oto 400Hz 120 setting gain frequency 903 Terminal 2 frequency to 300 0 1 100 100 setting gain 904 Terminal 4 frequency to 400Hz 01Hz setting bias frequency 904 Terminal 4 frequency Oto 300 0 1 2 setting bias 905 Terminal 4 frequency Oto 400Hz 01Hz setting gain frequency 903 Terminal 4 frequency ato 300 0 1 100 100 setting gain 2 X Pitney Bowes Drect Mail Solutions Selected St 00 07205 042 Date 5 7 2009 All Parameter List FIT 36 base VFD rev 2 19 09 No Name Setting Range Unit Initial Current Setting Comment Fen EEE _ ______ s Puconmwestedusmen oss __ 4 23 Parameter clear All parameter clear POINT set 1 in Fk CL Parameter clear all parameter clear to initialize all parameters Parameters are not cleared when 1 is set in Fx 77 Farameter write selection Refer to the extended parameter list on page 54 for parameters cleared with this operation Operation Display 1 Screen at powering on He Liviu The monitor display appears Li PLI indication is lit 2 Press PU choose the PLI operation mode ev Eng cum oy indication is lit 3 Press MODE to choose the parameter setting IMOD
2. Parameter and a setting value flicker alternately Parameter write pompletecl ZA 77 73 nun Parameter clear All parameter Faults a clear clear 7 zm 3 Initial value 4 change list Operation for displaying faults history Rafer fo page 242 Past eight faults can be displayed The latest fault is ended by When fault history exists is displayed 87 Pitney Bowes Drect Mail Solutions 4 1 3 Easy operation mode setting easy setting mode Setting of Pr 79 Operation mode selection according to combination of the start command and speed command can be easily Made Changing arain Start command external STFISTR frequency command operate with e ple Operation 1 Screen at powering on The monitor display appears 2 Press PU and 0 55 Flickering BD EXT 009 c on 3 Turn D until 19 appears a refer to the table below for other settings E M minum NU Operation Method TTE Start command Frequency command Flickering bal af External Analog Ex 9705 STF STR voltage input i Flickering Flickering Flickering gt External ET STF STR 1 i Flickering Analog voltage input 4 Press SET to set 9 en 3 gt Flicker Parameter setting The monitor display appears
3. Overcurrent trip during constant speed When the inverter output current reaches or exceeds approximately 200 of the rated current during constant speed operation the protective circuit is activated and the inverter trips 1 Check for sudden load change Check point 2 Check for output shart circ uitiqraund fault 3 Check that stall prevention operation is appropriate 1 Keep load stable Corrective action 2 Check the wiring ta make sure that output short circuittground fault does not occur 3 Perform stall prevention operation appropriately Refer fo page 77 Des cription Pitney Bowes Drect Mall Solutions wie 299 003 0 indication 2 FR PUO ercurrent trip during deceleration ar stop LLL the inverter autput current reaches ar exceeds approximately 200 of the rated inverter current during deceleration rather than acceleration or constant speed the protective circuit is activated and the inverter trips Check for sudden speed reduction Check for output shart circ uit qround fault Check for too fast operation af the motor s mechanical brake Check that stall prevention operation is appropriate Increase the deceleration time Check the wiring to make sure that output short circuitiqraund fault does not occur Check the mechanical brake operation Perform stall prevention operation appropriately Refer fo page 77 Operation panel cn i FR PUO4 ev Lt 1 FR PU
4. 07 is set this protective function does nat function Check point Find the cause of fault occurrence Eliminate the cause of the error preceding this error indication Des cription Pitney Bowes Drect Mall Solutions Operation pane PALME Fault en Name CPU ut Stops the inverter output if the communication fault of the built in CPU occurs Check for devices producing excess electrical noises around the inverter Take measures against noises if there are devices producing excess electrical noises around the inv erter Please contact your sales representative ame Lo Li FR PUO OC detect level current detection value IE This function is activated when the output current exceeds the Pr 130 Output current detection level Check the settings of Pr 150 Cupuf current detection level Pr 151 Output current detection signal delay time Pr 166 Output current defection signal retention Ame Pr 167 Cufput current defechon operation selection Refer fo page 122 Corrective action Check point Operation panel Ci Ay Inrush current limit circuit fault Des cription This function is activated when the resistor of the inrush current limit circuit overheats The inrush current limit circuit fault Check Checkpoint Check that frequent power ON OFF is not repeated Configure a circuit where frequent power GMIOFF is not repeated I
5. PitneyBowes DIRECT MAIL SOLUTIONS FLEXIBLE INKJET TRANSPORT 36 FIT BASE FIT 36 SERVICE MANUAL 12050 48th STREET NORTH CLEARWATER FL 33 02 4301 PHONE 727 971 3330 FAX 727 971 3443 TOLL FREE 1 800 INSERTER Copyright Pitney Bowes Inc 2009 All rights reserved Pitney Bowes Drect Mail Solutions VERSION HISTORY The table below summarizes the history of this document as it is published onto the company website s It identifies the version date of issue and revisions and changes VERSION DATE CHANGES FIT 36servrevO 4 24 2009 ORIGINAL RELEASE FIT 36servrev1 2 11 16 2009 Graphics Electrical Componets and Parameters REVISION CONVENTIONS DOCUMENT VERSION name of document with revision level of entire document level designates minor changes that do not require revision change DATE date of issue for copying and publication of document CHANGES details of document revision level FIT 36servrev1 2 2 Pitney Bowes Drect Mail Solutions Table of Contents Section I Installation FIT 36 Base Installation Orentation Floor Plan and Machine Requirements Enviornment Positioning the Components Electrical Setup Connections Leveling the Vacuum Base Electrical Cables Section Safety Features and Warnings Safety Features and Warnings Recommendations for Safe Operation opecial Safety Announcement Lock Out Procedure Suggested Lockout Devices Section Ill General Setup General Set Up
6. SPECIFICATION Installation 000000 Requirements Ground earth connection required Cooling Method Natural cooling FIT 36servrev1 2 8 Pitney Bowes Drect Mail Solutions Installation Positioning the Components Once the FIT 36 base has been removed from the shipping container perform the following 1 Inspect the location where the machine is to be set up Note The manufacturer recommends that the area be a relatively flat and smooth concrete or hard wood surface similar substrates are acceptable The area should be free of holes divots loose floorboards etc and not subject to retaining moisture from water seepage Warning In the event the floor does not meet the recommended requirements seek an alternate location or reschedule the installation after repairs to the floor have been completed Installation Electrical Setup Connections 2 Inspect the line current at the point where the power cable of the machine is to be plugged in Note Conventional wall sockets ceiling line drops and D Boxes should be free of cracks rust visible signs of heat stress and flash marks Special Note For installations in Europe check the condition of the voltage converter box or other voltage reducing device that may be in use In the event of a line voltage inspection failure report your findings to the person or persons in charge of the building and postpone the installation until corrections are made 3 Check the line voltage
7. UGI Ui PL indication is lit HHH cum Li LUI LI indication is lit ul number read previously appears S T Press SET to set Flicker Turn to read another parameter os Press SET to show the setting again QN Press ser twice ta show the next parameter Press MODE twice to return to frequency monitor D REMARKS 7 is displayed Why 4 1 5 Ere tri Er Write disable error Write error during operation appears Calibration error appears Mode designation error For details refer to page 242 he number of digits displayed on the operation panel is four Only the upper four digits ofw alues can be displayed and se values to be displayed have five digits or more including decimal places the fifth ar later numerals can not be displayed n Example For Pr 7 When is set 60 00 is displayed When 120Hz is set 120 0 is displayed and second decimal place is not display ed set Setting dial push Parameter setting complete Push the setting dial D display the set frequency currently set Appears when PU operation mode or external P U combined operation mode 1 is selected 72z 3 3 FIT 36servrev1 2 89 Pitney Bowes Drect Mail Solutions Selected St 00 FE D7 202 042 N Dat
8. 3 Contactor Switch NO NC NO Start Stop of vacuum base conveyor B pushbutton momentary 1 Contactor Switch NO Provides for jogging of conveyor Start stop of in feed feeder D Gap Speed Dial Potentiometer Feeder Speed Control E BaseSpeedDial Potentiometer 7 Base Speed Control F Reset pushbutton red 2 Contactor Switch NO NO __ Resets system after fault is corrected G E STOP pushbutton non illuminated 2 Contactor Switch NC NC Provides safety shutdown H Vacuum pump switch Rocker Style Switch Start stop of vacuum pump ___ FIT 36servrev1 2 56 Pitney Bowes Drect Mail Solutions Section VI Wiring Diagrams For FLEXIBLE INKJET TRANSPORT 36 FIT BASE FIT 36 SERVICE MANUAL FIT 36servrev1 2 57 Pitney Bowes Drect Mail Solutions Main Electrical Enclosure 16021 105 rD2 4 1609288 Control Enclosure 2 16013200 FIT Main Control Enclosure cover 1 _ 3 12012050 Back Panel Fit Control Enclosure 4 16009 180 Transformer Bracket FIT Control ee 98016 222 Terminal ring 1 4 14 16 AWG blue 1 EUR o Duct Wire with cover 1 X3 high density 7 98001 022 iva 35 8 9800806 A Transfrme234 117V 9 Terminal dbi pem shorted 4 way 48 98001431 Terminal 3 wire fuse disconnect 8 Fm emm Jumper 3 pole fuse terminal 34 9
9. Before starting operation confirm and adjust the parameters A failure to do so may cause some machines to make unexpected motions 4 Usage ZNNARNING e When you have chosen the retry function stay away from the equipment as it will restart suddenly after trip Since pressing key may not stop output depending on the function setting status provide a circuit and switch separately to make an emergency stop power OFF mechanical brake operation for emergency stop etc Make sure that the start signal is off before resetting the inverter alarm A failure to do so may restart the motor suddenly The load used should be a three phase induction motor only Connection of any other electrical equipment to the inverter output may damage the equipment Do not modify the equipment Do not perform parts removal which is not instructed in this manual Doing so may lead to fault or damage of the product A CAUTION amp The electronic thermal relay function does not guarantee protection of the motor from overheating It is recommended to install both an external thermal and PTC thermistor for overheat protection amp Do not use a magnetic contactor on the inverter input for frequent starting stopping of the inverter Otherwise the life of the inverter decreases Use a noise filter to reduce the effect of electromagnetic interference Otherwise nearby electronic equipment may be affected Take measu
10. Check the connection m w wire ar three wire type connection is wrong P d Connect STOP signal when three wire type is used of restarting froma input stop from PLI Pitney Bowes Drect Mail Solutions Possible Cause Counter meas ures Increase Pr setting by 0 596 increments while 0 Torque boost setting is improper when VIF control is observing the rotation of matar used If that makes no difference decrease the setting Check the Pr 78 setting Pr 74 Reverse rotation prevention selection set Set Pr 75 when you want to limit the motor rotation to ane direction E Select the operation made which corresponds with input are improper settings Set running frequency higher than Pr 13 The inverter does not start ifthe frequency setting signal is less than the value in Pr 13 Frequency settings of various running frequency such Set the frequency command according to the as multi speed operation are zero application Especially Px J Maximum frequency 15 zero Set Pr higher than the actual frequency used Pr lo frequency setting is lower than Pr 13 Starting Set Pr Ju frequency higher than Pr 13 Starting Sra quency Jrequency u Check Pr 79 Pr 335 Pr 339 Pr 537 and select an 193 Operation mode and a writing device do not match operation mode suitable forthe purpose 174 Parameter Start signal operation selection is set by the 220 Chec
11. FIT 36servrev1 2 16 Pitney Bowes Drect Mail Solutions Suggested Lockout Devices The following are some suggested devices specifically designed to provide a greater degree of safety when locking out the power supply to a machine These devices can be purchased from most safety equipment suppliers and vendors Lock Box designed for power cord plug connectors commonly used in combination with a key style padlock Note Appearance of Lock Out devices may vary depending Figure Il 5 on vendor Breaker Lock designed for use inside electrical breaker boxes commonly used in combination with a key style padlock Note Appearance of Lock Out devices may vary depending on vendor Figure 11 6 FIT 36servrev1 2 Pitney Bowes Drect Mall Solutions Warning Alert tags commonly used in combination with all lock out devices Front View of Lock Out Tag Back View of Lock Out Tag EQUIPMENT EQUIPMENT LOCKED OUT BY LOCKED OUT THIS TAG amp LOCK TO BE REMOVED ONLY BY THE PERSON SHOWN ON BACK Figure Il 7 FIT 36servrev1 2 Pitney Bowes Drect Mail Solutions Section lll General Set Up FLEXIBLE INKJET TRANSPORT 36 FIT BASE FIT 36 SERVICE MANUAL Pitney Bowes Drect Mail Solutions Section Ill This FIT 36 is designed to run off line or in line with most feeders FlowMaster inserters FIT bases FIT diverters and numerous conveyors These manuals can be obtained through your local Sales Representative or D
12. Circuit breaker Conveyor Motor L FiAA1BFUSE 1 25A Power Supply input L1 F2A2BFUSE 1 25A PLC input 3 15A J12 receptacle M TerminalBlock Ground Provides contact point for AC ground N MitsubishiPLC Programmable Logic Control runs machine program O Low Voltage Power Supply Supplies 24 VDC P Powerresistor 15 Q 50 wt Q Capacitor _____ 2200yF capacitor S CB2 4 Circuit breaker Vacuum Pump Variable frequency drive conveyor U TRANSFORMR 234 117 1000 VA 115 250V 16A Circuit breaker 10A 2 pole Er TB1 Terminal block for transformer FIT 36servrev1 2 48 Pitney Bowes Drect Mail Solutions Variable Frequency Drive Figure V 2 All controls and functions for the Mitsubishi Inverter FR D700 can be found in Section VIII of this manual Special Note Some of the Mitsubishi default operating parameter settings shown in Section VIII have been change for specific use in the 36 FIT Base application These changes are considered proprietary information of Pitney Bowes and are only intended for use by an authorized specialist Use of this information by an unauthorized person or persons may void any and all warranties either real or implied purchased or offered with the FIT 36 The manufacturer and all other companies connected with the promotion and sale of the FIT 36 shall be held harmless for any and all injuries sustained to any person or person
13. indication Made designation error You attempted to make parameter setting inthe operation made when Pr 77 is nat 2 1 Check that operation mode is PU operation mode Check point 2 Check the Pr 77 setting Refer fo page 199 1 After setting the operation made to the PU operation mode make parameter setting Refer fo page 183 Corrective action 2 After setting 2 in Pr 77 make parameter setting D es cription Des cription Corrective action Pitney Bowes Drect Mail Solutions Operation panel E Inverter reset Executing reset using RES signal ar reset command fram communication or PU Des cription Displays at powering OFF Corrective action action Turn OFF the reset command 21 Vamings When warning occurs the output is shut off epee Hi FR PUO4 9 OL EE e Stall prevention overcurrent When the output current of the inverter exceeds the stall prevention operation level Pr 22 During prevention level etc this function stops the increase in frequency until the overload current acceleration decreasesta prevent the inverter from resulting in overcurrent trip v hen the overload current has reduced below stall prevention operation level thisfunctian increases the frequency again During When the output current of the inverter exceeds the stall prevention operation level 22 Fall constant preve
14. 2 During Acc Overcurrenttrip during acceleration When the inverter output current reaches exceeds approximately 200 of the rated current during acceleration the P protective circuit is activated and the inverter trips Check for sudden acceleration Check that the downward acceleration time is nat long in vertical application Check for output short circuit ground fault Check point Check thatthe Pr 3 Base frequency setting is not amp Hz when the motor rated frequency is 50Hz Check that stall prevention operation is appropriate Check that regeneration is nat performed frequently Check that the output voltage becomes larger than the WF reference value atregeneration and overcurrent occurs due to increase in motor current Increase the acceleration time Shorten the downward acceleration time in vertical lift applic ation When E G C1 is always lit at starting disconnect the motor once and start the inv erter IT E GCT is still lit contact your sales representative Corrective action 3 Check the wiring ta make sure that output short circuitiground fault does nat occur Set 50Hz in Pr 3 Base frequency Refer fo page 53 Ferfarm stall prevention operation appropriately Refer fo page 77 Set base voltage rated voltage of the motor etc in Pr 19 Base frequency voltage Refer fo page 83 EO EGCC erpuor 000000000 indication Lc FR PUO
15. 2 flat head Allen screws located on the deck operator s side near the center see figure 5 A caution make sure to support the motor while removing the two Flat Head Allen screws in this step see figure 6 Figure IV 5 Remove the two flat head Allen screws to remove the motor and mount plate AN Caution Support the motor while performing this step FIT 36servrev1 2 39 Pitney Bowes Drect Mail Solutions Support the motor and motor mount plate while removing the flat head Allen screws as indicated in step A Once the Flat head Allen screws have been removed slide the drive belt off the pulley and set the motor down in the bottom of the machine see figure IV 6 Once the motor mount screws have been removed slide the drive belt off of the motor drive pulley Figure IV 6 With the Power turned off and the power supply disconnected from the machine it is not necessary to disconnect the power supply to the motor after lowering the motor to the bottom of the machine base If you choose to disconnect the power cable to the motor perform the following The connecting plug is located on the cable inside the base cabinet and is easily accessible after the front panel has been removed Flip the retainer clip up and pull connector apart See figure IV 7 Flip the retainer clip up to release Pull plug connector apart Fig IV 7 FIT 36servrev1 2 40 Pitney Bowes Drect Mail Solutions Figure 6
