ABB Spindle Drive Installation and Quick-Start User Manual

Transcription

1 ABB Spindle Drive Installation and Quick-Start User Manual

2 CONTENTS User Information... 3 Disclaimer... 3 Safety Precaution... 3 General Safeguards... 4 Unpacking the Spindle Drive... 6 Box Contents... 6 Installation Procedure... 7 General Spindle Drive Operation Keypad: Display and Keys Parameters Faults and Warnings Running in Local Parameters Groups and Common Parameter Modifications Parameter Grouping Overview Configuration Viewing: Group Parameter Configuration: Group Drive Troubleshooting Event Log History Graphs Common Problems Complete Spindle System Troubleshooting Guide Limited Warranty Policy Information Further Information... 38

3 USER INFORMATION This drive is capable of performing all the various combinations of Fadal machine configurations by simply changing the appropriate parameters outlined in these instructions, such as: Rigid Tap Non-Rigid Tap Closed Loop Vector Open Loop Inverter (V/F) Wye-Delta Switching All Spindle RPM's Single or Three Phase Input Power After reading these instructions, call ITS CNC at (406) if you need help or information on specific parameter changes. The common parameter adjustments are listed in this documentation. The information contained in this manual is supplemental or in addition to the manufacturer s manual and does not override or replace information provided by the manufacturer. Disclaimer In no event shall Independent Technology Service Inc., VMC Electric llc. or any of our affiliates be liable for any damages whatsoever, and in particular shall not be liable for special, indirect, consequential, or incidental damages, or damages for lost profits, loss of revenue, or loss of use arising out of use or attempted use of this product, whether such damages arise in contract, negligence, tort, under statute, in equity, at law, or otherwise. This document is based on information available at the time of its publication. While efforts have been made to be accurate, the information contained herein does not intend to cover all details or variations of the products, nor to provide for every possible contingency in connection with handling, installation, operation, or maintenance. Features may be described herein, which are not present in or on all products. We assume no obligation of notice to holders of this document with respect to changes subsequently made and make no representation or warranty, expressed, implied, or statutory with respect to, and assume no responsibility for the accuracy, completeness, sufficiency, or usefulness of the information contained herein. No warranties of merchantability or fitness for purposes shall apply Safety Precaution WARNING: DISCONNECT ELECTRICAL POWER WHEN PERFORMING MAINTENANCE OR SERVICE ON EQUIPMENT! THIS INCLUDES: WHEN ADJUSTING OR CHANGING TOOLS WHEN MAKING MECHANICAL ADJUSTMENTS WHEN PERFORMING MAINTENANCE WORK OR PERFORMING ANY SERVICE TO THE SPINDLE WHEN REMOVING ANY GUARD User Information Page 3

4 WHEN REMOVING ANY BELTS OR PULLEYS TO AVOID INJURY, ELECTRICAL POWER MUST BE OFF WHEN PERFORMING MAINTENANCE OR SERVICE ON EQUIPMENT! SERIOUS PERSONAL INJURY IS ALWAYS A HAZARD IN AN INDUSTRIAL ENVIRONMENT. EXTREME CAUTION, IN ALL FACETS OF SAFETY, SHALL BE MAINTAINED. ALL COMPANY SAFETY STANDARDS, PRECAUTIONS AND REGULATIONS OF O.S.H.A. SHALL BE MAINTAINED DURING TRAINING, INSTALLATION, AND REMOVAL OF THE SPINDLE DRIVE. WARNING: This equipment contains High Voltages; up to 500 DC Volts. Improper use can cause serious or fatal injury. Only qualified personnel should attempt the installation and start-up procedure. General Safeguards DO NOT OPERATE THE SPINDLE ASSEMBLY AND/OR ITS COMPONENTS UNLESS YOU HAVE READ THIS DOCUMENT. User Information Page 4

5 RETAIN FOR FUTURE REFERENCE. FOLLOW ALL WARNINGS AND INSTRUCTIONS IN THIS DOCUMENT AND/OR THE FADAL MANUALS. 1. Read and Follow Instructions. Read all the safety and operating instructions supplied by Fadal prior to operating the spindle and/or its components 2. Attachments and Equipment. Never add any attachments and/or equipment to the spindle assembly without approval of the manufacturer as such additions may result in spindle failure, personal injury and/or voiding of the warranty. 3. Servicing. Do not attempt to service the spindle drive and/or its components yourself as opening or removing covers and/or guards may expose you to dangerous hazards. Refer all servicing to qualified service personnel. 4. Power. Disconnect all power to the machine before any maintenance. 5. Protection. Always wear proper eye, foot and head protection when lifting, transporting and/or operating any machinery. 6. Water and Moisture. Do not use the spindle drive and/or its components where they become exposed to water (coolant). 7. Accessories. Any mounting of the spindle assembly and/or its components should follow the manufacturer s instructions, and should use a mounting accessory recommended by Fadal, if applicable. Handling the spindle drive. Do not place the spindle drive and/or its components on an unstable cart, stand, tripod, bracket or table. The spindle drive and/or its components may fall, causing serious personal injury and serious damage to the spindle drive and/or its components 8. Damage Requiring Service. Disconnect all power to the spindle assembly and/or its components and refer servicing to qualified service personnel under the following conditions: If the spindle assembly and/or its components do not operate normally by following the operating instructions. If the spindle drive and/or its components have been dropped or the shipping crate has been damaged. When the spindle assembly and/or its components exhibit a distinct change in performance. If the spindle assembly and/or its components have been crashed and exhibit a distinct change in performance. If the spindle assembly exhibits a rapid change in operating temperature. If the spindle assembly exhibits a rapid change in vibration level. g. If the spindle assembly exhibits a distinct audible change. If the spindle assembly locks-up and cannot rotate. User Information Page 5

