Indramat TDA 1 Technical manual

TDA 1
Main Spindle Controller
DOK-DIAX01-TDA********-PRJ1-EN-P
Project Planning Manual
mannesmann
Rexroth
engineering
Indramat
255533

2
• DOK-DIAX01-TDA********-PRJ1-EN-E1,44 • 07.97

3
• DOK-DIAX01-TDA********-PRJ1-EN-E1,44 • 07.97
Section
About this documentation
___________________________________________________________________
Contents
___________________________________________________________________________________________________
Presentation of the modular Main Spindle Controller TDA 1 1
___________________________________________________________________________________________________
Control cabinet design 2
___________________________________________________________________________________________________
AS programming module 3
___________________________________________________________________________________________________
Condition as-delivered 4
__________________________________________________________________
Equipment identification 5
___________________________________________________________________________________________________
Storage and transportation 6
__________________________________________________________________
Assembly 7
__________________________________________________________________
Installation guidelines 8
___________________________________________________________________________________________________
Comissioning guidelines 9
___________________________________________________________________________________________________
Servicing guidelines 10
__________________________________________________________________
Index 11
___________________________________________________________________________________________________
Supplementary documentation 12
___________________________________________________________________

4
• DOK-DIAX01-TDA********-PRJ1-EN-E1,44 • 07.97

5
• DOK-DIAX01-TDA********-PRJ1-EN-E1,44 • 07.97
About this documentation
TDA 1
Main spindle controller
Project Planning Manual
DOK-DIAX01-TDA********-PRJ1-EN-E1,44
• Mappe 7
• TDA1-PJ.pdf
• 209-0042-4112-01
This electronic document is based on the hardcopy document with document
desig.: DOK-DIAX01-TDA********-PRJ1-EN-P • 09.94
– to present the controller
– to mechanically integrate the controller into the control cabinet, and offer
guidelines on assembly and installation.
– to describe the AS programming module
– to illustrate the equipment delivered and their storage conditions
This documentation provides references to supplementary technical docu-
mentation
– for commissioning, operation and servicing
– for electrically integrating the controller, since all standardised electrical
connections for main spindle drives are contained in a separate document
– by means of the "Supplementary Overview", listing all technical documen-
tation for main spindle drives and their contents
– by means of the "Supplementary Documentation", listing all titles with their
order numbers
Titel
Type of documentation:
Documenttype
Internal file reference
Reference
This documentation
is used:
© INDRAMAT GmbH, 1994
Copyingofthisdocument,andgivingittoothersandtheuseorcommunication
ofthecontentsthereof,areforbiddenwithoutexpressauthority.Offendersare
liable to the payment of damages.
All rights are reserved in the event of the grant of a patent or the registration
of a utility model or design. (DIN 34-1)
The electronic documentation (E-doc) may be copied as often as needed if
such are to be used by the consumer for the purpose intended.
All rights reserved with respect to the content of this documentation and the
availability of the products.
INDRAMAT GmbH • Bgm.-Dr.-Nebel-Straße 2 • D-97816 Lohr
Telefon 0 93 52 / 40-0 • Tx 689421 • Fax 0 93 52 / 40-48 85
Dept ENA (MR, FS)
Copyright
Validity
Publisher
Designation of documentation Release- Coments
up to present edition date
DOK-DIAX01-TDA********-PRJ1-EN-P Sep/94 New Edition
DOK-DIAX01-TDA********-PRJ1-EN -E1,44 Jul./97 First E-Dok
Change procedures

6
• DOK-DIAX01-TDA********-PRJ1-EN-E1,44 • 07.97

7
• DOK-DIAX01-TDA********-PRJ1-EN-E1,44 • 07.97
Table of Contents
Table of Contents Page
1. Presentation of the modular main spindle controller TDA 1 9
2. Control cabinet design 14
2.1. Operating conditions ............................................................ 14
2.2. Mechanical data ................................................................... 16
2.3. Thermal data ........................................................................ 19
2.4. Electrical data....................................................................... 22
2.5. Overview of technical data ................................................... 29
2.6. Type codes........................................................................... 30
3. Programming Module AS 31
3.1. AS programming module versions ................................... 32
3.2. AS programming module compatibility ........................... 32
3.3. Rating plate......................................................................... 33
3.4. Type codes.......................................................................... 34
4. Condition as delivered 35
5. Equipment identification 36
6. Storage and transportation 38
7. Assembly 39
8. Installation notes 41
9. Commissioning guidelines 42
10. Servicing notes 43
10.1. Fault diagnosis.................................................................... 43
10.2. Unit replacement ................................................................. 43
11. Index 45
12. Summary of supplementary documentation 48