16. FIT 36 Set Up Paper Sensor Adjustment Control Panel and Switch Operation Principles of Operation Operating the FIT 36 Setting and Adjusting Run Speed Adjusting Vacuum Section IV General Maintenance General Maintenance FIT 36 Base Maintenance General Cleaning Cleaning Transport Belts Lubrication FIT36 Base Material Transport Belt Replacement FIT36 Base Shaft amp Roller Replacement Section V Electrical Components FIT 36 BASE Electrical Components Section VI Wiring FIT 36 BASE Wiring Diagrams Section VII Troubleshooting Trouble Shooting PLC Diagnostics Section VIII Component Programming Programmable Controller Inverter FIT 36servrev1 2 ONO 57 71 13 19 7 Pitney Bowes Drect Mail Solutions SPECIAL NOTES DEFINITIONS AND DISCLAIMERS Special Note Some pictures and illustrations may have color hue and contrast graphically altered for clarity when printing in black and white and may not necessarily reflect the actual color of the product when viewed on compact disk DEFINITIONS ON VAC volts alterant current VDC volts direct current WARNING or CAUTION FIT 36servrev1 2 Pitney Bowes Drect Mail Solutions Section Installation of the FLEXIBLE INKJET TRANSPORT 36 FIT BASE FIT 36 SERVICE MANUAL Pitney Bowes Drect Mail Solutions Section Orentation MODEL FIT 36 BASE Product Sensors Non Vacuum
17. a detachable screw type cable connection 4 Set the Light Dark pot setting using a small flat blade screw driver slowly and very carefully turn the pot setting located next to the electronic cable connection in a counter clock wise direction until full range of motion is felt see figure 111 5 Note If this adjustment is performed correctly the screw driver slot in the pot setting should be pointing towards the DO in the range scale next to the pot setting Caution stop point of this pot setting be damaged if excessive force is applied 5 Set the Gain pot setting by performing the following A Using a small flat blade screw driver slowly and carefully turn the pot setting located furthest from the electronic cable connection in a counter clock wise direction until full range of motion is felt see figure 111 5 The red LED indicator light should be off at this point B Using a small flat blade screw driver slowly and carefully turn the pot setting located furthest from the electronic cable connection in a clock wise direction until the red LED light comes on continue turning the pot setting in a clock wise direction another half turn 6 Return the plastic cover removed in step 3 to its original position FIT 36servrev1 2 22 Pitney Bowes Drect Mail Solutions DIFFUSE 1 Position the sensor directly over the center of the middle vacuum belt and attach the sensor to the sensor s
18. the FIT 36 base and a collecting conveyor 1 The FEEDER ON OFF switch only enables the feeder other start stop jog and reset switches permit the feeder s operation in parallel with the base conveyor a STOP Controls the stop circuits of VFD 1 leader for the base conveyor motor amp DC DRIVE follower for the feeder belt motor b JOG A PLC programmed set speed of base conveyor motor and feeder belt conveyor control is used for product set up c RESET Returns the machine to operating condition after an E STOP condition 2 BASE potentiometer the leader speed control input for the base conveyor VFD The VFD will output a signal to the feeder or upstream component to permit parallel operation the feeder motor will follow the leader base conveyor motor If any modification is needed to produce a different separation distance between conveyed product pieces refer to GAP potentiometer 3 GAP potentiometer the follower speed control input for the feeder motor only An increase in speed higher potentiometer setting produces a shorter separation distance gap between conveyed product pieces Larger gaps occur when the potentiometer is set lower 4 VACUUM switch energizes the vacuum pump motor Operating the FIT 36 Power 1 Turn power to the machine on by placing the white power switch located on the electrical enclosure in the up position See figure 111 8 REFERENCE CONTROL CONSOLE 2 Check E S
19. 3 Terminal input specifications Frequency can be changed by analog n input specifications setting 2010 5YDC 3 AE switchover Pr 73 potentiometer 1 Oto 10VDC Terminal 10 and terminal 2 2 ra BC Analog signal output are used as PTC input 5 TY 5 06 0 to 10VDC i terminal Pr 561 F 5 Analog common ata w 4 Teminal input i specifications can be Terminal 4 PU changed by analog input input 4 4 to 20mADC i connector specifications switchover Current gt Oto 5VDC input 05 Ei voltage current input i switch in the position i l to select voltage input 0 voli to 5V D to10V and I initial value to select Voltage current i Safety stop signal Shorting Output shutoff Line 1 For manufacturer setting Output shutoff Line 2 Common terminal 81 Pitney Bowes Drect Mail Solutions FIT 36servrev1 2 2 asingle phase 200 class FR D7208 008 to 042 sl Power supply Motor Earthing Grounding precautions e Always earth ground the motor and inverter 1 Purpose of earthing grounding Generally an electrical apparatus has an earth ground terminal which must be connected to the ground before use An electrical circuit is usually insulated by an insulating material and encased However it is impossible to
20. MUMBER REV 05 02 9 5 7 Sag Sono SELL 181 __ _ _ ____ E m E P i pm 4 9 m E Pitney Bowes rect Mail Solutions 335352389333 SSeeeegesecescecooo 20 6 UM 31925 LOM 09 37925 3 3215 1091 A34 114 Lig FILL M AIN LISE S3Mog MAE a 1110 44 3015 Q RCD TJEY7 357 jH3432vw 1d 73877 Wd 335 3805013N3 a 40 339 14 m OL 144971 JAE 5 2 0096 gt J g Pitney Bowes Dr Cols 90 e Lely Loot AIO 20 3u HELIN Syme LAO 3mm 123 258 LE 3 lu S3MO8 A3NLIdETE V FL 210 480 EJ Jzva NO WANIYA OL OMS ___ um ONnOMO WO 59112091 39v ld 230 207 ONIOMNOYS HO LL 3078 335 4230 OL 9015 221 509 32v 1d A aos 5 Nu gt n 5 amp G 08902 ea as o 900 6 HAT 598 LINK Or er SON Id LNIHd E 310H SOM AS 1441 MIA LNOH S4nSO INA 0 0 101 LE Cols 90 e DUD Lely Loot ALGO gt S3MOB m o a CREER omes il
21. Mail Solutions There are the following correspondences between the actual alohanumeric characters and the digital characters dis the operation panel Sa LOG ex wes LS 25 9 0 1 2 3 4 5 8 a 8 8 LOSS SES O gt 9 UJ CJ ES 9 0 9 UT e f ES CS neris rye ra FIT 36servrev1 2 108 Pitney Bowes Drect Mail Solutions 5 5 Check first when you have some troubles z POINT If the cause is still unknown after every check itis recommended to initialize the parameters initial value then Set the required parameter values and check again 5 5 1 Motor does not start Check _ Possible Cause Countermeasures points Power on moulded case circuit breaker fl CCB an earth leakage circuit breaker ELB ar a magnetic Appropriate power supply voltage is not applied 9 contactor Operation panel display is not provided Main didi P Check for decreased input voltage input phase lass and wiring Circuit otor is nat connected properly Check the wiring between the inverter and the motor Securely fit a jumper across ta F1 The jumper across F to P1 is disconnected When using reactor F RHEL remove the jumper across ta P1 and then connect the DC reactor Check the start command source and input a start signal Start signalis not input E FU
22. Ovdc E Stop Loop Pins J2 19 and J2 20 must be closed to Reset and Run Base Open to Stop 21 Sort Signal Dry Contact Common with J1 22 when Opto 3 is triggered through J10 connector 22 Sort Signal Dry Contact Common with J1 21 when Opto 3 is triggered through J10 connector 23 Remote Reset Dry Contact Common with J1 24 Momentarily closed when Reset Button is pushed 24 Remote Reset Dry Contact Common with J1 23 Momentarily closed when Reset Button is pushed 25 Speed Follow Output Supplies 0 10vdc or 0 5 for speed following applications 26 E Stop Dry Contact Common with J1 27 Closed when base is in a Run Condition 27 E Stop Dry Contact Common with J1 26 Closed when base is in Run Condition 28 Remote Reset Com To Reset Base Dry Contact this pin with J1 29 29 Remote Reset To Reset Base Dry Contact this pin with J1 28 30 2 Base Configuration E Stop Com Only used if two or more bases are connected together 2 Base Configuration E Stop Only used if two more bases connected together 32 Output Signal to tell Second Base it has Stopped 33 Input X15 Allows pin 32 from second base to say when it has stopped Stops base if Ovdc is applied to this pin 37 Chassis Ground FIT 36servrev1 2 53 Pitney Bowes Drect Mail Solutions Connection J3 Pin Function Divert Mocon Signal Supplies 24 when base is running Divert Mocon Common Divert Solenoid 24vdc
23. Reset To Reset Base Dry Contact this pin with J1 28 30 2 Base Configuration E Stop Com Only used if two or more bases are connected together 31 2 Base Configuration E Stop Only used if two or more bases are connected together 32 Output Signal to tell Second Base it has Stopped 33 Input X15 Allows pin 32 from second base to say when it has stopped Stops base if Ovdc is applied to this pin 37 Chassis Ground FIT 36servrev1 2 52 Pitney Bowes Drect Mail Solutions Connection J2 Function Pass Thru to J2 1 Ov Pass Thru to J2 3 Used for FlowMaster Stop Integration Pass Thru to J2 4 Remote Reset Input Requires Ov to fire CR4 to Reset Base Pass Thru to J2 6 Pass Thru to J2 7 FlowMaster Stop Integration Momentarily breaks on Stop button push and breaks on E Stop base has been Reset 9 Pass Thru to J2 9 10 Pass Thru to J2 10 11 Pass Thru to J2 11 12 Remote Run Supply Ov to this point when you want base to run must be constant when voltage drops out base will stop 13 Pass Thru to J2 13 14 Pass Thru to J2 14 15 Pass Thru to J2 15 16 Speed Follow Input Supply 0 10vdc to allow base to speed follow D 5 ANS 17 Conveyor Dry Contact Start Common with J2 18 when base is running 18 Conveyor Dry Contact Start Common with J2 17 when base is running 19 E Stop Loop Ovdc E Stop Loop Pins J2 19 and J2 20 must be closed to Reset and Run Base Open to Stop 20 E Stop Loop
24. Screws 2 flat head screws from the corners on the Operator s side Figure IV 10 FIT 36servrev1 2 43 Pitney Bowes Drect Mail Solutions H Lift the front edge of the transport belt top plate assembly up approximately 1 from the vacuum base and slide the old belts one at a time towards the front Operator s side to remove them see figure IV 11 A Warning This assembly weighs 100 pounds practice safe lifting techniques or ask for assistance with lifting to avoid injury Figure 11 I Slide the old belts off towards the operator s side Transport Belt Installation p Install the new Material Transport Belts on the vacuum base by performing the following A Slide the new transport belts back onto the transport belt top plate in the reverse order that the old belts came off B Return the idler roller assembly to the factory set position then secure the roller using the Allen screws tighten the Allen screws with moderate force see figure 8 C Follow steps 2 A 1 A thru 1 H in reverse order to install the idler roller re tension belts and re assemble the conveyor FIT 36servrev1 2 44 Pitney Bowes Drect Mail Solutions FIT 36 Base Rollers and Shafts Replacement Discharge Roller Shaft Assembly Removal Follow steps 1 E thru 1 H to gain access to the discharge roller Follow steps 2 A to release tension on the transpo
25. by increasing with 0 5 7 Wiring length is too long far VIF control and a voltage increments for low speed operation drop occurs Change to General purpase magnetic flux vector control Pitney Bowes Drect Mail Solutions 5 5 9 Operation mode is not changed properly Possible Cause Countermeas ures Check that the STF and STR signals are OFF Start signal STF ar STR is QM When either is QM the operation mode cannot be changed When Pr 79 Gneretion mode selection setting is O initial value the inverter is placed inthe External operation mode at input power QN To switch ta the Pl operation mode 2 AES Parameter Seting is improper press on the operation panel press eu when the Setting parameter unit FR PUO4F R PUOT is used At other settings d ta 4 6 7 the operation mode is limited accordingly Operation mode and writing device do not Check Pe 79 Pr 334 Pr 339 Pr 3351 and select an correspond operation mode suitable forthe purpose 5 5 70 Operation panel display is not operating Possible Cause Counter meas ures Check for the wiring and the installation Wiring or installation is improper sure that the connector is fitted securely across terminal Pi to P 1 Main Circuit M ain Circuit Control Circuit Power is not input Input the power Check the setting of Pr 257 mode operation command soured s lection ilf parameter R PUO4IFR PUOW
26. disconnected PU defection PU son selection This function stops the inverter output when communication errors occurred consec uty ely for more than permissible number of retries when a value other than 8398 is set in Pr 121 Mander of PU communication retries during the RS 485 communication with the PU connector use Pr 202 Son mode selection af communication error to charge This function also stops the inverter output if communication is broken within the period of time set in Pr 122 PU communication check Ame interval during the RS 465 cammunicatian with the PU connector Check that the parameter unit cable is connected properly Check the Fr 73 setting Check point Check that RS 465 communication data is correct And check that the settings of communication parameter at Inverter match settings of the computer Check that data istransmitted from the computer within atime set in Pr 722 communication check Ame interval Connect the parameter unit cable securely Corrective action Check the communication data and communication settings Increase the Pr 122 PO communtcation check fima interval setting Or set 3889 no communication check Operation panel cre FR PUO4 Retry Over Name Re count excess Ift operation cannot be resumed properly within the number af retries set this function trips the inverter Des cription Functions only when Pr 67 Member of refries af fault occurrence set When the initial value
27. fault signal is output 5 1 Reset method of protective function 1 Resetting the inverter The inverter can be reset by performing any af the following operations Note that the intemal thermal integrated value of the electronic thermal relay function and the number of reines are cleared erased by resetting the inverter Recover about 15 after reset is cancelled Operation 1 Using the operation panel press as to reset the inverter This may anh be pertamecd when fault occurs Reyer to page 257 for Operation 2 awitc OFF the power ance then switch it ON again after the Indicator af the operation panel tums OFF 3 Turn the reset signal RES mare than 0 15 lf the RES signal is kept Err appears flickers to indicate that ihe inverter is in reset status Pitney Bowes Drect Mall Solutions 5 2 List of fault or alarm indications Operation Panel Operation Panel Indication Indication Faults history E ILF Input phase loss HOLD Operation panel lock E OLT Stall prevention Stall prevention LO Cd Brake transistor alarm Password locked defection Output side earth ground Parameter write error fault overcurrent at start Output phase loss External thermal relay operation PTC thermistor operation Parameter storage device fault Pl disconnection E RET Retry count excess E45 CPU fault Output current detecti
28. for use under overload Refer fo page 78 Reduce the load weight Check the Pr 22 Stell prevention operation level setting Operation panel FR PUO4 ee oc Br Cet Fault indication FR PUO __ Brake transistor alarm detection When brake transistor alarm has occurred due to the large regenerative energy fromthe motor etc the brake Description transistor alarm is detected and the inverter trips In this case the inverter must be powered off immediately Corrective action Reduce the load inertia Check point Check that the frequency of using the brake is proper Check that the brake resistor selected is correct Replace the inverter c FR PUnD4 E GF G d Fault Output side earth ground fault overcurrent at start The inverter trips if an earth ground fault overcurrent flows at start due to an earth ground fault that occurred an the inverters output side load side Whether this protective function is used ar nat is set with Pr 249 ground faui defection af When the setting of Pr 249 Barth ground fault defection af is the initial value 249 07 this warning does not occur Check point Check for 2 ground fault in the motor and connection cable Remedy the ground fault portion Operation panel FR PUnD4 E LF T E LF indication ur FR PUO CE Output phase 1055 lf af the thr
29. involving disassembly of the machine either in whole or in part or replacing any of the electrical components Any persons working near any of the electrical motors or pump motors of the FIT 36 should use caution Electrical motors give off heat contact with or exposure to bare skin may result in burns The FIT 36 was designed to feed and transport paper only Do not attempt to feed and or run materials made of or containing glass metal wood liquids foods powders gasses explosives or toxic and hazardous chemicals on the FIT 36 Note The manufacturer and other companies connected with the promotion and sale of the FIT 36 do not assume any responsibility for any damage to the FIT 36 or product and shall be held harmless for any damages and or injuries sustained to person or persons resulting in this practice FIT 36servrev1 2 14 Pitney Bowes Drect Mail Solutions Special Advisement The manufacturer and all other companies connected with the promotion and sale of the FIT 36 shall be held harmless for any and all injuries sustained to any person or persons as a result of failure to comply with the recommendations for safe operation and maintenance of the FIT 36 as shown and or described herein The Lithium batteries used in our products may contain Perchlorate Material special handling may apply See www disc ca gov hazardouswaste perchlorate If any equipment is provided with a replaceable battery and if replace