6 Unpacking the Spindle Drive Each spindle drive ships in a highly stable shipping container to prevent damage to the spindle drive during shipment. Prior to opening do the following: 1. Inspect the shipping container for damage. 2. Document any damage with photographs. 3. Report any damage to the trucking company and to your distributor, supplier or the ITS Service Team. Box Contents Each ABB Drive contains the following. Verify the contents: ABB Spindle Drive Unit Two (2) mounting plates, top and bottom, hardware included. Two 24 ohm regen resisters. User Information Page 6

7 INSTALLATION PROCEDURE 1. Disconnect and Lock-out the Supply Power. Lock-out front door access to spindle. 2. Before removing any wires from the old drive, take notice and mark them. They will be installed in the same appropriate orientation of the new drive. There are basically four types that are hardwired to the drive: A) The motor connection wires - GND, T1, T2, T3 B) The power input wires - GND, L1, L2, L3 (230 VAC) C) The braking resistor(s) wires - R1, R2 (Resistors are located on top of the back cabinet). D) A six pin molex for CNC controls (signal, fault, FWD/REV) Options: i) The motor encoder 9 pin molex for Closed Vector operation (not Inverter). ii) Rigid tap encoder wires from the drive to the Fadal spindle controller (Slot #14 on 1060 board). iii) A six pin molex with 2 or 3 pins populated is for the 7500 RPM wye-delta winding (table) selector. Note: If only one pink wire is populated this connector is not used with the new drive. 3. Remove old drive and drive plate if present. Once the old drive is removed, it is worthwhile to clean the cabinet. 4. The ABB unit does not have nor use internal regenerative resistors. It requires a 12 ohm regen brake system. Most regen installed in your machine do not supply 12 ohms, and will need to be replaced. Included in the box are two 24 ohm regen resistors, wired in parallel. If you measure the ohmic value, it should measure 12 ohms. Notes that some drives, such as a Mitsubishi drives, use and internal regen resistor. ) Some Mitsubishi drives had the external brake resistor that was connected to a Glentek External Brake Driver, between the Drive and the Resistor(s). The new drive does not need the external braking unit that was supplied with some of the Mitsubishi drives; use only the resistor supplied with this drive. If the external box is missing, order and external kit from ITS. To install the new resistors, first remove the regen resistor box, located on the top of the inverter cabinet. To remove the box, first disconnect the extensions located inside the cabinet. Installation Procedure Page 7

8 Cut the wire ties around the black insulators, and remove. Using a 9mm wrench, remove the bolts and separate the wires. Save the hardware for the new resistors. Resistor Box Extension Connectors On the top of rear cabinet, remove the four screws attaching the resistor box. Pull the wires through the top of the rear cabinet, remove the box, and set aside to install the new resistors. The resistors are stacked on top of each other in the box, separated by metal spacers. To remove, undo the four flat head screws while holding the 3/8th nuts underneath in place. Set the old resistors aside and install the new resistors in the same fashion. Install the box back on top of the cabinet, and attach the wires to the extension with the hardware saved from before. Reinstall the black insulators and secure with wire ties. Installation Procedure Page 8

9 Using a multimeter, verify that the regens are wired for 12 ohms by completing a circuit from the two extension ends. Note that if you measure 48 ohms, the regens are wired in series, not parallel. Caution: failure to install the 24 ohm regen resistors supplied could cause damage to the drive 5. Mount the two adapter plates onto the drive. Mount the top plate on the top section of the mounting holes on the top of the ABB Drive. Mount the bottom plate on the bottom of the drive. Take note to follow the labels to orient both plates upward. Up Up Top Plate Bottom Plate 6. Before mounting the drive into the cabinet, install the bottom two mounting bolts in the cabinet. Leave plenty of room on the bolt to set the drive on top. Bottom Bolts (directly above the transformer) Place the drive onto the bottom bolts. While supporting it, install the top two bolts. Note that before tightening the drive's height can be adjusted up or down to provide more access room for the drive inputs. 7. To remove the white cover and access the terminals, insert a small flat head screw driver directly into the hole marked OPEN. Insert the drive straight to the back and gently press down to release Installation Procedure Page 9

10 the lock. 8. The power terminals are located on the bottom of the drive. From left to right, attach L1-L3, ground, R1-R2, and T1-T3. DO A PULL TEST ON ALL WIRES. 9. Attach CNC Pendant Load Meter wires to the two connector barrier strip on the drive, usually colored RED (+) and Black (-). Note: Do not attach any other wires than the two wires coming from the CNC Pendant Load Meter. 10. Rigid tap option: (proceed to the next step if the option not present). If you are unsure if your machine has rigid tap, remove the spindle controller card in the 1060 card cage, located in slot #14. The Eproms will be labeled as either RIGID TAP or ACLINEAR (non-rigid tap). Install the CNC spindle card feedback wires into the encoder adapter board following the below Installation Procedure Page 10

