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8510 AC Spindle Drive System

1. Figure 3 3 8510 Drive A06 10 Dia 8 Dia 433 450 75 120 8 Dia 2223 74 4 lt 175 gt Chapter 3 Dimensions Figure 3 4 8510 Drive A06 Mounting 27 Typical 4 Required 7 Chapter 3 Dimensions Figure 3 5 8510 Drive All 6 Holes at 7 Dia 8510 432 455 DIGITAL AC SPINDLE DRIVE Y lt 141 5 11 5 283 lt 13 5 310 gt 154 5 gt lt 107 Chapter 3 Dimensions Figure 3 6 8510 Drive All Mounting 16 27 Typical 6 Required e e A 432 4 oe Cut Out 7 5 lt 141 5 gt lt 283 gt
2. Test Point 1 amp Ground Resolver Excitation Signal ov DC A p p SIN Wave ii gt Y jJ A Test Point S2 amp Ground 0V DC Approx Resolver Excitation Signal 17 6V p p SIN Wave Test Point R1 amp Ground 0V DC Approx Resolver Feedback Signal 8 8V p p 128ys with motor stopped 11 135 Chapter 11 Troubleshooting Figure 11 4 High Resolution Magnetic Feedback Signals T depends on the number of gear teeth and gear speed 1 Test Point A VDC Vp p Nx 1 60 x S and Ground Anand N Number of Teeth S Speed rpm Test Point B Amplitude of A B and Ground V DC 2 5V Vp p 3V Amplitude of Z V DC 2 5V Test Point Z Vpp 3V and Ground Installation 252 Install the gear and sensor as shown The specifications a CW above should be set at CW rotation when the gear is viewed from the Z phase gear side A B Phase Gear Z Phase Gear 11 136 IGBT Test Procedure Chapter 11 Troubleshooting The following procedure provides the steps needed to properly test the IGBT modules to determine if replacement is necessary 1 2 Remove all power to the drive Remove the front cover from the drive Label and remove the three motor wires from the drive terminals U V and W Access to the IGBT modules must be gained by removing the following boards On 8510A A04 and
3. Power Board Bottom View of 8510A A11 A22 Drive 11 113 Chapter 11 Troubleshooting Power Distribution and Control 11 114 The initial power up sequence is described below Refer to Figure 11 2 for the associated power distribution and control circuitry 1 When AC power is applied to the drive the cooling fans and all internal control logic is immediately energized through AC control power fuse sets F1 F2 and F3 The external Coast to Stop input must be closed to allow any of the following power up sequence to be executed Closing this contact will close the coast to stop control relay K10 and allow the main contactor KM to close When the Drive Enable input is closed the DC bus discharge control relay KM3 is energized This disconnects the DC bus discharge resistor and allows the main contactor KM to be closed After KM3 energizes the DC bus precharge control relay KM1 is energized to allow the DC bus to charge through the precharge resistors When the DC bus voltage exceeds the under voltage trip level 250V DC the pilot relay for the main contactor KM2 will energize which closes the main AC contactor KM The precharge relay KM1 will also open at this time After the main contactor is closed the IGBT output inve
4. we Lo R 92 OO OOOOO GND V 5V 81 5 Chapter 11 Troubleshooting Figure 11 10 Power Board 8510A A04 A06 V FE FU FV PE 11 143 Chapter 11 Troubleshooting Figure 11 11 Board 8510A A11 A22 Display and Keypad Module Contrast Brightness INOud3 1088990100491 EEPROM ANAOUT 1 O ANAOUT 2 ANAIN 1 ANAIN 2 11 144 Chapter 11 Troubleshooting Figure 11 12 Main Control Board 8510A A11 A22 11 145 Chapter 11 Troubleshooting 11 146 Figure 11 13 Power Board 8510 11 IGBTM1 IGBTM2 IGBTM3 Send Yond Chapter 11 Troubleshooting Figure 11 14 Power Board 8510A A22 IGBTM 1 IGBTM2 IGBTM3 11 147 Introduction Appendix Renewal Parts The following provides a list of the renewal parts available for the 8510 AC Spindle Drive Information provided is subject to
5. Low Speed Contacts High Speed Contacts Auxiliary Contacts Interface Wiring All standard discrete digital control signals and analog inputs and outputs are connected to the drive through the 50 pin CN9 connector This interface is required for all 8510 systems Since both digital and analog signals are passed through the same connector it is recommended that two separate cables be run into the connector to achieve the proper shielding and grounding The recommended cables are Discrete Digital Signals Furukawa OAW C SB 18P 18 twisted pairs 28 AWG Analog Signals Belden 8164 4 twisted shielded pairs 24 AWG As previously described three termination options are available for this connector 1 a mating connector kit 2 a termination panel and 3 an interface cable assembly Table 8 G shows the I O function assignment for each of these termination options Figure 8 7 shows a typical interface to an Allen Bradley 9 Series CNC for a basic spindle application Additional I O connections will be required to access more of the 8510 drive features 8 83 Chapter 8 Wiring 8 84 Table 8 G Standard I O Interface Wiring Information Honda Termination Cable As Connector Panel Termi sem Wire Signal Description Pin Num nal Number Color and nwt Pr Digital Inputs Coast to Stop 1 Drive Enable 1 2 Black 1 Drive Reset 2 3 Pink 1 Digital Ground 3 4 Bro
6. 324 3 e Drive Accessory Mounting Removal of Drive Cover Chapter 5 Drive Installation Assure that sufficient cabinet space is available to mount the required drive accessories All wiring is to the bottom of the drive Provide the necessary clearances for wiring access and wire ways at the bottom of the drive Fuse Blocks The 8510 does not include the incoming AC line fuses inside the drive for drive component short circuit protection An optional fuse kit is available that includes the fuse block and fuses Make provisions for mounting the fuse block inside the enclosure See Figure 3 15 for dimensions of the optional fuse kits Termination Panels Signal connections to the drive are through multi pin Honda connectors If the optional termination panel assemblies are being used to allow wiring to terminal blocks provide sufficient mounting space and wiring access for these termination panels A 1 5 m 5 ft cable is provided to connect the termination panel to the drive See Figure 3 16 for dimensions of the termination panels The DIN 3 mounting rail is not provided with the termination panels Use Allen Bradley type 199 DR1 or equivalent mounting rail Depending on the system configuration the termination panels required will vary from one 50 pin and one 20 pin to one 50 pin and as many as four 20 pin units The front cover of the drive is mounted via two locating pins in the upper corners and two capt
7. AC Line Input Motor Fan Power Motor Output Bottom View of 8510A A11 A22 Drive Chapter 7 Interface Signal Descriptions End of Chapter Chapter Objectives General Wiring Information Chapter Wiring Chapter 8 provides the information needed to properly wire the 8510 AC Drive System Included in the chapter are general wiring recommendations and detailed wiring procedures for power and signal wiring Since most start up difficulties are the result of incorrect wiring every precaution must be taken to assure that the wiring is done as instructed All items must be read and thoroughly understood before the actual wiring begins for proper installation The National Electrical Code and any governing regional or local codes will overrule this information The Allen Bradley Company cannot assume responsibility for the compliance or the noncompliance to any code national local or otherwise for the proper installation of this system or associated equipment A hazard of personal injury and or equipment damage exists if codes are ignored during installation ATTENTION The following information is a general guide The information supplied in this manual on wire sizes practices layouts system configurations and grounding shielding techniques for the 8510 AC Drive System are presented as guidelines Due to the diversity of applications and systems no single method of wiring is completely applicable Importa
8. 1 3 Drive Design Features 1 3 VO Options i XR PSOE EY IINE RSEN ES 1 7 System Accessories o Lose Im RUE AA ea ee EA RM 1 8 Chapter 2 Chapter Objectives ios ode oye diag S Ue ees 2 1 Standard Single Speed 1327AB Motor amp 8510 Drive 2 1 Dual Winding Type 1327AD Motor amp 8510 Drive 2 3 Curves qr Ee 2 4 Chapter 3 Chapter Objectives soci aoe aa rete bero 3 1 Chapter 4 Chapter Objectives Lee Ue Oe 4 1 RECEIVING e aa de enone beater Severs 4 1 Unpacking io eg te oan eal gh EM I Ema nals 4 1 Inspection ees y iacet a bem er o ang pt tetrad AGE A s 4 1 4 1 Chapter 5 Chapter Objectives i sisse esos b 5 1 Environment 2 ern PERO 5 1 Mounting cibus BA ate 5 1 Heat Dissipation Bee eae Reed oe ancients 5 6 Drive Accessory Mounting 5 7 Removal of Drive Cover 5 7 Chapter 6 Chapter Objectives 6 1 Mounting Considerations 6 1 Coupling Considerations 6 1 Wiring Considerations 6 2 Table of Contents 8510 User Manual Interface Signal D
9. 86 5 28 0 20 Pin Note Includes 1 5 Cable with Connectors on Both Ends A 000000000000000000 0000000000004 O 0400000000000000000 71 0 3 33 Chapter 3 Dimensions Figure 3 17 Drive Panel Mounting 10 AROCKWELL INTERNATIONAL COMPANY DIGITAL AC SPINDLE DRIVE dm 8510 Y Y T js a 227 Typical 4 Required 3 34 Drive Catalog Number 8510A A04 x 8510A A06 x 8510A A11 x 8510A A22 x A 145 145 282 282 174 174 310 310 C 485 485 485 780 D 504 504 506 800 100 100 113 120 Figur
10. If problems were not found with other tests replace the Power Unit 11 123 Chapter 11 Troubleshooting No Problem 11 Inv Mtr Short displayed Current sensed by DC link current sensor CT S was too high Usually indicates problem with motor or IGBTs in inverter bridge 12 Need Parameter displayed A required parameter has not been programmed into the EEPROM before attempting to enable the drive 13 Parameter Err displayed Two programmed parameter values conflict with one another 14 Data Conflict displayed Pro grammed parame ter values conflict with one another 11 124 Table 11 E Continued Problems that Occur when Drive Enable applied or during operation Probable Cause See fault condition 10 Motor Short Malfunctioning drive interconnections Possible malfunctioning IGBT driver fuse on Main Control Board Gate Drive Board on A04 A06 Drive Malfunctioning IGBT module in inverter bridge Malfunctioning printed circuit board Malfunctioning Power Unit current sensor or circuit board Drive programming not completed Parameters are incorrectly programmed Parameters are incorrectly programmed Possible Solutions See fault condition 10 Motor Short 1 Check seating of Interconnect Boards into board connectors CN7 and CN8 15 and CN16 on A04 A06 drives 2 Remove Interconnect Board from CN7 and CN8 and inspect contacts in both connectors to assur
11. 1 Black 1 1 2 Red 1 2 3 Black 2 3 4 White 2 4 5 Black 3 6 Green 3 6 7 Black 4 7 8 Blue 4 8 9 Black 5 9 10 Yellow 5 11 Black 6 11 12 Brown 6 12 13 Black 7 13 14 Orange 7 14 15 Red 8 16 White 8 16 17 Red 9 17 18 Green 9 18 19 Red 10 19 20 Blue 16 These inputs can be driven by PLC or CNC digital outputs or from thumbwheel or selector switches Control 1 0 CN9 1 CN9 2 CN9 3 CN9 4 CN9 5 CN9 6 CN9 7 CN9 8 CN9 9 CN9 10 CN9 11 CN9 12 CN9 13 CN9 14 CN9 15 CN9 16 CN9 17 CN9 18 CN9 19 CN9 20 CN9 21 CN9 22 CN9 23 CN9 24 CN9 25 CN9 26 CN9 27 CN9 28 CN9 29 CN9 30 CN9 31 CN9 32 CN9 33 CN9 34 CN9 35 CN9 36 CN9 37 CN9 38 CN9 39 CN9 40 CN9 41 CN9 42 CN9 43 CN9 44 CN9 45 CN9 46 CN9 47 Optional 16 Bit Digital Speed or Orient Position Input Coast to Stop Drive Enable Drive Reset Digital Ground Forward Run Reverse Run Low Torque Limit Select Digital Ground Accel Decel Rate Select Spindle Servo Mode Select Servo Input Scaling Low High Digital Ground Orient Command Gear Ratio Active 1 Gear Ratio Active 2 Motor Winding Select Low High Digital Ground Drive Ready Hard Fault soft Fault Zero Speed Indicator At Speed Indicator Speed Level Indicator Load Level Indicator ET In Position Analog Input 1 Analog Input 1 Return Shield Analog Input 2 Analog Input 2 Return Shield Analog Output 1 Analog Output 1 Retur
12. Display has malfunctioned 11 120 1 Check fuses and FUIS and replace malfunctioning fuse 2 Check 5V DC power supply fuse F7 or F13 on A04 A06 size unit and replace malfunctioning fuse Intensity and contrast adjustment pots are directly below the display on the I O Board below and right on A04 A06 size unit Turn CCW to increase intensity and contrast Measure voltage at 5V DC test point to verify proper power supply operation If no 5V DC remove AC power and then remove cover from board connector CN8 CN15 on A04 A06 drive Reapply AC power and using a voltmeter verify voltage between pins 3 and 4 pins 1 and 32 on A04 A06 drive is 255 355V DC If supply voltage is OK replace Main Control Board or Gate Drive Board on A04 A06 drive If no 255 355V DC verify Interconnect Boards are properly seated in connectors Inspect contacts in both connectors to assure that they are making proper contact with the Interconnect Boards Replace drive Power Unit if 255 355V DC can not be obtained Replace I O Board and display assembly No Chapter 11 Troubleshooting Table 11 D Continued Problems that Occur when AC Power is Applied Problem Probable Cause AC Phase Loss An incoming 3 phase line is displayed Loss of open one phase of incoming AC line detected by drive Malfunctioning AC control power fuse Malfunctioning drive interconnections or hardware Malfunctioning printed circuit b
13. 1327AC AFM 02 F 20 27 10 4 0 1327AC AFM 04 x 2 213 7 27133 8 6 0 1327AC AFM 06 x 3 7 5 5 36 43 8 10 0 1327AC AFL 08 x 5 5 7 5 45 59 6 16 0 1327AC AFL 11 x 7 5111 73 91 3 25 0 1327AB AFL 15 x 11 15 97 112 2at4 2 at 1327AB AFL 19 x 15 18 5 120 135 16 0 1327AB AFL 22 x 18 5 22 122 153 2 at 3 2 at 1327AD ABL 04 x 25 34 2 ar 3 2at 1327AD ABL 06 x 3 715 5 37 45 25 0 3 1327AD ABL 08 E 5 5 7 5 50 68 1327AD ACL 08 F 7 5111 52 68 8 6 0 1327AD AAK 11 x 7 5111 65 87 8 10 0 1327AD AAK 15 x 11 15 83 102 6 16 0 1327AD AAK 19 x 15 19 95 110 6 16 0 9722 47250 AWG wire sizes are based on 75 C wire The mm wire sizes are based on 70 Qvatr6 Bathtratings are based on 30 C ambient 16 0 3 2 at 4 2 at If 909 C wire is used the wire sizes can be reduced about one wire size Refer to 6 for proper wire sizing for higher temperature wire Due to terminal block size limitations on the drive run two conductors per phase of the size indicated See Figure 8 3 for the configuration of a typical terminal box on a standard 1327AB series motor The power interconnect wiring between the drive and a standard 1327AB series motor is shown in the following diagram Figure 8 3 Terminal Box Standard Motor AMP Connector Dm A Fan Power Terminal Block Motor Power Terminal Block 8 81 Chapter 8 Wiring Figure 8 4 Standard Motor Power Connec
14. 4 If any voltages are out of tolerance or missing replace Main Control Board Gate Drive Board on A04 A06 drive 1 Verify that the resolver feedback cable is plugged into connector CN3 2 Verify that the resolver connector in the motor terminal box is properly inserted 3 Check each connector to verify that it is wired according to the 510 User Manual 1 On Main Control Board Gate Drive Board on A04 A06 drives check test points S1 and S2 for excitation sine waves these will not be smooth but will have a staircase look See Figure 11 3 for typical resolver waveforms If waveforms are not correct then unplug the resolver cable connector CN3 If the waveforms are now correct then the resolver cable is miswired or the resolver is malfunctioning If the waveforms are still not correct replace the Main Control Board or Gate Drive Board 2 Check test point R1 for a smooth clean feedback sine wave See Figure 11 3 for typical waveform If R1 waveform correct replace Main Control Board or Gate Drive Board 3 If RI waveform is missing or incorrect check resolver wiring If wiring OK replace motor resolver 11 121 Chapter 11 Troubleshooting No Problem No fault is indicated but the main contactor will not close and the Drive Ready output is not energized No Precharge displayed the DC bus failed to achieve the necessary voltage level during the allowed bus prechar ge time and the main conta
15. Check IGBT modules M4 5 and or IGBT2 in A04 A06 drive according to procedure provided later in this chapter Replace Power Unit if IGBT is malfunctioning If problems were not found with other tests replace Main Control Board Gate Drive Board and possibly CPU Board on A04 A06 drives If problems were not found with other tests replace Power Unit Check for proper hookup of contactors motor contactor coils and auxiliary contacts Check Catalog Num setting to verify that it matches the motor nameplate Disconnect motor at the drive Use a megger high voltage ohmmeter to verify that the insulation resistance to ground for each phase is at least 5 megohm For dual winding type motors disconnect the power wires at the motor terminal box and use the megger to measure phase to phase insulation resistance Verify that the insulation resistance between U amp V V amp W and W amp U is at least 5 megohms For single winding motors use an ohmmeter to measure resistance between phases depending on motor size value measured should be from 0 1 1 0 ohms and should be approximately the same between each phase Phase to phase and internal winding shorts may not be detected with this test Verify that the motor power cable is securely fastened to the drive and motor terminal blocks and that no stray wire strands are shorting out any phases Replace the Main Control Board Gate Drive Board and possibly CPU Board on A04 A06
16. Crimp Type For 1327AB Series B 1327AC Series A and 1327AD Series B Motors Connector Housing AMP 178289 5 10 pin housing Pins 9 required AMP 1 175217 2 24 20 AWG high force gold plated Connector Kit Catalog Number 8510SA CMRC Solder Type For 1327AB Series B 1327AC Series A and 1327AD Series B Motors Connector Housing AMP 178289 5 10 pin housing Pins 9 required AMP 1 175218 2 20 16 AWG high force gold plated with preformed ferrule Connector Kit Catalog Number 8510SA CMRS For the crimp type connectors AMP crimp tool 90683 1 or 91459 2 is required to properly crimp the pins to the wire 8 86 Chapter 8 Wiring A pin extraction tool AMP 914677 1 is required to remove a pin from the housing Both items are available from Allen Bradley as part of the 8510SA CTA crimp tool kit As previously described three termination options are available for the CN3 connector 1 a mating connector kit 2 a termination panel and 3 an interface cable assembly The following table shows the I O function assignment for each of these termination options Table 8 H Resolver Connector Cable information Termina Cable Connector Pin Honda tion Assembly Connector Connector Number for 1327AB Signal Connector Panel Wire Color Pin Number for Pin Number for Series Description Pin Num Terminal and Pair 1327AB Series 1327AD Series 1327AC Series A Stator S1 Red 1 Stator 53 14
17. Load Level Indicator CN9 32 33 This output is turned On any time the commanded torque exceeds a percent of available torque This is determined by the load value programmed for the Load Detect parameter In position CN9 34 35 The In Position output is turned On to indicate that the spindle orient cycle has been completed and the spindle is within the programmed distance of the target position The distance from the target position is programmed with the n Position parameter Analog Inputs Two analog inputs are available for providing analog speed or torque commands to the drive Which analog inputs are used and for which input signals is determined by programmable parameters and the drive operating mode selected Analog Input 1 9 36 37 38 In spindle mode the drive can be configured to accept either an analog or a digital speed command If the SPINDLE MODE Cmnd Source parameter is set to ANALOG the input command must be applied to this input Chapter 7 Interface Signal Descriptions In servo mode an analog speed command is required but it can be applied to either analog input If the SERVO MODE Analog In programmable parameter is set to INPUT 1 this input must be used for the servo mode analog speed command If the CNC or other control system has only a single analog output and the drive must operate in servo mode for functions such as spindle orient or C axis machining on a turning ce
18. 0 018 0 061 16 h9 0 0 0 043 10 h11 0 0 0 09 1327AD ABL 04 E A 48 h6 0 000 0 016 110 90 42 5 0 0 0 2 14 P9 0 018 0 061 14 h9 0 0 0 043 9 h11 0 0 0 09 1327AD ABL 06 E A 48 h6 0 000 0 016 110 90 42 5 0 0 0 2 14 P9 0 018 0 061 14 h9 0 0 0 043 9 h11 0 0 0 09 1327AD ABL 08 E A 55 m6 0 030 0 011 110 90 49 0 0 0 2 16 P9 0 018 0 061 16 h9 0 0 0 043 10 h11 0 0 0 09 1327AD AAK 11 E A 60 m6 0 030 0 011 140 110 53 0 0 0 2 18 P9 0 018 0 061 18 h9 0 0 0 043 11 h11 0 0 0 11 1327AD AAK 15 E A 70 m6 0 030 0 011 140 110 62 5 0 0 0 2 20 P9 0 022 0 074 20 h9 0 0 0 052 12 h11 0 0 0 11 1327AD AAK 19 E A 70 0 030 0 011 140 110 62 5 0 0 0 2 20 P9 0 022 0 074 20 h9 0 0 0 052 12 h11 0 0 0 11 3 27 Chapter 3 Dimensions Figure 3 11 1327AB Series B 1327AC Series A and 1327AD Series B Flange Mount Motor XN gt lt ci AA Shaft Detail A AC AK Blower Flange Mount Motor Dimensions are in millimeters Overall Conduit Box Flange Catalog Number Series AG BH AB AC XC XL XM XN AJ AK BF 1327AC AFM 02 F A 174 337 174 35 148 104 318 192 190 360 185 150 h7 0 000 0 040 5 15 11 1327AC AFM 04 F A 204 408 204 51 176 124 376 212 236 426 215 180 h7 0 000 0 040 5 18 14 5 1327AC AF
19. 13 and 14 In servo mode it is usually desirable to set the Servo P Gain and Servo I Gain as high as possible to achieve the most responsive servo performance When approaching the final speed the torque may overshoot with 1 2 rings but then should immediately settle out 9 100 o 16 o 17 Chapter 9 Start Up Ideally if the drive will be operated within a position loop the final tuning should be performed with the position loop closed by the CNC or other control system This will allow for the highest overall gains and system stiffness Independently tuning the velocity loop with step velocity commands leads to a conservative set of tuning parameters With an integrator in the velocity loop a very small command from the position loop will be integrated until it is large enough to cause spindle movement to null the error If there is a difference between static and dynamic friction it is possible the spindle will suddenly move too far when it finally moves and a stop move limit cycle will result To guard against this the droop parameter places a maximum limit on the integrator gain to prevent very small inputs from causing motion The Droop In Run parameter is used during very low speed servo operation when the drive is being controlled by an external position loop control The Droop In Hold parameter is used during spindle orient operation These parameters should be set as low as possible while still giving satisfact
20. 133 50 110 25 amp 32 68 150 1 00 amp 1 25 75 165 80 175 91 200 66 145 77 170 84 185 98 215 59 130 73 160 77 170 114 250 116 255 118 260 123 270 132 290 159 350 M N 51 25 2 00 1 00 51 2 00 64 2 50 64 2 50 64 2 50 25 amp 51 1 00 amp 2 00 Chapter 3 Dimensions End of Chapter Chapter Objectives Receiving Unpacking Inspection Storing Chapter Receiving Unpacking and Inspection Chapter 4 provides the information needed to unpack properly inspect and if necessary store the 8510 and related equipment The section entitled Inspection provides a complete explanation of the 8510 catalog numbering system It is the responsibility of the user to thoroughly inspect the equipment before accepting the shipment from the freight company Check the item s received against the purchase order If any items are obviously damaged it is the responsibility of the user not to accept delivery until the freight agent has noted the damage on the freight bill Should any concealed damage be found during unpacking it is again the responsibility of the user to notify the freight agent The shipping container must be left intact and the freight agent should be requested to make a visual inspection of the equipment Retain all of the instruction manuals found on top of the packing material for use during installation start up and mainten
21. Allen Bradley 8510 AC Spindle Drive System User Manual 1 ZU t W i RII Automation Important User Information Solid state equipment has operational characteristics differing from those of electromechanical equipment Safety Guidelines for the Application Installation and Maintenance of Solid State Controls Publication SGI 1 1 available from your local Allen Bradley Sales Office or online at http www ab com manuals gi describes some important differences between solid state equipment and hard wired electromechanical devices Because of this difference and also because of the wide variety of uses for solid state equipment all persons responsible for applying this equipment must satisfy themselves that each intended application of this equipment is acceptable In no event will the Allen Bradley Company be responsible or liable for indirect or consequential damages resulting from the use or application of this equipment The examples and diagrams in this manual are included solely for illustrative purposes Because of the many variables and requirements associated with any particular installation the Allen Bradley Company cannot assume responsibility or liability for actual use based on the examples and diagrams No patent liability is assumed by Allen Bradley Company with respect to use of information circuits equipment or software described in this manual Reproduction of the contents of this manua
22. Chapter 11 Troubleshooting Table 11 E Continued Problems that Occur when Drive Enable applied or during operation Probable Cause Momentary power outage while motor is regenerating to a stop Malfunctioning drive interconnections Possible blown IGBT driver fuse on Main Control Board Gate Drive Board on A04 A06 Drive Malfunctioning IGBT module in converter bridge Malfunctioning printed circuit board Malfunctioning Power Unit current sensor or circuit board Improper connection of winding changeover contactors when a dual winding motor is being used Incorrect motor selected in MOTOR SELECT Catalog Num parameter Shorted or voltage breakdown of motor or motor cabling to ground or another phase Improper motor power connections Malfunctioning printed circuit board Malfunctioning Power Unit Possible Solutions Remove power to the drive and restart 1 Check seating of Interconnect Boards into board connectors CN7 and CN8 CN15 and CN16 on A04 A06 drives 2 Remove interconnect board from CN7 and CN8 and inspect contacts in both connectors to assure that they are making proper contact with the Interconnect Board Make certain it is inserted correctly so that blank side if any is towards outside of drive Remove all twelve 0 3A fuses and check with ohmmeter Replace any bad fuses Important Be certain to properly reseat all fuses to avoid possible damage to IGBTs
23. Hazards of severe injury or death exist from Drive Enable CN9 2 When this input is turned On Coast to Stop input must also be On the drive power up sequence begins After 5 to 7 seconds for DC bus precharge if the DC bus was discharged the main AC contactor closes and the Drive Ready output is turned On which completes the power up sequence The drive is now ready to run If the Drive Enable command is turned Off while the motor is rotating the drive will regeneratively brake the motor turn the power transistors off and open the main AC contactor If the Coast to Stop input remains On the DC bus will not be discharged even though the AC contactor has been opened This shortens the time for the power up sequence to about 1 second after the Drive Enable is applied The Drive Enable and Forward or Reverse Run commands can be applied simultaneously within 200 ms In this case the drive will execute the power up sequence and then begin running at the commanded speed Chapter 7 Interface Signal Descriptions The Enable Torque programmable parameter will determine whether or not holding torque is available from the motor when the Drive Enable input is On If the parameter is set to Without Run holding torque is available as soon as the Drive Ready output turns On If the parameter is set to With Run either the Forward Run or Reverse Run inputs must be On before holding torque will be available The Drive Enable
24. Heat Dissipation 5 48 The drive must always be mounted in a sealed metal enclosure with the heat sinks extending through the enclosure wall or by using the optional panel mounting brackets with the heat sinks completely inside the enclosure In either case the enclosure must be sized to provide adequate surface area to allow the heat generated inside the enclosure by the drive and other devices to be dissipated through convection cooling If this is not possible a properly rated enclosure cooling unit must be added to cool the enclosure Typically a nonventilated convection cooled enclosure should be sized such that 10 watts of power are dissipated for each 1 square foot of enclosure surface This area should not include the enclosure bottom or surfaces of the enclosure mounted against a wall If smaller enclosures are desired an air conditioner or an air to air heat exchanger may be required The heat dissipated inside the enclosure is directly related to the power that is being delivered to the motor The following table gives the drive thermal dissipation for different motor power ratings Important For very heavy regenerative load applications the heat dissipated inside the enclosure for panel mounted drives may increase by up to 15 Table 5 A Watts Dissipated Inside Enclosure Motor Power Enclosure Panel Rating Wall Mounted CwzHP son wy i 430 W SITS Sy SST W 970 W 10 Ww BT Oi 57125