30. is causing a valtage current drop Take countermeasures against EMI such as usin Input signal lines are affected by external EMI z 3 shielded wires far input signal lines Check the settings of Pr J Maximum frequency and Pr 2 Pr Pr 2 Pr 18 calibration parameter C2 settings Minimum frequency If y ou want to run the motor at 120Hz are improper or higher set Pr 18 High speed maximum frequency Torque boost Ps 0 Pr 461 setting is improper under VIF lncreasefdecrease Pr 0 Torque boost setting value by Set rated frequency af the motorto Pr 3 frequency Pr 19 Base frequency voltage set the base voltage e g rated motor otage Parameter Pr 3 Pr 14 Pr 19 Pr 3 Pr 14 Pr 19 Change Pr 24 Load pattern selection according ta the load Setting Pi 82 characteristic Reduce the load weight Pr 22 ofall prevention operation level higher according Stall prevention is activated due to heavy load to the load Setting 22 too large may result in frequent overcurrent trip E Q CET Check the capacities af the inverter and the matar Auto tuning is nat performed under Genera purpase Perform offline auto tuning magnetic flux vector control During PID control output frequency is automatically controlled ta make measured value set point Main Brake resistor is connected between terminal and Connect an optional brake transistor MRS 5 Circuit P1 by mis
31. on drive motor and conveyors are not damaged broken or missing Vacuum Motor does not operate Check 4 amp Circuit Breaker input CB 2 4 Check K2 relay engages the vacuum power Check K1 relay MTR 1 and Vacuum pump Feeder is not feeding MTR 2 Check Feeder On Off Button Lamp illuminated On Check Connection at J1 receptacle Feeder needs to be full Product sensors engaged Check Y2 Output PLC FIT 36servrev1 2 72 Pitney Bowes Drect Mail Solutions PLC DIAGNOSTICS Check power supply ground I O cables are properly wired Turn power supply ON Check that the POWER LED is active Down load a small test program onto the PLC Using a programming device or PC with appropriate software for each output ON OFF Check output LEDs for operation POWER m RUN m ERROR HEMEDY Reset PLC power OFF then ON trigger RUN input POWER m RUN ERROR m REMEDY Power OFF Disconnect earth ground terminal Power ON REMEDY Possible program scan time error Check D8012 FIT 36servrev1 2 Place the PLC into RUN mode and check that the RUN LED is active POSSIBLE RESULTS LED OFF Was memory cassette installed or removed when powered up LED ON GO TO STEP 1 POSSIBLE RESULTS LED Flashing Check for programming error Ensure that earth ground cable is correctly rewired LED ON GO TO STEP2 POSSIBLE RESULTS D8012 gt D8000 13 Pitney Bowes Drect Mail Solutions COMMON ERRORS 2
32. operate or perform any type of maintenance on the FIT 36 in or around freestanding water Do not wear loose fitting shirts shirts with bellowing sleeves bracelets rings necklaces neckties or other loose apparel that may come into close proximity with moving parts of the machine Do not place any items near or over the Emergency Stop Switches that might inhibit or obstruct line of sight or access to the Emergency Stop Switches The Emergency Stop Switches must be clearly visible and accessible at all times Wear protective safety eyeglasses or goggles and use a particle mask or similar device when cleaning off the FIT 36 with compressed air Alert all other persons in the area to stand a minimum of thirty 30 feet from the area where compressed air is put to such use Hearing protection is not required for safe operation of the FIT 36 Typically decibel levels have been found to be less than 85 decibels in machines properly maintained and in good operating condition All persons having hair greater than shoulder length who operate work on or near the FIT 36 should keep their hair pulled back in ponytail fashion then pinned up or otherwise contained to the top of their head or confined under the back of their shirt Turn off the main power to the FIT 36 before opening any of the service panels for general cleaning and or general maintenance Follow the Lock Out Procedures as stated on page 16 for extensive repairs
33. the European Directive Low Voltage Directive a refer io the Insiallation Guideline 82 Pitney Bowes Drect Mail Solutions 23 2 Changing the control logic M The input signals are set ta sink logic SINK when shipped fram 7 ur lo the factory Ale To change the control logic the connector above the 2 3 control terminal must be moved to the other position pe Change the jumper connector in the sink logic SINK position DIR EN to source logic SOURCE position using tweezers a pair of B os lang nose pliers etc Change the jumper connector position SL before switching power ON 1 Standard control circuit terminal layout Recommend wire SIZE 3rmrmr to 2R5 485 communication When the PLI connector is connected with a personal FA or other computer by a communication cable a user program can run and monitor the inverter or read and write to parameters The protocol can be selected from Mitsubishi inverter and Modbus ETU PU connector pin outs Description Earth ground connected to terminal 5 EE Parameter unit power supply Inverter receiv e Inverter Inverter send receptacle sue sba Wweersmit Viewed bottom 8 to 1 Earth ground connected ta terminal 5 L BE Parameter unit power supply NOTE T Pins 2 8 provide power t
34. to ensure that the minimum and maximum requirements are present 4 Check to see what volt value the transformer located in electrical enclosure is pinned out to at the voltage selection block see figure 1 3 If the volt value is different from the line voltage you checked in step 3 the transformer will need to be re configured to match BLU z dl Di J 4 110 Pin j py A Configuration ei Fa Jl a FIT 36servrev1 2 Pitney Bowes Drect Mail Solutions Installation Leveling the FIT 36 Base 5 Position the FIT 36 base in the designated location then lower the leveler pads to raise the base to a comfortable operating height See figure 1 4 a Figure 1 4 Turn the lock nut clock wise to tighten Turn the leveler bolt counter clock wise to lower 6 Place a level in the center of the FIT 36base and adjust the leveler pads as needed to level the machine at the desired height Once the machine has been leveled tighten the leveler pad lock nuts see figure 5 Place level in the center of the FIT 36 Base adjust leveler pads until all four points are level Figure 1 5 FIT 36servrev1 2 Pitney Bowes Drect Mail Solutions Installation Electrical Cables 7 Plug the in feed conveyor or feeder cable into the J1 receptacle located on the RH side panel of the FIT 36 electrical enclosure See fi
35. vacuum pump 0 2 Indicates Status of Base Steady Light No Fault Slow Flashing Photo Eye Fault LED Indicator Quick Flashing Print Head Fault K otop Switch Interrupts power to Base FIT 36servrev1 2 26 Pitney Bowes Drect Mail Solutions Main Power ON OFF Switch Figure III 8 Flip switch UP to turn ON Warning Drive Motor is Enabled when this switch is in the UP position Press the Top Press the Lower portion of the switch portion of the switch to turn ON to turn OFF Figure 9 FIT 36servrev1 2 27 Pitney Bowes Drect Mail Solutions Setting and Re Setting the Emergency Stop Switch Figure 111 10 Set Stop Switch Re Set Emergency Stop Switch by pushing downward by lifting upward A Warning The Emergency Stop Switches Must be Visible and Accessible at all times Special Note Pursuant to Community Legislation on Machinery Comments on Directive 98 37 EC 1 2 Controls and 1 2 1 Safety and reliability of control systems The E Stop button buttons found on the FIT 36 vacuum base are by design in compliance to meet and or exceed the mandates and requirements as stated in the Community Legislation on Machinery Comments on Directive 98 37 EC By manufacture design the E Stop buttons are to be used in the event of an emergency once the E Stop button has been depressed it must be physically re set For a selective stop to interrup
36. wanra _ H3HSVM 8916 V M3HOS 72 0 74 0 V AB OYVONVLS OL 1337 3H3H 2230 N3HM 33H 230 OL GNNOYD SYNSO TINA TOYLNOQD SOL LZO9L t Mar Solutions EL SALON ASM HOUNJA Pitney Bowes Dr 0 Pitney Bowes Drect Mail Solutions Section VII Trouble Shooting FLEXIBLE INKJET TRANSPORT 36 FIT BASE FIT 36 SERVICE MANUAL ml Pitney Bowes DIRECT MAIL SOL U TIONS 12050 49th STREET NORTH CLEARWATER FL 33762 4301 PHONE 727 571 3330 FAX 727 571 3443 TOLL FREE 1 800 INSERTER IT 3 71 web sure feed com Pitney Bowes Drect Mail Solutions Troubleshooting Problem Things to Check No power to any component of Check Main Breaker Supply power machine Check power connection to the machine No power to base electrical enclosure Check 10 amp Circuit Breaker enclosure mounted CB 0 No power to VFD Check 3 amp Circuit Breaker back plate mounted CB 1 3 Check relay 1 No power to PLC Check F2A 2B fuses 1 25A input No power to PS1 DC Power Supply Check F1A 1B fuses 1 25A input Base Conveyor is not running MTR 1 Check 10 amp Circuit Breaker is ON Check PLC Switch to RUN Lamp is on Check power to PLC refer to No Power PLC Check Power to MTR1 refer to No Power VFD Check all E stop buttons Check that timing belts
37. 0 life display 257 Control circuit capacitor life 0 to 100 1 100 100 display 258 Main circuit capacitor to 100 1 100 100 display 259 Main circuit capacitor life 0 1 2 3 8 9 measuring frequency automatic 0 1 switchover 261 By 268 Monitor decimal digits selection 295 Magnitude of frequency change setting 0 1 2 0 1 2 0 1 9999 Power failure stop Termin al 4 input selection 9944 9944 0 0 01 0 10 1 00 10 00 0 01 Oto 32767 9999 9999 9999 0 1 9999 298 Frequency search gain 299 Rotation direction detection selection at restarting Communication operation command source Communication speed O12 command source 0 1 Communication startup 0 1 10 mode selection Communication write selection 0 1 343 450 495 Remote output selection 496 Remote output data 1 Stop mode selection at communication error Maintenance timer Communication error count 0 1 92989 9999 9999 0 1 10 11 Oto 4095 0 1 2 Second applied motar te Cal x I I m e a 0 504 Maintenance timer alarm output set time 1 to 9998 99989999 C La 9999 9999 548 Protocol selection Pitney Bowes Drect Mail Solutions FIT 36servrev1 2 Selected St 00 FE D720 042 N Date 5 7 2009 All Parameter List FIT 36 base rev 2 18 09 Mo Setting Range Unit Initial Cure
38. 1 2 104 Pitney Bowes Drect Mail Solutions ge panel FR PUO4 PUO4 14 Cine EILE Input phase lass Inverter trips when function v alid setting i21 is selected in Pr 872 Input phase loss protection selection and one phase af ihe three phase power input is last Refer fo pape 144 Des cription It may function if phase to phase voltage af the three phase power input becomes largely unbalanced When the setting of Pr 372 Input phase loss profection selection is the initial value Pr 572 0 this warning does not Occur Check that phase to phase voltage of the three phase power input is not largely unbalanced Wire the cables property Repair break portion in the cable Check the Pr 872 Input phase loss protection selection setting Set Pr without input phase loss protection when three phase input voltage is largely Unbalanced Available only three phase power input specification model Operation panel m FR PUO4 E OLT ER PUO Prev STP OL shown during stall prevention operation lf the output frequency has fallen to 1Hz by stall prevention operation and remains for 35 faut CE appears Des cription and the inverter trips OL appears while stall prevention is being acti ated E OLT may not occur if stall prevention OL is activated during output phase lass Check point Check the motor
39. 11 3 a Turning the retaining knobs in both material guides in a counter clock wise direction to loosen and slide material guides to each end of the crossbar b Place new product side guides onto top plate and attach each using a hand knob NOTE A machined relief is on each product side guide to provide clearance for outer non vacuum belts See figure 111 3 Optional product side guides Figure 111 3 FIT 36servrev1 2 21 Pitney Bowes Drect Mail Solutions Paper Sensor Adjustment Reflective and Diffuse The paper sensor is located at the In Feed end of the FIT 36 s vacuum base over the center vacuum belt This sensor is set to detect and confirm the presence of paper before passing under various attached components ie ink jet heads This sensor does not normally need to be adjusted for each job once the setting has been made it should remain set unless otherwise disrupted In the event the settings have been disrupted perform the following REFLECTIVE 1 Position the sensor directly over the center of the reflective tape located on conveyor top plate and attach the sensor to the sensor support bar using the two 2 outermost tapped holes 2 Place a blank piece of white paper on the vacuum belt directly under the paper sensor 3 Using a small flat blade screwdriver remove the pan head screw in the plastic cover located on the sensor next to the electronic cable connection see figure 1 4 Note This sensor will
40. 8001226 Fusehodenpopof 8 _ 3s 016221 Terminal Ring 8 14 16 AWG Re 2 39 98010200 Wire 18 AWG 600 V violet 4 40 9801047 Wire 18 AWG 600 V greenw yelow 7 41 98010 158 Wire 14 AWG 600 V black 000 9 FIT 36servrev1 2 58 Pitney Bowes Drect Mail Solutions Main Electrical Enclosure 16021 105 rD2 44 98010 208 Wire 18 AWG 600 V white w blue 16 15 15 Receptacle sq flange 17 14 pos 60 16015 038 Label 120 VAC 3 15 A Quick disconnect 0 187 female 18 22 AWG red Plug 3 pin 2 pole 15A 66 9800 19 Fuse 500mA 250 V 5 20 GMC time delay 1 68 18021 165 ASSY GROUND STRAP FT 40 2 69 980040900 Fuse 5X20 3 15 A slow blow 2 Finishing Plug 7 8 hole Receptacle sq flange series 3 17 3 Bridge 2 position 80 98016 2289 Terminal ring 10 14 16 AWG blue FIT 36servrev1 2 59 Pitney Bowes Drect Mail Solutions Main Electrical Enclosure 16021 105 rD2 PART NUMBER DESCRIPTION 98019 045 Heat shrink 1 4 black 98016 224 Terminal ring 10 18 22 AWG 3 DPD Onon 88 16008208 Bar Board blank FIT Base 1 80 98003 09 Receptacle 1 320 OPT 90 88020107 Fite RFL115 280 9A 1 96 98003 062 Plug 230 V 10 A CHINA 98 980133151 DYANAMICBRAKERESISTOR _ FIT 36servrev1 2 60 Pit
41. 9 9999 3 Multi speed setting speed 0 to 400Hz 9999 0 01Hz 9999 9999 9 234 Multi speed setting speed 0 to 40082 9999 01Hz 9999 9999 10 235 Multi speed setting speed 0 to 40082 9999 O O1THz 9999 9999 11 236 Multi speed setting speed 0 to 4002 9999 01Hz 9999 9994 12 231 Multi speed setting speed 0 to 400Hz 9999 01Hz 9999 9999 13 s J s 238 Multi speed setting speed 0 to 400Hz 9999 01Hz 9999 9999 14 239 Multi speed setting speed O ta 40082 9999 01Hz 9999 9999 15 240 operation 0 1 1 1 1 selection FIT 36servrev1 2 co NO FIT 36servrev1 2 Pitney Bowes Drect Mail Solutions Selected St 00 FR D7202 082 NA Date 5 7 2009 All Parameter List FIT 36 base 2 19 09 Mame Setting Range Initial Curent Setting Comment 241 Analog input display unit 10 1 switchover Cooling fan operation selection 245 Rated slip 246 Slip compensation time constant 244 e 0 01 0 015 9999 0 5 Oto 50 9999 9999 0 01 to 105 247 Constant power range slip 0 9999 9999 9999 compensation selection 249 Earth ground fault 0 detection at start Stop selection 9999 Cn ce Oto 1005 1000 to 0 15 9999 11005 8888 9999 251 Output phase loss protection selection c Life alarm status display 0 to 15 256 Inrush current limit circuit O to 100 195 100 10
42. 98001 130 NOTE TL L II 0 KOKO KCO KOT IC PSE EE 0101010 HO OT Tea 9 55 IX gl OR ROL 02 OOO O a DONY on mi nom 19 Ja 5 6 61010101 He e HOT TO uyer shorted wayi loyer terminal l way ayer 16 woy uyer shorted 6 wayi terminal dbl lover shorted way Ir Li E EL 8 1 End stop ter 2 Terminal dbl loye 3 Terminal dbi 3 Terminol dbi 2 Terminol dbl 9 Terminal 2 Terminol 9 Terminal 1 End cover dbl 1 End stop jorr of IPROETART ana H coped Pitney Bowes Drect Mail Solutions E in il 5 ut um f 5 E SOS Ho Lj TI RATE OO 70140 cOldO 0140 0130 one Leele ___ jeje oee 2 1 3 0 bm Ix dut EN NENNEN OV m m e LM D UMS t Mal Solutions Pitney Bowes Dr 0 9 13865 SNIM
43. A Loosen the tension of the material transport belts by performing the following 1 Remove the Allen screw from both ends of the idler roller Note Use caution to prevent the idler roller from dropping See figure IV 8 2 Set the idler shaft assembly aside Base to base drive Idler roller gt E belt Transport gt E 4 A NN NW Remove screw from each end Base conveyor motor drive belt not necessary to remove Figure IV 8 FIT 36servrev1 2 41 Pitney Bowes Drect Mail Solutions Remove all four 4 flat head Allen screws and lower the main electrical box to the floor see figure IV 9 LE R pl r i a Xm E emove 4 flat head allen screws 4 ace electrical box on floor O ___ _ __ lt I A Caution Do not move box away from machine The electrical cables are long enough to allow the box to be placed on the floor directly under the mount holes Figure IV 9 E Using an Allen wrench remove the two 2 flat head Allen screws in front corners Operator s side as shown in figure 10 F Using an Allen wrench loosen and extract approximately 1 4 the two 2 flat head Allen screws in back corners as shown in figure 10 FIT 36servrev1 2 42 Pitney Bowes Drect Mail Solutions Loosen 2 flat head screws from the corners on the back side and back them out approximately 74 Note Do Not Remove These
44. ACAUTION cause hazardous conditions resulting in medium or slight injury or may cause physical damage only Note that even the ACAUTION level may lead to a serious consequence according to conditions Please follow the instructions of both levels because these are important to personnel safety AWARNING 1 Electric Shock Prevention AWARNING Ahile power is or when the inverter is running do not open the front cover Otherwise you may get an electric shock Do not run the inverter with the front cover or wiring cover removed Otherwise you may access the exposed high voltage terminals or the charging part of the circuitry and get an electric shock Even if power is OFF do not remove the front cover except for wiring or periodic inspection You may access the charged inverter circuits and get an electric shock Before starting wiring or inspection switch OFF power check to make sure that the operation panel indicator is off wait for at least 10 minutes after the power supply has been switched OFF and check that there are no residual voltage using a tester or the like The capacitor is charged with high voltage for some time after power OFF and it is dangerous e This inverter must be earthed grounded Earthing grounding must conform to the requirements of national and local safety regulations and electrical code NEC section 250 IEC 536 class 1 and other applicable standards Use an neutral poin