11 diagram. It is easiest to first remove the board before installing the wires. Encoder Adapter Board The 1010 Encoder cable is colored in one of the following combinations: 31 - Green 32 - Blue 33 - Red 34 - Yellow 31 - Yellow 32 - Brown 33 - Red 34 - Green The 1010 Encoder Ground/Shield could be labeled pin #30 or #38; either way use the same terminal. Install the adapter board back into the connector, and secure the screws. 11. Plug in the Molex Connectors: One 6 pin molex for Control signals All machines, it s fully populated with 6 wires/pins. One 9 pin molex for Motor Encoder signals for rigid tap and all closed loop vector (NOT FOR INVERTER.) One 6 pin molex for 7500 RPM Wye-delta 6 Pin connector, populated with 2 or 3 wires/pins: Note: Some machines have a 6 pin molex with only a single wire, it is not for wye-delta and is not needed anymore; do not use it. 12. Turn on power to machine and perform a COLD START at the CNC control. 13. Verify the Drive Mode - REMOTE should be displayed on the upper right of the keypad display. The top of the first page indicates the current drive operation configuration. If not correct refer to the Common Parameter Modifications section below for setting your specific configuration. Note: The keypad will display the message "Fault Encoder" if your machine does NOT have the a motor encoder. To fix this, from the drive keypad navigate to: Menu > Parameters > Complete List > 74 ITS Setup > Mode. Select and save as mode [0] non-rigid tap inverter to run without an encoder. 14. VERIFY MOTOR SPEED IF INCORRECT IT COULD OVER-REV THE SPINDLE. The following are standard spindle-motor ratios: 10k spindle = max 5000 motor RPM (2:1 drive ratio, two mechanical auto Hi/Low idlers) Installation Procedure Page 11

12 7.5k spindle = max 7500 motor RPM (1:1 drive ratio, direct drive, wye-delta Hi/Low) 15k spindle = max 5000 motor RPM (3:1 drive ratio, direct drive) 15k spindle = max 7500 motor RPM (2:1 drive ratio, direct drive) *Note: there are some custom 10k and 15k machines with wye-delta switching. To change the motor speed navigate to: Menu > Parameters > Complete List > 74 ITS Setup > Max RPM (Motor) Select Edit and choose between 5000 and 7500 RPM. CAUTION: If you are unsure, check the spindle speed setting in the CNC control parameters using the SETP command or remove the machines head cover and verify the drive system and ratio. The drive parameter sets the maximum motor speed not the spindle speed! 15. Autotune the drive. The drive has been loaded with standard motor parameters for a new spindle motor. This procedure compensates for the various electrical and magnetic characteristics that change as the motor ages. NOTE: This procedure has a nine step test for Closed Vector. None of the tests should fail. A test failure typically indicates a problem with the encoder, motor, contractors, wiring or wrong drive size. Before following the steps below, set Parameter to [2] Advanced has three options: [0] Normal, [1] Reduced, and [2] Advanced. Use Advanced whenever possible for the best performance. There may be cases where Reduced or Normal is needed to successfully autotune a non standard motor. If the tuning fails, set the type to either Normal or Reduced and try again. 1. Verify the drive display reads REMOTE in the upper left corner. Press the Loc/Rem to toggle between Local and Remote. Do not start the motor. 2. Use MDI to set the spindle in low range by entering the command "S.1". 3. Set Autotune Begin to TRUE. Disregard any autotune alarm the keypad may show. 4. Put the drive into Local 5. Start the motor by pressing Start on the keypad. The autotune will run for one-and-a-half to two minutes. It will speed up and slow down automatically. 6. After the motor stops, the keypad will display Autotune Complete. 7. Low Range is now complete. If applicable (for VMC 10, VMC 15, 4020A, and 5020A - all 7500 wye-delta machines) place the CNC into S.2 high range (selects Delta) and repeat steps Set Autotune Save Results to TRUE to save values into the working memory. This may take several seconds. 9. Press Loc/Rem button to put the drive back into remote. Installation Procedure Page 12

13 16. Set the Signal Offset Trim. The Offset adjustment is important for the spindle orientation and rigid tap. The drive will measure the zero voltage bias coming from the Fadal 1010 Spindle Controller card, it then uses this measured value as a zero speed reference offset (like the balance pot on an amplifier). You can set the offset two ways: manually or automatically. Manually Set Analog Offset Using Parameter 74.06: To manually set the offset, navigate to: Menu > Parameters > Complete List > 74 ITS Setup > Analog Offset Select Edit, enter an offset, and select Save. Automatically Set Analog Offset Using Parameter (Recommended): To set the current analog input as the 0 speed point, navigate to Parameter Analog Offset Save. Menu > Parameters > Complete List > 74 ITS Setup > Analog Offset Save. Set this value to TRUE to copy the actual analog value to automatically. Once the copy is finished, returns to FALSE. 17. Test the drive operation from the CNC Control. To run the drive from the control, the drive must read REMOTE in the upper left corner of the keypad display. It important to make sure the maximum motor speed is correct for your machine configuration to avoid over speeding your spindle. Go to the SETP menu in the CNC control and verify the maximum RPM setting of the machine then verify the correct motor speed while running the spindle. The ABB will display the actual motor speed, not the spindle speed. If you are unsure or need information, go back to step 14. Perform the following basic operations Turn the spindle on: Run the spindle in MDI, through the various RPM ranges. Installation Procedure Page 13