25. Place Negative Meter Lead on each Screw Step 2 Step 4 Place Negative Meter Lead on each Screw Positive Meter Lead Positive Meter Lead Place Negative Meter Lead on each Screw Place Positive Meter Lead on each Screw Negative Meter Lead Negative Meter Lead Place Positive Meter Lead on each Screw Figure 11 6 Chapter 11 Troubleshooting IGBT Module Test Procedure for 8510SA A11 and A22 Drives Step 1 Negative Meter Lead Place Positive Meter Lead on this Screw Reading 1 Meg Ohm Step 3 Place Positive Meter Lead on this Screw Negative Meter Lead Reading 1 Meg Ohm Step 2 Place Positive Meter Lead on this Screw Negative Meter Lead Reading 535mV Negative Meter Lead Place Positive Meter Lead on this Screw Reading 535mV 11 139 Chapter 11 Troubleshooting Figure 11 7 Board 8510A A04 A06 Display and Keypad Module INOHd3 2085920100101 EH EEPROM Brightness O SG O O ANAOUTIH ANAOUT 2 ANAIN 1 ANAIN 2 11 140 Chapter 11 Troubleshooting Figure 11 8 CPU Board 8510A A04 A06 11 141 Chapter 11 Troubleshooting 11 142 Figure 11 9 Gate Drive Board 8510A A04 A06
26. This ground system provides a low impedance path that helps minimize shock hazards to personnel and damage to equipment caused by short circuits transient overvoltages and accidental connection of energized conductors to the equipment chassis Grounding requirements conventions and definitions are contained in the National Electrical Code or appropriate national codes Local codes will usually dictate what particular rules and regulations are to be followed concerning system safety grounds Wiring Clearance and Routing Although the minimum clearance should be maintained for proper cooling this space may not always provide proper wiring clearance The minimum allowable wire bending radius may necessitate that extra space be provided to accommodate power wiring Consult the National Electrical Code or the appropriate national or local code for the proper wiring method Signal Wiring The 8510 inputs and outputs are all rated for 24V DC The 24V DC voltage source must be supplied by the user Each input that is used requires about 10mA of input current and all outputs are physical contact closures All signal connections are made through MR series Honda connectors The mating connectors required for signal interfaces are as follows Function Number Honda Type Standard I O Always Required CN9 MR 50LF Motor Resolver Feedback Always Required CN3 MR 20LF Digital Position Speed Input Optional CN10 MR 20LF Spindle Orient Feedback
27. 0 0 0 0 0 1 2 3 4 5 6 0 1 2 3 4 5 6 Motor rpm x 1000 Motor rpm x 1000 1327AD ABL 04 x Iow speed winding 1327AD ABL 04 x high speed winding 8510A A04 x1 8510A A04 x1 8 160 8 40 7 140 7 35 a Peak Torque x 30 Minute Power 120 6 30 Minute Power 30 5 100 5 25 5 Peak Torque 1 4 Continuous Power amp 4 Continuous Power 20 5 a a 8 3 e amp 3 15 o a o 2 40 2 10 gt gt Continuous Torque 1 Continuous Torque 20 1 5 0 0 0 0 00 02 04 0 6 08 10 12 14 16 18 20 22 0 1 2 3 4 5 6 Motor rpm x 1000 Motor rpm x 1000 1327AD ABL 06 x low speed winding 1327AD ABL 06 x high Speed winding 8510A A06 x1 8510A A06 x1 10 200 10 50 Peak Torque 8 30 Minute Power 160 8 30 Minute Power 40 pie Peak Torque 6 Continuous Power 120 lt 6 Continuous Power 30 a Bg a 54 80 5 20 8 8 8 8 e Continuous Torque 2 40 2 10 Continuous Torque zT 00 02 04 06 08 10 12 14 16 18 20 22 0 1 2 3 4 5 6 Motor rpm x 1000 Motor rpm x 1000 2 14 Output Torque N m Output Torque N m Output Torque N m Output Power kW Output Power kW Output Power kW Chapter 2 Specifications Figure 2 1 continued Motor Curves 1327AD ABL 08 E low speed winding 1327AD ABL 08 E high speed winding 8510A A11 x2 8510A A11 x2 15 300 15 80 12 30 Minute Power 240 12 30 Minute Power 64 7 a Peak Torque Peak Torque Continuous Power 3 Contin
28. 0 000 0 016 80 75 27 0 0 0 2 10 P9 0 015 0 051 10 h9 0 0 0 036 8 h11 0 0 0 09 22 4 M5 x 10 deep 1327AB AFL 08 F A 48 h6 0 000 0 016 110 97 42 5 0 0 0 2 14 P9 0 018 0 061 14 h9 0 0 0 043 9 h11 0 0 0 09 38 4 M5 x 10 deep 1327AB AFL 11 F A 48 h6 0 000 0 016 110 97 42 5 0 0 0 2 14 P9 0 018 0 061 14 h9 0 0 0 043 9 h11 0 0 0 09 38 4 M5 x 10 deep 1327AB AFL 15 F A 48 h6 0 000 0 016 110 97 42 5 0 0 0 2 14 P9 0 018 0 061 14 h9 0 0 0 043 9 h11 0 0 0 09 38 4 M5 x 10 deep 1327AB AFL 19 F A 55 h6 40 000 0 019 110 98 49 0 0 0 2 16 P9 0 018 0 061 16 h9 0 0 0 043 10 h11 0 0 0 09 45 4 M5 x 10 deep 1327AB AFL 22 F A 55 h6 0 000 0 019 110 98 49 0 0 0 2 16 P9 0 018 0 061 16 h9 0 0 0 043 10 h11 0 0 0 09 45 4 M5 x 10 deep 1327AD ABL 04 F A 48 h6 0 000 0 016 110 90 42 5 0 0 0 2 14 P9 0 018 0 061 14 h9 0 0 0 043 9 h11 0 0 0 09 38 4 M5 x 10 deep 1327AD ABL 06 F A 48 h6 0 000 0 016 110 90 42 5 0 0 0 2 14 P9 0 018 0 061 14 h9 0 0 0 043 9 h11 0 0 0 09 38 4 M5 x 10 deep 1327AD ACL 08 F A 55 h6 0 000 0 019 110 90 49 0 0 0 2 16 P9 0 018 0 061 16 h9 0 0 0 043 10 h11 0 0 0 09 45 4 M5 x 10 deep 1327AD AAK 11 F A 60 h6 0 000 0 019 140 110 53 0 0 0 2 18 P9 0 018 0 061 18 h9 0 0 0 043 11 h11 0 0 0 11 50 4 M6 x 10 deep 1327AD AAK 15 F A 70 h6 0 000 0 019 140 110 62 5 0 0 0 2 20 P9 0 022
29. 0 036 8 h11 0 0 0 09 22 4 M5 x 10 deep 1327AC AFL 08 F A 48 h6 0 000 0 016 110 97 42 5 0 0 0 2 14 P9 0 018 0 061 14 h9 0 0 0 043 9 h11 0 0 0 09 38 4 M5 x 10 deep 1327AC AFL 11 F 48 h6 0 000 0 016 110 97 42 5 0 0 0 2 14 P9 0 018 0 061 14 h9 0 0 0 043 9 h11 0 0 0 09 38 4 M5 x 10 deep 1327AB AFL 15 F 48 h6 0 000 0 016 110 97 42 5 0 0 0 2 14 P9 0 018 0 061 14 h9 0 0 0 043 9 h11 0 0 0 09 38 4 M5 10 deep 1327AB AFL 19 F 55 h6 0 000 0 019 110 98 49 0 0 0 2 16 P9 0 018 0 061 16 h9 0 0 0 043 10 h11 0 0 0 09 45 4 M5 x 10 deep 1327AB AFL 22 F 55 h6 0 000 0 019 110 98 49 0 0 0 2 16 P9 0 018 0 061 16 h9 0 0 0 043 10 h11 0 0 0 09 45 4 M5 x 10 deep 1327AD ABL 04 F B 48 h6 0 000 0 016 110 90 42 5 0 0 0 2 14 P9 0 018 0 061 14 h9 0 0 0 043 9 h11 0 0 0 09 38 4 M5 x 10 deep 1327AD ABL 06 F B 48 h6 0 000 0 016 110 90 42 5 0 0 0 2 14 P9 0 018 0 061 14 h9 0 0 0 043 9 h11 0 0 0 09 38 4 M5 x 10 deep 1327AD ACL 08 F 55 h6 0 000 0 019 110 90 49 0 0 0 2 16 P9 0 018 0 061 16 h9 0 0 0 043 10 h11 0 0 0 09 45 4 M5 x 10 deep 1327AD AAK 11 F 60 h6 0 000 0 019 140 110 53 0 0 0 2 18 P9 0 018 0 061 18 h9 0 0 0 043 11 h11 0 0 0 11 50 4 M6 x 10 deep 1327AD AAK 15 F 70 h6 0 000 0 019 140 110 62 5 0 0 0 2 20 P9 0 022 0 074 20 h9 0 0 0 052 12 h11 0 0 0 11 60
30. 0 074 20 h9 0 0 0 052 12 h11 0 0 0 11 60 4 M6 x 10 deep 1327AD AAK 19 F 70 h6 0 000 0 019 140 110 62 5 0 0 0 2 20 P9 0 022 0 074 20 h9 0 0 0 052 12 h11 40 0 0 11 60 4 M6 x 10 deep 3 26 Chapter 3 Dimensions Figure 3 10 1327AB and 1327AD Series A Foot Mount Motor lt XN gt Y lt XC gt y 5 XM re re k e 7 e R e Shaft Detail AC gt 4 BA 2F gt lt gt lt AG Foot Mount Motor Dimensions are in millimeters Overall Conduit Box Mounting Feet Catalog Number Series P AG D BH AA AB AC XC XL XM XN A E G H J B 2F BA 1327AB AFM 04 E A 211 406 112 204 51 178 126 365 214 225 415 220 95 11 12 44 198 100 70 27 5 1327AB AFM 06 E A 211 435 112 204 51 178 126 405 214 265 455 220 95 10 12 44 238 140 70 27 5 1327AB AFL 08 E A 258 408 160 250 51 202 150 372 214 232 422 290 127 18 15 65 235 140 108 43 1327AB AFL 11 E A 258 448 160 250 51 202 150 412 214 272 462 290 127 18 15 65 261 178 108 43 1327AB AFL 15 E A 250 498 160 250 51 207 152 487 5 241 322 542 290 127 18 14 5 65 340 254 108 43 1327AB AFL 19 E A 250 549 160 250 63 207 152 537 5 241 372 592 290 127 18 14 5 65 365 279 108 43 1327AB AFL 22 E A 250 589 160 250 63 207 152 577 5 241 412 632 29
31. 1 84 21 84 2 1 84 2 1 000000000000 00000000 0000 The Serial Port is a 9 pin D shell connector located on the front of the drive The Serial Port is used to 1 read the diagnostic messages and 2 read and download the programmable parameters This port does not provide real time control of the drive Chapter 7 Interface Signal Descriptions Figure 7 3 8510 Connector Locations Standard 1 0 Digital Position Speed Command Orient Feedback Dual Winding Contactor Control Motor Resolver Important On some 8510A A06 A1 drives different designators are used for connectors CN1 CN2 and CN3 Although the connector designator may be different the I O function is located in the same physical location as shown Motor Output Motor Fan Power AC Line Input Bottom View of 8510A A04 A06 Drive Standard 1 0 Digital Position Speed Command Orient Feedback Motor Resolver Dual Winding Contactor Control A22 Drives Only FU FV FW FE CI C3 Ie Ie FU FV FE T
32. 25 250 Peak Torque s x 2 30 Minute Power 400 i 2 30 Minute Power 200 2 5 o 5 Continuous Power AT z T A Continuous Power lt Peak Torque amp 5 10 200 8 10 100 mu o Continuous Torque 5 100 5 50 Continuous Torque 2 5 0 0 0 0 00 01 02 0 3 04 05 06 07 08 0 9 1 0 1 1 12 13 14 0 1 2 3 4 5 Motor rpm x 1000 Motor rpm x 1000 1327AD AAK 19 x low speed winding 1327AD AAK 19 x high speed winding 8510A A22 x2 8510A A22 x2 35 700 35 350 30 600 30 300 Peak Torque 25 500 25 250 30 30 Minute Power s 20 Continuous Power 400 s 20 E Continuous Power 200 5 SCIES 5 e a s 5 300 Z 15 150 2 z Peak Torque 5 5 5 9 10 de 200 9 10 100 Continuous Torque 100 5 Continuous Torque ue 50 0 0 0 0 0 0 0 1 0 2 0 3 04 0 5 06 07 08 09 10 11 12 13 14 0 1 2 3 4 5 Motor rpm x 1000 Motor rpm x 1000 2 16 Output Torque N m Output Torque N m Chapter Dimensions Chapter Objectives Dimensions for the 8510 system components are detailed on the following pages Refer to the listing below for help in locating the desired drawing 8510 Drive A04 Figure 3 1 page 3 18 8510 Drive A04 Mounting Figure 3 2 page 3 19 8510 Drive A06 Figure 3 3 page 3 20 8510 Drive A06 Mounting Figure 3 4 page 3 21 8510 Drive All Figure 3 5 page 3 22 8510 Drive A11 Mounting Figure 3 6 page 3 23 8510 Drive A22 Figur
33. 4 M6 x 10 deep 1327AD AAK 19 F 70 h6 0 000 0 019 140 110 62 5 0 0 0 2 20 P9 0 022 0 074 20 h9 0 0 0 052 12 h11 0 0 0 11 60 4 M6 x 10 deep 3 28 Chapter 3 Dimensions Figure 3 12 1327AB Series B 1327AC Series A and 1327AD Series B Foot Mount Motor XN gt A gt lt o Y lt R Shaft Detail Blower Foot Mount Motor Dimensions are in millimeters Overall Conduit Box Mounting Feet Catalog Number Series D AB XC XM XN A E G H J B 2F XB 1327AC AFM 04 E A 204 395 112 51 176 124 363 212 223 413 220 95 11 12 44 198 100 70 30 5 1327AC AFM 06 E A 204 435 112 51 176 124 403 212 263 453 220 95 10 12 44 237 140 70 30 5 1327AC AFL 08 E A 250 401 160 51 199 147 375 212 235 425 290 127 18 14 5 65 235 140 108 43 1327AC AFL 11 E A 250 441 160 51 199 147 415 212 275 465 290 127 18 14 5 65 261 178 108 43 1327AB AFL 15 E B 250 491 160 51 206 151 484 5 242 319 539 290 127 18 14 5 65 340 254 108 43 1327AB AFL 19 E B 250 541 160 63 206 151 534 5 242 369 589 290 127 18 14 5 65 365 279 108 43 1327AB AFL 22 E B 250 581 160 63 206 151 574 5 242 409 629 290 127 18 14 5 65 404 318 108 43 1327AD ABL 04 E B 250 454 160 49 183 131 399 320 266 442 290 127 16 15 47 244 178 108 59 1327AD ABL 06 E B 250 492 160 49 183 131 437 320 304 480 290 127 16 15 55
34. 42 5 0 0 0 2 14 P9 0 018 0 061 14 h9 40 0 0 043 9 h11 0 0 0 09 1327AD ABL 08 E B 55 m6 0 030 0 011 110 90 49 0 0 0 2 16 P9 0 018 0 061 16 h9 0 0 0 043 10 h11 0 0 0 09 1327AD AAK 11 E B 60 m6 0 030 0 011 140 110 53 0 0 0 2 18 P9 0 018 0 061 18 h9 0 0 0 043 11 h11 0 0 0 11 1327AD AAK 15 E B 70 m6 0 030 0 011 140 110 62 5 0 0 0 2 20 P9 0 022 0 074 20 h9 0 0 0 052 12 h11 0 0 0 11 1327AD AAK 19 E B 70 m6 0 030 0 011 140 110 62 5 0 0 0 2 20 P9 0 022 0 074 20 h9 0 0 0 052 12 h11 0 0 0 11 3 29 Chapter 3 Dimensions Figure 3 13 High Resolution Magnetic Feedback Detecting Gear 6 Holes 5 5 Dia Equally Spaced A 2 Y A amp B Phase P dd Z Phase Detecting Gear Catalog Number of Teeth A B C D 8510SA PG225 225 90 8 h6 0 0 0 022 52 H6 0 019 0 0 82 67 0 1 0 1 8510SA PG256 256 103 2 h6 0 0 0 022 65 H6 0 019 0 0 92 80 0 1 0 1 8510SA PG300 300 120 8 h6 0 0 0 025 85 0 022 0 0 112 100 0 1 0 1 8510SA PG400 400 160 8 h6 0 0 0 025 120 H6 0 022 0 0 152 135 0 1 0 1 8510SA PG500 500 200 8 h6 0 0 0 029 150 H6 0 025 0 0 192 165 0 1 0 1 8510SA PG500P 500 200 8 h6 0 0 0 029 150 H6 0 025 0 0 192 165 0 1 0 1 3 30 P Minimum Length 2 000 Chapter 3 Dimensions Figure 3 14 High Resolution Magnetic Feedback Sensing H
35. 6000 6001 8000 8001 10000 10001 12000 user supplied contactor is required to switch the high and low speed windings 4 38 8510T First Position Bulletin Number A Second Posi tion Type Let er A I Description Autotrans former Isolation Transformer A Transformer 012 Third Position Fourth Posi tion Enclosure Continuous Type kVA Rating Let Description No kVA NEMA 006 6 A Typel 000 9 O Opencore 012 12 and coil 017 17 022 22 026 26 032 32 040 40 Chapter 4 Receiving Unpacking and Inspection B A Fifth Position Sixth Posi tion Primary Voltage Secondary amp Frequency Voltage Letter Description Let Description rm B 460 AC three phase 60 220 AC Hz A three phase 380 415 460V AC three phase 50 60 Hz Termination Panels 85105 505 First Position Bulletin Number Second Posi tion Type Code TPSOS TP20 D TP20 TP20 TP20 TP20 Description Termination panel for 50 pin standard I O connector includes 1 5 m 5 ft cable Termination panel for 20 pin digital speed position input connector includes 1 5 m 5 ft cable Termination panel for 20 pin optical encoder orient feedback connector includes 1 5 m 5 ft cable Termination panel for 20 pin high resolution magnetic orient feedback connector includes 1 5 m 5 ft cable Termination panel for 20 pin motor res
36. A06 drives remove the CPU Gate Drive and I O Boards On 8510A A11 and A22 drives remove the Main Control and I O Board The 8510A A04 and 06 drives have two modules while the 8510A A11 and A22 drives have six For proper testing each module must be checked four different ways The procedure for 8510A A04 and 06 drives is shown in Figure 11 5 The procedure for 8510A A11 and A22 drives is shown in Figure 11 6 On 8510A A11 and A22 drives the IGBT module will have 4 spade lugs for the gate connection Use these as a reference point for orientation Measurements must be taken with a Digital Voltmeter DVM equipped with a Diode setting The connection polarity for the meter is shown in each figure A reasonable ohm reading would be 1 meg to infinity A reasonable voltage drop would be 450 700mV If a measurement differs appreciably from these values the module is bad and the Power Unit must be replaced When testing replacement is complete replace board s cover and check for proper operation 11 137 Chapter 11 Troubleshooting Step 1 Step 3 Reading Infinity 11 138 Figure 11 5 IGBT Module Test Procedure for 85105 04 and A06 Drives Place Positive Meter Lead on each Screw Negative Meter Lead Negative Meter Lead Place Positive Meter Lead on each Screw Place Negative Meter Lead on each Screw Positive Meter Lead Positive Meter Lead
37. As explained in Chapter 10 the integral display and programming system is used to display drive diagnostic messages When a fault occurs the display will automatically change within about 2 seconds to the Current Fault display If any key is pressed the display will return to its previous state Through the DIAGNOSTICS menu the current fault and a fault history showing the eight 8 most recent faults can be accessed The fault history does not contain date time information and can not be reset The tables found later in this chapter group the fault conditions or the fault display messages by general classification describe the specific fault and show probable causes and possible solutions The general groupings are Problems that occur when AC power is applied Table 11 0 page 11 120 Problems that occur when Drive Enable is applied Table 11 E page 11 122 Problems that occur while the drive is operating Table 11 F page 11 125 Problems that occur during spindle orient Table 11 G page 11 129 Other faults that indicate a control hardware malfunction Table 11 H page 11 131 Problems specifically related to the I O Board Table 11 I page 11 133 Problems caused by programming errors Table 11 J page 11 134 For each fault condition or operating problem the causes and solutions are listed in order of decreasing probability of occurrence or increasing complexity of required tests To aid in locating a specific fault an alphabetized list of all fa
38. Board Type C2 152682 I O Board Type D2 152905 Keypad Display Board included with I O Board To avoid being forced to completely reprogram the drive remove the EEPROM from the malfunctioning I O Board and install it in the replacement I O Board A 2 www rockwellautomation com Power Control and Information Solutions Headquarters Americas Rockwell Automation 1201 South Second Street Milwaukee WI 53204 2496 USA Tel 1 414 382 2000 Fax 1 414 382 4444 Europe Middle East Africa Rockwell Automation Vorstlaan Boulevard du Souverain 36 1170 Brussels Belgium Tel 32 2 663 0600 Fax 32 2 663 0640 Asia Pacific Rockwell Automation Level 14 Core F Cyberport 3 100 Cyberport Road Hong Kong Tel 852 2887 4788 Fax 852 2508 1846 Publication 8510 5 1 August 1993 P N 152824 Supersedes May 1993 Copyright 1993 Rockwell International Corporation All rights reserved Printed in USA
39. If voltage is present and fan is not operating check for obstructions Otherwise replace motor or cooling fan Clean motor fan protective grill and fan Use pressurized air to clean cooling passages in each corner of the motor frame Check Catalog Num setting to verify that it matches the motor nameplate Incorrect parameter setting or oversized drive can result in excitation currents that exceed motor rating 1 Measure motor case temperature Thermal switch should open at 140 5 C Case temperature should be in excess of 110 C at this time 2 If motor case is below 110 C use an ohmmeter to check the thermal switch Approximately zero ohms should be measured between pins 15 amp 16 on the resolver connector in 1327AB series motor terminal box For 1327AD motors measure pins 9 amp 10 If an open circuit or high resistance is measured replace the motor 3 If thermal switch is OK check cable to drive and connectors for proper connection and continuity Repair or replace as required If problems were not found with other tests replace Main Control Board Gate Drive Board and possibly CPU Board on A04 A06 ee 21 Drive Ovrtemp displayed The drive detected that the thermal switch on the drive heat sink has opened Drive is overloaded by existing duty cycle Drive cooling fan not operative Insufficient air flow over heat sink or poor heat transfer Incorrect motor selected in MOTOR SELECT Catalog Num par
40. Rated Output Current 30 Minute Amperes Power Control Method Motor Braking Method Input Command Speed Control Range Speed Regulation Velocity Loop Bandwidth Programming System Drive Enclosure Type Drive Weight kg Ib Allowable Vibration Rated Ambient Temperature Storage Temperature 34 45 68 68 PWM inverter using IGBT power devices Power regeneration to the AC line 10V DC 0 10V DC with Fwd Rev input 16 bit binary or BCD digital command 0 to 30 000 rpm velocity resolution greater than 1 2 000 000 Transient change lt 0 4 of max speed steady state change lt 0 025 load 10 100 Up to 50 Hz load and motor dependent Integral 2 line by 16 character backlit LCD display and 4 button keypad Open style IP 00 for mounting in another enclosure heat sinks extend outside enclosure 14 31 15 33 26 57 26 57 Less than 0 5 G 0 to 55 C 32 to 131 F inside enclosure 0 to 40 C 32 to 104 F at heat sinks 0 to 65 C 32 to 149 F 30 minutes starting with cold motor Loaded for 60 of a 10 minute cycle 15 minute rating for 1327AB AFM 02 motor 1327AB AFM 02 and 1327AD ACL 08 only available as flange mount and 1327AD ABL 08 only available as foot mount Rw N 2 11 Chapter 2 Specifications Dual Winding Type 1327AD Motor amp 8510 Drive continued Motor 1327AD 1 Continuous kW HP S2 30 Minute kW HP S6 60 Duty kW HP Minute Peak kW HP Base RPM Max
41. The recommended cable type is Madison 08CFJ00004 4 twisted pairs with shield 24 AWG Three termination options are available for the CN2 connector 1 a mating connector kit 2 a termination panel and 3 an interface cable assembly There are unique versions of the 2nd and 3rd option for optical encoder feedback and high resolution magnetic feedback The following table shows the function assignment for each of these termination options for the optical encoder interface Actual connections to the encoder depend on the specific encoder chosen and connector type chosen for the encoder Chapter 8 Wiring Table 8 1 Optical Encoder Cable Information Honda Termination Cable Assem Signal Connector Panel Termi Wire Color Description Pin Num nal Number and Pair Fill ae Ae Channel A Output 16 Black 1 Ground 16 10 White 1 9 Channel Output 15 Red 2 Ground 15 9 Green 2 a y gt Channel Z Output 14 Brown 3 Ground 14 8 Blue 3 12V DC Power 5 Orange 4 Source 5 4 Yellow 4 Ground 4 1 Cable Shield arbre ri Table 8 J shows the function assignments for the high resolution magnetic feedback and the comparable wire color on the magnetic analog sensor cable Table 8 J High Resolution Magnetic Feedback Cable Information Honda Termination Cable Assem Magnetic Signal Connector Panel Termi Wire Color Sensor Description Pi
42. been given METER DISPLAY This is a menu title for all of the parameters that can be displayed in digital meter form on the drive display The following paragraphs describe the function of each item Motor Speed When selected the display will show the actual bipolar motor speed as measured from the resolver feedback Data Format RPM 00000 Spindle Speed Displays the actual spindle speed as calculated from the programmed gear ratio and actual motor speed The display is bipolar Data Format RPM 00000 Load Indicates the percent rated motor load The displayed data is determined from the torque command with continuous rated motor torque from zero speed to base speed and continuous rated power output from base speed to maximum speed This will give the same 100 output reading The maximum reading shows the peak capability of the drive motor combination as a percent of the continuous rating and may vary for different drive ratings This is a unipolar output Data Format 000 Torque When selected the percent rated motor torque is shown This is identical to the Load parameter except that it is a bipolar output Data Format 000 Power Output The motor output power expressed in kilowatts kW will be displayed At zero speed the motor power is zero regardless of the torque output For a percent load output equal to 100 throughout the speed range the Power Output will increase linearly from zero at zero speed to rat
43. change Refer to the 8510 Renewal Parts publication 8510 6 0 for current information For critical process applications it is recommended that a complete drive be maintained as a spare 8510A A06 xx Drive Part Number Description 145863 Fuse FUIR FUIS 145863 Fuse FU2R FU2S 151465 Fuse FU3R FU3S FU3T 148133 Gate Drive Fuses 148134 5V DC Power Supply Fuse 152687 CPU Board 152688 Gate Drive Board 152683 I O Board Type A1 152684 I O Board Type B1 152685 I O Board Type C1 152686 I O Board Type D1 152905 Keypad Display Board included with I O Board 8510A A11 xx Drive Part Number Description 145863 Fuse FUIR FUIS 145863 Fuse FU2R FU2S 151287 Fuse FU3R FU3S FU3T 148133 Gate Drive Fuses 148134 5V DC Power Supply Fuse 152678 Main Control Board 152679 I O Board Type A2 152680 I O Board Type B2 152681 I O Board Type C2 152682 I O Board Type D2 152905 Keypad Display Board included with I O Board To avoid being forced to completely reprogram the drive remove the EEPROM from the malfunctioning I O Board and install it in the replacement I O Board Appendix A Renewal Parts 8510A A22 xx Drive Part Number Description 145863 Fuse FUIR FUIS 145863 Fuse FU2R FU2S FU2T 151287 Fuse FU3R FU3S FU3T 148133 Gate Drive Fuses 148134 5V DC Power Supply Fuse 152678 Main Control Board 152679 I O Board Type A2 152680 I O Board Type B2 152681 I O
44. familiar with the 8510 AC result in component damage or a reduction in product life Wiring or application errors such as undersizing the motor incorrect or inadequate AC supply or excessive ambient temperatures may result in malfunction of the system ATTENTION An incorrectly applied or installed drive can Discharge sensitive parts and assemblies Static control precautions are required when installing testing servicing or repairing this assembly Component damage may result if ESD control procedures are not followed If you are not familiar with static control procedures reference A B publication 8000 4 5 2 Guarding Against Electrostatic Damage or any other applicable ESD protection handbook ATTENTION This drive contains ESD Electrostatic Drive Overview The Allen Bradley Series 8510 AC Spindle Drive System is designed to meet the requirements of world class machine tools The 8510 consists of a rugged AC spindle motor and a state of the art digital AC drive The system has been optimized to provide the highest level of performance combined with outstanding reliability The 8510 is fully microprocessor controlled and has the features required by modern high capacity machine tools including 1 Four quadrant line regenerative operation for high cycle rate applications 1 Extremely high dynamic performance for smooth operation under widely varying machining conditions 1 A wireless power structure maximizes
45. fault output information The Hard Fault output will be turned Off whenever a drive fault condition occurs that will prevent the drive from properly controlling the motor Refer to Chapter 7 for further fault output information In either case the 8510 display will show a short text message that describes the fault In addition the drive can display the last eight faults that have occurred 11 111 Chapter 11 Troubleshooting Circuit Board Descriptions 11 112 The functionality associated with each circuit board in the 8510 AC Spindle Drive is described below Refer to Figure 11 1 for board locations I O Board Includes all analog and discrete digital user interface functions along with the integral drive programming system The EEPROM for user programmed parameter storage is located on this board Main Control Board Used on 8510A A11 x2 and 8510A A22 x2 drives only This board contains all of the basic drive control circuitry including the digital control system for position velocity and commutation control motor current loops IGBT gate drive circuits with fuses logic power supplies with fuse resolver feedback interface spindle position feedback interface dual winding motor contactor control interface and fault diagnostics system CPU Board Used on 8510A A04 x1 and 8510A A06 x1 drives only This board contains the digital control system for position velocity and commutation control motor current loops spindle
46. lt 298 gt Chapter 3 Dimensions Figure 3 7 8510 Drive A22 6 Holes at 7 Dia ALLEN BRADLEY 8510 DIGITAL AC SPINDLE DRIVE Chapter 3 Dimensions Figure 3 8 8510 Drive A22 Mounting 199 P 27 Typical 6 Required o k 727 5 700 Cut Out n t je e lt 141 5 7 5 4l 283 298 3 25 Chapter 3 Dimensions Figure 3 9 1327AB and 1327AD Series A Flange Mount Motor lt AH gt lt XN gt lt XM t Shaft Detail T e AB BH AK Y 4 BF lt AG Flange Mount Motor Dimensions are in millimeters Overall Conduit Box Flange Catalog Number Series P AG BH AB AC xc XL XM XN AJ AK BB BE BF 1327AB AFM 02 F A 174 359 174 35 149 106 343 194 215 385 185 150 h7 0 000 0 040 5 15 11 1327AB AFM 04 F
47. orient is pro vided by the drive the spindle position feedback must be connected to the 8510 through the 20 pin CN2 connector see Figure 7 3 The 8510 drive can use either a conventional optical encoder or the high resolution mag netic feedback to provide spindle position feedback The feedback device must be mechanically coupled 1 1 to the spindle shaft being positioned If an optical encoder is used it must provide an A B and Z channel output have a single ended push pull type output and use a 12V DC input voltage The recommended Allen Bradley encoder is the 845T series with a type 3 electrical option and a type 3 signal option The 845T encoder provides an MS style connector for the interface The high resolution magnetic feedback from 225 000 to 500 000 counts turn consists of a precision gear that must be mounted to the spindle shaft and a sensor head that mounts to the headstock adjacent to the gear Refer to the instructions provided with the feedback sensor for installation details The sensor has an integral 2 meter 6 ft cable An interconnection box with terminal strips or connectors must be mounted in a convenient location to complete the wiring to the drive Assure that continuity of all cable shields is maintained through this box Both feedback types are connected to the drive through the CN2 connector with a unique set of pins for each feedback device The required interface cable type is the same for either device