45. Corroded contact points at some point in an I O wire I O device has been used outside its specified operating range 4 An input signal is active for less time than one program scan MAINTENANCE 1 Check interior temperature of the panel 2 Check for loose component mounting or wire terminations FIT 36servrev1 2 74 Pitney Bowes Drect Mail Solutions Section VIII Component Programming FLEXIBLE INKJET TRANSPORT 36 FIT BASE FIT 36 SERVICE MANUAL FIT 36servrev1 2 75 Pitney Bowes Drect Mall Solutions FIT 36servrev1 2 FX SERIES PROGRAMMABLE CONTROLLER Go to Mitsubishi website for latest updates and complete manual Programming Manual Manual number IY 9920899101 Manual revision D Date April 2003 Guidelines for the Safety of the User and Protection of the Programmable Controller PLC This manual proces information for the use of the FX of PLs The manual has been written ta be used by trained and competent personnel The definition of such person persons 15 as follow s Any engineer who is responsible far the planning design and construction of automatic equipment using the product associated with this manual should be of a competent rature trairec and qualified to the local and national standards required to fulfill that rale These engineers should be fully aware of all aspects of safety with regards to automated equipment bi Any commissioning or service engineer m
46. Deep Environmental standard specifications of inverter Surrounding air Ambient humidity ar less non condensing Atmosphere Free from corrosive and explosive gases free from dust and dirt Maximum altitude 1 000m 2760 80 feet or less 5 9mis or less at 10 to 55Hz directions of X Y Z axes Use the inverter at the altitude of within 1000m 3260 60 feet If itis used at a higher place itis likely that thin air will reduce 0 to 50 C 14 F to 1227F on freez ing ternperature the cooling effect and low air pressure will deteriorate dielectric strength Maximum 1000m 3280 80feet above sea level for standard operation After that derate by 3 for every extra 5007 1640 40feet up to 2500m 8202feet 91 2 1 1 Terminal connection diagram FIT 36servrev1 2 1 DC reactor FR HEL 5 Terminal is not available for single Sink logic When connecting a DC reactor remove the phase 100V power input model Mar circul inal jumper across P1 P circuit termina Single phase 100 power input model is not Control circuit terminal compatible with DC reactor Single phase power input 7 A brake transistor is not built in to the FR D 720 008 014 and FR D7203 008 014 and FR D7 10vv 008 014 Option 8 Brake resistor FR ABR MRS type type Install a thermal relay to prevent an overeat and bumout of the brake resistor The brake resistor can not be c
47. Divert Solenoid Signal Supplies to divert piece when Opto 4 is triggered through J10 connector E Stop Loop Ovdc E Stop Loop Break pins 5 amp 6 to Stop Base E Stop Loop Ovdc E Stop Loop Break pins 5 amp 6 to Stop Base eS DO Connection J4 Pin Function Divert Mocon Signal Supplies 24vdc when base is running Divert Mocon Common Divert Solenoid 24vdc Divert Solenoid Signal Supplies to divert piece when Opto 4 is triggered through J10 connector E Stop Loop Ovdc E Stop Loop Break pins 5 amp 6 to Stop Base E Stop Loop Ovdc E Stop Loop Break pins 5 amp 6 to Stop Base et ak TE D Connection 5 Pin Function 1 Remote Start Input Supply momentary Ovdc signal to Start base 2 Remote Stop Input Supply momentary Ovdc signal to Stop base 3 Remote Jog Input Supply Ovdc to Jog machine Connection J6 Pin Function 1 Remote Start Input Supply momentary Ovdc signal to Start base 2 Remote Stop Input Supply momentary Ovdc signal to Stop base 9 Remote Jog Input Supply to Jog machine Connection J7 Pin Function 1 Dryer Run Signal Supplies 24vdc to run dryer when base is running and pieces are making and breaking input sensor 2 Dryer Run Common Supplies Ovdc to run dryer when base is running Connection J10 Pin Function 24vdc Divert Signal Input Supply Ovdc to this point to trigger Divert Sort Signal Input Supply
48. E made MODE x The parameter number read previously appears Parameter clear 4A Turn until CALE Col appears rs E L Le All parameter clear Eg Dii rn HL Lt 5 Press SET to read the present set value um U reu L n initial value appears 6 Turn D to change it to the set value s 2 7 Parameter clear 7 Press SET to set a 1 pim EE SET gt ss All parameter clear Flicker Parameter setting completell Turn D to read another parameter 7 Press SET to show the setting again Press SET twice ta show the next parameter Mot executed m Set parameters back to the initial values Parameter clear sets back all parameters except 1 ealibration parameters termina function selection parameters to the initial values Refer fo fhe parameter Ist on page 24 for availability of parameter clear and all parameter clear FIT 36servrev1 2 95 Pitney Bowes Drect Mail Solutions 4 24 Initial value change list a Displays and sets the parameters changed from the initial value Operation Display 1 Screen at powering on The monitor display appears indic ation is lit HHH cmm wud indication is lit 3 Press to choose the parameter settin _ mode EON 3 gt The parameter number read previously appears PI 2 Press Fe to choose th
49. O EE Regenerative ervaltage trip during acceleration If regenerative energy causes the inverter s internal main circuit OC voltage ta reach or exceed the specified value Des cription the protective circuitis activated and the inverter trips The circuit may also be activated by a surge voltage produced in the power supply system 1 Check far 100 Ow de eleration e g during downward in vertical lift load 2 Check that the setting of Pr 22 otal prevention operation level is not too small 1 Decrease the acceleration time Corrective action Use regeneration avoidance function Pr 552 Pr 533 Pr 553 556 Refer fo page 224 2 Set the Pred prevention operation level carrecth Operation panel FR PUO4 F 0 2 Stedy Spd OV indication Regenerative ervaltage trip during constant speed Name regenerate energy causes the inverter s internal main circuit DC voltage ta reach or exceed the specified value D es cription the protective circuit iz activated to stop the inverter output The circuit may also be activated by a surge voltage produced in the power supply ey stem Check noint 1 Check far sudden load change 2 Check that the setting of Pe 22 prevention operation level is nat too small 1 Keep load stable regeneration avoidance function Pr 522 Pr 533 Pr 382 Pr 229 Refer fo page 224 Lise the brake resistor brake unit ar pow
50. Ovdc to this point to trigger Sort Conveyor 5 24vdc Input Common Supply 5 24 at all times to power Opto s controlling Sort Divert and Feeder Pause Feeder Pause Input Supply Ovdc to this point to Pause Feeder 5 24 Pull Up Supply 5 24vdc for run up signal for Print Trigger 0 24 Signal Output Supplies 0 24 depending on state of Opto for Print Trigger Output Pull Down Supply for run down signal for Print Trigger OV Ie FIT 36servrev1 2 54 Pitney Bowes Drect Mail Solutions Connection J11 Function Pass Thru to J15 1 Pass Thru to J15 2 Pass Thru to J15 3 Pass Thru to J15 4 Pass Thru to J15 5 Pass Thru to J15 6 Pass Thru to J15 7 Pass Thru to J15 8 Pass Thru to J15 9 D 5 Lon Connection J13 Pin Function 1 Divert Mocon Signal Supplies 24 when base is running 2 Divert Mocon Common 3 Divert Solenoid 24vdc 4 Divert Solenoid Signal Supplies to divert piece when Opto 4 is triggered through J10 connector Connection J15 Pin Function Pass Thru to J11 1 Pass Thru to J11 2 Pass Thru to J11 3 Pass Thru to J11 4 Pass Thru to J11 5 Pass Thru to J11 6 Pass Thru to J11 7 Pass Thru to J11 8 Pass Thru to J11 9 Oo Se FIT 36servrev1 2 Pitney Bowes Drect Mail Solutions Figure V 4 CONTROL CONSOLE COMPONENT LIST item Component 7 Device Description _ Function _ Pushbutton illuminated
51. Reset selection disconnected detection P U stop selection Pr 73 refer fo Des cription page 128 2 Check point Check for stop made by pressing ofthe operation panel Turn the start signal OFF and release with Pus paration panel FR PUO4 rb fama Regenerative brake prealarm Appears if the regenerative brake duty reaches or exceeds 85 of the Pr 70 Special re generative brake duty value When the setting of Pr 70 Special re generative brake duty is the initial value 70 07 this warning does not occur Ift the regenerative brake duty reaches 100 a regenerative overvoltage E QV occurs The REP signal can be simultaneously output with the RB display Forthe terminal used forthe REP signal output assign the function by setting positive logic ar 107 negative logic in 190 or Pr 192 foutpudferminal function selection Refer fo page 117 1 Check that the brake resistor duty is not high 2 Check that the Pr 30 Regenerative function selection and Pr 70 Special regenerative brake duty settings are correct Corrective action 1 Increase the deceleration time Corrective action 2 Check that the Pr 30 Regenerative function selection and Pr 70 Special regenerative brake duty settings FR PUO4 Cam mnm o Electronic thermal relay function prealarm Name if the cumulative value af the Pr 9 Flecfronte thermal relay r
52. TOP pull up to release 3 Press red RESET pushbutton to illuminate white led indicator on START STOP pushbutton or to clear E STOP condition see figure 111 15 4 Turn the vacuum pump motor on by depressing the upper half of the white switch until it lights up see figure 111 9 5 Press white FEEDER pushbutton to operate feeder with conveyor see figure 111 12 Note Feeder must have sufficient product 6 Press and hold the yellow JOG pushbutton located on the control panel to jog the machine forward until one 1 piece of material has been fed from the feeder onto the material vacuum transport belts of the FIT 36 vacuum base see figure 111 14 FIT 36servrev1 2 31 Pitney Bowes Drect Mail Solutions Press green START pushbutton to initiate feeder conveyor operation White led will be steady Please note that operation will cease automatically a time out condition if product is not sensed at leading sensor and white led will produce a slow flash condition NOTE RED RESET PUSHBUTTON MUST BE PRESSED TO CLEAR E STOP CONDITION Press green START AND yellow JOG pushbuttons simultaneously to by pass feeder out of paper condition conveyor will operate continuously until first product is sensed at leading sensor then step 7 conditions prevail If white led produces a fast flash condition then a paper jam has occurred at either leading or trailing sensor a paper jam is normally caused when more than one product is being s
53. Transport Belts Vacuum Transport Belt center Electrical Enclosure Control Panel Vacuum Base Figure l 1 FIT 36servrev1 2 Pitney Bowes Drect Mail Solutions Model FIT 36 BASE Base Layout Shown without Feeder Stand or Conveyors Lie 6 dl ms e mL 9 3 E r e e e E 2 gt 5 e a 2 a a a h gt La 36 20 TOP VIEW 39 35 Requirements Floor Space 7 5 sq Ft Electrical 110V 200 240 V 1 PH 90 60 Hz 15A 10 A Air None Vacuum None Waiaht 300 FRONT VIEW Figure 1 2 FIT 36servrev1 2 7 Pitney Bowes Drect Mail Solutions Environment The installation of the FIT 36 base is intended for operation in a specific environment See Operating Environment Table below for details Operating Environment Table ITEM ____ ___ _____ Temperature 000000000 30 to 95 RH with no condensation Humidity Environmental 5 to 95 RH with no condensation Conditions _ Humidity 02 Pollution level 2 conforming to UL EN60950 1 Pollution Level There must be no combustible or corrosive Corrosion Gas gas pir Pressure 86 kPa to 106 ____ than associated with UV dryer lamps
54. YHO 37918 LON DO 3725 3 5215 Saco LG Bl HOH AEMDOHOZJJE See Sr gt 090 IDD oQ 5050 o ojo ot TIE 000 COLI 742 285 cd 82 14 EE EE m HSS PR PA CLHO OL 155371 1 Z 3290178 3c ALO 5 9 puwa 2015 pug b GUIS PUNO SE Busds 2 279 ers 7 5 JU 7 62 vc Arddns Duwea gaj pug Em jours doys pu t juna Buds 2 asnj JAAD ok J3euoosip asn JDLBULIS 3509 720972 YOE 1090 ADI i 43019 Dune Buds Ex i 2072 voE AmH L puw dos pus IN i 07 IC MELON x ee dole oe ng L LL JM Foe LE ee _ gt 2 i z LSd L2 ld pedo aq oj H BUD Life LH Abai I Pitney Bowes Drect Mail Solutions FOLD 27 A TITLE BASE PRIMARY HGH VOLTAGE Ta LAYOUT DRA WONG
55. after 35 Anne Du REMARKS isdisplayed Why Parameter write is disabled with 1 set in Pr 77 Fee isdisplayed Why Setting can not be mate ee operation Turn the start switch tw STF ar STR OFF Press before pressing ser to return to the monitor display without setting In this case the mode changes to external operation mode when performed the PU operation mode PU JOG operation made and to PU operation made when performed in the external operation made Reset can be made with e The priorities af the frequency commands when Pr 79 3 are Multi speed operation RL RMIRHIREX gt PID control 14 gt terminal 4 analog input gt digital inputfram the operation panel FIT 36servrev1 2 88 Pitney Bowes Drect Mail Solutions 4 1 4 Change the parameter setting value Changing Change the Pr J Maximum frequency setting Operation 1 Screen at powering on The monitor display appears PU 2 Press Cu to choose the PU operation mode Pu ET TD 7 NEXT Am 3 Press to choose the parameter setting y mode MODE A Tum e until lim 9 Press to read the present set value ooa nm n T tet 0 20 0Hz nitial value appears B Turm e to change the set value to Firm 60 LL Lr E Pr appears n e a Display Vey
56. al 3 Set filter ta the analog input terminal using Pr 72 Input 150 Afer fme constant The frequency setting signal is affected by EMI d 9 Take countermeasures against EMI such as using 23 shielded wires for input signal lines Lise terminal terminal SO when source logic as a common terminal ta prevent a malfunction caused by undesirable current Malfunction is occurring due ta the undesirable current generated when the transistor output unit is connected Pr 80 Motor capacity setting is improper for the capacities of the inverter and the motor for General Check the 20 Motor capacity setting purpose magnetic flux vector control Fluctuat siae Change the Pr 19 Base frequency voltage setting about 99 UCTUATION power SU 15 100 large 3 398 under VIF control Parameter Disable automatic control functions such as energy Setting saving operation fast response current limit function regeneration avoidance function General purpose magnetic flux vector control and stall pr vention Adjust so thatthe control gain decreases and the lev el of safety increases Change Pr 72 frequency selection setting Wiring length ex ceeds 30m when General purpose i Perform offline auta tuning 105 magnetic flux vector control is performed Hunting occurs by the generated vibration for ex ample when structural rigidity at load side is insufficient Adjust Pr 0 Torgue boost
57. as been Reset 9 Pass Thru to J2 9 10 Pass Thru to J2 10 11 Pass Thru to J2 11 12 Remote Run Supply Ov to this point when you want base to run must be constant when voltage drops out base will stop 13 Pass Thru to J2 13 14 Pass Thru to J2 14 15 Pass Thru to J2 15 16 Speed Follow Input Supply 0 10vdc to allow base to speed follow 17 Speed Follow Output Supplies 0 10 or 0 5 for speed following applications for feeder Gap pot adjusts voltage Oe Oe Ba 18 Speed Follow Output Com Ovdc common for speed following applications 19 E Stop Loop Ovdc E Stop Loop Pins J1 19 and J1 20 must be closed to Reset and Run Base Open to Stop 20 E Stop Loop Ovdc E Stop Loop Pins J1 19 and J1 20 must be closed to Reset and Run Base Open to Stop 21 Feeder Dry Contact Start Common with J1 22 when base is running 22 Feeder Dry Contact Start Common with J1 21 when base is running 23 Remote Reset Dry Contact Common with J1 24 Momentarily closed when Reset Button is pushed 24 Remote Reset Dry Contact Common with J1 23 Momentarily closed when Reset Button is pushed 25 Speed Follow Output Supplies 0 10vdc or 0 5 for speed following applications 26 E Stop Dry Contact Common with J1 27 Closed when base is in a Run Condition 27 E Stop Dry Contact Common with 1 26 Closed when base is in Run Condition 28 Remote Reset Com To Reset Base Dry Contact this pin with J1 29 29 Remote
58. cover them with plastic to prevent air borne particles from getting into them Note if the inkjet base cabinet is being used to house a computer remove the computer from the cabinet Remowve all ink cartridges from the carriage Note If a continuous feed ink system is in use cover the spray orifices with plastic to prevent air borne particles from getting into them Hold the air nozzle firmly at arm s length and blow off the machine beginning with the top surfaces then work your way down Warning sure to keep the direction of compressed air blowing away from you Note High volume businesses running three 3 shifts five 5 days a week should plan this function once a week Businesses producing light to moderate volume should plan this function once a month FIT 36servrev1 2 34 Pitney Bowes Drect Mail Solutions Cleaning Vacuum Transport Belts 1 Acquire and use eye protection safety goggles or safety glasses with side guards 2 Turn off the machine and disconnect the power line 3 Clean the following v Transport Belts of the FIT 36 Base v Transport Belt Tracks and Vacuum Manifold Apply a liberal amount of Simple Green general purpose cleaner or Isopropyl Alcohol 70 by volume see warning below to a soft cloth and wipe down the belt you wish to clean Advance the belt being cleaned by hand until the entire belt surface has been cleaned Warning Do not spray or pour Simple Green general purpose cl
59. d Check point 2 Check that the setting of Pr 7 Appited motor for motor selection is correct Refer fo page 3 Check that stall prevention operation setting is correct 1 Reduce the load weight Corrective action 2 Fora constant torque motor set the constant torque motor in Pr 7 Appited motor 3 Check that stall prevention operation setting is correct Refer fo page 77 Resetting the inverter initializes the intemal thermal integrated data of the electronicthennal relay function ci FR PUOD4 heaton FFM EFI n mp Som Se If the heatsink overheats the temperature sensor is actuated and the inverter trips The FIM signal can be output when the temperature becomes approximately 95 of the heatsink overheat protection Des cription operation temperature For the terminal used for the FIM signal output assign the function by setting 26 posite logic or 126 negati logic in 190 Pr 192 oufput function selection Refer fo page 117 1 Check for too high surrounding air temperature Check point 2 Check for heatsink clogging Check point Corrective action 1 2 3 4 5 2 3 4 5 Description 3 Check thatthe cooling fan is not stopped Check that Fr is displayed on the operation panel 1 surrounding air temperature to within the specific ations Corrective action 2 Clean the heatsink 3 Replace the cooling fan FIT 36servrev