14 The M3 CNC code causes the drive keypad to display reverse and M4 causes it to display forward. Test M3 and M4 for correct command signal. If the drive is setup for rigid tap and the spindle card does not have the rigid tap software, the M3 will not turn the spindle but M4 will work. The same problem occurs if the drive is set up non-rigid tap and the CNC control sends a rigid tap signal. An Error #10 indicates the CNC is not seeing the Spindle Hall Sensor change states or the spindle card is not receiving encoder pulses (for rigid tap machines). Turn the spindle off: Upon disabling, the motor should ramp down to zero RPM. An error in the deceleration (or a fault condition) could indicate the braking resistor(s) is bad; remove and check the ohmic value the Regen braking resistor, and check the connections. Orient the spindle. In MDI, test the spindle orientation by using the M19 code. The orientation speed is adjusted by the SETP command. The offset trim in step 16 above is important to the orientation function. Note: If you are having a problem, the first thing to verify is the basic drive configuration. The most common mistake is setting the drive to the wrong rigid tap setting. For example, if the drive was set for rigid tap and the spindle card does not have the rigid tap software, this would cause a problem. To verify if you machine has rigid tap or not, you can check the spindle card. There are two types of software for the 1010 spindle card in slot #14. The card will be have either of the following labels: ACLINEAR is for non-rigid tap RIGID TAP is for rigid tap For information on configuring the drive to your machine, refer to the Parameter Groups and Common Parameter Modifications. Refer to the Troubleshooting sections below if you are experiencing any other problems. Installation Procedure Page 14

15 GENERAL SPINDLE DRIVE OPERATION Keypad: Display and Keys 1 Display 2 Left softkey 3 Right softkey 4 Status LED 5 Help 6 The arrow keys 7 Stop 8 Start 9 Local/Remote 10 USB connector 11 Clip 12 RJ-45 connector 13 Type code label 14 Battery cover General Spindle Drive Operation Page 15

16 1. Display. 1 2 Control location and related icons: this indicates how the drive is being controlled: No text: the drive is in local control, but controlled from another device. Local: The drive is in local and controlled from the control panel. Remote: The drive is in remote and controlled through I/O or fieldbus. Panel bus: Indicates that there are more than once drive connected to this panel. To switch to another drive, go to Options > Select Drive. Status Icon: Indicates the status of the drive and the motor. The direction of the arrow rotation indicates forward (clockwise) or reverse (counter-clockwise) rotation. 3 Drive name: If it has been given a name, it is displayed at the top pane. By default, it is 4 blank. To give it a name, go to Menu > Settings > Edit Text > Drive Name 5 Reference value: Speed frequency and so on are shown with the units. Content area: Displays the actual content of the view. The above example is the Home 6 view. 7 Softkey selections: Displays the functions of the softkeys in a given context. 8 Clock: Displays the current time. This can be changed in the Settings menu. 2. Left softkey. The left softkey is usually used for exiting and canceling. Its exact function in a given General Spindle Drive Operation Page 16

17 context is shown by the softkey selection in the bottom left corner of the display. Holding the key down exits each view in turn until you are back in the Home view. 3. Right softkey. The right softkey is usually used for selecting, accepting and confirming. The function of the key in a given context is shown by the softkey selection in the bottom right corner of the display. 4. Status LED. The keypad has a status LED that indicates if there are any faults or warnings present. the table below summarized the meaning of the LED indications. 5. Help. The help key opens a help page. The help page is context-sensitive; that is, the content of the page is relevant to the menu or view in question. 6. The arrow keys. The up and own arrow keys are used to highlight selections in menus and selection lists, to scroll up and down on text pages, and to adjust values. The left and right arrows are sued to move the cursor left and right in parameter editing and to move forward and backward in assistants. In menus, the left and right arrow keys function the same way as the left and right softkeys, respectively. 7. Stop. The stop key stops the drive when in local control. 8. Start. The start key starts the drive when in local control. 9. Local/Remote. The Local/Remote key (or the "location key") is used to switch the control between the control panel (Local) and remote control (Remote). When switching fomr Remote to Local while the drive is running, the drive keeps running at the same speed. When switching from Local to Remote, the status of the remove location is adopted. See the drive-specific firmware manual for more details (at Parameters Overview. In the Parameters menu, you can view and edit drive parameters. There are sub menus through which you can access the parameters. In each sub-menu, the grouping principle of the parameters is different. In each sub-menu, you can either view or edit it by pressing the right softkey, depending on the permissions. Complete List. In the Complete list sub-menu, all parameter groups are listed in numerical order. If you select a parameter group, all parameters in that group are listed and you can view and or edit General Spindle Drive Operation Page 17

18 the parameters. Favorites. In the Favorites sub-menu, only user selected parameters are listed. The order is determined by the parameter number. To edit the list of favorites do the following: 1. Select Edit. 2. Check parameters you want to show on the list by pressing the right softkey Select. 3. Press the left softkey Done to exit and save the changes. Modified. In the Modified sub-menu, only the parameters that differ from the defaults are listed. The order is determined by the parameter number. Change Parameter. You can edit parameter values with the arrow keys. 1. Press Select (right softkey) to select the desired parameter from the list. 2. Press the right softkey to Edit. 3. Use the left and right arrow keys to highlighted desired digits to change, if applicable. Use the up and down arrow keys to change the value. 4. Press the right softkey to Save the value, or press the left softkey to Cancel the parameter view and discard any changes. 5. Press the up and down arrows at the same time to set the default value of the parameter (this does not save it). NOTE: The 7500 RPM (wye-delta electronic HI/LOW) motor uses two sets of windings. It is like having two motors in one. The drive uses two sets of parameters, one for Low Range (T1) and another for High Range (T2). These machines require attention to which parameter Table number you are editing. The correct table is selected when using the S-word during AUTO or MDI. Programming S.1 in MDI will automatically shift the contractor w which is read by the drive to tell it which Table to select. Programming S.1 in MDI selects Table #2 for High Range. For specific descriptions of the parameter groups and a list of common parameters to change, see the Parameter Groups and Common Parameter Modifications section below. Faults and Warnings Faults and warnings are drive states that occur when the drive detects a problem in its operation. The codes and names of the active warnings/faults are displayed on the control panel of the drive. The displayed message, back light, icon, and LED indications will help you identify the problem. Sample Fault View Sample Warning View General Spindle Drive Operation Page 18