48. parameter value To assure that the drive will always orient the spindle without overshoot setup should be done with the largest expected reflected load inertia If expected maximum load inertias are not known always leave sufficient torque margin to assure successful operation with high inertias continued 9 101 Chapter 9 Start Up 9 102 o 18 The orient operation always starts by slowing to the orient speed locating the marker on the feedback encoder and then starting decel on the following revolution Shorter orient times can usually be achieved if the Orient Speed parameter is set relatively high With a setting of 300 rpm final decel to the orient position should begin within 200 ms of reaching the orient speed Adjust the value of Orient Start to give a quick decel without overshoot With Orient Speed set at 300 rpm a value of 120 degrees for Orient Start gives a position loop gain of 15 per second For accurate setup monitor the torque at test point TP2 If the maximum load inertias are well defined the Orient Speed or Orient Start parameters can be adjusted so that the torque peaks at 10 volts as the decel starts If setup is being done without tooling or a workpiece the maximum torque measured on a machining center should be 7 volts On a lathe the maximum torque should be only 4 volts to assure successful orient without overshoot If multiple gear range data sets are being used repeat the above procedure
49. programming and diagnostic displays The menu driven programming system is powerful yet simple to use Diagnostic features include a digital meter I O status and fault displays Programmed parameters are stored in EEPROM In addition an offline programming system and a file upload download utility are available Simple Drive Tuning Procedures All performance adjustments are digital parameters Analog inputs are self zeroing Scaling of zero and maximum command requires only the push of a button All velocity loop gains can be set with the drive operating Programmable Analog Outputs The user can configure two analog outputs to provide any of eight different output signals These include motor or spindle rpm load maximum power and orient error Options Chapter 1 Introduction The 8510 AC Drive I O can be configured in several ways as explained below Standard I O Drive Model 8510A Axx Ax This is the standard drive I O and includes the functionality required for normal spindle operations on conventional machine tools Drive Model 8510A Axx Bx In this version the standard I O is expanded to include the 16 bit parallel digital input that can be used for either a digital spindle speed command or an external spindle orient position command The inputs can be configured as either a 16 bit binary or a 4 digit BCD command Drive Model 8510A Axx Cx To the standard I O this version adds the high speed high linearit
50. resolutions of 225 000 to 500 000 parts per revolution with an absolute accuracy down to 0 015 degrees Mounting Adapters For installations where it is difficult to extend the 8510 heat sinks through the rear of the enclosure a special mounting adapter can be provided to allow the drive to be mounted within the enclosure A version to allow ducting the cooling air to the side or top of the enclosure is also available AC Line Fuse and Fuse Block Kit Incoming AC line fuses or circuit breakers are not included in the basic 8510 A kit that includes the necessary fuse blocks and fuses is available Transformers Both autotransformers and isolation transformers are available to match the main AC line voltage to the 200 230V AC drive input requirement Chapter Specifications Chapter Objectives Chapter 2 provides the specifications for the 8510 AC Spindle Drive System Specifications have been grouped by type of motor Standard Single Speed 1327AC Motor amp 8510 Drive Motor 1327AC AFM 02 AFM 04 AFM 06 AFL 08 AFL 11 Output Power Rating 51 Continuous kW HP 2 2 3 3 7 5 5 5 7 5 7 5 10 11 15 S2 30 Minute kW HP 3 73 59 5 5 7 5 7 5 10 11 15 15 20 S6 60 Duty kW HP 2 6 3 4 4 3 5 8 6 6 8 8 9 12 13 5 18 1 Minute Peak kW HP 4 5 6 6 7 9 9 12 13 5 18 18 24 Rated Speed Base RPM 1500 1500 1500 1500 1500 Maximum RPM 8000 8000 8000 6000 6000 Constant Power Speed Rang
51. signal the drive will only run for the time delay setting of the relay At the end of the timeout the motor contactor will be opened by passive circuitry causing the system to coast to a stop Important The magnitude of the time delay is application dependent and must be carefully chosen The delay should be sufficient to allow the drive to stop the motor from maximum speed with the maximum expected load inertia However excessive time delays could pose a safety hazard in the event of an electronic malfunction 7 57 Chapter 7 Interface Signal Descriptions ATTENTION If an electronic malfunction occurs that pre vents the drive from responding to the removal of the Drive En able input the motor will continue to operate under power until the user supplied time delayed dropout relay de energizes and opens the Coast to Stop input If this operation poses an unac ceptable risk of personal injury or machine damage immediate ly remove the Coast to Stop input and use an external braking system to provide rapid stops in an emergency situation ATTENTION The user has the ultimate responsibility to determine which stopping method is best suited to the applica tion and will meet applicable standards for operator safety This responsibility includes machine risk assessments to identify hazards associated with emergency conditions and the appropriate system solutions Chapter 7 Interface Signal Descriptions
52. supply are located on the Gate Drive or the Main Control Board depending on the drive rating The following tables show the fuse types used Refer to Figures 11 9 and 11 12 for fuse locations Table 11 B 8510A A04 x1 and 8510A A06 x1 Gate Drive Board Designator Rating Vendor Name amp Number P N Gate Drive 0 3A 250 V Daito Tsushin HM03 148133 Fuses F1 to F12 5V DC Power Supply 5 250 V Daito Tsushin MP50 148134 Fuse F13 Table 11 C 8510A A11 x2 and 8510A A22 x2 Main Control Board Designator Rating Vendor Name amp Number A B P N Gate Drive Fuses 0 3A 250V Daito Tsushin HM03 148133 F1 to F6 F8 to F13 5V DC Power 5A 250V Daito Tsushin MP50 148134 Supply Fuse F7 If the 5V DC power supply fuse has opened a white indicator will show in the window on the front of the fuse The 5V DC test point is before the fuse so measuring the test point voltage will not verify that the fuse is OK 11 116 Fault Diagnostics System Chapter 11 Troubleshooting The gate drive fuses can not be visually checked to determine if they have malfunctioned The fuse element is too small to allow a reliable visual check Use an ohmmeter to test these fuses with power off amp out of cir cuit IGBT gate drive fuses have opened or been removed The IGBT power module will be damaged if power is applied without the module gate leads connected to the control circuitry ATTENTION Do not apply power to the drive if any of the
53. that Occur while the Drive is Operating No Problem Probable Cause Possible Solutions 18 Bus Undervolt Incoming 3 phase voltage is out of Adjust taps on transformer or add step up transformer to keep displayed DC bus tolerance line voltage above 180V AC 50 60 Hz voltage less than the minimum Incoming AC line impedance is Increase kVA rating of supply transformer to proper rating for drive allowable level was too high size especially if fault occurs during accel or when the motor is detected running under heavy load see Table 8 C An incoming 3 phase line is open With drive operating in motoring or accel if possible check phase or has high impedance to phase line voltages for balanced conditions and verify that voltage is above 180V AC Check all incoming line connections for DAL M M e EE 19 AC Phase Loss Refer to fault condition 4 Refer to fault condition 4 displayed Loss of one phase of An incoming 3 phase line is open With drive operating in motoring or accel if possible check phase incoming AC line or has high impedance to phase line voltages for balanced conditions Check all incoming detected by drive line connections for tightness If a three phase motor is connected to the AC line a lost phase may not be detected by a voltage test on a lightly loaded 8510 system Incoming AC line impedance is Increase kVA rating of supply transformer to proper rating for drive too high size Especiall
54. the drive there are no internally detected fault conditions and the drive is waiting for or executing input commands If stated in digital terms this output would be called Hard Fault This output will be turned Off whenever a drive fault condition occurs that will prevent the drive from properly controlling the motor If the motor is rotating when a fault condition is detected the drive if it is still capable of controlling the motor will regenerate the motor to a stop and open the contactor If the drive is unable to control the motor the contactor will be opened and the motor will coast to a stop After a hard fault has occurred the fault condition must be corrected any inputs that command motion must be Off and the Reset input must be applied or the AC power cycled It is not necessary for the motor to stop rotating before resetting and restarting the drive Soft Fault CN9 24 25 The Soft Fault output will be On if power is applied to the drive there are no internally detected fault conditions and the drive is waiting for or executing input commands If stated in digital terms this output would be called Soft Fault This output will be turned Off as a result of motor overtemperature drive overtemperature or improper command sequences that can not be acted upon by the drive During a soft fault condition the drive will continue to operate normally After about 2 minutes for a motor overtemperature and 30 seconds fo
55. 0 127 18 14 5 65 404 318 108 43 1327AD ABL 04 E A 250 454 160 250 49 183 131 399 320 266 442 290 127 16 15 47 244 178 108 59 1327AD ABL 06 E A 250 492 160 250 49 183 131 437 320 304 480 290 127 16 15 55 278 210 108 59 1327AD ABL 08 E 250 569 160 250 49 183 131 513 5 320 380 5 556 5 290 127 16 15 55 375 305 108 59 1327AD AAK 11 E 310 643 180 310 61 212 158 623 330 447 678 320 139 5 16 19 55 390 254 121 50 1327AD AAK 15 E A 380 661 5 225 380 61 280 216 623 5 385 425 5 682 5 420 178 21 24 75 425 311 149 73 1327AD AAK 19 E 380 711 5 225 380 61 280 216 673 5 385 475 5 782 5 420 178 21 24 75 465 349 149 73 Shaft and Key Catalog Number Series U NW ES R Key W Key H 1327AB AFM 04 E A 28 h6 0 000 0 013 60 49 24 0 0 0 2 8 P9 0 015 0 051 8 h9 0 0 0 036 7 h11 0 0 0 09 1327AB AFM 06 E A 32 h6 0 000 0 016 80 70 27 0 0 0 2 10 P9 0 015 0 051 10 h9 0 0 0 036 8 h11 0 0 0 09 1327AB AFL 08 E A 48 h6 0 000 0 016 110 97 42 5 0 0 0 2 14 P9 0 018 0 061 14 h9 0 0 0 043 9 h11 0 0 0 09 1327AB AFL 11 E A 48 h6 0 000 0 016 110 97 42 5 0 0 0 2 14 P9 0 018 0 061 14 h9 0 0 0 043 9 h11 0 0 0 09 1327AB AFL 15 E A 48 h6 0 000 0 016 110 97 42 5 0 0 0 2 14 P9 0 018 0 061 14 h9 0 0 0 043 9 h11 0 0 0 09 1327AB AFL 19 E A 55 m6 0 030 0 011 110 98 49 0 0 0 2 16 P9 0 018 0 061 16 h9 0 0 0 043 10 h11 0 0 0 09 1327AB AFL 22 E A 55 m6 0 030 0 011 110 98 49 0 0 0 2 16 P9
56. 0 commands either the low speed or the high speed winding to be selected Within about 250 milliseconds the drive will turn off the motor current open one contactor close the other contactor turn on the motor current and give an output back to the control system to indicate that the winding has been changed To prevent excessive speed changes during the winding change operation the motor should be running at no load With dual winding motors totally independent parameter sets are stored for each motor winding to assure optimum performance in each speed range When these motors are used the gear range data sets are limited to three instead of four This gives a total of six unique sets of drive parameters 2 motor windings in each of 3 gear ranges Power Structure Design Internal discrete wiring has been nearly eliminated by the use of a printed circuit board to interconnect the entire power structure Use of a circuit board maximizes reliability and simplifies maintenance The 8510 uses high frequency low loss IGBT power devices The high switching frequency minimizes motor noise and reduces motor heating To remove much of the heat from the drive cabinet the 8510 heat sink extends through the rear of the cabinet As an option the drive can be mounted inside the cabinet and cooling air can be ducted out any side of the enclosure Programming and Diagnostics An integral 2 line by 16 character display and 4 button keypad is used for all
57. 131 around drive control structure Heat Sink Ambient 0 to 40 C 32 to 104 F at cooling air inlet to heat sinks Allowable Humidity 5 to 95 non condensing Allowable Vibration Not to exceed 0 5 g during normal operation Installation Altitude Up to 1 000 m 3 300 ft derate 3 for each additional 300 m 1 000 ft altitude Consult Allen Bradley for installations above 3 000 m 10 000 ft In order to maintain proper cooling the drive must be mounted in a vertical position The recommended clearances for all drive ratings are 150 mm 6 inches on the top and 75 mm 3 inches on the bottom position to assure proper cooling airflow Failure to observe this ATTENTION The drive must be mounted in the vertical mounting practice could result in overheating of the drive Two methods of mounting the 8510 in an enclosure are available Enclosure Wall Method the drive chassis is located inside the enclosure with the heat sink extended through the back wall of the enclosure 2 Panel Method the drive chassis and heat sink are inside the enclosure This method requires the optional panel mount brackets Selection of the mounting method is the responsibility of the user and is dependent on the application Mounting guidelines and instructions are provided for both methods 5 43 Chapter 5 Drive Installation ATTENTION The installation of the drive must be planned such that all cutting drilling tapp
58. 14 Black 1 1 1 Bl Pair Shield 8 Shield 1 3 2 Al Stator S2 1 White 2 2 Cut Cut Stator 54 15 15 Black 2 5 3 B2 Pair Shield 9 9 Shield 2 7 4 2 Rotor R1 Green 3 x x Rotor R2 17 17 Black 3 9 5 B3 Pair Shield 11 11 Shield 3 11 6 A3 Thermal Switch 3 3 Blue 4 10 Cut Cut Thermal Switch 20 20 Black 4 15 9 B5 Overall Shield 13 13 Braid Shield 16 10 5 for 1327AB Series A Motor See Figure 8 8 for typical resolver interconnect wiring Figure 8 8 Resolver Wiring ON m c MATE N LOK Pin Orientation fai CN3 4 53 CN 8 FG CN3 1 CN3 15 AX CN3 9 1 Resolver CN3 2 44 B1 CN3 17 decere to dul Re 3 11 0 LL y CN3 20 151 4G gorse CN3 13 1 16 T2 1 Indicator FG4 1 3 2 4 FG2 R1 R2 FG3 oL ISO SG Note See end of connector for A B labels numbers are labeled on side Dynamic Connector Pin Orientation for 1327AB Series B Motor 1327AC Series A Motor 1327AD Series A amp B Motor Resolver Important Pin designations for 1326AD Series A Motors are shown in parenthesis 8 87 Chapter 8 Wiring Orient Feedback Wiring In most systems the spindle orient function can be performed in either the CNC or the spindle drive If the position control for spindle
59. 214 407 204 51 178 126 376 214 235 425 215 180 h7 0 000 0 040 5 18 15 1327AB AFM 06 F A 214 447 204 51 178 126 416 214 275 465 215 180 h7 0 000 0 040 5 18 15 1327AB AFL 08 F A 270 418 250 51 202 150 383 214 243 433 265 230 h7 0 000 0 046 5 20 15 1327AB AFL 11 F A 270 458 250 51 202 150 423 214 283 473 265 230 h7 0 000 0 046 5 20 15 1327AB AFL 15 F A 250 508 250 51 207 152 496 5 241 331 551 265 230 h7 0 000 0 046 5 20 15 1327AB AFL 19 F A 250 560 250 63 207 152 546 5 241 381 601 265 230 h7 0 000 0 046 5 20 15 1327AB AFL 22 F A 250 600 250 63 207 152 586 5 241 421 641 265 230 h7 0 000 0 046 5 20 15 1327AD ABL 04 F 250 453 250 49 183 131 398 320 265 441 265 230 h7 0 000 0 046 5 18 15 1327AD ABL 06 F A 250 491 250 49 183 131 436 320 303 479 265 230 h7 0 000 0 046 5 18 15 1327AD ACL 08 F A 250 539 250 49 183 131 484 320 351 527 265 230 h7 0 000 0 046 5 18 15 1327AD AAK 11 F 330 687 310 61 212 158 667 330 491 722 350 300 h7 0 000 0 052 5 20 19 1327AD AAK 15 F 384 666 380 61 280 216 628 385 430 687 400 350 h7 0 000 0 057 5 22 24 1327AD AAK 19 F 384 716 380 61 280 216 678 385 480 737 400 350 h7 0 000 0 057 5 22 24 Shaft and Key Catalog Number Series U AH ES R S Key W Key H XA XB 1327AB AFM 02 F A 28 j6 0 009 0 004 60 1327AB AFM 04 F A 28 h6 0 000 0 013 60 49 24 0 0 0 2 8 P9 0 015 0 051 8 h9 0 0 0 036 7 h11 0 0 0 09 16 2 M6 x 10 deep 1327AB AFM 06 F A 32 h6
60. 278 210 108 59 1327AD ABL 08 E B 250 569 160 49 183 131 513 5 320 380 5 556 5 290 127 16 15 55 375 305 108 59 1327AD AAK 11 E B 310 643 180 61 212 158 623 330 447 678 320 139 5 16 19 55 390 254 121 50 1327AD AAK 15 E B 380 6615 225 61 280 216 623 5 385 425 5 682 5 420 178 21 24 75 425 311 149 73 1327AD AAK 19 E B 380 7115 225 61 280 216 673 5 385 475 5 732 5 420 178 21 24 75 465 349 149 73 Shaft and Key Catalog Number Series U NW ES R s Key W Key H 1327AC AFM 04 E A 28 h6 0 000 0 013 60 49 24 0 0 0 2 8 P9 0 015 0 051 8 h9 0 0 0 036 7 h11 0 0 0 09 1327AC AFM 06 E A 32 h6 0 000 0 016 80 70 27 0 0 0 2 10 P9 0 015 0 051 10 h9 0 0 0 036 8 h11 0 0 0 09 1327AC AFL 08 E A 48 h6 0 000 0 016 110 97 42 5 0 0 0 2 14 P9 0 018 0 061 14 h9 0 0 0 043 9 h11 0 0 0 09 1327AC AFL 11 E A 48 h6 0 000 0 016 110 97 42 5 0 0 0 2 14 P9 0 018 0 061 14 h9 0 0 0 043 9 h11 0 0 0 09 1327AB AFL 15 E B 48 h6 0 000 0 016 110 97 42 5 0 0 0 2 14 P9 0 018 0 061 14 h9 40 0 0 043 9 h11 0 0 0 09 1327AB AFL 19 E B 55 m6 0 030 0 011 110 98 49 0 0 0 2 16 P9 0 018 0 061 16 h9 0 0 0 043 10 h11 0 0 0 09 1327AB AFL 22 E B 55 m6 0 030 0 011 110 98 49 0 0 0 2 16 P9 0 018 0 061 16 h9 0 0 0 043 10 h11 0 0 0 09 1327AD ABL 04 E B 48 h6 0 000 0 016 110 90 42 5 0 0 0 2 14 P9 0 018 0 061 14 h9 40 0 0 043 9 h11 0 0 0 09 1327AD ABL 06 E B 48 h6 0 000 0 016 110 90
61. 27AD ACL 08 only available as flange mount and 1327AD ABL 08 only available as foot mount N Chapter 2 Specifications Dual Winding Type 1327AD Motor amp 8510 Drive Motor 1327AD ABL 04 ABL 06 ACL 08 ABL 08 Output Power Rating 51 Continuous KW 3 7 5 5 5 7 5 7 5 10 7 5 10 52 30 Minute kW HP 5 5 7 5 7 5 10 11 15 11 15 56 60 Duty kW HP 4 5 6 6 7 9 9 12 9 12 1 Minute Peak kW HP 6 7 9 9 12 13 5 18 13 5 18 Rated Speed Base RPM 500 500 600 500 Maximum RPM 6000 6000 6000 6000 Constant Power Speed Range 12 1 12 1 10 1 12 1 Rated Torque Continuous N m lb ft 71 52 105 77 119 88 142 105 Rated Current 30 Minute Output Amperes 34 45 68 68 Rotor Inertia kg m Ib in s2 0 0725 0 6416 0 1000 0 885 0 1200 1 062 0 1380 1 221 Bearing Load Max Radial kg Ib 310 682 Motor Weight kg Ibs Electrical Design Vibration Audible Noise Feedback Device Rated Ambient Temperature Possible Mounting Methods Drive Model Number 8510A 120 264 Reconfigurable winding for two speed ranges Less than 5 microns 0 0002 inches Less than 75dB A Scale 8 pole brushless resolver 65 536 counts revolution 0 to 40 C 432 to 104 Horizontal or vertical Foot or flange mounting available A04 A06 All All AC Input Voltage 200 to 220V AC 10 at 50 60 Hz 1 Hz and 230V AC 410 at 60 Hz 1 Required AC Input 30 Minute Rating kVA HZ 12 17 17
62. 402 404 COM Digital 1 0 Module 1 2 8500 E154 Ds ccu ee ME rc ELLE CN9 36 CN9 28 CN9 29 At Speed Indicator CN9 30 CN9 31 CN9 32 CN9 33 CN9 34 CN9 35 Module C s CN9 37 8500 ASM3 User Supplied Speed Meter AN CN9 38 CN9 39 CN9 40 CN9 41 CN9 42 CN9 43 CN9 44 CN9 45 CN9 46 CN9 47 Speed Level Indicator Load Level Indicator In Position Analog Input 1 Analog Input 1 Return Shield Analog Input 2 Analog Input 2 Return Shield Analog Output 1 Analog Output 1 Return Shield Analog Output 2 Analog Output 2 Return Shield jo uuooJ1 lu 0 6 esd AT L 8 2 Chapter 8 Wiring Resolver Feedback Wiring The motor resolver feedback signals and the motor thermal switch are connected to the drive through the 20 pin CN3 connector This interface is required for all 8510 systems Refer to Figure 7 3 for the location of this connector on the drive The feedback cable can be routed through the same conduit used for motor power leads but it is essential that a properly shielded cable is used The cable must have four twisted shielded pairs with an overall shield The recommended cable type is Belden 8164 4 twisted shielded pairs 24 AWG The cable is terminated
63. 7 102 110 PWM inverter using IGBT power devices Power regeneration to the AC line 10V DC 0 10V DC with Fwd Rev input 16 bit binary or BCD digital command 0 to 30 000 rpm velocity resolution greater than 1 2 000 000 Transient change lt 0 4 of max speed steady state change 0 025 load 10 100 Up to 50 Hz load and motor dependent Integral 2 line by 16 character backlit LCD display and 4 button keypad Open style IP 00 for mounting in another enclosure heat sinks extend outside enclosure 26 57 52 114 52 114 Less than 0 5 G 0 to 55 C 32 to 131 F inside enclosure 0 to 40 C 32 to 104 F at heat sinks 0 to 65 C 32 to 149 F 30 minutes starting with cold motor Loaded for 60 of a 10 minute cycle 15 minute rating for 1327AB AFM 02 motor Rw N 1327AB AFM 02 and 1327AD ACL 08 only available as flange mount and 1327AD ABL 08 only available as foot mount Motor Curves Typical speed torque curves for the 1327 AC Motors are shown on the following pages Output Power kW Output Power kW Output Power kW Figure 2 1 Motor Curves 1327AC AFM 02 F 8510A A04 x1 ua Peak Torque 4 30 Minute Power 3 Continuous Power 2 1 Continuous Torque 0 0 1 2 3 4 5 6 7 Motor rpm x 1000 1327 06 8510A A06 x1 12 10 Peak Torque 8 30 Minute Power 1 3 6 Continuous Power 2 Continuous Torque 0 1 2 3 4 5 6 7 Motor rpm x 1000 1327AC AFL 11 x 8510A
64. A11 x2 24 20 Peak Torque 16 30 Minute Power 12 Continuous Power 8 4 Continuous Torque 0 0 1 2 3 4 5 Motor rpm x 1000 30 25 20 60 50 40 30 20 120 100 80 60 40 20 Output Torque N m Output Torque N m Output Torque N m Output Power kW Output Power kW Output Power kW Chapter 2 Specifications 1327AC AFM 04 x 8510A A04 x1 10 8 lt Peak Torque 6 30 Minute Power 4 Continuous Power 2 Continuous Torque gt 0 0 1 2 3 4 5 6 7 Motor rpm x 1000 1327AC AFL 08 x 8510A A11 x2 18 15 lt Peak Torque 12 30 Minute Power Continuous Power 6 3 Continuous Torque 0 0 1 2 3 4 5 Motor rpm x 1000 1327AB AFL 15 x 8510A A22 x2 40 Peak Torque 30 20 30 Minute Power Continuous Power 10 o Continuous Torque 0 0 1 2 3 4 5 Motor rpm x 1000 50 40 30 2 g 5 20 2 5 10 0 90 75 60 z o 4 amp z 30 5 15 0 160 120 o 5 g 5 E 5 a 5 4 0 2 13 Chapter 2 Specifications Figure 2 1 continued Motor Curves 1327AB AFL 19 x 1327AB AFL 22 x 8510A A22 x2 8510A A22 x2 50 200 60 240 50 Peak Torque 200 n __ Peak Torque 160 T 40 160 PES 120 e 5 30 Minute Power 30 5 e 30 a 120 5 a x Continuous Power 220 8 5 d eee Continuous Power 8 2 80 10 Continuous Torque 7 40 10 Continuous Torque d
65. Description Standard I O for normal spindle use Option A plus 16 bit digital input for digital speed command or orient position command Option A plus high linearity A D converter for continuous path contouring C axis Options B and C B 15 E Sixth Posi tion Board Size No Description for A04 amp A06 drives 2 for All amp larger drives First Position Second Posi Third Position Fourth Position tion Bulletin Maximum AC Approx Continu Number Series Input Voltage ous Power Output Let Descrip Letter Voltage No Description 200 220 04 Upto3 7 Series AC 10 kW 5 hp A De 50 60 Hz and 06 Upto 5 5 sign 230V AC kW 7 5 input RESO cag Up to 11 22 kW 15 hp Up to 22 kW 30 hp 1327 Motor First amp Second Position Third Posi Fourth amp Fifth tion Position Bulletin Motor Rated Base Max Number Type Voltage Speed Speed Let Type Let Volts Te Standard 200 230 B A VAC Standard Input C Dual D Winding Type Letter rpm Letter lt 425 K 426 550 L 551 725 D 726 950 951 1200 1201 1500 Sixth Posi Seventh Posi tion tion Approx Continu Mounting ous Power Output Type Cod kW hp Let Description M 2 2 3 JIS Metric 02 3 7 5 E Foot Mount 04 5 5 JIS Metric Flange 06 T 5 7 9 Mount 08 7 5 10 11 11 15 15 15 20 19 18 5 22 25 22 30 4001 5000 5001
66. Display Type Menu ose rer re UAI SERAIS 10 5 Chapter 11 Chapter Objectives issus cuo RERO XR ID acess 11 1 Introduction 2 5 cecus e ry a e DENS red 11 1 Circuit Board Descriptions 11 2 Power Distribution and 1 11 4 Fuse Locations and Types 11 6 Fault Diagnostics System 11 7 Board Faults 11 21 IGBT Test Procedure usa De RR INSERIRE 11 25 Appendix A Chapter Objectives Manual Objectives Chapter Introduction Chapter 1 provides information on the general intent of this manual gives an overall description of the 8510 AC Spindle Drive System and provides a detailed description of the key features of this drive This information will help the reader to understand both the basic capabilities and the advanced features of the 8510 drive system and recognize opportunities to use these features to improve machine performance This publication provides planning installation wiring and diagnostic information for the 8510 AC Spindle Drive System To assure successful installation and operation the material presented must be thoroughly read and understood before proceeding Particular attention must be directed to the Attention and Important statements contained within Important Information about this Manual This manual has been prepared
67. EC for proper wire sizing for higher temperature wire The 8510 does not include incoming AC line overcurrent protection Either current limiting fuses or a high speed circuit breaker must be installed between the drive and the AC power source Optional fuse kits that include properly sized high speed current limiting fuses and the appropriate fuse block are available The components supplied in the fuse kits are defined in Table 8 E Table 8 E Recommended AC Line Fuses Fuse Kit for use Fuse Type Qty 3 Fuse Holder Catalog with Drive Gould Gould Number Model Bussmann Shawmut Bussmann Shawmut 8510SA FA04 8510A A04 x JKS40 A4J40 J60060 3C 606087 85105 06 1 JKS60 A4J60 R 606087 85105 11 8510 06 JKS100 A4J100 J60060 3C 610087 85105 22 1 JKS175 A4J175 R 620037 8510 11 J60100 3C Ka 8510A A22 x J60200 1C The recommended AC input power connection is showa Figure 8 2 If an autotransformer or isolation transformer is used follow the connection diagram supplied with the transformer to determine proper wiring to the drive 8 79 Chapter 8 Wiring Figure 8 2 Recommended AC Input Power Connection QD ALLEN BRADLEY DIGITAL AC SPINDLE DRIVE Optional Isolation Transformer or Autotransformer NEN 851084 Fuse Kit Drive Compone
68. Figure 7 1 Suggested Regenerative Emergency Stop Interface Time Delayed Relay Contacts Coast Coast to Stop IHHHILEEE os User Emergency Stop Control Drive Enable Drive Enable ows User Interlocks 24V DC User Supplied Time Delayed Dropout Relay 0V DC CN9 4 8 12 or 17 Drive Reset CN9 3 When On any fault conditions that are present will be reset and the drive will begin the initial power up sequence If the fault condition still exists the drive will immediately return to the fault shutdown condition If a fault occurred while the motor was running it is possible to reset and then restart the drive while the motor is still coasting The drive will regain control of the motor and either stop it or return it to the commanded operating speed depending on the input signals applied Important Approximately 2 3 seconds after a fault occurs the fault message is written to the fault history in EEPROM If the Drive Reset is turned On while the fault message is being written to EEPROM or while parameter value changes are being written to EEPROM the reset command will be ignored After the writing to EEPROM is complete the Drive Reset input must be replied to reset the drive To avoid this do not apply the Drive Reset input until at least 5 seconds after a fault has occurred Digital Ground CN9 4 8 12 17 These terminals serve as grounding points for the digital inputs Forward Run and Reverse
69. M 06 F A 204 448 204 51 176 124 416 212 276 466 215 180 h7 0 000 0 040 5 18 14 5 1327AC AFL 08 F A 250 410 250 51 199 147 384 212 244 434 265 230 h7 40 000 0 046 5 20 14 5 1327AC AFL 11 F 250 450 250 51 199 147 424 212 284 474 265 230 h7 40 000 0 046 5 20 14 5 1327AB AFL 15 F B 250 500 250 51 206 151 493 5 242 328 548 265 230 h7 40 000 0 046 5 20 14 5 1327AB AFL 19 F B 250 550 250 63 206 151 543 5 242 378 598 265 230 h7 40 000 0 046 5 20 14 5 1327AB AFL 22 F B 250 590 250 63 206 151 583 5 242 418 638 265 230 h7 40 000 0 046 5 20 14 5 1327AD ABL 04 F 250 453 250 49 183 131 398 320 265 441 265 230 h7 40 000 0 046 5 18 15 1327AD ABL 06 F 250 491 250 49 183 131 436 320 303 479 265 230 h7 40 000 0 046 5 18 15 1327AD ACL 08 F 250 539 250 49 183 131 484 320 351 527 265 230 h7 40 000 0 046 5 18 15 1327AD AAK 11 F 330 687 310 61 212 158 667 330 491 722 350 300 h7 40 000 0 052 5 20 19 1327AD AAK 15 F 384 666 380 61 280 216 628 385 430 687 400 350 h7 40 000 0 057 5 22 24 1327AD AAK 19 F 384 716 380 61 280 216 678 385 480 737 400 350 h7 40 000 0 057 5 22 24 Shaft and Key Catalog Number Series U AH ES R S Key W Key H 1327AC AFM 02 F A 28 j6 40 009 0 004 60 1327AC AFM 04 F A 28 h6 0 000 0 013 60 49 24 0 0 0 2 8 P9 0 015 0 051 8 h9 0 0 0 036 7 h11 0 0 0 09 16 2 M6 x 10 deep 1327AC AFM 06 F A 32 h6 0 000 0 016 80 75 27 0 0 0 2 10 P9 0 015 0 051 10 h9 0 0