60. d PR FIT 36servrev1 2 Pitney Bowes Drect Mall Solutions 12 Do nat apply a voltage higher than the permissible voltage to the inverter signal circuits Application of a voltage higher than the permissible voltage to the inverter 1 0 signal circuits or opposite polarity damage the devices Especially check the wiring to prevent the speed setting potentiometer from being conne incorrecth ta short terminals 10 5 13 Provide electrical and mechanical interlacks MC1 and MEZ which are used for bypass operation When the wirng is incorrect and if there is a bypass operation circuit as shown Power right the inverter will be damaged due to arcs generated atthe SuPPIY time of switch over or chattering caused by a sequence error MC 1 Inverter 14 If the machine must not be restarted when power is restored after a power failure provide a magnetic contactor ir Inverter s input side and also make up sequence which will nat switch ON the start signal If the start signal start switch remains ON after a power failure the inverter will automatically restart as soon power is restored 15 Instructions for avertaad operation When performing operation of frequent start stop af the inverter rise fall in the temperature of the transistor eleme the inverter will repeat due to a repeated flow of large current shortening the life from thermal fatigue Since the fatigue is r
61. d rotation reverse rotation are Check the wiring STF forward rotation STR reverse connected improperly rotation Adjustment by the output frequency is improper during the reversible operation with Pr 73 Analog inpuf selection Check the setting of Pe 125 Pr 126 Cz to C7 setting 5 5 6 Speed greatly differs from the setting Check points FE Frequency setting signal is incarrecthy input Measure the input signal level a Take countermeasures against EMI such as using The input signal lines are affected by external noise 38 shielded wires for input signal lines Check the settings of Fr 1 Maxi Pra Pr J 2 Pr 18 calibration parameter fo CY settings 51 Parameter Minimum frequency Pr 15 High speed maximum frequency are improper Setting ii Check the calibration parameter C2 fo CY settings Pr 31fo Pr 36 frequency jump settings are improper Narrow down the range of frequency jump Reduce the load weight Set Pr 22 atali prevention operation leve higher according Stall preventian is activated due to a heavy load to the load Setting Pr 22 too large may result in frequent overcurrent trip E G CLT 1 Check the capacities af the inverter and the motor Possible Cause Counter meas ures Parameter Setting Pitney Bowes Drect Mail Solutions 5 5 7 Acceleration deceleration is not smooth Refer Possible Cause Countermeasures t page Acceleratian decele
62. dentify the cause of the trip then remove the cause and power ON the breaker e When any protective function is activated take the appropriate corrective action then reset the inverter and resume operation 6 Maintenance inspection and parts replacement ANCAUTION Do not carry out a megger insulation resistance test on the control circuit of the inverter It will cause a failure 7 Disposal A CAUTION General instruction Many of the diagrams and drawings in this Instruction Manual show the inverter without a cover or partially open Never operate the inverter in this manner Always replace the cover and follow this Instruction Manual when operating the inverter FIT 36servrev1 2 Pitney Bowes Drect Mail Solutions eRemoval Example of 0740 036 1 Loosen the installation screws ofthe front cover The screws cannot be removed 2 Remove the front cover by pulling it like the direction of arrow 1 Installation screw eReinstallation Example of FR D740 036 1 Place the front cover in front ofthe inverter and install it straight 2 Tighten the installation screws on the front cover Installation screw Hold the side af the wirng cover and pull it downward for removal Also pull the winng cover downward with holding a To reinstall fit the cover to the inverter along the guides frontal part of the wiring cover LS Pitney Bowes Drect Mail Solutions
63. dicates point of further interest or further planation Software Warnings 4 Indicates special must be taken when using this elerrent of software 61 Indicates a special point which the user of the associate software elerrent should be aware of 2 A Indicates a point of interest ar further explanation E Pitney Bowes Drect Mail Solutions FIT 36sen INVERTER FR D 700 Thank you for choosing this Mitsubishi Inverter MANUAL IB NA O600368ENG B 11 18 2008 This Instruction Manual provides instructions for advanced use of the FR D700 series inverters Incorrect handling might cause an unexpected fault Before using the inverter always read this instruction manual and the Installation Guideline IB 0600367ENG packed with the product carefully to use the equipment to its optimum performance This section is specifically about safety matters Do not attempt to install operate maintain or inspect the inverter until you have read through the Instruction Manual and appended documents carefully and can use the equipment correctly Do not use this product until you have a full knowledge of the equipment safety information and instructions In this Instruction Manual the safety instruction levels are classified into WARNING and CAUTION Assumes that incorrect handling may cause hazardous conditions resulting in death or severe injury Assumes that incorrect handling may
64. e 5 7 2008 All Parameter List FIT 36 base VFD rev 2 19 08 Mame setting Range Unit Initial Curent Setting Comment Torque boost Oto 30 0 1 6 1 Maximum frequency Oto 1202 0 012 Minimum frequency Oto 1202 0 01Hz 00 75 RUE CE 0 4 Mult speed setting high to 400Hz 01Hz speed 5 Multi speed setting middle 0 to 400Hz 3 0 speed Multi speed setting row 400Hz 01Hz 1 0 speed Fi 8 1 5 5 2 4 0 3 0 1 5 0 Electronic thermal Oto 500A 0 014 1 3 5 0 Es 0 5 0 4 dd O gt 5 N DC Injection brake 120Hz 0 01 100 operation frequency OC injection brake 105 0 15 operation time 0 DC injection brake Oto 30 0 15 operation voltage 1 starting frequency ta 01Hz 075 5 frequency 0 to 400Hz 0 01Hz 25 e Jog 0 to 36005 0 15 0 acceleration deceleration time s 2 High speed maximum 120 to 400Hz frequency 0 0 Base frequency voltage to 1000 8888 9999 9994 9999 0 1 1 1 0 71 a Acceleration deceleration 1 ta 400Hz 01Hz 120 reference frequency 71 Stall prevention operation to 200 0 1 15 150 level Stall prevention op ration 0 to 200 999 0 1 9999 9999 level compensation factor at double speed 24 Multi speed setting speed 0 to 400Hz 9999 DTHz 9999 9999 4 Mlulti spe
65. e PU operation mode PU a ET 4 Turn e until f H appears gt 5 m t may take several seconds Pressing SET changes to the initial yalue FA for creating the initial value change list screen EL change li D fickers while creating the list 6 Turning e displays the parameter number changed ePress SET to read the present set value oy Turn and press SET to change the setting refer fo sfep band 7 on page 23 D to read another parameter ehe display returns to P after all parameters are displayed 7 Pressing 5 p status returns to the parameter setting mode L A Turning bei sets other parameters Pressing displays the change list again vo NOTE 1 Calibration parameters CT Pr 901 amp C7 Pr 905 are not displayed even when these are changed from the initial Settings Only simple mode parameter is displayed when simple mode is set 7 150 9999 initial value Py Jal is displayed independently of whether the setting value is changed not When parameter setting is Changed after creating the initial value change list the setting will be reflected to the initial Change list next time FIT 36servrev1 2 96 Pitney Bowes Drect Mall Solutions When a fault occurs in the inverter the inverter trips and the PU display automatically changes to any of t
66. eaches of exceeds 95 of the preset level If itreaches 100 of the Pr 9 Elecftrome thermal relay setting a motor overload trip E THM occurs D es cription The THF signal can be simultaneously output with the TH display For the terminal used far signal output assign the function by setting 8 positive logic 108 negative logic in 190 or Pr 192 foutpudferminal function selection Refer fo page 117 2 sthe Pr 9 Elgctronic fhemmal relay setting is appropriate Refer fo page 94 C 1 Reduce the load and frequency of operation Operation panel or FR PUI indication Maintenance signal Lame Maintenance the cumulative energiz ation time of the inverter has reached a given time Des cription When the setting of Pr 502 Maintenance fmer alarm output sef fime is the initial value 3504 9999 this warning doesnot occur Corrective action action Setting T in Pe 203 Maintenance timer erases the signal passen panel FR PUO4 is Y Uu j Underoltage If the power supply voltage of the inverter decreases the control circuit will nat perform normal functions In addition 101 the motor torque will be insufficient andfor heat generation will increase To prevent this if the power supply voltage Description decreases below about 115VA C about 230VAC for 400 class about 58vA C far 100 class this function stops the inverter out
67. ealer FIT 36 Setup 1 Fold one 1 piece of material in half to establish a center crease Note The crease needs to be made in the direction of travel that the material is to be run see figure 111 1 Center Crease Letter To John Q Public Figure 111 1 2 Align the center crease of the set up piece with the center of the vacuum transport belt belt with holes see figure 111 2 C O Q 2 84 3 Set the width of the material guides located on the transport deck by turning the retaining knobs a counter clock wise direction to loosen clock wise direction to tighten Adjust the material guides to center the material being run onto the vacuum belts see figure 111 2 Note Arrange the guides approximately 1 16 from the top and bottom edge of the material to prevent restricting the material on the transport belt Adjust material guide to Vacuum Transport Belt jt the width of the material p Figure 111 2 Standard material guides Loosen these knobs to adjust the material guides on the FIT 36 Base FIT 36servrev1 2 20 Pitney Bowes Drect Mail Solutions 4 Setting the width of the material guides located on the transport deck for narrow products If the product is narrower than the existing overall belt set width it will be necessary to move the standard material guides to the outermost position on the crossbar and use optional product side guides See figure
68. eaner or Isopropyl Alcohol directly onto the belts free flowing liquids may seep into some electronic components and cause damage Note Simple Green general purpose cleaner and or Isopropyl Alcohol can be purchased at most local grocery stores and drug stores A Warning Isopropyl Alcohol is FLAMABLE do not use near an open flame or any other source device that gives off heat General Maintenance Lubrication The pillow block bearings on each end of conveyor belt pulleys are provided with a grease fitting To access A Detach conveyor end belt guard s by removing 3 button head screws see figure 1 Using a 1 8 Allen wrench remove the 3 button head screws to detach end cover Grease fitting Guy Figure IV 1 FIT 36servrev1 2 35 Pitney Bowes Drect Mail Solutions FIT 36 Base Material Transport Belt Replacement Prepare the work area clear off the top surface of the vacuum base and be sure power source has been disconnected Top Plate Dissemble for belt removal A Warning Before beginning the process turn off and disconnect the power to the machine 1 Dissemble the top plate This can be accomplished in the following manner A Remove knobs from both product side guides if used and place both aside B Using an Allen wrench remove the button head Allen screws found in the mounting bar brackets at both ends of the material hold down bar sensor mounting bars and print head supports R
69. ed setting speed to 400Hz 9999 0 01Hz 9999 9999 5 Multi speed setting speed 010 400 2 9999 9999 9999 6 7 nate gt o g 2 2 2 Multi speed setting speed 0 to 400Hz 9999 9999 9999 7 Acceleration deceleration 0 1 2 pattern selection Regenerative function 0 1 2 1 selection Frequency jump 14 to 400Hz 9999 0T1Hz 9999 9999 Frequency jump 1B 400Hz 9999 9994 9999 Frequency jump 2 Oto 400Hz 9999 9999 9999 4 Frequency jump 2B to 400 2 3899 9999 9999 35 Frequency jump O to 400Hz 3999 9999 9999 FIT 36servrev1 2 1 EE o B 9 0 1 3 24 33 3 CO Pitney Bowes Drect Mail Solutions Selected St 00 FR D7208 042 NA Date 5 7 2009 All Parameter List FIT 36 rev 2 19 09 Mame setting Range Unit Initial Curent Setting Comment Frequency jump 3B Oto 400 2 9999 D OTHz 9999 9999 Speed display 0 0 01 to 9998 0 001 0 3 3 6 40 RUN key rotation direction 0 1 selection 1 Up to frequency sensitivity to 100 0 1 I 2 Output frequency detection to 400Hz 0 01Hz 3 Output frequency detection 0 to 400Hz 9999 01Hz 9999 9999 for reverse rotation 4 Second Oto 38005 0 5 5 acceleration deceleration time EN mE I amp Second torque boost Oto 30 9999 9999 9999 F Second V F base to 400Hz 9999 O 01Hz 9999 9999 frequency 8 Second stal
70. ee phases LU Vv W on the inverter s output side load side 15 1051 during inverter operation except Des cription during OC injection brake operation and when output frequency is under 1Hz irw erter stops the output Whether the protective function is used ar nat is set with Pr 257 Cuiput phase loss protection selection Check noint Check wiring Check that the motor is normal Check that the capacity of the motor used is not smaller than that af the inverter Wire the cables properly Corrective action Corrective action Check the Pr 221 phase loss protection selection setting FIT 36servrev1 2 105 D es cription Pitney Bowes Drect Mail Solutions Operation panel nur External thermal relay operation If the external thermal relay provided for motor overheat protection ar the internally mounted temperature relay in the motor etc Switches an fcontacts open the inverter outputis stopped Functions when 7 OH signal is set in ary of Pr Pr 182 input terminal function selection This protective function does not function in the initial status signalis not assigned Check point Check for motor overheating Check that the value of 7 OH signal is set in any of Fr 173 fo Pr 152 input terminal function selection Reduce the load and frequency of operation Even if the relay contacts are reset automatically the inverter will not restart
71. elated to the amount of current the life can be increased by reducing current at locked condition sta current etc Decreasing current may increase the life However decreasing current will result in insufficient torque the inverter may not start Therefore choose the inverter which has enough allowance for current ta 2 rank larg capacity 16 Make sure that the specifications and rating match the system requirements 17 When the motor speed is unstable due to change inthe frequency setting signal caused by electromagnetic noises the inverter take the following measures while applying the motor speed by the analog signal Do not run the signal cables and power cables inverter cables in parallel with each other and do not bundle tr Run signal Cables as far as possible from power cables inverter cables Use shield cables as signal cables Install a ferite core an the signal cable Example ZCAT 3039 1330 FIT 36servrev1 2 89 Pitney Bowes Drect Mail Solutions 4 1 1 Names and functions of the operation panel The operation panel cannot be removed from the inverter Operation mode indication PL Litto indicate PU operation mode EXT Litto indicate Externa operation mode Lit at povera M at initial setting NET Litto indicate Network operation made PU EXT Litto indicate External P Ll combined operation mode 1 2 These turn OFF when command source is hot on operation pane
72. emove the mounting brackets See figure 2 Caution The mounting brackets with sensors on them should be placed gently to the non operator side of the machine It is not necessary to remove the sensors if sufficient care is taken Side guides and knobs Sensor with quick disconnect cable not shown mounted to sensor mounting bar Figure IV 2 Material Mounting bar bracket Print head support bracket Top plate hold down bar bracket FIT 36servrev1 2 36 Pitney Bowes Drect Mail Solutions Remove front panel with control panel of FIT 36 base See figure 3 1 Using an Allen wrench remove 2 button head screws from front panel 2 Lift front panel up to be free from bottom retaining clips and carefully set aside A Caution Control panel electrical cables are still attached to the electrical enclosure can be detached from enclosure if necessary R View of front cover off the machine Note the cable are long enough to leave connected to the electrical box Disconnecting them is optional Figure IV 3 FIT 36servrev1 2 37 Pitney Bowes Drect Mail Solutions D Detach conveyor end belt guard s by removing 3 button head screws See figure 4 Using an 1 8 Allen wrench remover the 3 button head screws and remove cover Figure IV 4 FIT 36servrev1 2 38 Pitney Bowes Drect Mail Solutions Remove the motor and motor mount plate by performing the following A Remove the two
73. ensed i e overlapping pieces Clear jam and re start Setting Run Speed 1 Once the material is being transported by the vacuum transport belt green START button is active and LED indicator is steady adjust the speed of the FIT 36 base by turning the Base Speed Control Knob in a clock wise to increase the speed or counter clock wise to decrease the speed see figures 111 11 Note Set the speed to best accommodate the material and fonts being run Set the FEEDER gap by adjusting the Gap Control knob in a clock wise direction to shorten the gap between each piece of material as it feeds or counter clock wise to increase the gap between each piece of material as it runs see figure 111 11 Adjusting level of vacuum Normally there is no need to adjust the vacuum level available at the perforated vacuum transport belt between different products However if the product is subject to damage from standard vacuum levels there is vacuum adjustment valve available to decrease the overall vacuum available to an appropriate level This valv4e is located inside the machine between the pump motor and the back cover see figure 111 15 Adjustment valve is located between the pump motor and back cover Note back cover is missing in this view Turn valve clock wise to decrease vacuum counter clock wise to increase vacuum Figure 1Il 15 FIT 36servrev1 2 32 Pitney Bowes Drect Mail Solutions Section IV General Maintena
74. er regeneration common converter R Cv as required 2 Set the Pred Mell prevention operation level c orrectiy aparaton panel FR PUO4 mim E EGUS 0 Regenerative ervaltage trip during deceleration ar stop Lm E f regenerate energy causes the inverter s internal main circuit DC voltage ta reach ar exceed the specified value Des cription the protective circuit is activ ated to stop the inverter output The circuit may also be acth ated by surge voltage produced in the power supply ev ster Check for sudden speed reduction Increase the deceleration time Set the deceleration time which matches the moment of inertia of the loach the brake cycle langer Use regeneration avoidance function Pr 882 Pr 483 Pr 482 Pr 350 Refer fo page 224 Lise the brake resistor brake unit ar power regeneration common converter as required D es cription Check point Corrective action E w BR Corrective action Corrective action FIT 36servrev1 2 103 Pitney Bowes Drect Mail Solutions cr FR PUO4 ton 587 0 Inverter overload trip electronic thermal relay function M temperature ofthe output transistor element exceeds the protection level under the condition that current not Description less than the rated inverter current flows and overcurrent trip does not occur 200 or less the electronic ther