19 You can read also access any active warnings or faults through Group 04 in the Complete List of Parameters. The following are some icons and their descriptions: Event Fault activate Fault reset Warning activate Warning deactivate Pure event activate Pure event deactivate Icon Faults. Faults are problems that require your attention before you start the drive again. Faults conditions latch inside the drive and cause the drive to trip, stopping the motor. After the source of the fault is removed, the fault can be reset, and the drive restarted. Note that some faults require a reboot of the control unit - this is mentioned wherever appropriate in the fault listing. Refer to the following steps to solve the fault situation: 1. Identify and eliminate the cause of the fault. In the fault view, you can see the Fault code. Refer to the fault and warnings manual on the ITS CNC website for more information on the fault. 2. Reset the fault by pressing the right softkey on the keypad. In the Fault view, the keys have the following functions: Left softkey (Hide) and/or any of the arrow keys: press to temporarily hide the fault and go back to the previous view. The fault view reappears after 60 seconds if no keys have been pressed. Right softkey (Reset): press to reset the fault and return to the previous menu. Help key: press to open the context-sensitive help menu, giving you more information on the fault. For more help addressing faults, see the ABB Drive Troubleshooting section below. Warnings. Warnings indicate that a possible problem has been detected and may need attention. Warnings do not need to be reset; they stop showing when the cause of the warning ceases. Warnings do not latch and the drive will continue to operate. Press the left softkey (Hide) to temporarily hide the warning message and go back to the previous view. If the warning still is active after 60 seconds and no key has been pressed, the Warning view reappears automatically. Press the right softkey (How to Fix) to receive more context on the warning. Press the help key to open the context-sensitive help dialog. NOTE: if multiple warnings are active, all are displayed. Use the up and down arrow keys to scroll through the warnings. General Spindle Drive Operation Page 19

20 Running in Local The local mode allows you to operate the motor from the drive, separate from the CNC. All of the following functions only work when the drive is in local mode. Verify the keypad displays local in the top left of the screen. If it displays Remote, jog the Loc/Rem key until it is in local. Starting and stopping the drive. Press the green start key to enable the drive. Press the red stop key to disable it. Setting the reference (Speed). In the Options menu, select Reference. Change the reference by using the arrow keys. Use the left and right keys to select a digit to edit. Use the up and down keys to change the value of the selected digit. To adjust the reference from the Home view, press the up or down arrow key and the reference will change immediately. The reference number is highlighted when you are changing it. If you hold the key down, the rate at which the value changes accelerates. Changing the direction. In the Home view, press the left softkey (Options) to open the Options menu and select direction change. The arrow on the top of the keypad display indicates the direction. Forward is clockwise, backwards is counter-clockwise. General Spindle Drive Operation Page 20

21 PARAMETERS GROUPS AND COMMON PARAMETER MODIFICATIONS Parameter Grouping Overview To view and edit parameters, from the home view select Menu > Parameters > Complete List. The parameters are grouped into the following categories. Group 01: Actual values. Group 01 is for reading diagnostic values on the drive. All locations are read only. Group 03: Input references. Group 03 is used to read input speed references. In this application, the only value of significance is the Panel Reference Parameter 03.01, which shows the RPM the drive would run if in local keypad mode. Group 04: Warnings and faults. Group 04 is used to read any active warnings or fault. You can access the warning and fault history for diagnostic purposes. Group 05: Diagnostics. Group 05 is used to read diagnostic information such as the run time counter for hours of operation, percent of auto life used, and inverter temperature. Group 06: Control and status words. Group 06 is only used by factory personal. These values are read only. Group 07: System info. Group 07 shows information such as drive rating, part number, and firmware version. Group 09: View ITS Setup. Group 09 is a read-only group displaying the status and the selected choices from Group 74 ITS Settings. This group can be used to check for settings like analog input levels and commands from the CNC controller. See the section below for more information. Group 74: ITS Setup. Group 74 is a read and write group. You can use this group to configure the drive to the machine. For a more details, see the section below. Configuration Viewing: Group WyeDelta Active displays the currently active table the drive is using. This value is only updated at the time a run command is received WyeDelta Input displays the status of the wye-delta input terminal on the drive Mode is used to select between the three following operating modes: Rigid Tap Closed Vector Non-Rigid Tap Closed Vector Open Loop VFD Inverter Mode Parameters Groups and Common Parameter Modifications Page 21