8
• DOK-DIAX01-TDA********-PRJ1-EN-E1,44 • 07.97

9
• DOK-DIAX01-TDA********-PRJ1-EN-E1,44 • 07.97
1. Presentation of the modular main spindle controller TDA 1
Fig. 2: Modular main spindle controller TDA 1
1. Presentation of
the modular main
spindle controller
TDA 1
The main spindle controller TDA 1 is dedicated to the intelligent digital
control of INDRAMAT asynchronous main spindle motors 2AD and
frameless spindle motors 1MB with a continuous power rating of 3 to 10
kW at the motor shaft.
DrivesequippedwiththecontrollerTDA1aredistinguishedbytheirhigh
stiffnessandawidespeedrangeatconstantpower.Theyare,therefore,
particularly suited for use as a main spindle drive on numerically
controlled machine tool centres.
Besidesits wide speedrange, an a.c.main spindledrivewith TDA1has
an integral position control circuit capable of automatically positioning
thespindle (e.g.,for workpiecechange) witha maximumresolution of1/
4 000 000 revolutions in response to a signal. The internal controller
positionloopisclosedeitherbythemotorfeedbacksignal(fordirectdrive
or gear ratio 1:1) or by an additional, optional spindle feedback signal
(switchable gear, belt-driven gears).
Main Spindle Drive
Spindle positioning

10
• DOK-DIAX01-TDA********-PRJ1-EN-E1,44 • 07.97
The TDA 1 operates in conjunction with other controllers for feed axes.
Acombinationofpowersupplymodule,modularmainspindleandservo
drive controllers permits individual matching of the drive to the task of a
CNC machine tool.
Fig. 3: Drive package with modular main spindle controller TDA 1
Power supply
module TDA 1 Servo drive controllers
The a.c. main spindle drive with TDA 1 is also capable of operating the
spindle as a servo axis (C-axis) with a high-accuracy position control
loop. The main spindle motor is fitted with a high-resolution motor
feedbackdevicetocopewiththelowspeedsrequiredinthisapplication.
The controller detects the rotor position with a maximum resolution of 1/
2 000 000 revolutions, thus allowing even the lowest speeds to be
precisely controlled.
Since the spindle operates as an interpolating axis in C-axis mode and
the NC controls require information on the spindle position, the TDA 1
supplies compatible position signals for incremental encoders through
an optional output. The increments are derived either from the high-
resolution motor feedback device or from an additional, optional spindle
feedback device. The spindle feedback, in the latter case, is a high-
resolutionmainspindlepositionencoderfromINDRAMAT.Itismounted
directlyontothespindle.Thedefinitionoftheincrementalencoderoutput
isselectableandprovidesamaximumresolutionof360000increments/
revolution in C-axis mode.
1. Presentation of the modular main spindle controller TDA 1
C-axis mode
Controller for modular
drive package
Incremental encoder output

11
• DOK-DIAX01-TDA********-PRJ1-EN-E1,44 • 07.97
1. Presentation of the modular main spindle controller TDA 1
The controller TDA 1 has been designed to operate with parameters.
Parameter values are used to match the controller to the main spindle
motor, the machine conditions and the requirements of the application.
Parameters
Fig. 4: Designation of TDA 1 features
Control voltage bus, design.
Digital position command, design.
Earth connection
Incremental encoder output, design.
Interfaces, feedback
Interfaces, NC control unit
Motor feedback connection, design.
Motor thermistor connection, design.
Position command design.
Programming module, design.
Ready contact, design.
Serial interface, design.
Signal outputs, design.
Speed command, design.
Standard interface, design.
Synchronization input, design.
Terminal block for motor and DC link
Typisierung:
Fertigungsnummer:
X1
ATTENTION!
BLOWER SUPPLY VOLTAGE
Lüfterspanngung
220VAC
X8
L+
L-
A3
A2
A1
DANGER HIGH VOLTAGE
AC - MAINSPINDEL DRIVE
READY FAULT
X11
Bb Bb X3 X5
X2 X4
Parameter
MOTOR POWER OUTPUT
Motoranschluß
1 2 3
T1 T2
X12
SWITCH OFF
VOLTAGE BEFORE
CHANGING MODULE
AS
Prog. ModulAS
nicht unter
Spannung wechseln
DANGER POWER
300 VDC INPUT
DISCHARGE TIME
Entladezeit > 1 Min.
POWER SUPPLY OUTPUT
VOLTAGE RATING, MUST
NOT EXCEED POWER
INPUT VOLTAGE DATA
Nur mit Versorgungsein-
heit gleicher od. kleinerer
POWER-Spannungs-
angabe betreiben
Motor: Contr.: Software: Parameter: Serien-Nr.:
Earth connection
Programming moduleAS 7
Motor thermistor
connection
Terminal block
for motor and
d.c. link circuit
Control panel
Connection for
"ready" contact Additional interface (X6, optional)
- digital position set-point, 16 bit parallel
- incremental encoder output
- serial interface RS 232C
Interfaces for NC:
• Control inputs,
signal and analogue outputs
(X2, standard interface)
• Speed command value (X4)
- analogue ±10V (optional)
- digital 16 bit parallel (optional)
- Sercos interface (optional)
Interfaces for feedback:
• Motor feedback connection
(X3)
• Additional encoder input for
spindle feedback or second
motor feedback signal (X5, optional)
• Synch. input for
master spindle feedback
(X5a, optional)
Front.FH3
X5a
Connection
for control
voltage bus