75. er setting mode Monitor indication Lit to indicate monitoring mode Stop operation Used to op Run command Fault can be reset when protective function is activated fault Operation mode switchover Used to switch between the PLI and external operation mode When using the external operation mode foperation using a separately connected frequency setting potentiometer and start signal press this key to light up the EXT indication Press MODE simultaneous 0 55 Rafer to mage or change Pr 79 setting to change combined made 2 FU PU operation mode EXT External operation mode Cancels PLI stop also The rotation direction can be selected by setting Pr 40 Pitney Bowes Drect Mail Solutions 4 1 2 Monitor frequency setting Parameter setting Faults history FIT 36servrev1 2 Basic operation factory setting Operation mode switchover At powering on extemal operation mode MANN ULU UI EXT im H gt PU Jog operation mode H 77 gt F Value change gt gt LLLI LI Output current monitor PU operation mode output frequency monitor E and frequency flicker Frequency setting has been written and complete di nn m Output voltage monitor FA Parameter setting mode Refer fo page J3 Value change Display the Current setting gt
76. f the problem still persists after taking the above measure please contact your sales representatie Analog input fault Appears if valtagercurrent is input ta terminal 4 when the setting in Pr 267 Terminai 4 input selection and the setting of voltagercurrent input switch are different Check Checkpoint Check the setting of Pr 267 Terminal 4 input selection and voltagefcurrent input switch Refer fo page 148 Cairochue actan Either give a frequency command by current input set Pr 267 Terminai 4 input selection and valtagercurrent input switch to voltage input Operation panel FR PUO4 Fault 14 Fault indicati FR PUO indication LIT ESAE Safety circuit fault circuit fault D es crintion Nome LI I when safety circuit is malfunctioning Appears when of the lines between 51 and SC or between 82 and SC is opened f the indication appears when safety stop function is nat used check that shorting wires between S1 and SC 52 Check point and SC are connected Check that the safety relay module is properly connected Des cription E 1 E f protectrve functions of E ILF E E PTC E CDO E SAF actwated when using the FR PUO4 Fault 14 TNT is displayed Also when the faults history is checked on the FR PUM the display is E 11 f faults other than the above appear contact your sales representatve FIT 36servrev1 2 107 Pitney Bowes Drect
77. gure 11 3 Label shown at actual size Burn Warning oymbol indicating burn hazard Found posted on the dryer Figure 1 4 Note This symbol AN appears as a visual alert in the text of this manual next to written warnings regarding possible safety issues and or possible machine damage that may occur as a direct result of failure to follow specific instructions as written Pitney Bowes Drect Mail Solutions Recommendations for Safe Operation Note The safety devices warning labels and stickers are installed by the manufacturer to safeguard all persons operating and or working on or around the FIT 36 Removing altering or disabling any of these items will void any and all warranties either real or implied purchased or offered with the FIT 36 All companies connected with the manufacturing promotion and sale of the FIT 36 shall be held harmless for any and all injuries and damage in the event the safety devices door locks warning labels and stickers are removed altered or disabled In addition to the safety devices and warnings installed on the FIT 36 by the manufacturer the following recommendations for safe operation and maintenance of the FIT 36 are as follows gt Any persons designated to operate work on or near the FIT 36 must be fully trained by a factory authorized representative Do not operate or perform any type of maintenance on the FIT 36 while under the influence of drugs or alcohol Do not
78. gure I 6 Collecting Conveyor 2 Product J2 r Sensors Infeed P8 P9 Conveyor Or Feeder J1 Figure 1 6 8 Plug the collecting conveyor cable into the J2 receptacle located on the LH side panel of the FIT 36 electrical enclosure See figure 6 9 Plug the gray sensor cables P9 and respectively into the upstream and downstream receptacles located on the FIT 36 electrical enclosure FIT 36servrev1 2 11 Pitney Bowes Drect Mail Solutions Section Il Safety Features amp Warnings SERVICE MANUAL Pitney Bowes Drect Mail Solutions Section Il Safety Locks and Warnings All covers panels to cabinets containing moving parts and electrical components are attached with Allen head screws that require the use of an Allen wrench to open All FIT 36 bases are provided with caution or warning labels or stickers to safeguard persons operating and or working on or around this equipment These are as follows General Warning oymbol indicating possible safety hazards Found posted on the front service panel of the FIT 36 Base Figure 11 1 Label shown at actual size Shock Hazard Symbol indicating possible shock hazard Found posted on the service cover on the electrical enclosure mounted on the backside of the FIT 36 Base Figure 11 2 Label shown at actual size Mechanical Warning oymbol indicating pinch hazard Found posted on the mounting plate of the transport belt drive motor Fi
79. he following fault alarm indications If fault does not correspond to any of the following faults ar if you have any other problem please contact your sales representative e Retention of fault output signal When the magnetic contactor MC provided on the input side of the inverter is opened when a fault occurs the inverters Control power will be lost and the fault output will not be held Fault or alarm indication When a fault or alarm occurs the operation panel display automatically switches to the fault alarm indication Resetting method When a fault occurs the inverter outoutis kept stopped Unless reset therefore the inverter Cannot restart Refer to page 240 ev hen any fault occurs take the appropriate corrective action then reset the inverter and resume operation Not doing so may lead to the inverter fault and damage Inverter fault ar alam indications roughly divided as below 1 message regarding operational fault and setting fault by the operation panel and parameter unit FR PU Dd FR PUO is displayed The inverter does not trip 2 Warnings The inverter does nat trip even when warning is displayed However failure ta take appropriate measures will lead to a fault 3 Alam The inverter does nat trip You can also output an alarm signal by making parameter setting 4 Fault When a fault occurs the inverter trips and a
80. he smoothing capacitar When accessing the inverter forinspection wait for atleast 10 minutes after the power supply has been switched off and then make sure that the voltage across the main circuit terminals P and M of the inverter is not mare than SOVDC using tester etc The capacitor is charged with high voltage for some time after power off and it is dangerous 8 A Short circuit or earth ground fault on the inverter output side may damage the inverter modules Fully check the insulation resistance of the circuit prior to inverter operation since repeated short circuits caused by peripheral circuit inadequacy or an earth ground fault caused by wiring inadequacy or reduced motor insulation resistance may damage the inverter modules Fully check the to earth ground insulation and phase to phase insulation of the inverter output side before power on Especially for an old motor ar use in hostile atmosphere securely check the motor insulation resistance etc 10 Donat use the inverter input side magnetic contactor to start stap the inverter Always use the start signal tum ON OFF STF and STR signals to start stop the inverter fo page 42 11 Across and PR terminals connect only an extemal regenerative brake discharging resistor Do not connect mechanical brake The brake resistor can nat be connected to the FR D7Y20 008 and 014 FR 07205 008 and 014 FR 0710 008 and 014 Never short between terminals an
81. is connected while Pr 557 9999 initial setting all the operation mode displays turn Command sources atthe PU operation mode is not at Parameter the operation panel Setting None of the operation mode displays is lit 5 5 11 Motor current is too large Possible Cause Countermeas ures Set rated frequency of the motorto Pr 3 frequency Use Pr 19 frequency voltage to set the base voltage VIF pattern is improper when VIF control is performed e g rated motor voltage Pr 3 Pr 14 Pr 13 Change Pr 14 Load pattern slechon according to the load m Par ameter characteristic Setting Reduce the load weight Pr 22 Mali prevention operation level higher according to the load Setting Pe 22 too large may result in frequent overcurrent trip 7 Check the capacities of the inverter and the motor Auto tuning is not performed under General purpose 3 3 Perform offline auta tuning 103 magnetic flux vector control Stall prevention function is activated dueto a heavy load Pitney Bowes Drect Mail Solutions 5 5 12 Speed does not accelerate Check points Possible Cause Countermeasures Check if the start command and the frequenc Start command and frequency command are chattering command are correct The wiring length used for analog frequency command l i oe Perform analog input biasqain calibration is taa lang and it
82. isplay shows an error 2 9 E G CT action then reset the inverter and resume the EN operation FIT 36servrev1 2 110 Pitney Bowes Drect Mail Solutions 5 5 2 Motor or machine is making abnonnal acoustic noise Check Hefer Tem Possible Cause Countermeasures to poin ES Disturbance due to EMI when frequency command is Setting operation cannot be performed due to EM I In the initial setting Pr 240 Soft P HAM operation selection jS enabled ta change motor noise ta an unaffendindg complex tane Therefore carrier frequency noises 1458 metallic noises are generated Set 240 0 to disable this function Set 31 Fr 36 Frequency jump When it is desired ta avoid resonance attributable to the Resonance occurs output frequency 22 natural frequency af a mechanical system these parameters allow resonant frequencies to be jumped Parameter Change Pr 2 PWM frequency selection setting Mo carrier frequency noises metallic noises are generated Setting Changing the PYM carrier frequency produces an effect Resonance occurs carrier frequency 145 on avoiding the resonance frequency of mechanical system ora motor Auto tuning is not performed under Genera purpose Perform offline auto tuning 03 magnetic flux vector control To stabilize measured value change the proportional band Pr to a larger value the integral time Pr 130 Gain adjustment during PID contr
83. k Pr 200 setting and connection of STF and STR Hs Setting selection signals When power is restored ensure the safety and turn OFF the start signal once then turn OM again to restart Inverter restarts when Pr 261 2 7 13 Saring frequency setting is greater than the running frequency Inverter decelerated to a stop when power failure deceleratian stap functian is selected When offline auta tuning ends press of the operation panel forthe PLI operation Far the External operation turn OFF the start signal STF or This operation resets the offline auto tuning and the P s monitor display returns to the normal indication Without this operation next operation cannot be started Disable the automatic restart after instantaneous power failure function and power failure stop function Reduce the load Increase the acceleration time if the automatic restart Automatic restart after instantaneous power failure function or power failure stop function is acti ated Performing overload operation with single phase power input specification model may cause voltage insufficiency and results in a detection of power failure after instantaneous power failure function ar power failure stop function occurred during acceleration Load is too heavy Reduce the load Load Shaft is lacked Inspectthe machine motor TN When any fault occurs take an appropriate corrective Operation panel d
84. l Rafer to page J ALD Unit indication Hz Litto indicate frequency Flickers when the set frequency monitor is display ed Litto indicate current Both Hz and A turn of when other than the above is displayed Monitor 4 digt LED Shows the frequency parameter number ete Setting dial Setting dial Mitsubishi inverter dial Used ta change the frequency setting and parameter values Press to display the following Displays the set frequency in the monitor mode Present set value is displayed during calibration Displays the order in the faults history mode Mode switchover Used change each setting rode _ FPU _ Pressing ET simultaneously changes the operation mode Refer fo page 22 Pressing far awhile 25 can lack Operation Refer fo page 230 Determination of each setting If pressed during operation monitor changes as below Output vo tage FIT 36servrev1 2 status display Start command Lit or flicker during inverter operation On Indicates that forward rotation operation is being perform ed Slow fick ening 1 45 cycles Reverse rotation operation Fast flickering 0 25 ce fo When was pressed or the M command was given but the operation can not be made frequency command is less than the starting frequency When the MES signal is input Parameter setting mode indication Lit ta indicate paramet
85. l prevention Oto 200 9999 0 1 9999 9999 operation current Second deceleration time Oto 36005 9999 0 15 9999 9999 1 Second electronic thermal 0 to 5004 9999 9999 9999 OL relay 52 main display data 0 5 8 to 12 14 20 23 to selection 25 52 to 55 6162 64 100 Frequency monitoring 0 to 400Hz 0 01 120 reference 56 Current monitoring Oto 500A 014 4 4 2 reference 7 Restart coasting time 0 0 1 to 55 9999 9999 9999 Energy saving contral selection 5 Rey selection stall prevention operation O to 400Hz 0 01 r duction starting 67 Number of retries at fault Oto 10 101 to 110 occurrence Retry waiting time 0 1 to 6005 E NN Ed ER ES duty 9 7 NEN 1 15 1 1 1 1 1 15 1 LE Lg ED ____ 1 Applied motor 0 1 3 13 23 40 43 50 53 frequency selection mE 9999 Rated motor voltage Oto 1000V 200 1 1 Analog input selection 1 T4 Input filter time constant 1 1 1 1 Reset Oto 3 14 10 17 1 selection disconnected PU detection PU stop selection 0 1 2 3 4 5 7 1 0 2 1 1 1 1 1 5 1 1 1 1 5 4 4 2 78 9 5 L1 mE EN mE a 1 a FIT 3 No Name setting Range Unit Initial Current Setting Comment Rated motor frequency 10 to 120Hz 0 01Hz 90 Motor constant R1 50ohm 9999 0 001oh
86. m 9999 Pitney Bowes Drect Mail Solutions Selected St 00 FE D7 208 042 NA Date 5 7 2009 All Parameter List FIT 36 base rev 2 19 09 1 61 1 2 100 d d NN setting Range Unit Initial Current Setting Comment 166 Output current detection Oto 105 9999 0 15 0 1 0 1 signal retention time Output current detection 0 1 1 1 op ration selection 168 Parameter for 1 8134 manufacturer setting Do 169 Parameter for 1 1 manufacturer setting Do Operation hour meter clear 0 9999 9999 9999 178 STE terminal function to selection 5 8 10 12 14 15 18 24 25 50 52 65 to 57 9999 179 STR terminal function Ota selection 578 1012 41518 2425 51 62 65 to 67 9999 180 RL terminal function ta selection 5 8 10 12 14 15 18 24 25 52 55 to 57 9899 181 RM terminal function Ota selection 5 8 10 12 14 15 18 24 25 52 65 to 67 9999 182 RH terminal function Ota selection 0 1 8 10 12 14 16 16 24 25 52 55 to 67 9999 190 RUWN terminal function selection 16 25 26 46 47 64 70 80 8 0 91 93 95 96 93 99 100 1 01 103 104 107 103 111 to 116 125 126 146 147 164 170 180 190 191 193 195 196 196 199 9999 A B C terminal function 0 1 3 4 7 8 11 to selection 16 25 26 46 47 70 80 8 0 91 95 96 93 99 100 101 103 104 107 108 111 to 116 125 126 146 147 164 170 180 190 191 195 196 198 199 39899 Multi speed setting speed 0 to 400Hz 3999 O01Hz 999
87. mal relay activates to stop the inverter output Overload capacity 150 805 200 0 52 Check that acceleration deceleration time is nat toa short Check that torque boost setting is nat taa large small Check that load pattern selection setting is appropriate far the load pattern af the using machine Check the motor for use under overload Check for too high surrounding air temperature Increase acceleratian deceleratian time Adjust the torque boost setting load pattern selection setting according to the load pattern af the using machina Reduca the load weight surrounding air temperature to within the specific ations person panel FR Puod Motor Ovrload Motor overload trip electronic thermal TET function 1 __ Wo electronic thermal relay function in the inverter detects motor overheat due ta overload or reduced cooling capability during constant speed operation and pre alarm display is output when the integrated value reaches 09 Of the 9 Fleefronte thermal relay setting and the protection circuit is activated to stop the inverter output when the integrated value reaches the specified value When running a special matar such as multkpol motor or multiple motors provide a thermal relay an the inverter output side since such motoris cannot be protected by the electronic thermal relay function 1 Check the motor for use under overloa
88. manufacture an insulating material that can shut off a leakage current completely and actually a slight current flow into the case The purpose of earthing grounding the case of an electrical apparatus is to prevent operator from getting an electric shock from this leakage current when touching it To avoid the influence of external noises this earthing grounding is important to audio equipment sensors computers and other apparatuses that handle lovelevel signals ar operate very fast 4 Earthing grounding methods and earthing grounding work As described previously earthing grounding is roughly classified inta an electncal shock prevention type and noise affected malfunction prevention Therefore these two types should be discriminated clearly and the following work must be done to prevent the leakage current having the inverter s high frequency components from entering the malfunction prevention type earthing grounding possible use independent earthing grounding for the inverter If independent earthing grounding D Is Impossible use joint earthing grounding 1 where the inverter is connected with the other equipment at an earthing grounding point Joint earthing grounding as in II must be avoided as the inverter is connected with the other equipment by Common earth ground cable Also a leakage current including many high frequency components flows in the earth ground cables af the i