22 09.06 Max Motor RPM displays the currently selected maximum motor RPM Min Motor RPM displays the minimum motor RPM, if applicable. This setting is only used with non-rigid tap machines. Note that some machines will not stop the spindle when this value is set above 21 RPM. This is the minimum speed used for tool changing Analog Offset displays the analog voltage setting required to give the drive a zero speed reference Analog Input displays the current analog input level speed reference from the CNC controller. This location acts as volt meter that is always active FWD Input displays the state of the FWD input terminal REV Input displays the state of the REV input terminal Code Version displays the version of the custom ITS program installed Pkg Version displays the package used by the custom ITS program installed OEM Lock displays the state of the OEM Lock function which hides the majority of the drive parameters. Parameter Configuration: Group 74 For help on how to change parameters please review the Change Parameter section in the General Spindle Drive Operation chapter above Mode allows you to change the drive's internal parameters to match the CNC's operation, such as rigid tap, closed loop vector, and so on. Select the right softkey (Edit) to change this parameter. The following table provides a description of the three modes. Note: any change made in will be saved only by setting to TRUE. See the below description for parameter for more details. Item Mode Description [0] Non-Rigid Tap Inverter Drive will operate with no encoder. Note: Encoder warning will be displayed on the keypad. This is normal in this mode. To switch to this mode, see special steps below. [1] Non-Rigid Tap Closed Vector Drive operates with an encoder and uses its internal acceleration and deceleration times. [2] Rigid Tap Closed Vector Drive operates with an encoder, and has a 0 second acceleration ramp and a.8 second deceleration ramp. The following procedure is only for chaning the drive from vector to inverter mode. The other two modes can be changed normally. Procedure to change the drive from Vector to Inverter mode 1. Select new mode 2. Set Mode/Max to True. 3. Reset any alarms that show, this is normal during mode change. 4. If Mode/Max does not show alarms it can hang in True and not be reset to False. If so cycle power, reset any alarms and repeat step 2. Parameters Groups and Common Parameter Modifications Page 22

23 5. After Mode/Max changes to False bump drive (start and stop motor with control) to ensure proper table is selected. Note: This ensures the proper settings are saved in the correct table. 6. Set Save settings to True. 7. When Save settings reverts to False cycle power. 8. Drive mode change is completed Max RPM (Motor) allows you to set the maximum motor RPM. Select between 5000 and 7500 RPM. Note: any change made in will be saved only by setting to TRUE. See the below description for parameter for more details Mode/Max Save. If or are changed, then must be set to TRUE to initialize internal variables and save the parameter change. Push Edit and select [1] TRUE will set itself back to FALSE after the save has been made Min Motor RPM. This parameter establishes the minimum speed of the motor unless rigid tap mode is selected. If this setting is over 21 RPM on a non-rigid tap machine the CNC controller may not release the run command once started. Double check there is no delay stopping Analog Offset. This parameter allows you to manually set the and offset to compensate for any analog drift. Select Edit, and set a value by using the arrow keys. The left and right keys select the digit, and the up and down keys change the value Analog Offset Save. This parameter changes the offset automatically to compensate for any analog drift, setting the current analog input as the 0 speed point. To run 74.07, select Edit, and set the value to [1] TRUE and press Save. Make sure the CNC controller is outputting 0 speed before setting this value to TRUE. Once set to TRUE, the drive copies the analog offset value to returns its value to FALSE once the copy is complete. Parameters are the drive autotune settings. For step by step instructions on how to perform an autotune, see step 15 of the Installation Procedure chapter Autotune Type. This parameter allows you to run three different types of tuning: [1] Normal, [2] Reduced, [3] Advanced. The preferred setting is [3] Advanced. If the tune fails, set to either option and try again Autotune Acknowledge initiates the autotune. Select Edit, and set the parameter to [1] TRUE. The autotune will start once you select Save and enable the drive from the keypad Autotune Save Results. This parameter saves the autotune results into the drive. Select Edit, and set the value to [1] TRUE. It is automatically set itself to FALSE after the save is complete Accel allows you to set a custom acceleration ramp. Select Edit and use the arrow keys to set a value. Note that the acceleration ramp will have a preset value based upon the mode you are in. You can override that value using this parameter Decel allows you to set a custom deceleration ramp. Select Edit and use the arrow keys to set a value. Note that the deceleration ramp will have a preset value based upon the mode you are in. You can override that value using this parameter OEM Lock Enable. When set to TRUE, this parameter will hide the parameters. The only way to reveal them is to download the custom ITS program again. Parameters Groups and Common Parameter Modifications Page 23

24 DRIVE TROUBLESHOOTING The ABB drive comes with many helpful tools that can aid you in troubleshooting problems. This chapter gives an overview of the most helpful features in the Main Menu, along with a list of thirteen common problems you see when installing a new drive. Event Log In the Event log menu, you can view information collected on faults and warnings. Events are automatically logged. To access the Event log menu, from the Home view, press the right softkey (Menu) to view the Main Menu. Navigate down until you see the Event log menu. Faults. The Faults sub-menu displays all the faults that have tripped the drive. You can navigate through the complete history of faults and get details on each fault. For more detailed looks at the faults, see the fault firmware manual on the ITS CNC website. Other events. The Other events sub-menu displays all other faults and warnings, and their details. Active faults and Active warnings. These sub-menus display the faults and warnings that are active. History Graphs The History graphs menu contains graphs that can help you monitor certain aspects of the drive's performance. It contains the Trends and Load profile sub-menus. Trends. This functionality is available in a future release. Load profile. in this sub-menu, you can view and configure load profiles. The menu contains the following four sub-menus: Amplitude logger 1: Opens a Histogram view, which displays the motor current as a distribution histogram. This logger cannot be reset. Amplitude logger 2: Opens a Histogram view, which displays the contents of an amplitude logger as a distribution histogram. You can select the signal to be monitored in the Load profile configuration submenu at 200 ms intervals, and specify a value that corresponds to 100%. The collected samples are sorted into 10 read-only parameters according to their amplitude. Each parameter represents an amplitude range 10 percentage points wide, and displays the percentage of the collected samples that have fallen within that range. Load profile configuration: Select the signal to be monitored in Amplitude logger 2. Peak value logger: Select a signal to be monitored by a peak value logger. The logger records the peak value of the signal along with the time the peak occurred, as well asa motor current, DC Drive Troubleshooting Page 24