70. Optional CN2 MR 20LF Dual Winding Motor Control Optional CNI MR 20LF Three termination options are available for each of the connectors 1 A mating connector kit that requires the user to supply the cable and terminate directly to the Honda connector This is a solder type connector A crimp connector the MRP series is available from the manufacturer 2 A termination panel that provides a prefabricated 1 5 m 5 ft cable from the drive connector to a DIN rail mounted terminal block interface module User wiring is to the terminal block 3 A cable assembly in varying lengths with the Honda connector wired to one end The other end is loose cable leads for user termination as required 8 75 Chapter 8 Wiring Figure 8 1 Connector Wiring Short Screw amp Nut Cable Clamp Connector Housing Long Screw Washer Cli Connector Honda Connector Wiring and Assembly Refer to the following information and the instruction sheet provided with the connector kit for assembly procedure 1 Disassemble the connector by removing the 2 short screws and nuts see Figure 8 1 Since the connector contains a number of small pieces care should be taken during disassembly 2 Prepare cable and wire ends Using a rosin core solder carefully solder wires to connector using the ca
71. Return 43 44 Black 3 Shield 44 45 Drain 3 Analog Output 2 45 46 Blue 4 Analog Output 2 Return 46 47 Black 4 shiii Aa Shields should be terminated only at the signal source end 68 8 9 Series CNC Sub Processor Board E Stop Terminal Block BT101 Digital 1 0 Module 1 2 8500 E154 12 A13 A14 A15 1 User s E Stop Status Relay K1 CN9 1 i CN9 2 CN9 3 CN9 4 CN9 5 CN9 6 CN9 7 CN9 8 User Supplied Power Source Common 24V DC Control CN9 9 CN9 10 CN9 12 CN9 13 CN9 14 CN9 15 CN9 16 Typical E Stop String CN9 17 CN9 18 CN9 19 CN9 20 CN9 21 8510 Drive Coast to Stop Drive Enable 1 0 B oard Drive Reset Digital Ground Forward Run Reverse Run Low Torque Limit Select Digital Ground Accel Decel Rate Select Spindle Servo Mode Select Servo Input Scaling Low High Digital Ground Orient Command Gear Ratio Active 1 Gear Ratio Active 2 Motor Winding Select Low High Digital Ground Current Motor Winding Selected gt Drive Ready CN9 22 CN9 23 Hard Fault Analog Servo E Stop Status Relay CN9 24 CN9 25 Soft Fault User Supplied CN9 26 CN9 27 Zero Speed Indicator ele e e e
72. Run CN9 5 6 Turning either the Forward or Reverse Run inputs On will cause the motor to run at the speed commanded by the appropriate analog or digital speed command input The relationship between the direction of rotation and the Forward Run and Reverse Run digital commands and the analog velocity input command are shown below Direction of rotation is determined when viewing the motor output shaft end Velocity Command input voltage Volts Volts Forward Run Command On Counterclockwise Clockwise Reverse Run Command On Clockwise Counterclockwise 7 59 Chapter 7 Interface Signal Descriptions When a digital speed command or a unipolar 0 10V DC analog speed command is used these two inputs will reverse the direction of motor rotation When this input is turned Off the motor will be regeneratively braked to zero speed Whether or not zero speed holding torque will be available will depend on the setting of the programmable parameter Enable Torque Figure 7 2 shows the relative timing required for the Coast to Stop Drive Enable and Forward or Reverse Run inputs to assure proper drive operation Figure 7 2 Timing Coast to Stop Input Must be greater than or equal to 0 ms Drive Enable Input Must be greater than or equal to 0 ms Forward Run Input K lt About 6 seconds Drive Ready Output 7 Not Runni TESTER Motor Operation PUN UE Running if either Run command is O
73. This parameter indicates the status of all outputs For ease in identifying each output successive letters of the alphabet are used to show when they are On When an output is Off a dash will be displayed Refer to Table 10 B for the output associated with each letter Data Format line 1 I O Outputs Data Format line 2 I O ABCDEFGHI Table 10 B Outputs Display Letter Output Signal Name Zero Speed At Speed Speed Level Indicator Load Level Indicator No Hard Fault No Soft Fault Drive Ready In Position High Motor Winding Selected o m mo m gt Current Fault Indicates the current fault diagnostic message The message uses 13 characters on line 2 of the display Fault History Indicates a fault diagnostic message from the fault history queue The 8 most recent messages are retained with 1 being the newest message The message can use the last six characters on line 1 and 13 characters on line 2 of the display The Scroll and Scroll keys are used to scroll through the message queue 10 109 Chapter 10 Display Panel amp Fault Diagnostics End of Chapter 10 110 Chapter Objectives Introduction Chapter Diagnostics Troubleshooting The purpose of this chapter is to assist you in determining the cause of a drive fault or improper drive operation and to define possible corrective actions Possible corrective actions include n Correcting programming or wiring errors n Replaci
74. ain proper signals or replace the sensor head If problems were not found with other tests replace Main Control Board CPU Board on A04 A06 drives 11 129 Chapter 11 Troubleshooting No 27 28 Problem Bad PG Count displayed An incorrect number of spindle position feedback counts was detected between two successive markers pulses as deter mined by the programmed number of lines on the feedback device Bad PG Output displayed The electrical signals from the high resolution magnetic feedback device are abnormal 11 130 Table 11 G Continued Problems that Occur during Spindle Orient Operation Probable Cause The number of encoder lines has been incorrectly programmed Feedback device is incorrectly phased Feedback device not correctly connected to the drive The ORIENT TUNE Orient Start parameter value is much too low relative to the value of ORIENT TUNE Orient Speed parameter Malfunctioning feedback device Malfunctioning printed circuit board Wrong type of feedback device has been specified The gear or sensor are not correctly installed Interconnecting cable or sensor are defective Malfunctioning printed circuit board Possible Solutions Use the ORIENT SETUP FEEDBACK DEFN Encoder Lines parameter to set the correct encoder line count or number of teeth on the high resolution feedback gear Use the ORIENT SETUP FEEDBACK DEFN Encdr Phasing par
75. al velocity posi AMP Mate N Lok type tion input on drive only AD AMP Mate N Lok connector used on 1327AB series motors for resolver feedback AMP Mate N Lok connector used on 1327AD series motors for resolver feedback 4 40 Chapter 4 Receiving Unpacking and Inspection AC Line Fuse Kits 8510SA 04 First Position Second Posi Third Position tion Bulletin Fuse amp Number Fuse Block Fuse Ratings Code Description 04 Fuses amp fuse blocks for A04 drive 06 Fuses amp fuse blocks for A06 drive Fuses amp fuse blocks for A11 drive A22 Fuses amp fuse blocks for A22 drive Drive Mounting Adapters 85105 M First Position Second Posi Third Position tion Bulletin Mounting Adapter Number Adapter Components Code Description 04 Brackets to panel mount the A04 drive inside an enclosure Brackets to panel mount the A06 drive inside an P22 enclosure Brackets to panel mount the 11 drive inside an enclosure V06 Brackets to panel mount the A22 drive inside an enclosure Vil Panel mounting brackets plus adapter to allow ducting cooling air from side of enclosure to an A04 drive 22 Panel mounting brackets plus adapter to allow ducting cooling air from side of enclosure to an 06 drive Panel mounting brackets plus adapter to allow ducting cooling air from side of enclosure to an All drive Panel mounting brackets plus adapter to allow ducting coolin
76. ameter Load requires a torque that exceeds motor torque limit setting Motor phase is open When using 1327AD series dual winding motors Malfunctioning winding change contactor Resolver or resolver wiring is malfunctioning Malfunctioning Power Unit Malfunctioning printed circuit boards Possible Solutions Use the parameter PARAMETER SET ELECT CONFIG Motor Phasing to reverse the relative phasing of the motor to the resolver Check Catalog Num setting to verify that it matches the motor nameplate Incorrect parameter setting can cause torque loss 1 Change duty cycle to reduce required motor torque 2 Turn Low Torque Limit Select input Off or increase setting of Low Torq Lmt parameter to allow sufficient torque to drive the load Increase rating of motor drive system if necessary to drive the load Check all power wiring to the motor for continuity and tight connections Use an ohmmeter to verify phase to phase continuity for each motor phase Check the contactors to assure they are making proper connections at all times Replace contactors if necessary Refer to fault condition 6 for solutions If problems were not found with other tests replace Power Unit If problems were not found with other tests replace Main Control Board gate drive and CPU Boards on A04 A06 drives 23 Mtr Windg Chg displayed The auxiliary contacts on the winding change contactors did not cycle as expected during the windi
77. ameter Malfunctioning printed circuit board When drive cools the thermal switch will close and the fault will clear Reduce duty cycle loading or increase size of motor drive system Check fuses FU2R and FU2S Verify that fan power cable is plugged into the Power Board The A11 uses connector XB10 in top left corner of Power Board The A22 uses connector XB9 in the upper right corner and XB10 in the lower right corner of the Power Board If fuses OK and fans inserted then cooling fan malfunctioning Replace Power Unit Thoroughly clean the heat sink using pressurized air Assure that there is sufficient clearance above and below heat sink to allow adequate air flow Check Catalog Num setting to verify that it matches the motor nameplate Incorrect parameter setting can cause current oscillation that exceeds drive rating If problems were not found with other tests replace Main Control Board Gate Drive Board and possibly CPU Board on A04 A06 drive 11 127 Chapter 11 Troubleshooting No Problem 22 Spd Error Hi displayed A motor stall condi tion or an unex pected motor acceleration or deceleration was detected Table 11 F Continued Problems that Occur while the Drive is Operating Probable Cause If during startup the motor runs at a constant low speed or reverses direction frequently the motor versus resolver phasing is incorrect Incorrect motor selected in MOTOR SELECT Catalog Num par
78. ameter to reverse the phasing of the orient feedback device 1 Verify that connector CN2 is connected to the drive 2 Verify the wiring of the connector at the drive and at the feedback device Either increase the value of ORIENT TUNE Orient Start or decrease the value of ORIENT TUNE Orient Speed 1 If an optical encoder is used verify that the A B and Z channel outputs are present and have proper amplitude phase relationships and that the signals are relatively free of electrical noise 2 If the high resolution magnetic feedback is used follow the procedure shown in Figure 11 4 to verify the output signals Adjust the mounting of the gear and the position of the sensor relative to the gear to obtain proper signals or replace the sensor head If problems were not found with other tests replace Main Control Board CPU Board on A04 A06 drives If an optical encoder is being used the ORIENT SETUP FEEDBACK DEFN Encoder Type parameter must be set to OPTICAL PULSE When this parameter is changed and then stored in EEPROM AC power must be removed from the drive and then reapplied to reset this parameter value in the drive control software The gear and sensor must be installed in accordance with the mechanical tolerance specifications in the High Resolution Magnetic Feedback Instructions 8510 5 13 At test point A on the Main Control Board CPU Board of A04 A06 drive the amplitude modulation of the signal shoul
79. ance of the drive Remove the top half of the protective foam shell from the drive Using the mounting flanges near the bottom of the drive lift the drive from the bottom half of the protective shell Remove the plastic bag that encloses the drive The drive is now ready for installation Important Before the installation and start up of the system a general inspection of mechanical integrity i e loose parts wires connections packing materials etc must be made After unpacking check the item s nameplate catalog number against the purchase order An explanation of the catalog numbering system is included on the following pages as an aid for nameplate interpretation The drive nameplate is located on the back side of the cover Refer to Chapter 5 for drive cover removal information The drive should remain in its shipping container prior to installation If the equipment is not to be used for a period of time it must be stored according to the following instructions Store a clean dry location Store within an ambient temperature range of 0 to 65 32 to 149 F Store within a relative humidity range of 5 to 95 non condensing Do not store equipment where it could be exposed to a corrosive atmosphere Do not store equipment in a construction area Chapter 4 Receiving Unpacking and Inspection 8510 A A 8510 Drive 04 A Fifth Posi tion Board Version Let er A
80. ange 1H h Under GEAR RANGES Copy Data select RANGE 1 or RANGE IL if the dual winding motor is being used as the source to copy data from 1 If the configuration or parameter presetting of this gear range is to be different from the parameters set in step e adjust the parameters for this gear range Repeat steps f g and h for each gear range data set that will be used in this application For dual winding motors both the and H data sets must be programmed for each gear range data set j k Up to now all parameter changes have been held in RAM To permanently store the changes in EEPROM it is necessary to exit the DRIVE SETUP mode Simultaneously press the Mode and Scroll keys twice This will cause the display to change to DISPLAY TYPE METER DISPLAY and all parameter changes will be written to EEPROM When the data is being written to EEPROM the symbol will be momentarily shown at character 3 of line 2 on the display Once the motor and drive are defined for each gear range data set the drive is ready to run at a performance level determined by the initial settings The default parameter values will provide a relatively low level of performance Chapter 9 Start Up ATTENTION In the following steps the motor will begin to o 9 o 10 11 rotate It is possible that the motor will rotate at an uncontrolled rate or cause incorrect machine movem
81. ar that must be mounted directly to the spindle shaft and a sensor that picks up signals as each gear tooth passes The ring gears are available with between 225 and 500 teeth pitch diameters of 90 mm to 200 mm 3 5 to 7 9 in Within the 8510 drive each tooth is resolved into 1000 parts giving resolutions of 225 000 to 500 000 parts per revolution With the 500 tooth gear absolute accuracy of 0 015 degrees can be achieved with precision mounting of the gear to the spindle Orient is to a single preset orient position or with the optional 16 bit digital command input an external 4 digit BCD or 16 bit binary orient position command can be given After reaching orient position the drive can be programmed to hold the spindle in that position or to remove motor torque and allow free movement of the spindle Chapter 1 Introduction Control Of Dual Winding Motors A 12 1 constant power range can be obtained by using dual winding motors AC motors are usually wired internally into either a A or a Y winding configuration With the dual winding motors a pair of externally mounted contactors are used to reconfigure the motor windings between A or Y connections while the motor is running This winding reconfiguration shifts the base speed operating point of the motor and effectively extends the overall constant power operating range These externally mounted contactors are directly controlled by the 8510 drive A single digital input to the 851
82. back CN1 17 amp 10 Low speed contactor auxiliary switch input to indicate that the low speed contactor has closed 7 69 Chapter 7 Interface Signal Descriptions Digital Command Signals Serial Port When the drive is supplied with I O option B or D Catalog number 8510A Axx Bx or 8510A Axx Dx connector CN10 will be present to accept 16 bit digital input signals for spindle speed or orient position commands Refer to Figure 7 3 for connector location Refer to Chapter 8 for specific wiring instructions for the connector Digital Command Inputs 1 4 CN10 1 2 3 amp 4 Inputs used for bits 0 through 3 when binary data is supplied and 1 s digit when BCD data is supplied Digital Command Inputs 5 8 CN10 6 7 8 amp 9 Inputs used for bits 4 through 7 when binary data is supplied and 10 s digit when BCD data is supplied Digital Command Inputs 9 12 CN10 11 12 13 amp 14 Inputs used for bits 8 through 11 when binary data is supplied and 100 s digit when BCD data is supplied Digital Command Inputs 13 16 CN10 16 17 18 amp 19 Inputs used for bits 12 through 15 when binary data is supplied and 1000 s digit when BCD data is supplied Signal Grounds CN10 5 10 15 amp 20 Inputs to use as ground references for the digital command inputs Table 7 B Digital Input Command Weighting Input Number 16 15 14 13 121110 9 8 7 6 5 4 3 2 1 Binary Weight 2 15 14 13 12 1 10 9 8 7 6 5 4 3 2 1 0 BCD Weight 8 42
83. ble information provided in this chapter 3 Install cable clamp around cable s To allow positioning do not tighten clamp completely 4 Place connector into housing and slide cable clamp to position shown in Figure 8 1 Tighten cable clamp 5 Install the 2 long screws and washers through the holes in the connector Position screws and washers as shown in Figure 8 1 6 Place clips into housing and secure remaining housing piece over assembly using the 2 short screws and nuts previously removed The maximum wire size that the terminals in the Honda connector can accept is 24 AWG 0 28 mm For each connector the cable type recommended in this chapter or an equivalent must be used to assure proper system operation If larger wire sizes are preferred the optional Termination Panels will allow use of up to 16 AWG 1 mm wire If larger cable sizes are used the cable configuration and shielding must conform to that specified for the standard cable All shields must be terminated in accordance with the following wiring diagrams If one end of a shield is to be left open take care to insulate and properly isolate the open end of shield to avoid shorting it to ground Chapter 8 Wiring Motor and Drive Power Wiring In accordance with NEC the power wiring size should be based on the 30 minute overload rating of the applicable motor The user must determine if national or local codes specify other requirements All power wir
84. ctor is blocked from closing Table 11 E Problems that Occur when Drive Enable is Applied or during operation Probable Cause Improper command sequence has been applied Contactor coil circuit not completed via the Coast to Stop input Loose connections on contactor Malfunctioning pilot relay on I O Board Malfunctioning pilot relay on Power Board or malfunctioning contactor AC line voltage out of tolerance Malfunctioning drive interconnections Malfunctioning IGBT module in converter bridge Malfunctioning bus precharge KM1 or bus discharge KM3 relay Malfunctioning printed circuit board Possible Solutions Assure that the Coast to Stop input is energized before any other input command is applied Assure that Drive Enable is energized before either run command or the orient command Refer to Figure 7 2 for proper sequence Assure that the jumper cable is connected between connector J3 in the lower left corner of the I O Board and the EM1 EM2 terminal block on the upper left of the power circuit board Remove control boards and tighten all connections to main contactor Remove power Remove the jumper cable from connector J3 on the Board Use a small piece of insulated wire to short between the terminals of the plug on the jumper cable Important 230V AC is present on this plug when AC power is applied If the contactor will now close when power is turned On and the Drive Enable is a
85. d I Gain tuning First set Spindl I Gain equal to zero Observe test point TP1 during an accel decel cycle to a low speed Increase Spindl P Gain until the desired response rate is achieved but allow no more than one overshoot of the commanded speed Then increase the Spindl I Gain until the desired level of low frequency and static stiffness is achieved Proper adjustment of the P Gain and I gain should provide a step response with a relatively sharp corner and minimal overshoot of commanded speed If the system overshoots with a high frequency ringing the Spindl P Gain is too high A low frequency ringing indicates excess Spindl I Gain b Observe the TP2 test point during an accel decel cycle As the actual speed approaches commanded speed the torque should drop from maximum to a low running torque with only a small overshoot The overshoot should settle without ringing Raise the Spindl P Gain and lower the Spindl I Gain to reduce the ringing While running at maximum speed the peak to peak torque ripple should be less than 2V DC Lower both the Spindl P Gain and Spindl I Gain to reduce the torque ripple o 15 If the 8510 must operate in servo mode apply 24V DC to the Spindle Servo Mode Select input to activate servo mode Servo mode can be configured to operate over two different input selectable maximum operating speed ranges Apply 24V DC to the Servo Input Scaling input to select the high operating speed range and then repeat steps 12
86. d be less then 0 1 volts when the gear is properly installed The magnitude of the signal can be changed by changing the gear to sensor airgap 1 Verify that proper signals are received from the sensor See Figure 11 4 for correct waveforms 2 If not correct check cables and connectors for continuity and proper connections 3 If cables and connections are OK replace sensor If problems were not found with other tests replace Main Control Board CPU Board on A04 A06 drives No 29 30 31 Problem Main RAM Err displayed A parity or functional error was detected in RAM on the Main Control Board CPU Board on A04 A06 drive Comm Err displayed No communications occurring between microprocessor on Main Control Board CPU Board on A04 A06 drive and microprocessor on Board Main CPU Loss displayed CPU on Main Control Board CPU Board on A04 A06 drive unable to complete calculations during Chapter 11 Troubleshooting Table 11 H Other Faults that Indicate Control Hardware Malfunction Probable Cause Possible Solutions RAM is malfunctioning Replace Main Control Board CPU Board on A04 A06 drive Hardware malfunction on either 1 Verify that EPROMs on both the I O Board and Main Control Board or Main Control Board Board are inserted correctly CRU Board op On 2 Verify that the I O Board connectors are fully seated into the Main Control Board or CPU Board conn
87. d to attach lifting hooks from a properly rated lifting device The lifting hooks should extend no more than 12 5 mm 0 5 in inside the drive or they may damage internal drive components ATTENTION To guard against drive damage and or personal injury when using a lifting device assure that the device is operated per manufacturers instructions flat metal resistor element attached to the back of the heat sink ATTENTION During heavy regenerative load operations the may become very hot in excess of 125 C or 257 F and could cause burns if touched Use of the heat sink cover described below and shown in Figure 5 2 would help guard against accidental touching of this resistor Chapter 5 Drive Installation Figure 5 1 Gasket Assembly Enclosure Wall Gasket 9 Nut Lockwasher 5 To protect the heat sink from an excessive build up of dirt which will reduce the heat transfer efficiency a simple sheet metal cover should be placed over the heat sink Ample air inlet and outlet slots or openings must be provided near the top and bottom of this cover to allow unrestricted flow of cooling air See Figure 5 2 for a typical cover configuration Chapter 5 Drive Installation Figure 5 2 Heat Sink Cover 150 mm 6 in Clearance N Minimum between Drive and Top of Cover Top of Cover is Solid Air Inlet amp Outlet Slots All 3 Sides 150 mm 6 in on Top 75 mm 3 in Clearance Minimum betwee
88. dex through the possible selections until the key is released When the end of the menu list is reached it will roll over to the beginning and continue to increment The function of this key is identical to the Scroll key except that it causes the display to decrement rather than increment Pressing this key will cause the sub menu or parameter shown on line 2 of the display to become the active menu or parameter This sub menu or parameter name will move to line 1 and the new menu choices or parameter value will now be displayed Key Combinations Pressing the Mode and Scroll keys will cause the display to jump to the first menu in the section Figure 10 4 provides a diagram showing the keys needed to select the various items of the DISPLAY TYPE menu 10 105 Chapter 10 Display Panel amp Fault Diagnostics Figure 10 4 Display Type Menu Tree 2L DISPLAY TYPE Scroll Scroll METER DISPLAY DIAGNOSTICS Line 2 Mode Mode Line 1 Line 1 2L METER DISPLAY 2L DIAGNOSTICS Scroll m Scroll Motor Speed Line 2 Line 2 Power Output a Mode Mode Scroll Motor Speed I O Inputs RPM 03572 J LM Q T 10 106 Display Type Menu Chapter 10 Display Panel amp Fault Diagnostics The DISPLAY TYPE menu is the top level of the menu tree This will always be the initial top line display when power is first applied to the drive and after the Reset input has
89. e 11 G Chapter 11 Troubleshooting Problems that Occur during Spindle Orient Operation Probable Cause Feedback device is incorrectly phased Wrong type of feedback device has been specified The number of encoder lines has been incorrectly programmed Malfunctioning printed circuit board Either the velocity loop or the orient position loop is not tuned correctly The accel decel ramp rate settings are too slow relative to the orient position loop settings The orient mode tuning requires a faster decel rate than the drive can provide The number of encoder lines has been incorrectly programmed Feedback device not correctly connected to the drive Malfunctioning feedback device Malfunctioning printed circuit board Possible Solutions Use the ORIENT SETUP FEEDBACK DEFN Encdr Phasing parameter to reverse the phasing of the orient feedback device The ORIENT SETUP FEEDBACK DEFN Encoder Type parameter must be set to OPTICAL PULSE when an optical encoder is used and to MAGNET ANALOG when the high resolution magnetic feedback is used Change this parameter to the correct setting and store it in EEPROM by energizing the Drive Enable input After the correct setting is stored AC power must be removed from the drive and then reapplied to reset this parameter value in the drive control software Use the ORIENT SETUP FEEDBACK DEFN Encoder Lines parameter to set the correct encode
90. e 3 18 AC Power Transformer Dimensions are in millimeters and inches if Wall Mounted 00000000000000000000000 00000000000000000000000 00000000000000000000000 00000000000000000000000 00000000000000000000000 00000000000000000000000 25 4 1 0 Catalog Number 8510T AA006 BA 8510 009 8510 012 8510 006 8510 009 8510 012 8510T IA006 BA 8510 017 8510 022 8510 026 8510 032 8510 017 8510 022 8510 026 8510 032 8510T IA009 BA 8510T IA012 BA 8510T IA017 BA 8510 040 8510 040 8510T IA022 BA 8510T IA026 BA 8510T IA032 BA 8510T IA040 BA A B 438 286 356 17 25 11 25 14 00 495 19 50 419 16 50 483 19 00 622 24 50 521 20 50 622 24 50 D 375 14 75 419 16 50 546 21 50 E 419 16 50 470 18 50 597 23 50 Chapter 3 Dimensions n B gt 63 5 2 5 12 7 0 5 Typ 50 8 2 0 gt F L 178 241 7 00 9 50 254 10 00 254 254 10 00 305 10 00 12 00 P Knockout F2 gt F 14 2 0 56 Dia 6 Places P Weight Knockout kg 1 19 amp 25 30 65 0 75 amp 1 00 39 85 50 110 45 100 52 115 60
91. e 3 7 page 3 24 8510 Drive A22 Mounting Figure 3 8 page 3 25 1327A Flange Mount Motor Figure 3 9 page 3 26 1327A Foot Mount Motor Figure 3 10 page 3 27 High Resolution Magnetic Feedback Figure 3 13 page 3 30 AC Line Fuse Kits Figure 3 15 page 3 32 Termination Panels Figure 3 16 page 3 33 Drive Panel Mounting Figure 3 17 page 3 34 AC Power Transformer Figure 3 18 page 3 35 Please note that dimensions are in millimeters unless otherwise stated Chapter 3 Dimensions Figure 3 1 8510 Drive 04 8510 DIGITAL AC SPINDLE DRIVE gt Chapter 3 Dimensions Figure 3 2 8510 Drive 04 Mounting 7 Typical 4 Required uL Chapter 3 Dimensions