12
• DOK-DIAX01-TDA********-PRJ1-EN-E1,44 • 07.97
Programming module Thevariousparametersrelatingtoboththemachineandtheapplication
areenteredonsiteduringcommissioningusingthekeypadonthecontrol
panel. Together with the parameter values for motor matching, these
parameter values are stored in the controller’s plug-in programming
module.
Intheeventofa faultrequiringunitreplacement,only thecontrolleritself
is replaced, the programming module being transferred to the new
controller.Thecharacteristicsofthedrivearestoredintheprogramming
module and are therefore immediately available on re-start.
1. Presentation of the modular main spindle controller TDA 1
Interface options
The controllers can be supplied with a variety of speed command
interfaces:
• Analogue speed command
±10 V for connection to commercially available NC controllers,
• Digital speed command
16bitparallel for connection toPLCs, useful in thecaseof long cables
and small command values,
•SERCOS interface
forrealtimecommunicationwiththeNCcontrollerrelatingtocommand
and actual value of speed, position and torque, including parameter
handling.
An additional encoder input is available for connection of a spindle
feedback signal to the controller’s internal position loop. For spindle
synchronisation, both the additional encoder input and a synchronous
input (connection for master spindle feedback signal) are supplied.
ThecontrollerTDA1alsocomprisesanadditionalinterface,availableas:
•Incremental encoder output
for position control by the NC controller in C-axis mode or for thread
cutting,
•Serial interface
for saving and loading parameter values using a PC,
•Input for digital position command
16 bit parallel, for 3600 positions selectable by PLC.
Speed command value
Additional encoder input,
synchronisation input
Additional interface

13
• DOK-DIAX01-TDA********-PRJ1-EN-E1,44 • 07.97
1. Presentation of the modular main spindle controller TDA 1
Fig. 5: Components of a modular main spindle drive with their designations
Kompon.fh3
Main spindle controller TDA1.1
Electrical
connection
accessories
Programming
module
Motor feedback cable
Motor blower cable
Main spindle motor
Motor power cable
Electrical connection accessories
Main spindle drive components
Main spindle motor
Motor fan cable
Motor feedback cable
Motor power cable
Motor, components

14
• DOK-DIAX01-TDA********-PRJ1-EN-E1,44 • 07.97
2. Control cabinet design
Information on integrating the main spindle controller TDA 1 into the
design is structured according to
– operating conditions
– mechanical data
– thermal data
– electrical data
– technical data/type code
The values given in the selection data for main spindle drives are
unconditionally valid when the controller is operated within an ambient
temperature range of +5 to +45°C. The maximum permissible ambient
temperature is +55°C, at which the given values for torque and power
ratings will be limited according to the graph shown in Fig. 6.
2. Control cabinet
design
Fig. 6: Temperature-related limitation of drive ratings
100
80
60
40
20
00 10 20 30 40 50 60
Ambient temperature ϑ[°C]
Temperature factor [%]
2.1. Operating conditions
Ambient temperature