25 voltage, and motor speed at the time of the peak. The peak value is sampled at 2 ms intervals. Common Problems The following are common problems that often come up when installing a new drive. 1. CNC Error #2 during M3 and M4 (closed loop only). This error means that the rigid tap software in the 1010 spindle card is not reading encoder pulses. The encoder is fine if the drive runs smooth when running in LOCAL mode from the ABB keypad. Verify the encoder connections from the drive to the spindle controller card. The ground/shield wire attached to the encoder output board (installation step 10) is critical to the axis card receiving pulses. A loose connection will cause this problem. 2. Spindle turns M3 but not M4 Change parameter Mode to [1] Non-Rigid Tap Closed Vector. The spindle will turn M3 but not M4 when drive's configuration does not match up with the spindle card. The drive expects a -10 to +10 volt signal (rigid tap mode) but the spindle card is non-rigid tap. To verify your machine as either rigid tap or non-rigid tap, simply look at the spindle card. The 1010 spindle card is in slot #14. The Eproms will read either ACLINEAR for a non-rigid tap machine or RIGID TAP for rigid tap. 3. Spindle turns back and forth or rotates slowly in one direction and does not go full RPM. If the spindle "jerks" and/or moves slowly in one direction when enabled and displays a high reading on the Load Meter, check the T1, T2, and T3 motor wires. This happens normally when the motor rotation is backwards to the encoder, usually because of a rewound motor. If problem persists, perform Encoder test below. 4. Drive displays Fault 7381 ENCODER Fault 7381 means the drive is not sensing the encoder while in closed loop mode, usually due to a bad encoder or a faulty connection between the drive and the spindle motor encoder. First verify all the connections in the encoder circuit. Check both the input and output on the drive, the molex connection, etc. If everything is connected correctly, test the encoder signal by following below. On the encoder, wires 2-5 are channel wires with wire 8 as supply voltage (+5 VDC). Wire 9 is common. The encoder signal is a square wave the alternates between 0 and 3.5 VDC as the spindle is slightly rotated and stopped. The state relationship between the channels will always be as displayed in the below table, depending where the spindle is stopped. To test the encoder signal, measure the DC voltage from each channel wire at the molex connection that connects the motor encoder to the drive (NOT the drive to the control). In order for you to measure the voltage, the molex must be connected; do not unplug it. Using a multimeter, you can access the edge of the pins from behind either the female or male connector. See the wiring diagram below for the pin numbering. Drive Troubleshooting Page 25

26 Using wire 9 as signal common, slightly rotate and stop the spindle until you read either 3.5 or 0 VDC, whichever was not measured originally. Test all four channel wires. A+ High A+ Low Wire 2 (A+) Wire 3 (A-) Wire 4 (B+) Wire 5 (B-) The point of the test is to see the states change at the drive input. If you do measure the correct voltage, either the encoder or the wiring from the encoder to the drive is bad. If the encoder passes this test and the drive still displays the encoder fault, see ABB fault manual on the ITS CNC website for more troubleshooting procedures. 5. Fault 2310 Overcurrent The overcurrent protection fault is displayed anytime the drive output current exceeds its maximum output current limit. This could happen during a heavy cut that exceeds the continuous or peak current duty cycle of the drive. Follow the procedures below if this is occurring while not taking a heavy cut. Verify the encoder coupler is not loose on the spindle motor shaft. Check the motor pin and coupler. Verify the encoder is working through the described tests in Problems 6 (above) and 7 (below). The standard spindle motor electrical and magnet properties can change over time as well as with rewound motors. These changes can be outside of the normal vector parameters of a standard spindle motor. If the Overcurrent fault continues and you have checked the above conditions, perform an autotune to compensate for any changes in the motor properties. See Installation step 15 for instructions on how to perform an autotune. Drive Troubleshooting Page 26