92. e 5 33 1 5 33 1 5 33 1 4 1 4 1 Rated Torque Continuous N m lb ft 14 2 10 5 23 7 17 5 35 6 26 3 47 5 35 0 71 52 5 Rated Current 30 Minute Output Amperes 27 33 43 59 91 Rotor Inertia kg m Ib in s2 0 0093 0 0819 0 0213 0 1881 0 2750 0 2438 0 0550 0 4867 0 0700 0 6195 Bearing Load Max Radial kg Ib 133 292 165 364 167 368 313 688 335 737 Motor Weight kg 165 38 84 59 130 67 147 94 207 108 238 Electrical Design Vibration Single winding configuration for single speed range Peak to peak vibration less than 3 microns 0 00012 inch Audible Noise eS SD 6 a A gt n gt x 7 o sQWA eedback Device Rated Ambient Temperature T oA SS ERAS Possible Mounting Methods m Heri Drive Model Number 8510A A04 A04 A06 All All AC Input Voltage 200 to 220V AC 410 at 50 60 Hz 1 Hz and 230V AC 410 at 60 Hz 1 Required AC Input 30 MinueRa ngkVA _ 8D 1H 29 Rated Output Current 30Minute Amperes 7 43 aono Power Control Method PWM inverter using IGBT power devices Motor Braking Method Power regeneration to the AC line Input Command 10V DC 0 10V DC with Fwd Rev input 16 bit binary or BCD digital command Speed Control Range 0 to 30 000 rpm velocity resolution greater than 1 2 000 000 Speed Regulation Transient change lt 0 4 of max speed steady state change 0 025 load 10 100 Veloci
93. e Noise 55 Feedback Device Less thar 750B tr Scato Rated Ambient Temperature pole brushtess resotver 65 530 coumts revotution Possible Mounting Methods 0049 032 toT B Drive Model Number 8510A A 22 AC Input Voltage 200 to 220V AC 10 at 50 60 Hz 1 Hz and 230V AC 10 at 60 Hz 1 Required AC Input 30MinueRa ngkVA DW 32 a a Rated Output Current 30 Minute Amperes 112 135 153 Power Control Method PWM inverter using IGBT power devices Motor Braking Method Power regeneration to the AC line Input Command 10V DC 0 10V DC with Fwd Rev input 16 bit binary or BCD digital command Speed Control Range 0 to 30 000 rpm velocity resolution greater than 1 2 000 000 Speed Regulation Transient change lt 0 4 of max speed steady state change 0 025 load 10 100 Velocity Loop Bandwidth Up to 50 Hz load and motor dependent Programming System Integral 2 line by 16 character backlit LCD display and 4 button keypad Drive Enclosure Type Open style IP 00 for mounting in another enclosure heat sinks extend outside enclosure Drive Weight kg Ib 52 114 52 114 52 114 Allowable Vibration Less than 0 5 G Rated Ambient Temperature 0 to 55 C 32 to 131 F inside enclosure 0 to 40 C 32 to 104 F at heat sinks Storage Temperature 0 to 65 C 32 to 149 F 30 minutes starting with cold motor Loaded for 60 of a 10 minute cycle 15 minute rating for 1327AB AFM 02 motor 1327AB AFM 02 and 13
94. e that they are making proper contact with the Interconnect Board Make certain it is inserted correctly so that blank side if any is towards outside of drive Remove all twelve 0 3A fuses and check with ohmmeter Replace any bad fuses Important Be certain to properly reseat all fuses to avoid possible damage to IGBTs Check IGBT modules M1 M2 and M3 or IGBT1 in A04 A06 drive according to procedure later in this chapter Replace Power Unit if IGBT is malfunctioning If problems were not found with other tests replace Main Control Board Gate Drive Board and possibly CPU Board on A04 A06 drives If problems were not found with other tests replace the Power Unit 1 Verify that the motor catalog number and drive catalog number are properly programmed 2 In orient mode verify proper feedback definition Re examine programmable parameters for compatibility start with the ones most recently changed Refer to the 8510 Programming Manual publication 8510 5 2 as needed Re examine programmable parameters for compatibility start with the ones most recently changed Refer to the 8510 Programming Manual publication 8510 5 2 as needed No 15 16 Problem Motor runs in a random or uncon trolled manner or with excessive vibration when either the Forward or Reverse Run command is energized Abs Overspeed displayed Motor shaft speed exceeding the programmed value of the Overspd Trip parameter
95. ead 5 3 Dia 2 Plcs 50 0 1 lt x 70 Max Z Phase Sensor Center A B Phase Sensor Center lt 33 Max m 16 5 ry 5 Max 9 11 40 0 02 38 Chapter 3 Dimensions Figure 3 15 AC Line Fuse Kits Dimensions are in Inches 8510SA FA04 8510SA FA06 2 lt 4 13 16 lt 1 1 2 o 1 2 7 32 17 39 Eu 17 64 Dia 7 1 4 tlg 16C Bore Y 8510SA FA11 29 32 5 19 64 lt gt 15 16 41 1 2 gt AL Dia 1 2 C Bore 6 9 32 3 9 64 Y M 28 1 3 4 gt 1 1 2 8510SA FA22 3 4 C Bore 11 32 Dia Chapter 3 Dimensions Figure 3 16 Termination Panels A 71 0 DIN 3 Rail 199 DR1 or Equivalent Not Supplied
96. ectors 3 If problem remains replace I O Board 4 If problem remains replace Main Control Board CPU Board on A04 A06 drive Firmware problem or hardware 1 Verify that the EPROM on the Main Control Board is inserted malfunction on Main Control correctly ae CRD Boge on A040 2 If problem remains replace Main Control Board CPU Board on A04 A06 drive 3 If problem remains contact factory allotted time cycle mm 32 33 34 Main Comm Err displayed No communications occurring between master and slave processors on Main Control Board CPU Board on A04 A06 drive Main Watchdog displayed The watchdog timer on the Main Control Board CPU Board on A04 A06 drive tripped out Main A D Conv displayed The A D converter on the main control board CPU Board on A04 A06 drive faulted or sensed excessive offset Hardware malfunction 1 Verify that the EPROM on the Main Control Board is inserted correctly 2 If problem remains replace Main Control Board CPU Board on A04 A06 drive The microprocessor on Main 1 Verify that EPROMs on both the I O Board and the Main Control Control Board ran out of execution Board CPU Board on A04 A06 drive are inserted correctly time or stopped 2 If problem remains replace Main Control Board 3 If problem recurs contact factory Hardware malfunction Replace Main Control Board CPU Board on A04 A06 drive 11 131 Chapter 11 Tr
97. ed power at base speed It will then remain constant from base speed to maximum speed This is a unipolar output Data Format KW 000 0 10 107 Chapter 10 Display Panel amp Fault Diagnostics 10 108 Orient Error When selected indicates that the display is currently showing the value of the position error when the drive is in spindle orient mode This is a bipolar output Data Format DEG 00 000 DIAGNOSTICS The information displayed on the diagnostic display can help to isolate a malfunction in the drive The following paragraphs describe the diagnostic displays available Refer to Chapter 11 for further troubleshooting information Inputs This parameter indicates the status of all inputs For ease in identifying each input successive letters of the alphabet are used to show when they are On When an input is Off a dash will be displayed Refer to Table 10 A for the input associated with each letter Data Format line 1 I O Inputs Data Format line 2 JKLMNOPQRSTUV Table 10 A I O Inputs Display Letter Input Signal Name Coast to Stop Drive Reset Drive Enable Forward Run Reverse Run Low Torque Limit Select Accel Decel Rate Select Spindle Servo Mode Select Servo Input Scaling High Low Gear Ratio Active Bit 2 Gear Ratio Active Bit 1 Orient Command High Motor Winding Select Command lt Z lt x Chapter 10 Display Panel amp Fault Diagnostics I O Outputs
98. ent Be prepared to remove drive power by opening the branch circuit disconnect device if this occurs Incorrect movement may be due to a wiring programming error or system component malfunction and must be corrected before proceeding with this procedure Damage to machine system components can occur due to uncontrolled machine movements It is recommended that the motor be mechanically disconnected from the load if A Improper direction of rotation could cause damage to equipment B Uncontrolled motor rotation due to improper phasing will cause damage to the equipment Apply 24V DC to the Coast to Stop and Drive Enable inputs Forward Run Reverse Run and Orient Command must be Off After about 5 7 seconds the main contactor will close and the Drive Ready output will turn On In addition the letter should appear on the DIAGNOSTICS I O Output display If the main contactor does not close and the Hard Fault output is still On verify that the two wire cable is attached to connector J3 in the lower left corner of the I O Board This cable provides the hard wired connection of the Coast to Stop input to the main AC contactor control circuit If it is not connected the contactor can not be closed Apply 24V DC to either the Forward Run or Reverse Run inputs The drive will now run in Spindle Mode at Acc Rate 1 Depending on configuration programming either an analog speed command on Analog Input 1 or a digital speed comma
99. ent are not properly programmed For the gear range selected Verify that each of the parameters listed under Probable Cause is set one or more of the following to a valid value that must be greater than zero parameters has a pro grammed value of zero SET RATIOS Spindle Revs SET RATIOS Motor Revs ORIENT TUNE Orient Speed ORIENT TUNE 56 Sp Mtr 1 P Er displayed An error was detected in the motor parameter table values For the gear range selected Change the MOTOR SELECT Catalog Num parameter setting to the motor type selected by the correct catalog number for the motor connected to the system the MOTOR SELECT Catalog Num parameter has If this does not correct the problem contact the factory been set to NON STD MTR 1 and this motor has not been defined or is incorrectly ee LL 57 Sp 2 P Er displayed error was detected in the motor parameter table values For the gear range selected Change the MOTOR SELECT Catalog Num parameter setting to the motor type selected by the correct catalog number for the motor connected to the system the MOTOR SELECT Catalog Num parameter has If this does not correct the problem contact the factory been set to NON STD MTR 2 and this motor has not been defined or is incorrectly LLL OO G c f 11 134 Chapter 11 Troubleshooting Figure 11 3 Resolver Signals
100. er 8 Wiring Power Transformers The allowable AC input voltage range is 200 to 230V AC 10 at 60 Hz and 200 to 220V AC 10 at 50 Hz In larger plants with high capacity power systems it is not uncommon to encounter exceptionally high AC line voltage that will exceed the 10 specification during part of the day In these cases the nominal secondary voltage of the transformer should be set for 5 10 less than the maximum allowable nominal input voltage of the drive This will help avoid drive damage caused by the high AC line voltage Transformers supplied by Allen Bradley are wound with 220V AC secondaries Either autotransformers or isolation transformers can be used When using isolation transformers a Y secondary with the neutral grounded is recommended Power transformer kVA requirements depend on the power rating of the motor being used Table 8 C defines the transformer requirements Table 8 C Transformer Requirements Motor Rating Transformer Rating Cont 30 Min kW kVA 2 2 3 7 6 3 7 5 5 9 5 5 7 5 12 7 5111 17 11 15 22 15 18 5 26 18 5 22 32 22130 40 Power Grounding The wire size used for power grounds must be at least as large as the wire gauge of the power conductors or as defined by local codes Other Devices and Noise Suppression Inductive devices e g solenoids motor starters and relays must be equipped with suppression devices that will not allow a dv dt of greater than 200 V
101. er plug is installed in the fiber optic displayed A system fiber optic input connector on the Main Control Board CPU Board on A04 A06 interrupt was sensed drive The fiber optic connector is located adjacent to connector through the test CN2 17 fiber optic 2 If problem remains replace Main Control Board CPU Board on eens A04 A06 drive 40 Hi Accel Rate Firmware error Reset drive If fault persists contact Allen Bradley displayed 4 Hi Firmware error Reset drive If fault persists contact Allen Bradley displayed 42 Hi Positn Err Firmware error Reset drive If fault persists contact Allen Bradley displayed 43 Hi Speed Firmware error Reset drive If fault persists contact Allen Bradley displayed Board Faults When problems occur with the I O Board the first line of the display will show either Fault I O Board or Warning I O Brd The second line provides more detailed information about the exact nature of the fault 11 132 No Problem 44 EEPROM No Data displayed The I O Board microprocessor could not find programmed data in the EEPROM 45 Bad EEPROM displayed The The Board micropro cessor can not communicate with the Table 11 I Chapter 11 Troubleshooting Problems Specifically Related to the I O Board Probable Cause The drive was not programmed EEPROM not properly installed or malfunctioning EEPROM not properly installed or malfunctioning Po
102. es AC spindle motors to the drive Refer to Figure 7 3 for the connector location Refer to Chapter 8 for the specific motor connector to CN3 wiring instructions Resolver Stator CN3 8 amp 14 and 9 amp 15 Sine and cosine excitation of the resolver stator Chapter 7 Interface Signal Descriptions Resolver Rotor CN3 11 amp 17 Rotor feedback from the motor resolver Chapter 7 Interface Signal Descriptions Orient Feedback Signals Thermal Switch CN3 13 amp 20 Thermal switch that is embedded in the motor windings to indicate a motor overtemperature condition Cable Shields CN3 1 2 3 amp 4 The resolver cable must contain twisted shielded pairs with an additional overall shield and all shields must be terminated to these pins Connector CN2 provides the connection to the orient feedback sensor when the drive is being used to perform spindle orient If spindle orient is being done by the CNC the sensor must be connected to the CNC and not to the drive Either an optical encoder or the high resolution magnetic sensor can be terminated to this connector Refer to Figure 7 3 for the connector location Refer the Chapter 8 for specific wiring instructions for each feedback type Optical Encoder Feedback Use an Allen Bradley 845T series encoder with a type 33 electrical interface or an equivalent optical encoder with an A B and Z channel that uses a push pull type single ended output and a 12V DC input v
103. escriptions Wiring Start Up Display Panel amp Fault Diagnostics Troubleshooting Renewal Parts Chapter 7 Chapter Objectives 22 2 2 et 7 1 Interfaces ccs er aia 7 1 Conventions used in this 1 7 2 Signal Level Descriptions 7 2 Interface Signal Descriptions 7 3 Resolver Feedback Signals 7 13 Orient Feedback Signals 7 14 Dual Winding Contactor Signals 7 15 Digital Command Signals 7 16 Seral Port E i a ae yh ua a kia 7 16 Chapter 8 Chapter Objectives AERE 8 1 General Wiring Information 8 1 Power Wining a 8 7 Signal 8 11 Chapter 9 Chapter Objectives s uses rre Con Eee ER IRR 9 1 Conventions used in this 1 9 1 Start Up Procedure uyu eh I eS ERAS RA ee ee ade sa 9 1 Chapter 10 Chapter Objectives bea E EH e e 10 1 Menu Format and Conventions 10 1 Display Description 10 2 Display 125 sce gobs bees we ge ead reed 10 3
104. for each data set If the setups are similar for each gear range use the GEAR RANGES Copy Data function to copy the initial gear range configuration data to the succeeding gear ranges Display Panel amp Fault Diagnostics Chapter Objectives This chapter explains the 8510 display panel and how it is used to show different measurements and perform fault diagnostics Included is an explanation of the display and descriptions of the various parameters that can be displayed Menu Format and Conventions The menu system is based on the 16 character by 2 line display used in the 8510 The menu is arranged in a tree format see Figure 10 1 to allow easy access to any item Menu items will be displayed two different ways 1 UPPER CASE letters capitals indicate the item is a menu heading with a group of sub menus or parameter names below it 2 Initial Capital letters indicate the item is the name of a parameter In this manual any text that shows the exact display format of a menu or parameter name is shown in italics Any text that shows the exact display format of a parameter data value or selection is enclosed in quotes When power is first applied to the drive or a reset is performed after a fault the software version number is indicated on the display during the initial diagnostic checks Have this software version number available before contacting the factory concerning a malfunctioning drive After power is applied t
105. g air from side of enclosure to an A22 drive 4 4 Chapter 4 Receiving Unpacking and Inspection High Resolution Magnetic Feedback 8510SA P G225 First Position Second Posi Third Position tion Bulletin High Resolution Feedback Number Magnetic Feedback Elements Code Description G225 Standard class 225 tooth feedback G256 gear G300 Standard class 256 tooth feedback G400 gear G500 Standard class 300 tooth feedback G500 gear PSA Standard class 400 tooth feedback gear Standard class 500 tooth feedback gear Precision class 500 tooth feedback gear Sensing head with analog output Offline Programming Software 8510SA SSD C First Position Second Posi tion Bulletin Number Type Code Description SSD Spindle Drive Configuration software for use with ODS SFT File Transfer Utility for IBM compatible PCs U 4 42 Chapter Objectives Environment Mounting Chapter Drive Installation Drive installation information including environmental conditions and mounting requirements are presented in this chapter The information presented will serve as a guideline in planning the installation of the drive Mounting To a flat rigid vertical surface Enclosure Type Sealed enclosure that will prevent drive from being subjected to moisture oil mist dust corrosive vapors etc Drive heat sinks normally extend through the enclosure wall Ambient Temperature Control Ambient 0 to 55 C 32 to
106. gen Inverter W E Converter es AC Line Input FU3R AC Phase Fuss Sensing and FU3T Regen Control F7 on A11 and A22 F13 on A04 and A06 FUIR gt FUIS KM3 STB 1 DE Used in A11 and A22 Only KM2 5182 o 2 Relay and Contactors I KM Main AC Input Contactor J3 1 J3 2 KM1 DC Bus Precharge Relay Ki KM2 Pilot Relay for KM 0 KM3 DCC Bus Discharge Relay K10 Coast to Stop Relay located I O Board CN9 1 CN9 4 Coast to Stop 11 115 Chapter 11 Troubleshooting Fuse Locations and Types Fuse location and specific fuse information is provided in the paragraphs that follow AC Control Power Fuses The electrical location of the AC control power fuses is shown in Figure 11 2 Refer to Figures 11 10 11 13 and 11 14 for fuse locations Table 11 A provides information on fuse types Table 11 A AC Control Power Fuses Power Board Designator Rating Vendor Name amp Number A B P N FUIR FUIS 5 250 V Fuji FGBO 5A 250V 1 145863 FU2R FU2S FU2T 5 250 V Fuji FGBO 5A 250V 1 145863 On All amp A22 only 0 5A 250 V Fuji FGBO 0 5A 250V 1 151287 FU3R FU3S FU3T On A04 amp 06 only 0 5A 250 V Daito Tsushin HM05 151465 FU3R FU3S FU3T Any substitute fuse for the Fuji FGBO type fuses must be a metric style measuring 6 35 mm diameter by 30 mm long Gate Drive and 5V DC Fuses Fuses for each of the IGBT gate drive circuit outputs and for the 5V DC logic power
107. he DISPLAY TYPE menu will be shown This menu allows selection of the METER DISPLAY or DIAGNOSTICS mode Figure 10 1 Display Type Menu Tree 2L DISPLAY TYPE METER DISPLAY DIAGNOSTICS 2L Inputs 2L METER DISPLAY 2L DIAGNOSTICS JK MNO RST V Motor Speed T O Inputs 2L Spindle Speed 2L Outputs Spindle Speed I O Outputs RPM 2387 AB DE HI 10 103 Chapter 10 Display Panel amp Fault Diagnostics Display Description 10 104 The 8510 display which is used for status and diagnostic messages consists of a 16 character 2 line LCD Liquid Crystal display The display can be broken into several different sections as shown in Figure 10 2 Refer to the paragraphs that follow for explanations Figure 10 2 LCD Display Motor Winding Selected by Digital Gear Range Inputs Selected by Digital Menu Level Menu Information Inputs Indicator DISPLAY DIHGHOSTICS Menu Level Indicator when applicable Menu Information Line 1 characters 1 amp 2 are used to display the current gear range and motor winding that have been selected by the digital inputs Character 1 will show the selected gear range 1 4 and if a 2 speed motor is used character 2 will show the motor winding H high speed winding L low speed winding This gear range and motor winding defines the data set that is currently being used for drive operation Line 1 character 3 is a va
108. high speed operation a small unbalance will cause significant vibration Take care to accurately dynamically balance any gears pulleys or couplings that are mounted to the motor shaft Best results are obtained by balancing after the device is mounted to the shaft If the motor is belt coupled the belt tension must not exceed the radial load capabilities of the motor bearings as shown in Table 6 A Chapter 6 Motor Installation Table 6 A 1327A Radial Load Capabilities Motor Catalog Number 1327AC AFM 02 1327AC AFM 04 1327AC AFM 06 1327AC AFL 08 1327AC AFL 11 1327AB AFL 15 1327AB AFL 19 1327AB AFL 22 1327AD ABL 04 Maximum Radial Load 133 kg 292 1b 165 kg 364 Ib 167 kg 368 Ib 313 kg 688 Ib 335 kg 737 Ib 356 kg 784 Ib 373 kg 820 Ib 384 kg 844 Ib 300 kg 660 Ib 1327AD ABL 06 310 kg 682 lb 1327AD ABL 08 360 kg 792 Ib _ 1327AD ACL 08 380 kg 836 Ib 1327AD AAK 11 580 kg 1276 1b 1327 15 600 kg 1320 Ib 1327AD AAK I9 610 kg 1342 Ib 1 Load applied at dimension AH 3 or N W 3 from the shaft tip Wiring Considerations Read through and understand the following points before wiring the 1327 motor The terminal box includes two cable entry holes One hole has a solid cover plate and the other hole has a cover plate to accommodate either IS0 228 PF type conduit fittings or ANSI NPT type conduit fittings On request cover plates to accommoda
109. imum RPM Constant Power Speed Range Output Power Rating Rated Speed Rated Torque Continuous N m Ib ft Rated Current 30 Minute Output Amperes kg m Ib in s Max Radial kg Ib kg Ibs Rotor Inertia Bearing Load Motor Weight Electrical Design Vibration Audible Noise Feedback Device Rated Ambient Temperature Possible Mounting Methods Drive Model Number 8510 AAK 11 AAK 15 AAK 19 11 15 15 20 18 5 25 15 20 18 5 25 22 30 13 5 18 18 5 25 22 30 18 24 22 30 27 36 400 400 400 4800 4800 4800 12 1 12 1 12 1 261 193 357 263 440 325 87 102 110 0 338 2 991 0 473 4 186 0 548 4 850 580 1276 600 1320 610 1342 260 572 355 781 405 891 Reconfigurable winding for two speed ranges Less than or equal to 10 microns 0 0004 inches Less than 80dB A Scale 8 pole brushless resolver 65 536 counts revolution 0 to 40 432 104 Horizontal or vertical Foot or flange mounting available All A22 A22 AC Input Voltage 200 to 220V AC 10 at 50 60 Hz 1 Hz and 230V AC 410 at 60 Hz 1 Required AC Input 30 Minute Rating kVA B 26 32 Rated Output Current 30 Minute Amperes Power Control Method Motor Braking Method Input Command Speed Control Range Speed Regulation Velocity Loop Bandwidth Programming System Drive Enclosure Type Drive Weight Allowable Vibration kg lb Rated Ambient Temperature Storage Temperature 8
110. imum motor speed is determined by the HI SPD RANGE parameter menu Independent loop gain parameter sets can also be programmed for each of these speed ranges Orient Command CN9 13 Turning this input On will activate the integral spindle orient function The drive velocity control loops will be switched to high speed range servo mode gains and the position loop will be closed in the drive using the spindle position feedback device Deceleration and stopping will be controlled by the orient function software When this input is turned Off the drive will return to the standard velocity control mode in less than 30 ms and resume operation at the commanded speed The programmed value for the ORIENT TUNE Hold Position parameter will determine whether the spindle will be in a free turning or a servo lock condition after the orient operation is completed If the parameter is set to Torque Hold the drive system will supply holding torque to maintain the orient position as long as the Orient Command is On If the Forward and Reverse Run commands are turned Off during orient the orient operation will be terminated and the motor will be regeneratively braked to a stop 7 61 Chapter 7 Interface Signal Descriptions If the orient operation is terminated by removing either the Forward or Reverse Run commands the orient cycle will not automatically resume when the Forward or Reverse Run commands are turned On The orient command m
111. inadvertently set to zero this fault may occur as soon as the power is applied to the drive With a setting of zero even a one bit change from the resolver decoding circuit will cause this fault Never allow the motor to become disconnected from the load or the drive to be disconnected from an external control loop while the drive is operating in torque mode Reduce the overhauling load to a value that is less than the torque limit setting of the drive Check the resolver signals as defined under fault condition 6 If problems were not found with other tests replace Main Control Board Gate Drive Board and possibly CPU Board on A04 A06 drives 17 Bus Overvoltg displayed DC bus voltage that exceeded maxi mum allowable limits was detected Incorrect motor selected in MOTOR SELECT Catalog Num parameter Incoming 3 phase voltage is out of tolerance If overvoltage is detected during regeneration incoming AC line impedance may be too high Malfunctioning regeneration control circuit Check Catalog Num setting to verify that it matches the motor nameplate Adjust taps on transformer or add step down transformer to keep AC line voltage below 253V AC 60 Hz or 242V AC 50 Hz Increase kVA rating of supply transformer to proper rating for drive size See Table 8 C Replace Main Control Board Gate Drive Board on A04 A06 drives 11 125 Chapter 11 Troubleshooting Table 11 F Continued Problems
112. ing and welding can be accomplished with the drive removed from the enclosure The drive is of the open type construction and any metal debris must be kept from falling into the drive Metal debris or other foreign matter that becomes lodged in the drive circuitry frequently results in significant drive damage when power is applied Enclosure Wall through the wall Mounting The following procedure provides the steps needed to properly mount the 8510 through the enclosure wall 1 Locate the area that the drive is to be mounted leaving at least 75 mm 3 inches of clearance on all sides and 150 mm 6 inches on the top Prepare the enclosure using the panel cutout information provided in Chapter 3 All holes must be deburred inside and outside the enclosure Remove any sharp edges that may be present around the cutout Unfold the gasket and position paper side toward drive around the drive Remove the protective paper from the adhesive on the top side of the gasket Carefully align the gasket holes with the drive mounting holes and press the gasket into place Repeat this procedure for the remaining sides See Figure 5 1 Securely bolt the drive and gasket into the enclosure Use 6 mm or 1 4 in bolts with lockwashers Alternately tighten the nuts to assure uniform compression of the sealing gasket Torque to 5 5 N m 50 Ib in To assist in handling larger size drives there are holes on the sides of the drive that can be use
113. ing should be terminated to the bolt or screw terminals on the drive and motor using ring type terminal lugs or damage to equipment the interconnections to the motor and feedback device must be made as explained in this chapter Failure to do so could cause loss of motor control and or severe oscillation of the motor shaft ATTENTION To guard against the hazard of personal injury The size of the power terminal connections on the drive for incoming AC line power and motor power terminations is shown below Table 8 A Power Terminal Sizes Drive Catalog Number Bolt Screw Maximum Lug 8510A A04 x1 12 1 8510A A06 x1 mm in 8510 11 2 8510 22 2 The size of the power terminal connections in the motor terminal box for motor power is shown in Table 8 B Table 8 B Motor Terminal Sizes Motor Catalog Bolt Screw Maximum Lug Number Size w idth 1327AC AFM 02 F M5 13 mm 1327AC AFM 04 x M5 13 mm 1327AC AFM 06 x M5 13 mm 1327AC AFL 08 x M6 17 mm 1327AC AFL 11 x M6 17 mm 1327AB AFL 15 x M8 24 mm 1327AB AFL 19 x M8 24 mm 1327AD ABL 04 x M8 23 mm 1327AD ABL 06 x M8 23 mm 1327AD ABL 08 E M8 23 mm 1327AD ACL 08 F M8 23 mm 1327AD AAK 11 x M8 23 mm 1327AD AAK 15 x M10 29 mm To minimize radiated PWM noise the individual motor phase wires must be part of a single multi conductor cable or run very close together The motor cables should be contained in grounded metal conduit or raceways 8 77 Chapt
114. ings designed for a 15 000 hour B10 life a high voltage insulation system tested to 1 500 volts and the precision rotor balance to assure a superior motor life Mounting Versatility Metric foot mount and flange mount motors are available for either horizontal or vertical mounting The following design features are standard on the Series 8510 AC Spindle Drive System Multiple Control Modes To provide the flexibility and control capability to meet the demands of increasingly sophisticated machine tools and other types of automation equipment the 8510 provides multiple operating modes Through discrete inputs the user can instantaneously switch the 8510 drive between Spindle Mode Servo Mode and Torque Mode operation Each mode has a unique set of programmable drive configuration input scaling and control loop tuning parameters to allow optimized performance in each operating mode Spindle Mode provides smooth quiet operation over the wide constant power range required for normal machining In typical machine tool spindle applications this is the only operating mode that is required The drive can operate from analog or digital speed commands with programmable acceleration ramp rate generators and provides a traditional PI type velocity control loop During lightly loaded operation the motor flux is reduced to minimize motor heating Spindle mode assumes that the drive is operating as an open loop speed controlled drive withou