89. ment by an incorrect type could result in an explosion for example with some lithium batteries the following applies Ifthe battery is placed in an operator access area there shall be a marking close to the battery or a statement in both the operating and servicing instructions Ifthe battery is placed elsewhere in the equipment there shall be a marking close to the battery or a statement in the servicing instructions This marking or statement shall include the following or similar text CAUTION RISK OF EXPLOSION IF BATTERY IS REPLACED BY AN INCORRECT TYPE DISPOSE OF USED BATTERIES ACCORDING TO THE INSTRUCTIONS FIT 36servrev1 2 15 Pitney Bowes Drect Mail Solutions Section Il Lock Out Procedure Before beginning extensive repairs involving disassembly of the machine either in whole or in part performing general maintenance or replacing any of the electrical components the machine must be locked out of service to ensure that power will not be restored to the machine while the work is being performed To lock a machine out of service perform the following AN Warning The following procedure is published herein for the expressed purpose of providing a safe work environment conducive to persons performing repairs and or maintenance and or general cleaning of the FIT 36 and or any other components connected to or associated with the FIT 36 This procedure must be followed without exception to ensure the safety of a
90. n circuit cable voltage drop will cause the motor torque to decrease especially at the output of alow frequency Refer to page 77 for the recommended wire sizes 81 The overall wiring length should be 500m 1640 12 maximum Especially far lang distance winng the fas response current limit function may decrease or the equipment connected to the secondary side may malfunction or become faulty under the influence of a charging current due tothe stray capacity of the wiring Therefore note the overall wiring length Fesser to page 79 6 Electromagnetic wave interference The inputoutput main circuit of the inverter includes high frequency components which may interfere with the communication devices such as radios used near the inverter In this case install the FR BIF optional capacitor type filter for use in the input side ar FR BSFO1 ar FR ELF common mode filter ta minimize interference 7 Do not install a power factor correction capacitor surge suppressor or capacitor type filter on the inverter output side This will cause the inverter to trip or the capacitor and surge suppressor to be damaged If any of the above devices are connected immediately remove them When using capacitor type filter FR BIF a single phase power input model make sure of secure insulation of T L3 phase and connect to the input side of the inverter 8 For some short time after the power is switched OFF a high voltage remains in t
91. nce amp Service FLEXIBLE INKJET TRANSPORT 36 FIT BASE FIT 36 SERVICE MANUAL Pitney Bowes Drect Mail Solutions Section IV FIT 36 Base Maintenance The general maintenance of the FIT 36 base is limited due to the design and materials used in manufacturing The frequency of general cleaning required for the FIT 36 is dependent on the amount of running time put on the machine General Cleaning Blowing off the machine with compressed air 1 Acquire and use eye protection safety goggles or safety glasses with side guards Also use respiratory protection a simple disposable cloth or paper style particle mask is sufficient Alert all other people in the area to stand clear of the work area a minimum of 30 feet 7 7 meters where compressed air is being used to blow off machines Turn off the machine and disconnect the power line Warning To prevent accidental injury refer to The Lock Out Tag Out Procedure on page 16 Remove any loose items from the surfaces of the machine i e Ballpoint pens pencils tape dispensers paper clips rubber bands etc Open all service doors located on the front side of the machine and remove any loose items that might have been left inside i e spare parts tools personal effects such as purses car keys etc Note After a complete visual inspection has been completed and loose items removed leave the service doors open Remove the keyboard and monitor from the stand or
92. ney Bowes Drect Mail Solutions 0 FA REV 02 gt OF SHEET ui a n wl Ui a a 2 tn E GROURG ROUTING FIT BASE NUMBER 2105 BISPITNEY BOWES 8 M ms LIE Bel 3 BBE Se Ta e E pem 2 CES popu Ca LE D 0 Co TB3 LI HE LIBE BE Bg l SUE LLIEEIIEIEIIIILDILLLTS E Ee Ec g M ua me di Farb Dru E Aci h ou e ud T B E SE Dtg all tr 522 Pitney Bowes Drect Mail Solutions 0 m gt LL gt SCALE DO NOT SCALE DRAWING SHEET PANEL LAYOUT 5 DRAWG NUMBER ST TITLE Oat 0 9 C 060 ion Bed 71 m Sls J Wed TO To Wh COO ge ES 24V OV ot 5 Eu DE Es IL of 1 Pitney Bowes Drect Mail Solutions amp OF ti lt SCALE 00 NOT SCALE DRAWING SHEET 8 l X Lr Le l AT Sze IN TB3 2B TO TB3 3B AND TB3 23B TO TB3 24B TITLE IF 2 BASES ARE HOOKED TOGETHER PLACE TWO 2 POSITION JUMPER
93. nt Setting i comment 551 mode operation command source selection soo Current average time 5 Data output mask time Current average value monitor signal output 9999 9999 RSR 4 2 0 reference current 561 PTE thermistor protection 0 5 to 30kohm 9999 level 263 Energization time Oto 65535 1 carrying over times 0 01 9999 9999 on ny cn olol al al gt T to en pal o eio CQ M NLME 564 Operating time Oto 65535 carrying over times 571 Holding time at a start Oto 105 9999 9999 9999 Output interruption 3600s 9999 0 15 detection time 2 6 Qutput interruption Oto 400Hz COTE detection level 577 Output interruption cancel 900 to 110096 1000 1000 level 611 Acceleration time at a Oto 3500s 9999 0 15 9999 9999 restart 0 2 1 53 Speed smoothing control Oto 200 665 Regeneration avoidance 200 0 1 0 frequency gain 882 Regeneration avoidance 0 12 1 operation selection 0 0 0 1 1 E oo Regeneration avoidance compensation frequency limit value 586 Regeneration avoidance to 200 0 1 voltage gain 591 Cumulative power monitor 010 4 9999 1 9999 9999 digit shifted times 907 terminal calibration 902 Terminal 2 frequency 400Hz 01Hz setting bias frequency 8021 Terminal 2 frequency 300 0 1 setting bias 883
94. ntion operation level this function reduces frequency untilthe overload current decreases to speed prevent the inverter from resulting in overcurrent trip When the overload current has reduced below operation stall prevention operation level this function increases the frequency up to the set value Des cription When the output current of the inverter exceeds the stall prevention operation level Fe 22 Fall During prevention operation level etc 1 this function stapsthe decrease in frequency untilthe overload current deceleration decreasesta prevent the inverter trom resulting in overcurrent trip When the overload current has decreased below stall prevention operation level this function decreases the frequency again Check that the Pr 0 Torque boost setting is not taa large Check that the Pe 7 Acceleration fime and Pr 3 Deceleration fime settings are not taa small Check that the load is nat taa heavy Are there any failure in peripheral devices Check that the Pr 13 Starting feguency is not too large Checkthat the 22 prevention operation level is appropriate Increase or decrease the Pr Torgue boost setting by 1 and check the motor status Refer fo page 21 Set a larger value in Acceleration Ome and 5 Deceleration Ame Refer fo page 94 Reduce the load weight General purpose magnetic flux vector control Change the Pe 14 Load pattern selection setting Set s
95. nverter and inverter driven motor Therefore use the independent earthing grounding method and be separated fram the earthing grounding of equipment sensitive to the aforementioned noises In a tall building it yall be a good policy to use the noise malfunction prevention type earthing grounding with steel frames and out electric shock prevention type earthing grounding in the independent earthing grounding method h This inverter must be earthed grounded Earthing rounding must conform ta the requirements of national and local safety regulations and electrical cades NEC section 250 536 class 1 and other applicable standards Use neutral paint earthed grounded power supply for 400 class inverter in compliance with standard cjUse the thickest possible earth ground cable The earth ground cable should be of not less than the size indicated in the table on the previous 27 4 earthing grounding point should be as near as possible to the inverter and the earth ground cable length should be as short as possible the earth ground cable as far away as possible fram the wiring of equipment sensitive to noises and run them in parallel in the minimum distance Other Other Other Inverter Inverter Inverter equipment equipment Independent earthing mman earthing Good l ommon earthing Hat alkwed POINT Ta be compliant with
96. ny person or persons performing the previous stated task The manufacturer and other companies connected with the promotion and sale of the FIT 36 shall be held harmless for any and all injuries sustained to any person or persons and or damage to the FIT 36 and or any other components connected to or associated with the FIT 36 as a result of failure to comply with the Lock Out Procedure 1 Turn the main power switch to the off position 2 Disconnect the power cable from its source by performing the following a Follow the main power line from the machine back to the receptacle or source of supplied power and disconnect it at the source b Place the plug connecter close to the machine in such a position that will remain in your field of vision while repairs or maintenance is being performed 3 Notify all other persons in the area where the work is being performed that the machine will be out of service especially if the work you are performing requires you to be crouched behind or beside the machine or in some other way obscured from the sight of other persons in the area 4 When the work has been completed reconnect the plug to the power source and then test cycle the machine to ensure that power has properly restored and the machine is fully functional 5 Notify all other persons in the area that machine is fully operational and that drive motors will become enabled when the power switch is placed in the on position
97. o the parameter unit Do not usethese pins for R5485 communication E When making RS 485 communication between the FR D700 series FR E500 series and 5500 series incorrect connection of pins No and 8 parameter unit power supply of the above PU connector may result in the inverter malfunction failure Do not connect the PU connector to the computer s LAM board FAX modem socket or telephone modular connector The praduct could he damaged due to differences in electrical specifications FIT 36servrev1 2 Pitney Bowes Drect Mail Solutions 3 8 Precautions for use of the inverter The FR D DnD series is a highly reliable product but incorrect peripheral circuit making or aperatian handling method may shorten the product life ar damage the product Before starting operation always recheck ihe following items 11 Use crimping terminals with insulation sleeve to wire the power supply and motor 21 Application of power to the output terminals Ll M of the inverter will damage the inverter Never perform such wiring 3j After wiring wire must not be leit in the inverter Vire offcuts can cause an alarm failure or malfunction Always keep the inverter clean When drilling mounting holes in an enclosure etc take care not to allow chips and other foreign matter to enter the Inverter 4 Use cables of the size to make a voltage drop 2 maximum If the wiring distance is long between the inverter and motor a mai
98. ol is insufficient to a slightly longer time and the differential time Pr 134 210 to a slightly shorter time Check the calibration of set point and measured value Adjust machinefequipment so that there is Mechanical looseness mechanical looseness Operating with output phase loss Checkthe motor eck the motor Checkthe motor Contact the motor manufacturer FIT 36servrev1 2 111 Pitney Bowes Drect Mail Solutions 5 5 3 inverter generates abnonnal noise Possible Cause Counter meas ures 5 5 4 Motor generates heat abnormally Check points M atar fan is nat working Clean the motor fan Dust is accumulated Improve the environment Phase to phase insulation of the matar is insufficient Check the insulation of the motor a M ain T Check the output voltage of the inverter e inverter autput voltage are unbalanced Circuit ees Check the insulation of the motor Parameter Setti The Pr 77 Applied motor setting is wrong Check the Pr 71 Apphed motor setting ing O M otor current is large Refer ta 5 5 11 Motor current is taa large 5 5 5 Motor rotates in the opposite direction Possible Cause Co unter meas ures Check Possible Cause Co unter meas ures points Main Phase sequence of output terminals U W and Y is Connect phase sequence of the output cables terminal Circuit Incorrect LU Vv WS ta the motor correct The start signals Harwar
99. on j value exceeded Inrush current limit circuit Analog input fault E SAF Safety circuit fault fa fault occurs when using withthe 004 Fault 14 is displayed on FR PLIOA E Stall prevention overcurrent otall prevention over oltage EU core Regenerative brake prealarm ro Lt Electronic thermal relay function prealarm FU stop Maintenance signal output Under otage Safety stop acceleration constant Teee deceleration or stop ES avervaltage Regenerative avervaltage trip during deceleratian ar stop Inverter overload trip electronic thermal relay function bl otor overload trip E IHM electronic thermal relay function ac 79 Ta Pn Pn Un 35 Cr m m onm FIT 36servrev1 2 98 Pitney Bowes Drect Mall Solutions 5 3 Causes and corrective actions 1 A message regarding operational troubles is displayed Output is nat shutoff Operation panel M NP HOLD indication Name Operation pane ook T STOP _ D es cription Operation lack mode is set Operation other than RESET is invalid Refer fo page 23 7 Check point Corrective action Press MODE 25 to release lock Operation panel nr LOCd Name _ Password locked Pas
100. onnected to the FR D720 008 014 and FR D720S 008 014 and FR D710w 008 014 rR Single phase AC power supply 1 Inrush current AC power 137 limit circuit supply Relay output Control input signals No voltage input allowed current input 4 to 20mA input switch 4 5 It is recommended to use 2 when the frequency setting signal is changed frequently 1 1 Forward i Terminal functions vary rotation start nt Fe 1 EE with the input terminal Le pag Relay output Dy Fr 192 A B C terminal Wi R everse 1 Fault output fection selection assignment Pr 178 t rotation start 11 l 1 High LL 1 speed T IE 1i 3 1 Multi speed selection Le Open collector output spee 2 When using terminals PC Low M i cons poti SD as 24VDC power speed 0915 Running Pr 190 RUN terminal function supply take not to P ra selection short across terminals ENT ep urea 24 i 1 PC SD P a Open collector output common 24VDC power supply DE Sink source common Common for external power supply transistor 14 _________________________________ Frequency setting signals Analog ef 3 10 5
101. operation mode RUN External operation mode STF STR signal Turn OM only ane af the forward and reverse rotation Both the forward and reverse rotation start signals Start signals STF or STR STF are input simultaneously When the STF and STR signals are turned ON simultaneously a stop command is given Check the frequency command source and enter frequency command Frequency command is era When the frequency command is Hz and the run command is entered RUN LED of the operation panel flickers Turn MRS RES signal OF F Inverter starts the operation with a given start command Output stop signal MRS or reset signal RES is and afrequency command after turning OFF MES or RES signal Before turning OFF ensure the safety Check thatthe control logic switchover jumper connector is correctly installed If it is nat installed correcth input signal is nat recognized Shorting wires between 51 and S C 52 and SC are Short between 81 and SC 52 and SC with shorting 2p disconnected wires Set Pr 73 Pr 267 and a valtage current input switch correctly then input an analog signal in accordance with the setting Jumper connector of sink Source is wrongly selected V nltage current input switch is nat carrectly set far analog input signal 0 ta 57D to 10 4 to 208 STOP was pressed During the External operation mode check the method ee Operation panel indication is P S 8 T nus
102. put and displays Lu E camo cou o insi uud came ua Ium ams rdc Des cription Check point Pitney Bowes Drect Mail Solutions Ci FR PUO4 58 Safety stop Description Description Appears when safety stop function is ated during output shutoff If the indication appears when safety stop function is nat used check that shorting wires between 51 and S C 52 and Check point SC are connected Ift the indication appears when safety stop function is nat used short between 51 and SC 827 and SC with shorting Corrective action wires 3 Alarm When an alarm occurs the output is nat shut aff You can also output an alam signal making parameter setting set Ha Pr Foor 192 output terminal junction selection Reyer to paga 127 FR PUO4 eue Fo CE Fan fault Far the inverter that contains a cooling fan m m appears an the operation panel when the cooling fan stops due to an alarm of different operation from the setting of Pr 244 Cooling fan operation selection Check point Check the cooling fan an alarm Corrective action Check for fan alarm Please contact your sales representative Des cription 4 Fault When afault occurs the inverter trips and fault signal is output PARDON panel cnr FR Puod d FR pugz
103. ratian time 12100 short Increase acc elerationideceleration time Torque boost Pr 0 Pr 461 setting is improper under VIF Incerease decrease Pr 0 Torgue boost setting value by 7 control sa the stall prevention function is activ ated 0 5 increments to the setting l 3 7 Far VIF control set Pr 3 Base frequency and Pr 47 Second The base frequency does match the motor hase frequency apa mince 54 Rated Reduce the load weight Setting Set Pr 22 ali prevention operation leve higher according to the load Setting Pr 22 too large may result in 4 frequent overcurrent trip E O CDT 3 Check the capacities of the inverter and the motor If the frequency becomes unstable during regeneration Regeneration avoidance operation is performed avoidance operation decrease the setting of Pr 46 224 Regeneration avoidance voltage gain Stall prevention function is activated due ta heavy load characteristic 5 For Generabpurpose magnetic flux w ector control set Pr 5 5 8 Speed vanes during operation When the slip compensation is selected the output frequency varies between 0 and 2Hz as with load fluctuates Check Possible Cause Countermeasures points ulti speed command signal is chattering Take countermeasures to suppress chattering Load varies during an operation Select General purpose magnetic flux vector control Frequency setting signal is varying Check the frequency reference sign