27 6. Spindle not turning with no drive faults. If the spindle is not turning, and there are the drive is not in a fault condition, review the following common failure points: Verify the drive is in the REMOTE mode. Review Problem 2 "Spindle turns M3 but not M4." Verify the FWD/REV relays are working. The drive REV or FWD should light up when enabled by the CNC. 7. Encoder test using the drive. Any missing encoder pulses will cause improper calculated motor speed. This creates problems in the vector calculations and results in high current output to the motor. This test procedure will run the motor in open loop mode and verifies what RPM the encoder is showing. To perform the encoder test: 1) From the home screen, press the left softkey (Menu), select Parameters, and select Complete List. Navigate to parameter Mode in group 74 ITS Setup. Press Edit, and select [0] Non-Rigid Tap Inverter. Set Mode/Max Save to TRUE to save the change. Reset any faults that come up. The drive will now operate without an encoder. 2) From the home screen, press the right arrow key once. The bottom of the new screen has a tool called "Motor speed used." The motor speed used tool either measures or estimates the motor speed depending on which type of feedback is selected. In this case it will estimate the motor speed because the drive is running without an encoder. 3) Start the spindle running from the CNC pendant at 1800 RPM or at any RPM range that fails. Be sure to use an M49 code to disable the spindle override pot. 4) Observe the RPM displayed on the Motor speed used tool on the ABB keypad. The motor is running at a constant speed in V/F (inverter) open loop mode; it is not following the encoder. The speed measured should be fairly constant ± 15 RPM or better. A bad encoder will not be stable and occasionally jump a couple of hundred RPM or give an RPM value that is different than what it should be. Change the RPM speed and monitor it at various speeds and check all connections. Replace the encoder if necessary. Note that you can continue running the machine in the Inverter mode while you wait for a replacement encoder. The only limitation is the machine will not be able to rigid tap. To restore close loop vector, navigate again to parameter and select the appropriate mode. Set to TRUE to save the change. 8. Spindle orientation failures and/or rigid tap failing at doing G84.2 If (A) the spindle orientation is slow or goes past orientation position then locks after one or two rotations or (B) the rigid tap pre-cycle (G84.2) fails, check the following: Reset the signal offset trim. For instructions on how to reset it, review installation step 16 "Set the Signal Offset Trim" above. Drive Troubleshooting Page 27

28 Reduce the deceleration time (parameter 74.16) in hi-range for 7500 RPM spindles. Adjust the control orientation factor using the SETP command on the CNC. A factor too low will cause little or no motion and a factor too high will cause overshoot and instability. With hi/low drives, you need to balance both the high range and the low range. 9. Drive displays Fault 7191 BC Short Circuit Check the regen breaking resistor connection. If the resistors are connected correctly, measure the ohm value. First remove resistor wires from the drive before testing. Using a multimeter, verify that the regens are measure 12 ohms by completing a circuit from the two extension ends. Note that if you measure 48 ohms, the regens are wired in series, not parallel. Any ohmic value less than 12 ohms indicates the braking resistor is burnt out and needs replacing. 10. Spindle orientation is slow/cogging. Of the spindle is not orienting correctly, try each of the following, if applicable: Adjust the Orientation Factor using the SETP command of the CNC. A factor too low will cause little or no motion and a factor too high causes overshoot and instability. Note that with 10k hi/low drives you will need to balance both the high range and the low range. For non-rigid tap machines, set Parameter Min Motor RPM to a minimum value of 25 RPM and set both Parameter Accel and Parameter Decel to 1 second each. Adjust both parameters in high and low range for wye-delta configuration. Perform an autotune. See step 15 "Autotune the Drive" in the Installation Instructions chapter above for more information on how to perform an autotune. 11. Autotune failure First verify the drive is in the local mode. Then try running the tuning with each of the three autotune types in parameter The drive is shipped with the correct motor parameters for a standard new original motor. The autotune procedure compensates for motor breakdown. The procedure should not fail unless something is wrong with the motor, encoder, contactors (wye-delta) or wiring. It uses resistance, voltage and current to measure and adjust for optimum settings. It also tests the motor more thoroughly then a ohm or mega-ohm test can do. Note that the drive cannot tune a motor that is bad or out of the normal range of the drives rating; a 10 hp drive cannot tune a 15 hp motor. Verify you have the correct drive for your motor. The wye-delta contactors are a common failure component and should be replaced when a drive is replace. Review Troubleshooting Guide in the following section. 12. Spindle stops and coasts a couple of turns (M19 and G84). Adjust Min Motor RPM to a lower value. This parameter determines an RPM slow enough to disable the drive. Drive Troubleshooting Page 28

29 Note that in Inverter (V/F) mode reducing this value can improve spindle orientation and G84 Tapping. 13. Spindle runs but rotates the wrong direction If your drive in Inverter mode, swap the T1 and T2 motor wires. For closed vector, swap the T1 and T2 motor wires and the motor encoder wires #2 (A+) and #3 (A-) to reverse the encoder counting. Drive Troubleshooting Page 29

30 COMPLETE SPINDLE SYSTEM TROUBLESHOOTING GUIDE WARNING: THIS EQUIPMENT CONTAINS HIGH VOLTAGES; UP TO 500 DC VOLTS. ONLY QUALIFIED PERSONNEL SHOULD ATTEMPT SERVICING THE MACHINE. This chapter lists common failure points outside of the drive system. We recommended you review the following if you are experiencing problems, and have gone through the previous troubleshooting chapter. Below is a general diagram of the spindle system. Use this to help target failure points. 1. Rigid Tap and Wye-Delta General Spindle System Diagram For machines with wye-delta wiring, verify the drive mode is set to rigid tap. This allows an approximate one second dwell for the wye-delta contactors to switch and settle before a spindle ON is sent to the spindle drive. This delay helps to avoid contactor arcing. This parameter was also added to allow a dwell after shifting ranges and before commanding a spindle on command. This allows time for the slower hydraulic idlers to fully engage. An incorrect setting can cause the belts to "chirp" at spindle on. 2. Main Power Disconnect Main power disconnections could be due to the following two problems: Check the fuses. Replace them if they are old; note that even if they carry voltage and look decent with a volt meter, they might not supply the needed current. Check the blade engagement contacts. Clean, and remove any corrosion or pitting in them. A bad Complete Spindle Section Troubleshooting Guide Page 30