115. input can not be applied until the drive has completed the initial power on diagnostics and the Hard Fault output has been turned On to indicate that no control malfunctions were detected If this input is turned On before the power on diagnostics are completed it will be ig nored Important The Drive Enable input must not be used by itself to provide a regenerative emergency stopping capability since an electronic malfunc tion could potentially prevent the drive from stopping To achieve regener ative braking in an emergency stop situation the following circuit that combines the Drive Enable and Coast to Stop input functions is suggested A single output from the emergency stop circuit of the CNC or control station connects to the Drive Enable input of the drive see Figure 7 1 This same output is also connected to a user supplied relay with an electro mechanical or pneumatic controlled time delayed dropout A contact from the time delayed relay is connected in series with the Coast to Stop input of the drive Removing Drive Enable will cause the drive to regenerate to a stop and drop the contactor when zero speed is reached When the time delay relay opens at the end of the time delay the contact breaks the coil circuit of the contactor The drive is then placed in a state in which no silicon circuitry is depended upon for maintaining the power off state If a drive malfunction occurs causing it to ignore the disable
116. inside the motor terminal box to a connector see Figure 8 3 or Figure 8 5 On 1327AB Series A and 1327AD Series A motors an AMP Commercial MATE N LOK connector is used On 1327AB Series B 1327AC Series A and 1327AD Series B motors an AMP Dynamic Series connector is used Different sizes of the AMP Commercial MATE N LOK connector are used on the 1327AB and 1327AD series motors The connector component part numbers and the Allen Bradley connector kit catalog numbers are For 1327AB Series A Motors Connector Housing AMP 1 480438 0 16 pin housing Pins 12 required AMP 60617 6 24 18 AWG phosphor bronze with gold Connector Kit Catalog Number 8510SA CABC For 1327AD Series A Motors Connector Housing AMP 1 480285 0 10 pin housing Pins 9 required AMP 60617 6 24 18 AWG phosphor bronze with gold Connector Kit Catalog Number 8510SA CADC These connectors use crimp type pins AMP crimp tool 90123 2 is recommended to properly crimp these pins to the wire As an alternative any similar sized hand crimp tool or pliers can be used for the basic mechanical connection The lead must then be soldered to complete the electrical connection With the AMP Dynamic Series connector the same connector is used on all motors However the mating connectors are available for either crimp or solder type wire termination The component connector part numbers and the Allen Bradley connector kit catalog numbers are
117. ive retaining screws in the bottom corners To remove the cover loosen the two retaining screws and pull the bottom of the cover outward until the cover is clear of the drive bottom Next lift the cover upward until the locating pins are removed from the locating holes on the top of the drive It may be necessary to remove one or more of the Honda connectors to obtain the necessary clearance at the bottom of the cover To replace the cover hold it with the bottom tilted slightly away from the drive Engage the cover locating pins into the holes on the top of the drive and carefully swing the bottom toward the drive Assure that the two guides on the sides of the drive near the bottom of the cover are both inside the cover Important The top edge of the hole for the programming display may hit the top of the display bezel Do not force the cover backward to its final position or it will bend and possibly damage the I O Board Push upward on the bottom of the cover until the edge of the hole clears the top of the bezel It may be necessary to gently pull downward on the edge of the bezel while pushing upward on the cover to make the cover clear the top of the bezel When the display bezel is properly located tighten the two retaining screws in the bottom of the cover Chapter 5 Drive Installation End of Chapter Chapter Objectives Mounting Considerations Coupling Considerations Chapter Motor Installation Chapter 6 pr
118. l in whole or in part without written permission of the Allen Bradley Company is prohibited Throughout this manual we use notes to make you aware of safety considerations circumstances that can lead to personal injury or death property ATTENTION Identifies information about practices or damage or economic loss Attentions help you e identify a hazard e avoid the hazard recognize the consequences Important Identifies information that is especially important for successful application and understanding of the product Shock Hazard labels may be located on or inside the drive to h alert people that dangerous voltage may be present SCANport is a trademark of Rockwell Automation PLC is a registered trademark of Rockwell Automation COLOR KEYED is a registered trademark of Thomas amp Betts Corporation IBM is a registered trademark of International Business Machines Corporation Windows 95 is a registered trademark of Microsoft Corporation Introduction Specifications Dimensions Receiving Unpacking and Inspection Drive Installation Motor Installation Table of Contents 8510 User Manual Chapter 1 Chapter 1 1 Manual Objectives eicere eRe epe Le aeons Ive 1 1 General Precautions 1 2 Drive Overview et oed e aae eae e eod 1 2 1327A AC Motor Overview
119. lation For more accurate setup an oscilloscope must be used Following the procedure in the Programming Manual program Analog Output 1 to output Motor Speed and Analog Output 2 to output Torque Simultaeously press the Mode and Scroll keys twice to store the parameter changes to EEPROM and cause the display to change to DISPLAY TYPE METER DISPLAY Then remove and reapply Drive Enable for these settings to take effect Near the center of the Board smaller board in lower left corner of drive are test points for Analog Output 1 ANAOUT 1 TP1 Analog Output 2 ANAOUT 2 TP2 and Analog Signal Ground ANA SG On both test points 10V DC maximum output 9 99 Chapter 9 Start Up troubleshooting it must be properly grounded The oscilloscope chassis may be at a potentially fatal voltage if not properly grounded Always connect the oscilloscope chassis to earth ground ATTENTION If an oscilloscope is used during start up or When using an oscilloscope it is recommended that the test probe ground be connected to the test point labeled GND a Optimum tuning is obtained by observing the small signal step response The step should be small enough to assure that the drive output does not become torque limited In addition the Acc Rate parameter setting should be fast enough so that it does not limit the acceleration rate To simplify the tuning process it is best to separate the P Gain an
120. lected Analog Inputs Two inputs with 14 bit A D resolution can be programmed for the following input functions Spindle Mode Command Input 1 Servo Mode Command Selectable Input 1 or Input 2 Torque Mode Command Input 2 7 53 Chapter 7 Interface Signal Descriptions Conventions Used in this Manual Signal Level Descriptions Analog Outputs Two analog outputs with 12 bit D A resolution can be programmed to provide any of the following output signals Motor rpm zero to maximum rpm or maximum to maximum rpm Spindle rpm zero to maximum rpm or maximum to maximum rpm Load Torque Power Output Orient Error full scale is 2 degrees error Serial Port Used for parameter data file upload and download The port can be configured jumper selectable for RS 232 or RS 422 at 9600 baud To help differentiate input output names programmable parameters and programmable values the following conventions will be used throughout this chapter and the remainder of this manual Input and Output Names will appear in Initial Capital Letters Programming Display Text will appear in italics Menu Names will appear with ALL CAPITALS Parameter Names will appear with Initial Capital Letters Programmable Parameter Values will appear in quotes The signal level requirements for the various inputs and outputs of the 8510 are as follows Digital Inputs An open or grounded input
121. ming Manual publication 8510 5 2 Replace the EEPROM or complete I O Board data in the gt gt 6 gt gt 48 H8 CPU RAM displayed The RAM that is internal to the H8 microprocessor will not pass a The microprocessor on the I O Board is malfunctioning Replace I O Board read write test _ _ 49 TO DURM dis played The dual port RAM used to communicate to the Main Control Board will not pass a The dual port RAM on the T O Board is malfunctioning Replace I O Board read write test 50 LCD Timeout displayed Commu nications between the T O Board micropro cessor and the programming display module did not occur The I O Board is malfunc tioning Replace I O Board li 51 Any other Fault I O Board fault message displayed Indication of firmware or hardware malfunction on I O Some hardware or firmware on the I O Board is malfunctioning Replace the I O Board Board 11 133 Chapter 11 Troubleshooting No Problem 52 BadComb M amp D displayed The motor and drive catalog numbers that are selected are not compatible with one another 53 Max Spd None displayed Table 11 J Problems Caused by Programming Errors Probable Cause Possible Solutions For the gear range selected Verify that motor and drive catalog numbers have been programmed the MOTOR SELECT for the selected gear range Verify tha
122. n Low Torque Limit Select CN9 7 When this input is On the maximum allowable motor torque output is restricted to the value programmed with the Low Torq Lmt parameter When this input is Off the motor torque is allowed to go to the maximum rating for that specific motor drive combination Accel Decel Rate Select Torque Mode Enable CN9 9 During normal spindle mode operation this input is used to select different motor accel decel ramp rates When this input is Off the motor accel decel rate is determined by the value programmed with the Acc Rate 1 parameter When this input is On the motor accel decel rate is determined by the value programmed with the Acc Rate 2 parameter In servo mode operation there is no ramp control supplied to the analog input signal The drive will immediately respond to any input signal with output torque up to the maximum capability of the motor drive system or to the Low Torq Lmt level if selected In torque mode operation this input will have a different function If the TORQUE MODE Torque Enable parameter has been set to Enable during the drive setup programming this input is used to switch the drive between velocity control operation and torque control operation When this input is Off the drive runs as a normal velocity controlled drive with the speed command either digital or from Analog Input 1 When this input is On the drive operates as an open loop torque controlled drive with
123. n Shield Analog Output 2 Analog Output 2 Return Shield CN10 1 through CN10 20 1 0 Board Figure 8 11 8510 System Interconnect 8510 Drive Power Board Chapter 8 Wiring 8510SA FAxx AC Input Power 200 220V AC 50 60 Hz 3 ph 230V AC 60 Hz 3 ph with ground TTT Terminal Block Current Motor Winding Selected Motor Winding Selected High Spd Return Motor Winding Selected Low Spd Return Spd Return Motor Winding Select Cmd Low Spd Return Shield Motor Winding Select Cmd Hig Main Control Board U r Optional r Contactors for Winding Selection Ba Terminal Block 1327A Motor Connector Encoder for Spindle Orient when using the 8510 for Orient 8 93 Chapter 8 Wiring End of Chapter Chapter Objectives Conventions Used in this Manual Start Up Procedure Chapter Start Up The steps needed to start up the 8510 AC Drive System are provided in this chapter To help differentiate input output names programmable parameters and programmable values the following conventions will be used throughout this chapter and the remainder of this manual Input and Output Names will appear in Initial Capital Letters Programming Display Text will appear in italics Menu Names will appear with ALL CAPITALS Pa
124. n Drive and Bottom of Cover Enclosure Wall Air Inlet amp Outlet Slots All 3 Sides 75 mm 3 in on Bottom or Leave Bottom of Cover Open 75 mm 3 in Clearance Minimum between Drive and sides of Cover Chapter 5 Drive Installation Panel Mounting Panel mounting allows the entire drive to be mounted inside an enclosure without extending the heat sink through the enclosure wall The drive is mounted inside the enclosure using the panel mounting brackets Cat No 8510SA Mxxx that can be supplied as an accessory Care must be taken to provide the required clearances at the top and bottom of the drive to assure that the airflow across the heat sink is not obstructed Mounting dimensions can be found in Chapter 3 continuous output when the heat sinks are in a 40 C 104 F ambient temperature To obtain the rated continuous output of the drive amplifier the temperature of the air entering the heat sink must be maintained at 40 C 104 F or less If the temperature of the air entering the heat sink exceeds 40 C 104 F the drive amplifier must be derated in accordance with the curve shown in Figure 5 3 ATTENTION The drive is designed to provide its rated Figure 5 3 Percent Rated Load vs Ambient Temperature Over Heat Sinks 110 Percent Rated Load 30 35 40 45 50 55 60 Ambient Temperature Degrees C 5 47 Chapter 5 Drive Installation
125. n Num nal Number and Pair Wire Color Channel A Output 19 Black 1 Blue Ground 19 13 White 1 Blue Black Channel B Output 18 Red 2 Green Ground 18 12 Green 2 Green Black Channel Z Output 17 Brown 3 Yellow Ground 17 11 Blue 3 Yellow Black 12V DC Power 5 Orange 4 Red Source 5 3 Yellow 4 Black Ground 3 1 Cable Shield Shield tse KS jae Figure 8 9 shows the basic wiring for each of these feedback devices 8 89 Chapter 8 Wiring Figure 8 9 Orient Feedback Wiring 845T Wiring High Resolution Magnetic Sensor Wiring 0901 dy 0271 0 0946 aa d 62 9 0240 AA Return CN2 13 00905 845 00 00 18 Mag O 929 1 Encoder AB Return 9 22 12 Sensor DZ CN2 14 A CN2 17 ONS __ AZRetumn Oe 0 08 0 05 02 024 d 92 3 Dual Winding Motor Contactor Control Wiring When a dual winding 1327AD series motor is used with the 8510 the user must supply two power contactors that will be used to switch the motor between the A and Y winding configurations In addition 24V DC power source must be supplied to operate the contactors Refer to Table 7 A for the specific contactors that are required for each drive size The drive will control the operation of these contactors through the 20 pin CN1 connector see Figure 7 3 for location The interface cable for this func
126. nd from the optional digital command inputs will be used If the motor does not turn runs only at a slow speed or slowly oscillates forward and reverse the motor phasing must be reversed Remove the Run and Drive Enable inputs Important Before changing any parameters in response to observed drive operation always verify that the gear range indicator number shown in the first position of each line on the display is the same If they are not use the GEAR RANGES Select Range parameter to change the number on the second line to match the number on the first line of the display Change the setting of the PARAMETER SET ELECT CONFIG Motor Phasing parameter to reverse the motor phasing without physically changing the wiring to the motor Reapply the Drive Enable and Run inputs and check for correct operation o 12 o 13 o 14 Chapter 9 Start Up When a positive analog speed command is applied along with the Forward Run command the motor should rotate counterclockwise when viewed from the output shaft end If it does not rotate in this direction remove the Run and Drive Enable inputs Use the PARAMETER SET ELECT CONFIG Cmnd Phase 1 parameter to reverse the phasing of the input command Reapply the Drive Enable and Run inputs and check for correct operation If an analog speed command is being used the most accurate calibration is achieved by allowing the drive to measure the zero speed command and maxim
127. nector CN9 See Figure 7 3 for connector location Digital Inputs Coast to Stop CN9 1 The Coast to Stop input is wired in series with the coil of an auxiliary relay that directly controls the operation of the main AC input contactor in the drive When this input is Off the auxiliary relay is de energized causing the main contactor to open and the motor to coast to a stop Regenerative braking will not occur when this input is Off When the main contactor opens the DC bus discharge circuit is activated and the DC bus will be discharged to less than 10 volts within 15 seconds Internal interlocks require the bus to be discharged below a threshold level requires about 4 seconds before drive power up sequence can be initiated again When this input is On the coil circuit of the auxiliary relay is completed Then when the Drive Enable input is applied the auxiliary relay is energized and the main AC contactor will close If stated in digital logic terms this input would be called Coast to Stop Important In situations requiring immediate de energizing of the drive opening this input will remove power from the motor and the motor will coast to a stop This input must be a hardwired physical contact that is not controlled by electronics unintended machine motion if an electronic malfunction occurs This input must be Off any time a person is required to physi cally touch any portion of the machine driven by this drive ATTENTION
128. ng change operation Whenever the Motor Winding Select Low High input is Off the auxiliary contact on the Low Speed Contactor should be closed Whenever the Motor Winding Select Low High input is On the auxiliary contact on the High Speed Contactor should be closed This fault is monitored only when a 1327AD series dual winding motor has been selected with the MOTOR SELECT Catalog Num parameter Interconnection problem between the drive and the winding change contactors One of the winding change contactors are malfunctioning Malfunctioning printed circuit board 1 Verify that connector is properly connected to the drive 2 Verify that the connector 1 and the contactors are correctly wired 3 Check the cable for continuity Check the contactors to verify that they operate properly Verify the operation of the auxiliary contacts If problems were not found with other tests replace Main Control Board Gate Drive Board and possibly CPU Board on A04 A06 drives 11 128 No 24 25 26 Problem Motor runs contin uously at the Orient Speed parameter setting without faulting and without orienting The spindle overshoots the target position and oscillates several times before stopping Bad PG Marker displayed A correct marker pulse was not detected within one revolution of the feedback device as determined by the programmed number of lines on the feedback device Tabl
129. ng blown fuses n Replacing subassembly modules that have malfunctioned n Replacing the complete drive The drive performs a number of diagnostic tests at different times during system operation The different classes of tests include the following n Power On Tests when AC power is applied all logic level functionality is checked and the data tables are tested to verify data integrity n Drive Enable Tests when the Drive Enable input is applied the DC bus is energized and the power section is checked for correct operation n Normal Operation Tests various data integrity control system functionality and power section tests are performed on a continuous or periodic basis during normal drive operation many of the checks specified in this chapter Some voltages present are at incoming line potential To avoid injury to person nel and or damage to equipment only qualified service person nel should perform the troubleshooting procedures provided Thoroughly read and understand any procedure before begin ATTENTION Power must be applied to the system to perform The drive provides two discrete digital outputs to indicate fault conditions Soft Fault and Hard Fault The Soft Fault output will be turned Off as a result of motor drive overtem perature or improper command sequences that can not be acted upon by the drive During a soft fault condition the drive will continue to operate normally Refer to Chapter 7 for further
130. ng the winding change operation the motor will resume supplying torque Then within 250 ms the output that indicates which winding is selected will change state Finally within about 750 ms the system will have returned to a stable fully controlled operation Changing windings will simultaneously select the appropriate new set of drive set up parameters In most systems it will be desirable to have the same velocity command scaling for each winding Having the same scaling will make it possible to command a speed greater than the maximum achievable speed on the low speed winding If the low speed winding is selected and the commanded speed is greater than the maximum achievable speed with that winding the drive will clamp the command at the maximum achievable speed Chapter 7 Interface Signal Descriptions Digital Outputs Current Motor Winding Selected Low High CN9 18 19 When this output is Off the low speed motor winding is connected When this output is turned On the high speed winding has been connected Drive Ready CN9 20 21 The Drive Ready output is turned On after the Drive Enable signal has been applied and the drive has successfully completed the power up sequence ready for the Forward or Reverse Run commands If for any reason the drive is unable to respond to the Forward or Reverse Run commands this output is turned Off Hard Fault CN9 22 23 The hard fault output will be On if power is applied to
131. nt Overcurrent Protection Disconnect and Branch Circuit Overcurrent Protection Supplied by User AC Lono Incoming Power 9 07 wn SiteGround Power From 8510 Drive To The 1327A Series Motor The motor power output terminals are located at the bottom of the drive as shown in Figure 7 3 Motor current requirements and wire size are dependent on the specific motor type Table 8 F defines the drive output current requirements when used with the various motor catalog numbers Wire sizes are selected per NFPA 79 and IEC 204 for wires in a cable or raceway and are based on 75 C wire 70 C for IEC 204 The motor fan should be wired to the motor fan power terminals on the bottom of the drive see Figure 7 3 for terminal locations The terminals in both the drive and motor use M4 screws The motor fan current ranges from 0 3A in the smallest motor to 1 2A in the largest motor The power output terminals are fused in the drive with 5A fuses A 20 AWG 0 50 mm wire is adequate for the motor fan wiring 8 80 Chapter 8 Wiring Table 8 F Motor Current Requirements Motor Power Rating Current Rating Wire Size 1 2 Catalog Number Cont 30 Minute Cont 30 Minute AWG mm
132. nt This information represents common system wiring configurations size and practices that have proven satisfactory in a majority of applications The National Electrical Code local electrical codes special operating temperatures duty cycles or system configurations will take precedence over the values and methods listed Important For proper interconnection it is recommended that Allen Bradley Termination Panels Cable Assemblies and or connectors be used Chapter 8 Wiring Wire Sizes Unless noted the wire sizes in this manual are recommended minimums and assume type MTW wire machine tool wire 75 C minimum per NFPA 79 In all cases the user is responsible for selecting the appropriate wire type to comply with all applicable national and local codes and to satisfy the needs of the particular application and environmental conditions Since ambient conditions vary widely on certain applications a derating factor has to be taken into account Also wiring to systems or motors exceeding 15 meters 50 feet in length total includes to and from device may cause excessive voltage drops Consult the National Electrical Code or appropriate national or local code for factors on ambient conditions length etc Shielding Reasonable care must be taken when connecting and routing power and signal wiring on a machine or system Radiated noise from nearby relays relay coils should have surge suppressors transformers other electr
133. nter the servo mode speed command should be applied to this input If this input is used for both the spindle and servo modes a given analog input level may result in three different motor speeds The different speeds are dependent on the operating mode selected and the maximum speed programmed for each operating mode The SPINDLE MODE Max Cmnd Spd SERVO MODE LO SPD RANGE Max Cmnd Spd and SERVO MODE HI SPD RANGE Max Spd parameters define the scaling to be used The Spindle Servo Mode Select and Servo Input Scaling Low High inputs determine which factor will be used Analog Input 2 9 39 40 41 During servo mode operation if the SERVO MODE Analog In programmable parameter is set to INPUT 2 this input must be used for the servo mode analog speed command If the CNC or other control system has a separate analog output that is used for servo mode operation like the 9 Series CNC when configured for C axis machining on a turning center the servo mode speed command must be applied to this input In servo mode the maximum motor speed at maximum command will be changed based on the current state of the Servo Input Scaling Low High digital input The programmed values of the LO SPD RANGE or HI SPD RANGE menus will determine the maximum motor speed scaling that is to be used for each input state The 8510 drive can also be configured to operate as a torque controlled drive instead of a speed cont
134. oard Faulty Power Unit Power Supply Low voltage power supply displayed An malfunction internal power supply voltage that is missing or out of tolerance was detected Resolver Loss Incorrect wiring to resolver displayed Im proper or no signals from motor resolver have been detected Resolver waveforms not correct Possible Solutions Measure all phase to phase voltages Check all incoming line connections for tightness Check fuses FU3R FU3S and FU3T 1 Check seating of Interconnect Board into board connector CN8 CN16 on A04 A06 drives 2 Remove Interconnect Board from CN8 and inspect contacts in both connectors to assure that they are making proper contact with the Interconnect Board Make certain it is plugged back in correctly so that blank side if any is towards outside of drive 3 Remove Control Boards and check tightness of incoming power connections to Power Board Check for other loose power interconnects If problems were not found with other tests replace Main Control Board Gate Drive Board on A04 A06 drive If problems were not found with other tests replace main Power Unit 1 Check 5V test point on Main Control Board Should be 4 75V to 5 25V Note test point is before the 5 0A fuse in the circuit 2 Check 15 test point on Main Control Board Should be 14 25V to 15 75 V 3 Check 15V test point on Main Control Board Should be 14 25V to 15 75V
135. oltage Encoder line count should be selected to meet the application requirements Maximum input frequency is 250 kHz The encoder must be mounted with a 1 1 mechanical connection to the spindle shaft that is being oriented Encoder Channel A Input and Ground CN2 16 amp 10 Channel A output from the orient optical encoder Encoder Channel B Input and Ground CN2 15 amp 9 Channel B quadrature output from the orient optical encoder Encoder Channel Z Input and Ground CN2 14 amp 8 Channel Z marker pulse output from the orient optical encoder Encoder Power Supply and Ground CN2 6 amp 4 Control power 12V DC to the optical encoder High Resolution Magnetic Sensor With the 8610SA PSA sensing head and matching 8510SA PGxxx feedback gear orient resolutions of 225 000 to 500 000 parts per revolution can be obtained The sensing head provides offset sine waves for the analog A B and Z channel outputs Refer to Chapter 1 for a more complete description of this function Magnetic Sensor Channel A Input CN2 19 amp 13 Channel A sine output from the high resolution magnetic sensor Dual Winding Contactor Signals Chapter 7 Interface Signal Descriptions Magnetic Sensor Channel B Input CN2 18 amp 12 Channel B cosine output from the high resolution magnetic sensor Magnetic Sensor Channel Z Input CN2 17 amp 11 Channel Z marker pulse output from the high resolution magnetic sensor Magnetic Sensor Power Su