104. res to suppress harmonics Otherwise power supply harmonics from the inverter may heatidamage the power factor correction capacitor and generator When 400 class motor is inverter driven please use an insulation enhanced motor or measures taken to suppress surge voltages Surge voltages attributable to the wiring constants may occur at the motor terminals deteriorating the insulation of the motor When parameter clear or all parameter clear is performed reset the required parameters before starting operations Each parameter returns to the initial value The inverter can be easily set for high speed operation Before changing its setting fully examine the performances of the motor and machine in addition to the inverter s holding function install a holding device to ensure safety Before running an inverter which had been stored for long period always perform inspection test operation For prevention of damage due to static electricity touch nearby metal before touching this product to eliminate static electricity from your body 78 Pitney Bowes Drect Mail Solutions 5 Emergency stop ANCAUTION e Provide a safety backup such as an emergency brake which will prevent the machine and equipment from hazardous conditions if the inverter fails e When the breaker on the inverter input side trips check for the wiring fault short circuit damage to internal parts of the inverter etc I
105. rt belts 4 Remove the discharge roller shaft assembly on the FIT base by performing the following A Using an Allen wrench remove the button head Allen screws located in slots on top plate from each of the pillow block bearings See figure 8 Remove these two Allen screws found on the top deck over the pillow block bearings Figure IV 8 Pillow block bearing B Remove drive belts from sprockets and set them aside for re use if not worn Remove discharge roller and replace if necessary C Reassemble the machine FIT 36servrev1 2 45 Pitney Bowes Drect Mail Solutions Section V Electrical Components FLEXIBLE INKJET TRANSPORT 36 FIT BASE FIT 36 Pitney Bowes Drect Mail Solutions WI lu BAD 718 fo ee lin il ch Figure V 1 FIT 36servrev1 2 Pitney Bowes Drect Mail Solutions Electrical Enclosure Identification Table Function A Terminal Block Provides point of contact from components to cables B Terminal Block 24 VDC Provides 24 VDC Provides 0 VDC D F4Fuse 1 25A Power Supply output E 5 500 mA PLC output F Optolsolator OFF 1 2 1 FEEDER PAUSE 2 PRINT TRIGGER G Opto Output Module 3 4 3 SORT 4 DIVERT CR1 Relay Internal E Stop Latch Hi CR2Relay VED H2 CR3Relay External E Stop Latch H3 CR4Relay ____ RESET 1 RSfRockeswich Speed Following Switch Transformer output Vacuum pump input K CB
106. s and any damage to the machine or any other product connected there on as a result of failure to comply with this notice FIT 36servrev1 2 49 Pitney Bowes Drect Mail Solutions Figure V 3 Left Side Main Electrical Box iam ad LA E Connection Function or Reference Page RS Speed Following Switch P9 Up Stream Sensor Refeenepage J1 Reference page _____ J40 Reference page _____ J 11 Reference page H 120 VAC 120 3 15 AMP Power Supply ___ Figure 4 Right Side Main Electrical Box Item Connection Function or Reference Page _ A P 7 Power to Dryer P 8 __ ___ Down Stream Sensor ___ D J3 Reference J2 Reference F None Circuit Breaker Switch ___ G PowerCable ____ FIT 36servrev1 2 50 Pitney Bowes Drect Mail Solutions Figure V 3 Reference _____ Reference J 20 Blank 2 48 FIT 36servrev1 2 51 Pitney Bowes Drect Mail Solutions Open Connectors on Fit Enclosure Plug Configuration Connection J1 Pin Function Pass Thru to J2 1 Ov Pass Thru to J2 3 Used for FlowMaster Stop Integration Pass Thru to J2 4 Remote Reset Input Requires Ov to fire CR4 to Reset Base Pass Thru to J2 6 Pass Thru to J2 7 FlowMaster Stop Integration Momentarily breaks on Stop button push and breaks on E Stop base h
107. se the brake resistor may excessively overheat due to damage of the brake transistor and such causing a fire Do not connect a resistor directly to the DC terminals and Ni This could cause a fire Pitney Bowes Drect Mail Solutions 3 Injury Prevention A CAUTION e Apply only the voltage specified in the instruction manual to each terminal Otherwise burst damage etc may occur Ensure that the cables are connected to the correct terminals Otherwise burst damage etc may occur Always make sure that polarity is correct to prevent damage etc Otherwise burst damage etc may occur While power is ON or for some time after power OFF do not touch the inverter since the inverter will be extremely hot Doing so can cause burns 4 Additional Instructions Also note the following points to prevent an accidental failure injury electric shock etc 1 Transportation and mounting A CAUTION Transport the product using the correct method that corresponds to the weight Failure to observe this could lead to injuries Do not stack the inverter boxes higher than the number recommended that installation position and material can withstand the weight of the inverter Install according to the information in the instruction manual Do not install or operate the inverter if it is damaged or has parts missing e When carrying the inverter do not hold it by the front cover or se
108. sword function is active Display and setting of parameter is restricted Check point Enter the password 297 Password lockunlock to unlock the password function before operating Refer fo page Corrective action 161 Operation panel indication 0 Write disable error ou attempted to make parameter setting when Pr 77 Parameter write selection has been set to disable parameter write Frequency jump setting range overlapped The PU and inverter cannot make normal communication Check the setting of Pr 77 Parameter write selection Refer fo page 159 Check point Check the settings of Pr 31 fo Pr 36 frequency jump Refer fo page 82 Check the connection ofthe PU and inverter Operation panel Er indication Write error during op ration When parameter write was performed during operation with a value atherthan 2 writing is enabled independently of operation status in any operation mode is set in Pr 77 andthe STF STR is OM 1 Check the 77 setting 129 Check point ae du i 2 Check that the inverter is not operating 1 Set 2 in Pr 77 2 After stopping operation make parameter setting Operation panel Er3 eam 0 0 Calibration error Analog input bias and gain calibration values too close Check point Check the settings of C3 C4 C and C7 calibration functions Refer fo page 151 Operation panel _
109. t earthed grounded power supply for 400V class inverter in compliance with EN standard Any person who is involved in the wiring or inspection of this equipment should be fully competent to do the work Always install the inverter before wiring Otherwise you may get an electric shock or be injured e Perform setting dial and key operations with dry hands to prevent an electric shock Otherwise you may get an electric shock e Do not subject the cables to scratches excessive stress heavy loads or pinching Otherwise you may get an electric shock Do not change the cooling fan while power is ON It is dangerous to change the cooling fan while power is ON Do not touch the printed circuit board with wet hands Otherwise you may get an electric shock e When measuring the main circuit capacitor capacity the DC voltage is applied to the motor for 1s at powering OFF Never touch the motor terminal etc right after powering OFF to prevent an electric shock 2 Fire Prevention A CAUTION Install the inverter on a nonflammable wall without holes so that nobody can touch the inverter heatsink on the rear side etc Mounting it to or near flammable material can cause fire e If the inverter has become faulty switch off the inverter power continuous flow of large current could cause a fire e When using a brake resistor make up a sequence that will turn off power when an alarm signal is output Otherwi
110. t normal machine operation depress the Red control Stop button The machine can be re started without delay at the operator s discretion FIT 36servrev1 2 28 Pitney Bowes Drect Mail Solutions Setting Control Dials Loosen Lock Ring before Loosen Lock Ring adjusting the Control Dial by turning counter clock wise Figure 111 11 Feeder Power Switch Start Stop Switch W Indicator FEEDER engage the Feeder Power switch depress the switch The switch will be maintained ON until pressed again To engage the Start Stop switch depress the switch and release The switch will automatically return to normal height Figure 111 12 Figure 111 13 FIT 36servrev1 2 29 Pitney Bowes Drect Mail Solutions Jog Switch To engage the Jog switch depress the switch and release The switch will automatically return to normal height To engage the Reset switch depress the switch and release The switch will automatically return to normal height Figure 111 14 Figure 15 Print Heads If print heads are included or are to be attached to the vacuum base set up the print heads in accordance with the manufacturer specifications FIT 36servrev1 2 30 Pitney Bowes Drect Mail Solutions PRINCIPLES OF OPERATION The manually operated switches and potentiometers are provided to co ordinate the operation of various components An example of a basic machine consists of a feeder
111. take FR ABR between terminal Pi and PR 5 5 13 Unable to write parameter setting VIF pattern is improper when VIF control is performed Possible Cause Countermeasures Stop the operation When Pr 0 initial value write is enabled only during stop Choose the PU operation mode Or set 77 2 ta enable parameter write regardless of the operation mode s lection setting Seeing key lock is activated by the Pr 16 Frequency Check Pr 167 Frequency lock operation selection Operation mode and a writing device do not Check Pr 79 Pr 338 Pr 339 Pr 531 and select an Operation is being performed signal STF or STR is ON You are attempting ta set the parameter in the External operation mode FIT 36servrev1 2 115 Pitney Bowes Drect Mail Solutions Bowes Direct Mail Solutions nd of Publication FIT 36servrev1 2 116
112. tall prevention operation current in Pr 22 ofall prevention operation level The initial value is 150 The acceleratianideceleration time may change Increase the stall prevention operation level with Pr 22 Siaili prevention operation level or disable stall prevention with Pe 156 atali prevention operation selection Operation at OL Occurrence can be selected using Pr 73565 pen i FR PUO4 Cae OL prevention avervaltage regenerative energy of the motor becomes excessive to exceed the regenerative energy consumption capability this function stops the decrease in frequency ta prevent avervaltage trip During 5 soon as the regenerative energy has reduced deceleration resumes deceleration Ifthe regenerative energy of the motor becomes excessive when regeneration avoidance function is selected Pr 442 1 this function increases the speed to prevent overvoltage trip Refer fo pape 2241 Che k 1 Check for sudden speed reduction C poin Check that regeneration avoidance function 552 aad Pr 552 Pr 459 is used Refer to page 224 The deceleration time may change Increase the deceleration time using Pr 2 Deceleration Ame Check point Corrective action Mm d 039 R30 Des cription Pitney Bowes Drect Mail Solutions Operation panel FR PUO4 indication FR PUO stop Stop with e of the PLI is set in 75
113. tting dial it may fall off or fail Do not stand or rest heavy objects on the product Check the inverter mounting orientation is correct Prevent other conductive bodies such as screws metal fragments or other flammable substance such as oil from entering the inverter As the inverter is a precision instrument do not drop or subject it to impact Use the inverter under the following environmental conditions Otherwise the inverter may be damaged Surrounding air 10 to 50 C 14 F to 122 F non freezing temperature Ambient 90 RH less non condensing Storage M 20 C to 65 C 4 F to 149 F 1 Indoors free from corrosive gas flammable gas Atmosphere 5il mist dust and dirt Maximum 1000m 3280 80feet above sea level for standard operation After that derate by 3 for Altitude every extra 500m 1640 40feet up to 2500m vibration 8202feet 91 5 9m s or less at 10 to 55Hz directions of X Y Z axes x1 Temperature applicable for a short time e g intransit 2 Wiring A CAUTION Do not install a power factor correction capacitor or surge suppressoricapacitor type filter on the inverter output side These devices on the inverter output side may be overheated or burn out e The connection orientation of the output cables U V W to the motor will affect the direction of rotation of the motor FIT 36servrev1 2 3 Trial run A CAUTION
114. unless it is reset Operation panel C Orc FR PUO4 Fault ni indication C FR PUO PTC activated PTC thermistor operation Inverter trips when resistance of PTC thermistor connected between terminal 2 and terminal 10 is more than the Des cription value setin Pr J l PTC thermistor protection level This protective function does not function when Pr 367 setting is initial value Pr 261 9999 Check the connection of the PTC thermistor Check point Check the Pr 567 thermistor protection level setting Check the motor for operation under overload Reduce the load weight Operation panel mor FR PUO4 t M Farameter storage device fault control circuit board Appears when a fault accurred in the stored parameters EEPROM fault Check point Check far too many number of parameter write times Please contact your sales representativ e Des cription Corrective action When performing parameter write frequently for communication purposes set 1 in Pr 342 to enable RAM write that powering off returns the in erter to the status before RAM write Operation panel rr FR PUI PUL Out Indication ER PUO7 Pave disconnection This function stops the inverter output if communication between the inverter and PU is suspended e g the parameter unit FR PUO4 FR PUOSS is disconnected when 72 73 15 ar 17 was set in Pr 75 Rest selection
115. upport bar using the two 2 center tapped holes 2 Place a blank piece of white paper on the vacuum belt directly under the paper sensor 3 Using a small flat blade screwdriver remove the pan head screw in the plastic cover located on the sensor next to the electronic cable connection see figure 111 4 Note This sensor will have a detachable screw type cable connection 4 Setthe Light Dark pot setting using a small flat blade screw driver slowly and very carefully turn the pot setting located next to the electronic cable connection in a counter clock wise direction until full range of motion is felt see figure 111 6 Note If this adjustment is performed correctly the screw driver slot in the pot setting should be pointing towards the LO in the range scale next to the pot setting A Caution The stop point of this pot setting can damaged if excessive force is applied 5 Set the Gain pot setting by performing the following A Using a small flat blade screw driver slowly and carefully turn the pot setting located furthest from the electronic cable connection in a counter clock wise direction until full range of motion is felt see figure 111 6 The red LED indicator light should be off at this point B Using a small flat blade screw driver slowly and carefully turn the pot setting located furthest from the electronic cable connection in a clock wise direction until the red LED light comes on continue t
116. urning the pot setting in a clock wise direction another half turn 6 Return the plastic cover removed in step 3 to its original position Remove the plastic cover from the sensor to gain access to the pot settings Sensor shown has detachable electrical cable fitting FANNER Fitting for electronic cable Figure 111 4 FIT 36servrev1 2 23 Pitney Bowes Drect Mail Solutions REFLECTIVE View of Detachable Cable style Sensor Gain Pot Setting Red LED Light Light Dark Pot Setting 4 Pin detachable cable fitting Figure 11 5 FIT 36servrev1 2 24 Pitney Bowes Drect Mail Solutions FIT 36servrev1 2 DIFFUSE View of Hard Wired Cable style Sensor Shown in reverse orientation as it appears on the ink jet base Gain Pot Setting Red LED Light Light Dark Pot Setting Hard wired electronic cable Figure 1 6 25 Pitney Bowes Drect Mail Solutions FIT 36 BASE Operator Control Panel Note This switch is located on the back of the machine on the side of the electrical box 9 i5 VACUUM POWER Figure 111 7 Item Description Function Cycle all components of machine while pressed F Bas Control Dial __________ increases and decreases speed of base G ___ ResetButton ResetsanyComectedFaut _______ H Emergency Stop Button Interrupts power to all components ofthe machine ____ Vacuum Power Switch Engages power to the
117. ust be of a competent rature trained and qualified to the local and stanclards required to fulfill that job These engineers should also be trained in the use and maintenance of the completed product This includes being completely familar with all associated documentation for the said product All rraintens nce should be carried out in accordance with established safety practice s All operators of the completed equipment see Note should tained to use this product ina safe manner in complance to established safety practices The operators should also be familar with documentation which is associated wth the operation of the completed equiprrent Note the term completed equipment refers to third party constructed device which contains or uses the product assoceted with this mangal Hotes on the Sy mbols in this Manual At varius times throughout this manual certain symbols will be used to highlight points of Information whieh are intended to ensue the users personal safety and protect the integrity of equipment Whenever any of the Glowing symbols are encountered associated note must be read and understood Each of the symbols used will now be listed with a brief description Its meaning Hardware Wamings 11 Indicates that the identified danger WILL cause physicaland property darnage 2 Indicates that the identified danger could POSSIBLY cause physical and property 3 In
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