136. olver feedback connector includes 1 5 m 5 ft cable Termination panel for 20 pin dual winding contactor control connector includes 1 5 m 5 ft cable 4 39 Chapter 4 Receiving Unpacking and Inspection Cable Assemblies 85105 200 10 First Position Second Posi Third Position Fourth Position tion Bulletin Cable As Connector and Cable Cable Number sembly Type Length Code Description Letter Description 20D 20 pin connector with cable for digital 10 Length in meters allowable speed position input lengths are 5 10 15 20 meters 20E 20 pin connector with cable for optical The 20E 20M and 20R are encoder orient feedback also available in 30 and 40 20M 20 pin connector with cable for high meter lengths resolution magnetic orient feedback 20R 20 pin connector with cable for motor resolver feedback 20W 20 pin connector with cable for winding change contactor control used with 1327AD series motors 50S 50 pin connector with cable for standard analog and discrete I O Mating Connector Kits 85105 50 5 First Position Second Posi Third Position Fourth Position tion Bulletin Connector Connector Connector Termination Number Kit Purpose Types Code Description Letter Description 50 50 Honda type for standard I O on S Solder type 20 drive 20 amp 50 pin Honda type 20 pin Honda type for motor feedback C only spindle orient feedback dual winding Crimp type Motor control or digit
137. onditions Chapter 1 Introduction High Resolution Velocity Control Optimum velocity control and smoothness is provided by a 14 bit A D converter for the command and a multi pole resolver with 16 bit resolution for velocity feedback For C axis operation in Servo Mode the input can be rescaled to achieve full 14 bit resolution over both the rapid traverse and the feed speed ranges An optional 16 bit parallel digital input can be used to provide a 4 digit BCD or 16 bit binary digital speed command input when operating in Spindle Mode High Response Control Loops To provide the dynamic response required by state of the art machine tools the 8510 delivers up to a 50 Hz velocity loop bandwidth For improved response feedback is sampled every 0 4 ms and Servo Mode command is sampled every 0 8 ms Spindle Orient The spindle orient function can be provided by a CNC that can close a position loop around the spindle drive or by a spindle orient capability that is part of the spindle drive itself With the 8510 spindle orient using either an optical encoder or a high resolution magnetic feedback device is a standard feature The user provided feedback device must be mounted with a direct 1 1 ratio to the spindle shaft that is to be oriented If an optical encoder is used the resolution is 360 4 x encoder lines degrees A special high resolution magnetic feedback device is available This consists of a fine pitch very accurate ring ge
138. onic drives etc may be induced into the signal lines causing undesired movement of the motor All signal wiring must use shielded cables All power wiring must be installed in a metal conduit or wireway Power leads are defined here as the transformer primary and secondary leads motor leads and any 115V AC or above control wiring for relays fans thermal protectors etc Signal wiring is defined as velocity command feedback enable lines and low level logic signal lines Feedback command signal and other shields must be insulated from each other and terminated as specified in this chapter This helps to minimize radiated and induced noise problems and ground loops Refer to the paragraph entitled Grounding Open ended shields must be insulated so that they do not accidentally cause ground loops All analog signals to and from the drive use twisted shielded pairs The typical installation practice is to terminate the shield at the signal source end While this usually gives good results there may be systems that require other shield grounding schemes for best results If noise is a problem with the typical shield grounding methods try terminating the shields at the load end or at both ends and evaluate the results There is no single solution that is best for all situations Chapter 8 Wiring Grounding All equipment and components of a machine or process system shall have their chassis connected to a common earth ground point
139. ory operation on the machine Effectively droop assures smooth quiet operation at rest or very low speeds and tends to minimize small shaft disturbances If two servo mode speed ranges are being used remove the 24V DC from the Servo Input Scaling input to select the low operating speed range Repeat step 15 If the 8510 drive must perform the spindle orient operation verify that all of the ORIENT SETUP FEEDBACK DEFN parameters are correctly set for the type of feedback device being used Verify that the GEAR RANGES SET RATIO parameters accurately define the ratio between the motor and the spindle being oriented Incorrect settings for either of these parameter groups will cause a drive fault when orient is attempted While the drive is running apply 24V DC to the Orient Command input The motor should slow to orient speed and then orient to the target position either preset or entered via the optional digital inputs If it continues to run at the low orient speed the feedback phasing must be reversed Use the ORIENT SETUP FEEDBACK DEFN Phasing parameter to reverse the feedback phasing The orient function gives an exponential deceleration to the target position The effective position loop gain is defined by the setting of the ORIENT TUNE Orient Speed and ORIENT TUNE Orient Start parameters The effective gain can be increased by either increasing the Orient Speed parameter or reducing the Orient Start
140. oubleshooting No 35 36 Table 11 H Continued Other Faults that Indicate Control Hardware Malfunction Problem Probable Cause Possible Solutions Main CPU1 Err Hardware malfunction 1 Verify that EPROM chip on Main Control Board CPU Board on displayed The A04 A06 drive is inserted correctly master cpu on the Main Control Board 2 If problem remains replace Main Control Board CPU Board on A04 A06 drive CPU Board on A04 A06 drive malfunctioned Main CPU2 Err Hardware malfunction 1 Verify that EPROM chip on Main Control Board CPU Board on displayed The A04 A06 drive is inserted correctly slave cpu on the Main Control Board CPU Board on A04 A06 drive 2 If problem remains replace Main Control Board CPU Board on A04 A06 drive malfunctioned S 37 38 Main RAM Init Hardware malfunction Replace Main Control Board CPU Board on A04 A06 drive displayed Function al error detected in RAM on Main Control Board CPU Board on A04 A06 drive Main CPU Ovfl Firmware error or hardware 1 Verify that both EPROMs on Board and Main Control Board displayed CPU on malfunction are inserted correctly 2 If problem remains replace Main Control Board CPU Board A04 A06 drive ran A04 A06 drive If problem recurs contact Allen Bradley out of execution eny 39 Optical Intpt Bright flash of light triggered the 1 Assure that the rubb
141. ovides the information needed to properly install the 1327A AC Motor Included are environmental conditions that must be met and physical mounting considerations The following items must be considered when mounting the 1327A motor The motor can be mounted horizontally or vertically with the shaft down or up Horizontally mounted 1327AD Series motors must always be mounted with the terminal box on top of the motor If other orientations are required contact the factory for special motor modifications The motor is fan cooled with air flow from the drive end to the fan end Both air inlets and outlets must be free of obstructions Maintain a clearance of at least 150 mm 6 inches at the fan exhaust area When mounted the motor must not be exposed to direct splash or spray of cutting fluids or lubricating oils Flange mounted motors include a labyrinth type shaft seal with flinger which provides excellent protection against oil splash However it will not provide protection against oil flooding Important If mounted into a gearbox assure that the lubricating oil level is about one shaft diameter distance below the bottom of the motor shaft The points listed below must be considered when making mechanical connections to the motor Assure that the motor is aligned with the shaft parallel to the driven shaft The motor has been precision balanced with a half height key installed in the keyway During
142. ower Supply 5 Current Fault Resolver Loss 6 Current Fault Spd Error HI 22 Current Fault Sp Mtr 1 P Er 56 Current Fault Sp Mtr 2 P Er 57 Fault I O Board Bad EEPROM 45 Fault I O Board Bad Optional A D 46 Fault I O Board EEPROM Sumchk 47 Fault I O Board H8 CPU RAM 48 Fault I O Board I O DURM 49 Fault I O Board LCD Timeout 50 Fault Board Misc Messages 51 Warning EEPROM No Data 44 The basic approach to hardware maintenance is to replace the I O Board Control Board or complete power section Component level repair of any board or the power section is not a recommended field repair procedure 11 118 Chapter 11 Troubleshooting ATTENTION High voltage that presents an electrical shock hazard is present on the Main Control Board of the 8510A A11 x2 and 8510A A22 x2 drives The upper right half of the board contains the IGBT gate drive circuits while the upper left quarter contains the power supply DC bus voltage approximately 325V DC is present in both of these areas These areas contain the voltage warning symbol see example and are outlined with a heavy white line To avoid injury only qualified personnel should perform start up or maintenance procedures on this drive ATTENTION This product contains stored energy devices To avoid hazard of electrical shock verify that all voltage on the capacitors has been discharged before attempting to service repair or remove this unit A relay connects a resisto
143. position feedback interface and fault diagnostics system Gate Drive Board Used on 8510A A04 x1 and 8510A A06 x1 drives only This board contains the IGBT gate drive circuits with fuses logic power supplies with fuse resolver feedback interface and dual winding motor contactor control interface Power Board Interconnects all items in the power structure to minimize power wiring The board includes the snubber networks power filtering control relays and AC control fuses The following assemblies are mentioned in the sections that follow Locations are not shown in Figure 11 1 but will be described in text as appropriate Interconnect Boards These are three small circuit boards used to interconnect signals from the Power Board to the Main Control or Gate Drive Board Power Unit The Power Unit is the complete drive structure less the I O and Main Control Board or CPU and Gate Drive Boards Chapter 11 Troubleshooting Figure 11 1 Circuit Board Locations Board CPU Board Gate Drive Board Power Board Bottom View of 8510A A04 A06 Drive Main Control Board Board
144. pplied replace I O Board If problems were not found with other tests replace Power Unit Verify that AC line voltage is between 180 252V AC 1 Check seating of Interconnect Board into board connectors CN6 and CN7 CN14 on A04 A06 drives 2 Remove Interconnect Board from CN6 and CN7 CN14 and inspect contacts in both connectors to assure that they are making proper contact with the Interconnect Board Make certain it is inserted correctly so that blank side if any is towards outside of drive 3 Remove Control Boards and check for any loose hardware on Power Board In particular check connections to the terminal block AC line inductor and IGBT modules M4 M5 and M6 or IGBT2 in A04 A06 drive Check IGBT modules M4 M5 and M6 or IGBT2 in A04 A06 drive according to the IGBT Test Procedure presented later in this chapter Replace Power Unit if IGBT is malfunctioning If problems were not found with other tests replace Power Unit If problems were not found with other tests replace Main Control Board Gate Drive Board and possibly CPU Board on A04 A06 di LLL 11 122 No 10 Problem Convrtr Short displayed Current sensed by DC link current sensor CT R was too high Usually indicates problem with IGBTs in converter bridge Motor Short dis played Current sensed by motor phase current sensors CT U or CT V was too high Usually indicates a problem with the motor or motor wiring
145. pply and Ground CN2 5 amp 3 Control power 12V DC to the magnetic sensing head Refer to page 1 6 for a complete description of this function When using a dual winding motor a pair of contactors are connected between the drive and the motor to perform the winding selection The contactor coils and auxiliary switches are wired to CNI Refer to Figure 7 3 for the connector location and Chapter 8 for specific wiring instructions Allen Bradley Bulletin 100 contactors with 24V DC coils are used to perform the winding selection Refer to the following table for the specific contactor type required for each motor type 2 required Table 7 A Required Contactors Motor Catalog Contactor Part Number 1327AD ABL 04 100 A18 NZ243 1327AD ABL 06 100 A18 NZ243 1327AD ABL 08 100 A38 NZ243 1327AD AAK 11 100 A38 NZ243 1327AD AAK 15 100 A38 NZ243 High Speed Winding Select Command CN1 2 amp 3 Contact output to complete the 24V DC coil circuit and close the contactor that connects the motor winding into a A configuration for high speed operation Low Speed Winding Select Command CN1 4 amp 5 Contact output to complete the 24V DC coil circuit and close the contactor that connects the motor winding into a Y configuration for low speed operation High Speed Winding Selected Feedback CN1 18 amp 11 High speed contactor auxiliary switch input to indicate that the high speed contactor has closed Low Speed Winding Selected Feed
146. primarily to support the installation of 8510 AC Spindle Drive System It is a standard document that is intended to help the user understand some of the operating characteristics and limitations of this equipment including hazards associated with equipment handling installation and wiring procedures Note the following points v This equipment has been designed to meet the requirements of a component in an integrated system It must be noted that special considerations are to be given to characteristics of other peripheral solid state control equipment and the cumulative impact on safety v Manufacturers and engineering groups responsible for specification or design of electrical control equipment must refer to applicable industry standards and codes for specific safety guidelines and interface requirements v the actual factory environment the user is responsible to assure compliance with applicable machine and operator safety codes or regulations which are beyond the scope and purpose of this document Chapter 1 Introduction General Precautions In addition to the precautions listed throughout this manual the following statements which are general to the system must be read and understood Drive System and associated machinery should plan or implement the installation start up and subsequent maintenance of the system Failure to comply may result in personal injury and or equipment damage ATTENTION Only personnel
147. procedures on this drive Chapter 9 Start Up avoid hazard of electrical shock verify that all voltage on the ATTENTION This product contains stored energy devices To capacitors has been discharged before attempting to service repair or remove this unit A relay connects a resistor across the DC bus to discharge the capacitors Normally the capacitors will discharge within 15 seconds An LED on the upper right side of the Main Control Board on 8510A A11 x2 and 8510A A22 x2 drives will be illuminated when the bus voltage is above 50V DC Prior to performing the following procedure installation and wiring should have been performed as explained in Chapters 5 6 7 and 8 1 o 2 o 3 o 4 o 5 o 6 o 7 o 8 Verify that the 8510 drive has been correctly wired in accordance with Chapter 8 of this manual Assure that all AC input power is removed from the drive Remove the AC line input fuses mounted outside of 8510 drive Apply AC power Use a voltmeter to measure the voltage at the AC line fuse block The voltage must be as follows 50 Hz power Voltage must be between 180 242V AC 200 220V AC 10 60 Hz power Voltage must be between 180 253V AC 200 230V AC 10 Important AC line voltage greater than the voltages stated will overheat the coil in the main AC contactor and significantly shorten its life Remove the AC power and replace the AC line fuses Apply AC power to the 8510 d
148. ptional Converter True 14 bits over 10 DC or 1 22 mV 1 LSB Sample Rate 0 8 ms Noise Filtering Baluns Capacitors and Clamp Diodes The drive continuously samples to determine long term zero reference drift of the analog circuitry within the drive and compensates for this drift Analog Outputs The two analog outputs are single ended outputs suitable for driving voltmeter displays or providing input signals to other electronic control devices The outputs have the following characteristics Output Voltage 10V DC D A Resolution 12 bits over 10 DC or 11 bits over 0 10V DC 4 88 mV 1 LSB Output Update Interval 1 6 ms Output Current 1 mA typical short circuit protected Output Impedance 440 Ohms Noise Filtering Baluns and Capacitors Output Output capable of driving normal loads such as meters and analog input circuits through normal shielded or unshielded cables The outputs can be configured through programming to provide either unipolar or bipolar outputs The unipolar output represents the absolute value of the variable while the bipolar output represents both magnitude and direction of the variable Serial Port The Serial Port can be jumper configured for RS 422 or RS 232 serial communications with a baud rate of 9 600 baud 7 55 Chapter 7 Interface Signal Descriptions Interface Signal Descriptions This section describes the various inputs and outputs available at the stan dard I O Interface con
149. r a drive overtemperature the fault will be changed to a hard fault and the motor will be regenerated to a stop If the condition is corrected before it converts to a hard fault the soft fault is automatically cleared and the output will again be turned On Chapter 7 Interface Signal Descriptions Improper command sequences that would cause a soft fault are application of the Forward Run Reverse Run or Orient commands prior to applying the Drive Enable input Application of the Motor Winding Select Com mand Low when the present motor speed exceeds the maximum allowable motor speed on the low speed winding would also cause a soft fault Zero Speed Indicator CN9 26 27 This output will be turned On when the motor speed drops below 20 rpm This output will be turned Off at 25 rpm At Set Speed Indicator CN9 28 29 This output will be turned On when the actual motor speed is within a percentage of the commanded speed The percentage is determined by the percent of commanded speed value programmed with the At Set Speed parameter The actual turn On band is the greater of the programmed commanded speed band or 25 rpm If either the Forward Run or Reverse Run commands are On this signal will be output at any operating speed down to zero when the conditions are satisfied Speed Level Indicator CN9 30 31 This output is turned On any time the actual motor speed is below the value programmed for the Speed Detect parameter
150. r across the DC bus to discharge the capacitors Normally the capacitors will discharge within 30 seconds An LED on the upper right side of the Main Control Board on 8510A A11 x2 and 8510A A22 x2 drives will be illuminated when the bus voltage is above 50V DC 11 119 Chapter 11 Troubleshooting Table 11 D Problems that Occur when AC Power is Applied No Problem Probable Cause 1 Display does not Loss of incoming AC power illuminate and drive and motor cooling fans do not start Loose power connection in Power Unit 2 Drive and motor Malfunctioning AC control cooling fans power fuse do not start Loose or disconnected fan wiring Possible Solutions Measure AC voltage between terminals R S and T on the bottom of the drive to verify that the line to line voltage is 180 253V AC at 60 Hz or 180 242V AC at 50 Hz Check and tighten screws that connect the Power Board to the power terminal block Check for other loose screws or connectors in Power Unit Check fuses FU2R FU2S and on A22 only FU2T and replace malfunctioning fuse 1 Verify that drive cooling fan cables are plugged into Power Board 2 Verify that motor cooling fan is properly wired to drive and Seem tor terminal blacks f R F Drive programming Malfunctioning AC control diagnostics display power fuse or 5V DC power does not illuminate supply fuse Display intensity or contrast is misadjusted Logic power supply has malfunctioned
151. r line count or number of teeth on the high resolution feedback gear If problems were not found with other tests replace Main Control Board CPU Board on A04 A06 drives Adjust SERVO MODE HI SPD RANGE P and I gains to obtain quick stopping without overshoot when the Run command is energized de energized The accel decel ramp rate setting limits the decel rate that can be obtained during orient and a slow decel rate can cause overshoot Reduce the value of the Acc Rate 1 or Acc Rate 2 parameter setting or select the quicker accel decel rate setting Reduce the value of the ORIENT TUNE Orient Speed parameter setting or increase the value of the ORIENT TUNE Orient Start parameter setting As explained in the 8510 Programming Manual publication 8510 5 2 these parameters control the orient position loop gain and define the required deceleration rate Use the ORIENT SETUP FEEDBACK DEFN Encoder Lines parameter to set the correct encoder line count or number of teeth on the high resolution feedback gear 1 Verify that connector CN2 is connected to the drive 2 Verify the wiring of the connector at the drive and at the feedback device 1 If an optical encoder is used verify that the marker pulse is present and of proper amplitude and width relative to the A and B channel outputs 2 If the high resolution magnetic feedback is used verify the output signals per Figure 11 4 Adjust the sensor relative to the gear to obt
152. rameter Names will appear with Initial Capital Letters Programmable Parameter Values will appear in quotes Since most start up difficulties are the result of incorrect wiring every precaution must be taken to assure that the wiring is done as instructed All items must be read and thoroughly understood before the actual wiring begins ATTENTION Power must be applied to the system to perform many of the adjustments specified in the following paragraphs Some of the voltages present are at incoming line potential To avoid injury to personnel and or damage to equipment only qualified service personnel should perform the following start up procedure Thoroughly read and understand the following procedure before beginning If an event does not occur while performing this start up Do Not Proceed Remove Power by opening the branch circuit disconnect device and correct the malfunction before continuing ATTENTION High voltage that presents an electrical shock hazard is present on the Main Control Board of the 8510A A11 x2 and 8510A A22 x2 drives The upper right half of the board contains the IGBT gate drive circuits while the upper left quarter contains the power supply DC bus voltage approximately 325V DC is present in both of these areas These areas contain the voltage warning symbol see example and are outlined with a heavy white line To avoid injury only qualified personnel should perform start up or maintenance
153. reliability 1 High frequency IGBT power devices minimize audible motor noise 1 Through the wall heat sinks remove most drive heat from the cabinet 1 Universal analog and discrete I O interface adapts easily to CNC systems 1327A AC Motor Overview Drive Design Features Chapter 1 Introduction The 1327A AC Spindle Motors have been specifically designed to meet the needs of modern machine tools To cover the variety of application requirements both a standard series and a dual winding series are available Some of the key features of these motors include n Small Size Advanced electromagnetic and cooling system designs provide extremely compact motors n High Speeds In the standard series 8 000 rpm maximum speed is available up to 5 5 kW 7 5 HP and 6 000 rpm through 22 kW 30 HP continuous output All motors are 1 500 rpm base speed n Precision Balance For high precision machine tools precision balance to less than 3 micron 0 00012 peak to peak vibration is standard n Wide Constant Power Range With the dual winding motors 12 1 constant power ranges can be obtained Constant power speed ranges of 500 to 6 000 rpm or 400 to 4 800 rpm can frequently eliminate the need for multi speed spindle headstocks n High Reliability The resolver feedback eliminates all electronics from the high temperature motor environment to significantly increase motor ruggedness and reliability This is combined with bear
154. riable length bar moving from the bottom up that represents the current depth level in the menu system Line 1 characters 4 16 are used to display the name of the current menu level or selected parameter The menu options or parameter value associated with the item displayed on line 1 will be displayed on line 2 Line 2 character 3 is a variable length bar moving from the bottom up that represents the current depth level in the menu system that has been selected For each level the user moves down the menu tree another bar is added to the display Line 2 characters 4 16 are used to display the options that are available at the current menu level or the value of the parameter that has been selected Display Operation Chapter 10 Display Panel amp Fault Diagnostics The 4 button keypad see Figure 10 3 is used to access the status and diagnostic systems Key functions are explained below Figure 10 3 8510 Keypad and Display 1 _DTSPERY Display DIBGHOSTICS Keypad Pressing this key will cause the display to change to the previous menu level within the DISPLAY TYPE menu section If the top item of the menu is shown the Mode key will have no effect mem Pressing this key once will cause the parameter or sub menu names shown on line 2 of the display to increment to the next possible choice for the menu listed on line 1 If this key is pressed and held the display will continuously in
155. rive Use the DIAGNOSTICS I O Output display to verify that a fault was not detected when power was applied When no faults are present the hard fault indicator the letter E should be showing on the display Program all of the drive configuration and tuning parameters according to the information in the 8510 Programming Manual publication 8510 5 2 The initial programming of the drive must be performed according to the following procedure Chapter 9 Start Up a Assure that Drive Enable and Coast to Stop are Off b Use GEAR RANGES Select Range to select gear range 1 for programming If a dual winding motor 1327AD series is being used select gear range 1L c Under GEAR RANGES Default Data select YES This assures that all parameters are initialized to the default values d Under MOTOR SELECT Catalog Num scroll down the list of motor catalog numbers and select the number that matches the motor being used in this system e Under PARAMETER SET ELECT CONFIG Drive Cat Num select the catalog number of the drive being used in this system f Complete the remainder of the configuration and presetting of drive parameters for gear range 1 or 1L g If a multi speed gearbox is being used or multiple gear range parameter sets will be used use GEAR RANGES Select Range to select gear range 2 for programming If a dual winding motor 1327AD series is being used select gear r
156. rolled drive If the TORQUE MODE Torque Enable programmable parameter is set to ENABLED the analog torque command must be applied to this input and the SERVO MODE Analog In programmable parameter must be set to INPUT 1 The Torque Mode Enable Accel Decel Rate Select input is used to switch between speed controlled operation either spindle mode or servo mode using Analog Input 1 and torque controlled operation using Analog Input 2 In torque mode the maximum analog input signal is always equal to the maximum torque capability of the drive motor combination Analog Outputs Analog Output 1 CN9 42 43 44 Analog Output 2 CN9 45 46 47 The two analog outputs can be programmed to output one of several different control variables These variables include Chapter 7 Interface Signal Descriptions Resolver Feedback Signals Motor Spindle Speed These outputs can be programmed to display either motor or spindle speed The actual motor speed is determined from the resolver feedback and can be output directly or it can be adjusted for the selected gear range and then output as spindle speed Full scale calibration is determined by the SPINDLE MODE Max Cmnd Spd parameter If spindle speed is being output the full scale calibration is at Max Cmnd Spd in the highest speed gear range The output voltage at full scale output is 8 volts If speed overshoot occurs because of improper tuning or setup the outp
157. rter is turned on and the motor is ready to operate If the Drive Enable or Coast to Stop inputs are opened the main contactor KM will be opened either after the motor has stopped or immediately depending on which input is opened If the Coast to Stop input is opened the DC bus discharge relay KM3 will be de energized which connects the bus discharge resistor across the DC bus A time delay guards against the relay being energized again until the bus discharge current has decreased to a level that will not damage the relay contacts ing it must be properly grounded The oscilloscope chassis may ATTENTION If an oscilloscope is used during troubleshoot be at a potentially fatal voltage if not properly grounded Always connect the oscilloscope chassis to earth ground When using an oscilloscope it is recommended that the test probe ground be connected to the test point labeled GND Chapter 11 Troubleshooting Figure 11 2 8510 Main Power and Control Interconnect Diagram Drive Cooling Fan FU2R FU FU2S E FU2T A22 Only To Motor Cooling Fan FW FE KM1 gt Bus Voltage Feedback s Main Motor Power AC Line 7 R e Y Y Rectifier IGBT U S are and Output v T IGBT Re
158. ssible Solutions Perform the complete drive setup programming procedure as described in the 8510 Programming Manual publication 8510 5 2 Verify that the EEPROM is properly installed in the socket If problem remains replace I O Board Verify that the EEPROM is properly installed in the socket If problem remains replace I O Board EEPROM 46 Bad Optional A D displayed The I O Board microproces sor can not communi cate with or is receiving bad data from the optional A D converter on the This version of the I O Board does not have the optional 14 bit linear A D converter installed Malfunctioning A D converter or I O Board If the drive catalog number does not end in either Cx or Dx the optional A D converter is not installed Either program drive to use standard A D converter or install I O Board that includes the optional A D converter Replace I O Board Board 47 EEPROM Sumchk displayed The I O Board microproces sor has read an incorrect check sum value from the EEPROM which indicates corrupted Data has become corrupted due to noise or some other means EEPROM is malfunctioning Perform the complete drive setup programming procedure as described in the 8510 Program
159. t an external position control loop closed around the drive 1 3 Chapter 1 Introduction 1 4 Servo Mode configures the drive to be used as a velocity servo in a closed position loop system Whenever the CNC is operating the spindle drive in a closed position loop such as during spindle orient or when performing C axis machining on a turning center this operating mode should be used In servo mode only analog speed commands can be used the acceleration rate ramp generators are disabled and a maximum integrator gain clamp is added to guard against limit cycle conditions in high friction applications The analog input scaling can be set for a different maximum speed in servo mode than is used in spindle mode An optional high speed high linearity A D converter can be added for contouring and high bandwidth applications The 8510 has ample dynamic performance to allow using it as a high power axis servo Torque Mode configures the drive to function as a torque controlled drive rather than a speed controlled drive When this mode is active the analog input is commanding a level of motor torque rather that a specific motor speed The connected load or an external control loop must provide the speed control or the motor will be accelerated to maximum speed and the drive will shut down on an overspeed condition A single digital input can instantaneously switch the drive between torque control and speed control modes Torque mode allo
160. t the selected motor and drive Catalog Num and the ELECT catalog numbers are a compatible set A 5 5 kW drive can be used CONFIG Drive Cat Num with any motor rated 5 5 kW or smaller An 11 kW drive can be used parameter values not with any motor rated from 5 5 kW through 11 kW A 22 kW drive compatible or are not can be used with any motor rated from 11 kW through 22 kW 4 fit eed AAS s O _ gt TF For the gear range selected Verify that the SPINDL PRESET Overspd Trip parameter is set to a the value for the SPINDL value other than zero The microprocessor can not find a value programmed for the SPINDL PRESET Overspd Trip parameter 54 Op Dig Set Er displayed The drive has been pro grammed to use the optional 16 bit parallel inputs for two different functions simulta neously PRESET Overspd Trip parameter is set to zero For the gear range selected Within a given gear range the optional 16 bit digital command input the SPINDLE MODE can be used as either a spindle speed command or as an orient Cmnd Source parameter has position command not both Verify that only one of these functions been set to either 4 DIGIT are programmed for the BCD or binary command input BCD or 16 BIT BINARY and the ORIENT TUNE Position Data parameter has been set to either BCD INPUT or BINARY INPUT 55 Orient Prm Er displayed One or more of the critical parameters for ori
161. te DIN 40430 PG type conduit fittings are available Both motor power and motor feedback leads can be brought through the same conduit Carefully follow all grounding and shielding procedures outlined in Chapter 8 The motor fan must be operating whenever the spindle motor is operating The motor will quickly overheat if it is operated with the fan de energized 6 52 Chapter Objectives I O Interface Chapter Interface Signal Descriptions Chapter 7 provides detailed information on the various inputs and outputs available as part of the 8510 AC Drive System Included are signal level definitions and detailed function descriptions of each I O point The universal I O interface of the 8510 provides a wide range of inputs and outputs as listed below Detailed explanations of the inputs and outputs is provided on the following pages Digital Inputs Coast to Stop Drive Enable Drive Reset Forward Run Command Reverse Run Command Low Torque Limit Select Accel Decel Rate Select Spindle Servo Mode Select Servo Input Scaling Low High Orient Command Gear Ratio Active Motor Winding Select Command Low Speed High Speed Orient Position or Digital Speed Command 16 bit binary BCD Digital Outputs Hard Fault Soft Fault Drive Ready In Position After Orient Zero Speed At Set Speed Speed Level Indicator Load Level Current Motor Winding Se
162. the torque command from Analog Input 2 Chapter 7 Interface Signal Descriptions When the Torque Enable parameter is set to Enable the Acc Rate 2 parameter is disabled The Acc Rate 1 parameter is still active in spindle mode Spindle Servo Mode Select CN9 10 This input selects the velocity loop configuration and gains for the spindle or servo operating modes Refer to page 1 3 for a description of the various control modes When this input is Off the spindle mode is active This mode is designed for basic velocity control without an external control loop The velocity input must be an analog signal at Analog Input 1 or a 16 bit digital signal on the optional Digital Speed Orient Position inputs When this input is On the servo mode is active The servo mode is designed for use in a closed position loop system This mode should be used during spindle orient operation from the CNC and during C axis operation on a turning center The velocity command must be an analog signal with the loop programmed to use either Analog Input 1 or 2 Analog Input 2 can not be used if TORQUE MODE Torque Enable has been programmed Servo Input Scaling Low High CN9 11 This input is used to switch the scaling of the analog command input while in the servo mode When this input is turned Off the maximum motor speed at maximum analog command is determined by the LO SPD RANGE parameter menu When this input is turned On the max
163. tion requires four twisted pairs The recommended cable is Madison 08CFJ00004 4 twisted pairs with shield 24 AWG Three termination options are available for the connector 1 a mating connector kit 2 a termination panel and 3 an interface cable assembly The following table shows the I O function assignment for each of these termination options 8 90 Chapter 8 Wiring Table 8 K Dual Winding Contactor Control Cable Information Description tor Pin Number Panel Terminal Wire Color and Motor Winding Select 2 Command High 2 Black 1 3 Return for High Speed 3 White 1 Setect Command 22222222222 4 Motor Winding Select 4 Red 2 ommant Lbow F 7 p Pp T O _ 5 Speed 5 Green 2 ReturrforEow Speed Select Command 11 Brown 3 Motor WiTdirrp TE Selected Confirm P High Speed 18 Blue 3 10 Return for High Speed Winding Confirm 10 Orange 4 24 17 Motor Winding Selected Confirm 1 Yellow 4 Low Speed 8 Return for Low Speed Wimdnee S2d yisimows the signal interconnect wiring for the dual winding pager control contactors Figure 8 10 Dual Winding Contactor Wiring Low Speed Contactor High Speed Contactor amp User Supplied 24V DC Supply x CN1 2 A B Motor Winding Select Cmd High Spd Lows noe PET Eu d CN1 5 Motor Winding Select Cmd Low Spd Return Mo
164. tions ALLEN BRADLEY DIGITAL AC SPINDLE DRIVE Motor Power and Ground Motor Fan Power and Ground If a 1327AD series dual winding motor is being used two additional power contactors must be mounted and wired to the drive Refer to Table 7 A for the specific contactors that are required with each motor See Figure 8 5 for the configuration of a typical terminal box on a dual winding type 1327AD series motor The externally mounted contactors used with the 1327AD series motors must be wired according to Figure 8 6 Figure 8 5 Terminal Box Dual Winding Motor Motor Power Terminal Block Ske She D Fan Power Terminal Block Connector Signal Wiring Chapter 8 Wiring Figure 8 6 Dual Contactor Wiring ALLEN BRADLEY 8510 DIGITAL AC SPINDLE DRIVE EWVUXYZ
165. tor Winding Selected High Spd EIER one CN1 10 CN1 8 Return Motor Winding Selected Low Spd Return Shield 8 91 Chapter 8 Wiring 8 92 Digital Position Speed Command Wiring When the 8510 is ordered with the or Dx I O option a 16 bit parallel digital command input can be applied through connector CN10 This command can be used for either a digital speed command or orient position command Refer to Figure 7 3 for the location of this connector on the drive The interface cable for this function requires 10 twisted pairs with an overall shield The recommended cable is Madison 20QFK00001 10 twisted pairs w shield 24 AWG Three termination options are available for the CN10 connector 1 a mating connector kit 2 a termination panel and 3 an interface cable assembly Table 8 L shows the I O function assignment for each of these termination options Table 8 L Digital Speed Position Wiring Signal Description Input 1 Bit 0 Input 2 Bit 1 Input 3 Bit2 Input 4 Bit 3 Signal Common Input 5 Bit 4 Input 6 Bit 5 Input 7 Bit 6 Input 8 Bit 7 Signal Common Input 9 Bit 8 Input 10 Bit 9 Input 11 Bit 10 Input 12 Bit 11 Signal Common Input 13 Bit 12 Input 14 Bit 13 Input 15 Bit 14 Input 16 Bit 15 Signal Common I Honda Termination Cable Assem Connector Panel Termi Wire Color Pin Num nal Number and Pair
166. ty Loop Bandwidth Programming System Drive Enclosure Type Drive Weight kg Ib Allowable Vibration Rated Ambient Temperature Storage Temperature Up to 50 Hz load and motor dependent Integral 2 line by 16 character backlit LCD display and 4 button keypad Open style IP 00 for mounting in another enclosure heat sinks extend outside enclosure 14 31 14 31 15 33 26 57 26 57 Less than 0 5 G 0 to 55 C 32 to 131 F inside enclosure 0 to 40 C 32 to 104 F at heat sinks 0 to 65 C 32 to 149 F Notes see page 2 Chapter 2 Specifications Standard Single Speed 1327AB Motor amp 8510 Drive Motor 1327AB AFL 15 AFL 19 AFL 22 Output Power Rating S1 Continuous kW HP 15 20 18 5 25 22 30 S2 30 Minute kW HP 18 5 25 22 30 30 40 S6 60 Duty kW HP 18 5 25 22 30 27 36 1 Minute Peak kW HP 22 30 26 5 36 36 48 Rated Speed Base RPM 1500 1500 1500 Maximum RPM 6000 6000 6000 Constant Power Speed Range 4 1 4 1 4 1 Rated Torque Continuous N m lb ft 95 70 119 87 5 142 105 Rated Current 30 Minute Output Amperes 112 135 153 Rotor Inertia kg m Ib in s2 0 0925 0 8186 0 1150 1 018 0 1325 1 173 Bearing Load Max Radial kg Ib 356 784 373 820 384 844 Motor Weight kg 165 130 286 150 330 166 365 Electrical Design Single winding configuration for single speed range Vibration Peak to peak vibration less than 3 microns 0 00012 inch Audibl
167. ult display messages and a Problem Number is provided This listing can be used to quickly locate an explanation of the fault in the tables that follow Display Text Line 1 Display Text Line 2 Problem Number Current Fault Abs Overspeed 16 Current Fault AC Phase Loss 4 19 Current Fault Bad Comb M amp D 52 Current Fault Bad PG Count 27 Current Fault Bad PG Marker 26 Current Fault Bad PG Output 28 Current Fault Bus Overvoltg 17 Current Fault Bus Undervolt 18 Current Fault Convrtr Short 9 Current Fault Data Conflict 14 Current Fault Drive Overtemp 21 Current Fault Hi Accel Rate 40 Current Fault Hi Positn Cmd 41 11 117 Chapter 11 Troubleshooting Current Fault Hi Positn Err 42 Display Text Line1 Display Text Line 2 Problem Number Current Fault Hi Speed Cmd 43 Current Fault Inv Mtr Short 11 Current Fault Comm Err 30 Current Fault Main A D Conv 34 Current Fault Main Comm Err 32 Current Fault Main CPU Loss 31 Current Fault Main CPU Ovfl 38 Current Fault CPU1 Err 35 Current Fault Main CPU2 Err 36 Current Fault Main RAM Err 29 Current Fault Main RAM Init 37 Current Fault Main Watchdog 33 Current Fault Max Spd None 53 Current Fault Motor Overtemp 20 Current Fault Motor Short 10 Current Fault Mtr Windg Chg 23 Current Fault Need Parametr 12 Current Fault No Precharge 8 Current Fault Op Dig Set Er 54 Current Fault Optical Intpt 39 Current Fault Orient Prm Er 55 Current Fault Parameter Err 13 Current Fault P
168. um speed command input voltages a Select the ANALOG CAL MEASURE INPUT Zero Volt In parameter and apply the actual zero speed input command from the CNC or other control system Press Select to store the value b Select the ANALOG CAL MEASURE INPUT Max Volt In parameter and apply the actual maximum speed input command from the CNC or other control system Press the Select key to store the value This completes the analog channel calibration for spindle mode Velocity loop compensation can be tuned while the drive is enabled The step response of the drive can be tested by applying and removing the speed command or by turning the Forward or Reverse Run input On and Off Basic adjustment can be obtained by observing the motor shaft or spindle as the motor stops in response to a step command The Spindl P Gain and Spindl I Gain should be adjusted to give a smooth quick stop without visible motor reversal When running the motor should not make growling or rumbling noises Excess motor or gear box noise indicates excess torque ripple and excess gain The general effect of the P and I gain parameters is Increasing P shortens response time and increases bandwidth Increasing I increases bandwidth and quickens system response to load and command transients Static velocity error is eliminated Too much P will cause high frequency oscillation Too much I will cause overshoot of commanded speed or low frequency oscil
169. uous Power 3 A 5 Ziya n 5 6 120 6 32 5 5 s 6 3 Te 60 3 Continuous Torque 16 Continuous Torque 0 0 0 0 00 02 04 0 6 08 10 12 14 16 18 20 22 0 1 2 3 4 5 6 Motor rpm x 1000 Motor rpm x 1000 1327AD ACL 08 F low speed winding 1327AD ACL 08 F high speed winding 8510A A11 x2 8510A A11 x2 15 300 15 150 30 Minute Power 749 12 30 Minute Power 120 pot ee 2 Peak T 5 Peak T 5 eak Torque eak Torque 5 9 a 180 4 o Continuous Power Continuous Power 3 o a o 6 120 6 60 5 5 3 Continuous Torque em 60 3 30 Continuous Torque 226 0 0 0 0 0 0 0 1 02 0 3 04 0 5 0 6 07 0 8 09 1 0 14 12 13 14 15 0 1 2 3 4 5 6 Motor rpm x 1000 Motor rpm x 1000 1327AD AAK 11 x low speed winding 1327AD AAK 11 x high speed winding 8510A A11 x2 8510A A11 x2 20 500 20 200 16 30 Minute Power 00 16 30 Minute Power 160 on _ _ Peak Torque Peak Torque 12 Continuous Power 30070 12 Continuous Power 120 I VAUY ODO p 5 5 5 8 200 8 8 80 8 o 8 4 Continuous Torque ad 100 4 40 Continuous Torque 0 0 0 0 0 0 04 02 03 04 05 06 07 08 09 10 14 12 13 14 0 1 2 3 4 5 Motor rpm x 1000 Motor rpm x 1000 2 15 Chapter 2 Specifications Figure 2 1 continued Motor Curves 1327AD AAK 15 x low speed winding 1327AD AAK 15 x high speed winding 8510A A22 x2 8510A A22 x2 30 600 30 300 25 500
170. usec Devices that produce a strong magnetic field e g chokes transformers and reactors must not be mounted closer than 254 mm 10 in to the drive The associated wiring to any of these devices must be physically separated from any low level signal wiring to minimize induced voltages Power Wiring Chapter 8 Wiring AC Input Power To the 8510 Drive AC line input terminals are located at the bottom of the drive as shown in Figure 7 3 Input current requirements and wire size are dependent on the motor kW rating and the AC line voltage The following table defines the drive AC line input current requirements at a nominal 220V AC line voltage and at the low line voltage limit of 180V AC Wire sizes are selected per NFPA 79 and IEC 204 for wires in a cable or raceway and are based on 75 C wire 70 C for IEC 204 Table 8 D AC line Input Current Requirements Motor Power 30 Minute Current Rating Wire Size 1 Cont 30 Min kW at 220V AC at 180V AC i 221341 15 18 3 7 5 5 22A 27A 5 5 7 5 30A 37A 12 2 5 7 5111 42 51 10 4 0 Ne I 11 15 55A 67A 15 18 5 65A 79 S 100 18 5 22 78 95 6 16 0 22130 100A 122A 4125 0 2 1 AWG wire sizes are based on 220V 10 with 75 C wire TRe AM wire sizes are based on 70 C wire For other input voltages select wire size according to local electrical codes If 90 C wire is used the wire sizes can be reduced about one wire size Refer to the N
171. ust be applied after the Forward Reverse Run commands Gear Ratio Active 1 2 CN9 14 15 Refer to page 1 4 for a description of this function These two inputs inform the drive of the gear range selected on the machine Based on these inputs the drive will select the appropriate group of programmed parameters for optimized performance in each gear range Up to four gear ranges can be used Gear Ratio Active Input 1 2 Gear Range 1 Selected Off Off Gear Range 2 Selected On Off Gear Range 3 Selected Off On Gear Range 4 Selected On On Not available when a dual winding motor is used Motor Winding Select Low High CN9 16 Refer to page 1 6 for a description of this function When this input is Off a two winding motor will be operating with the low speed winding When the input is On the high speed winding of a two winding motor will be selected If the drive is running and this input is turned On the drive will initiate the winding change action in less than 30 ms If the drive is running and this input is turned Off the winding change action will be initiated in less than 30 ms if the motor speed is within the speed range of the low speed winding If the current speed is faster than the maximum speed on the low speed winding the winding change will be delayed until the commanded and actual motor speed is reduced to a speed that is within the operating range of the low speed winding Within 150 200 ms after beginni
172. ut can go to 10 volts or 125 of full scale calibration By parameter selection this output can be programmed to be either a unipolar or a bipolar output In the bipolar mode this output can be used as an analog tachometer output updated at a 1 6 ms rate Load This is a unipolar output that indicates the level of commanded torque output as a percent of the torque that can be generated at that specific speed If the drive operates at maximum torque output from zero speed to base speed and maximum power output from base speed to max speed the output will be 10V DC throughout the entire range Full scale output is the maximum overload rating of the motor and drive combination i e 120 of the intermittent 30 minute duty rating Torque This output is identical to Load except that it is a bipolar output This output can be used as a set up monitoring point or as a torque command to a slave drive in a master slave drive combination Power Output This output is a unipolar representation of motor power in kW throughout the entire speed range Full scale is the maximum overload rating 120 of the intermittent power rating of the motor drive combination Orient Error In the orient mode the position error is shown as the spindle is oriented to the final position The full scale range of this output is 2 degrees of the target position Connector CN3 is used to connect the resolver and thermal switch that are located in the 1327A seri
173. was detected Table 11 F Chapter 11 Troubleshooting Problems that Occur while the Drive is Operating Probable Cause Resolver phasing is incorrect Motor phase is open Resolver or resolver wiring is malfunctioning MOTOR SELECT Catalog Num and or ELECT CONFIG Drive Cat Num programmed as NONE SELECTED when the Coast to Stop input is turned On Overspd Trip parameter set too low relative to commanded speed Motor disconnected from load while drive in torque mode Excess overhauling load Malfunctioning resolver or resolver signals Malfunctioning printed circuit board Possible Solutions Use the programming parameter ELECT CONFIG Motor Phasing to reverse the relative phasing of the motor to the resolver Check all power wiring to the motor for continuity and tight connections Use an ohmmeter to verify phase to phase continuity for each motor phase When 1327AD series dual winding motors are used check both winding change contactors for proper operation Refer to fault condition 6 for solutions Correctly program the MOTOR SELECT Catalog Num and ELECT CONFIG Drive Cat Num parameters before applying 24V DC to the Coast to Stop input Increase setting of Overspd Trip parameter or reduce setting of Max Spd parameter The overspeed trip point should be set about 10 higher than the maximum command speed to avoid nuisance trips Important If the Overspd Trip parameter is
174. will result in an Off condition Inputs must be pulled high by the external signal to obtain an On condition An On condition requires an input between 18 and 30V DC at no more than 10 mA The reference or ground side of the user supplied source voltage should only be connected to the drive through the Digital Ground terminals on the and CN10 I O connectors All inputs are filtered and electrically isolated to withstand voltage impulses in accordance with 01 508 Digital inputs are read at 102 4 ms intervals Digital Outputs The digital outputs use dry contact relays rated 200 mA at 24V DC The relays provide isolation for the control electronics against voltage impulses in accordance with UL 508 Unless otherwise noted when the output is On the relay will be energized and the contact closed Chapter 7 Interface Signal Descriptions Analog Inputs The analog inputs are single ended inputs with the following characteristics Maximum Input Voltage Range 10V DC A D Converters Two converters selectable via software controlled analog switches Standard converter for spindle and positioning applications and optional converter for continuous path contouring applications and torque mode operation A D Resolution Standard Converter Effective 14 bits over 10V DC or 1 22 mV 1 LSB Within 0 039 lt x lt 0 039 range 0 076 mV 1 LSB Sample Rate Small Input Change 0 8 ms Large Input Change lt 26 4 ms A D Resolution O
175. wn 2 Forward Run 4 5 Pink 2 Reverse Run 5 6 Red 3 Low Torque Limit Select 6 7 Pink 3 Digital Ground 7 8 Orange 4 Accel Decel Rate Select 8 9 Pink 4 Spindle Servo Mode Select 9 10 Yellow 5 Servo Input Scaling Low High 10 11 Pink 5 Digital Ground 11 12 Green 6 Orient Command 12 13 Pink 6 Gear Ratio Active 1 13 14 Blue 7 Gear Ratio Active 2 14 15 Pink 7 Motor Winding Select High Low 15 16 Black 8 Digital Ground 16 17 White 8 Digital Outputs 000 Current Motor Winding Selected 18 Current Motor Winding Selected 18 19 Red 10 Return 19 20 White 10 Drive Ready 20 21 Orange 11 Drive Ready Return 21 22 White 11 Hard Fault 22 23 Yellow 12 Hard Fault Return 23 24 White 12 Soft Fault 24 25 Green 13 Soft Fault Return 25 26 White 13 Zero Speed Indicator 26 27 Blue 14 Zero Speed Indicator Return 27 28 White 14 At Speed Indicator 28 29 Violet 15 At Speed Indicator Return 29 30 White 15 Speed Level Indicator 30 31 Gray 16 Speed Level Indicator Return 31 32 White 16 Load Level Indicator 32 33 Pink 17 Load Level Indicator Return 33 34 White 17 In Position 34 35 Black 18 In Dosition R 25 EE 36 Analog Input 1 36 37 Red 1 Analog Input 1 Return 37 38 Black 1 Shield 38 39 Drain 1 Analog Input 2 39 40 White 2 Analog Input 2 Return 40 41 Black 2 Analog Qutputs _n B Analog Output 1 42 43 Green 3 Analog Output 1
176. ws the drive to operate as the torque follower in leader follower or anti backlash dual drive configuration Some motion control systems close both the position and velocity loops from a single feedback device and output torque commands to the drive amplifier In torque mode the 8510 can be used with these motion control systems Optimized Performance For Multi Speed Gear Boxes Many multi speed spindle gear boxes provide very different drive loading or have different performance requirements in each gear range Some directly driven spindles may have large differences in load inertia or performance requirements in certain situations To provide optimum performance in each of these different situations the 8510 drive can store totally independent sets of all drive configuration and tuning parameters for up to four different gear ranges or sets of operating conditions Two binary coded digital inputs allow the CNC or other control system to select the appropriate parameter set while the drive is running Changeover takes only about 30 milliseconds Since all configuration parameters can be changed for each data set this feature could be used to select multiple preset orient positions change the maximum speed at maximum command scaling or change any of the preset speed or load detectors in addition to optimizing the dynamic response of the drive This flexibility can help eliminate the need for making performance compromises in different operating c
177. y 14 bit A D converter for use in continuous path contouring applications This I O option should be used when the 8510 will be used for C axis solid tapping and large servo axis applications or will operate in Torque Mode Drive Model 8510A Axx Dx This version combines the features of both Option B and Option C It would be used for lathe applications requiring C axis operation and multi position orient or indexing with external position commands Chapter 1 Introduction System Accessories Various accessories are available for the 8510 to facilitate system installation or to support the drive system Mating Connector Kits All signal interconnections to the 8510 utilize Honda multi pin connectors Mating connector kits are available for all the Honda connectors A mating connector kit is also available for the AMP connector used for feedback from the motor Termination Panels and Cables As an alternative to terminating all signal wiring to the Honda connectors termination panels with cables are available to fan out the connections to conventional barrel type terminal blocks Cables in various lengths with a Honda connector on one end are also available for termination directly to the machine control panels High Resolution Spindle Position Feedback The high resolution magnetic feedback consisting of a precision ring gear and a pickup unit can be used for high accuracy spindle orient This system can provide
178. y if fault occurs during accel or when the motor is running under heavy load See Table 8 C Malfunctioning IGBT module in Check IGBT modules M4 M5 and M6 or IGBT2 in A04 A06 converter bridge drive according to procedure later in this chapter Replace Power Unit if IGBT is malfunctioning Malfunctioning printed circuit Replace the Main Control Board Gate Drive Board and possibly board CPU Board on A04 A06 Malfunctioning Power Unit If problems were not found with other tests replace the Power Unit 11 126 No Problem 20 Motor Ovrtemp displayed The drive detected that the thermal switch in the motor has opened Chapter 11 Troubleshooting Table 11 F Continued Problems that Occur while the Drive is Operating Probable Cause Motor is overloaded by existing duty cycle Motor fan not operating Insufficient air flow through motor cooling passages Incorrect motor selected in MOTOR SELECT Catalog Num parameter Motor thermal switch or wiring through resolver cable has malfunctioned Malfunctioning printed circuit board Possible Solutions When the motor cools the thermal switch will close and the fault will clear Reduce duty cycle loading or increase size of motor drive system 1 Measure voltage at fan terminal block in motor terminal box If voltage not 200 to 230V AC when AC power is applied to the drive check fuses FU2R FU2S and FU2T on A22 drive only and wiring to fan 2

8510 AC Spindle Drive System

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