15
• DOK-DIAX01-TDA********-PRJ1-EN-E1,44 • 07.97
2. Control cabinet design
The maximum operating altitude is 1000 meters above sea level. At
higher elevations, the values given in the main spindle drive selection
datafortorque power ratingswill be limited accordingto the chart inFig.
7.
ThemaximumpermissiblerelativehumidityofaircorrespondstoHumid-
ity Class F according to DIN 40 040.
This means that the controller may be operated in locations subject to
humidity, such as workshops in cold, temperate and hot, dry climate
zones. The mean relative humidity of air may not exceed 70% in the
wettestmonth! Moisturemust neverbe allowedto condenseon theunit!
For more details, see DIN 40 040!
Electrical protection is IP 10 according to DIN 40 050.
This means that the controller is protected against the ingress of solid
foreign particles with a diameter of more than 50 mm.
The controller is not protected against
– the ingress of water, or
– intentionalcontact,e.g.byhand,butdoespreventcontactoflargebody
surfaces.
For more details, see DIN 40 050!
The TDA 1 has been designed for installation in a control cabinet or a
closedhousing inconformity withDIN VDE01 160,sections 5.5.1.3and
6.5.1.3. Adequate protection against unintentional contact must be
providedbythemanufacturerofthecabinetaccordingtothevalidsafety
specifications for the respective application. (For industrial equipment,
e.g., EN 60204 / DIN VDE 0113, part 1.)
Altitude
Permissible relative
humidity of air
Fig. 7: Altitude-related limitation of drive ratings
100
80
60
40
20
00 1000 2000 3000 4000 5000
Altitude above sea level [m]
Altitude factor [%]
HöhenRed
Electrical protection

16
• DOK-DIAX01-TDA********-PRJ1-EN-E1,44 • 07.97
2.2. Mechanical data
2. Control cabinet design
Fig. 8: Dimensional specification of main spindle controller TDA 1
A1
A2
A3
L- L+
X1
X8
READY
X3 X5 (option) additional
encoder input
X4
52.5
373 ±0.2
390
X2
X11
X12
Programming
module AS 7
FAULT
LCD display
PARAM.-
Earthing bolt
325
355
10
Protection against contact
(transparent plate)
Stud bolt
Plug-in terminal 3-pin
Plug-in connector 16-pin
X6 (option) additional interface
Tightening torque ratings of stud bolts
Motor connection D.C. link circuit Earthing
Terminal desig.
A1,A2,A3
L+, L-
Thread size
M6 M5 M5
Tightening torque
5Nm 3Nm 3Nm
Weights:
TDA1.1- in [kg] 50
10.5 100
10.5
Permissible orientation: vertical (earthing stud at the top!)
8
50 50
Maße_TDA
front view
D-sub plug-in connector
X5a (option) synch. input
7
52.5
30
60
13
7
8
150
X4 (option) speed set-point
Plug-in terminal, 2-pin)
D-type subminiature connector Tightening torque for stud bolts
Dimensions Stud bolts
Earthing bolt Weight, TDA 1 controller
Inspection plate Plug-in terminal
Plug-in terminal strip Protective cover

17
• DOK-DIAX01-TDA********-PRJ1-EN-E1,44 • 07.97
2. Control cabinet design
Fig.9:Drillingpatternforthecabinetrearwall(forassemblyclearance,seealsoFig.10)
Assembly clearance Assembly clearance
M 6
373
±0,2
Minimum clearance
80 mm
Bohrbild
View of the inside of the cabinet rear wall
M 6
Minimum thickness
of mounting panel
or cabinet rear wall:
3mm for steel
6mm for aluminium
M 6
60

18
• DOK-DIAX01-TDA********-PRJ1-EN-E1,44 • 07.97
2. Control cabinet design
110 ±0.5
155 ±0.5
KDV 3.1 TDA1.1 TDM 1
TDM 2
110 ±0.5 155 ±0.5
KDV 1
KDV 2 TDA1.1 KDS
Minimum
clearance
80
137 ±0.5
TDA 1.1 TDM3
TDM4
155 ±0.5
TDA1.1 TDA 1.1
MontAb
TVD TVM
110 ±0.5
110 ±0.5
Fig. 10: Assembly clearance; distances between adjacent units in the drive
equipment package and top clearance

19
• DOK-DIAX01-TDA********-PRJ1-EN-E1,44 • 07.97
2.3. Thermal data When in operation the controller TDA 1 dissipates heat through the air
vents in its housing to the air inside the control cabinet.
2. Control cabinet design
100 200 300 350
3,5
5,5
7,5
9,5
PN/kW
of the
motors
TDA 1.1-050
TDA 1.1-100
Power dissipation Pv/W
verlstg.fh3
The power dissipated by the TDA 1 is dependent on the load. In terms
of dimensioning the cabinet or the air cooling system, it is however,
sufficient toknow thepower dissipationrelated tothe continuouspower
rating of the main spindle motor used.
Fig. 11: Cooling principle of the controller TDA 1
Fig. 12: Power dissipation of the TDA 1
completely enclosed
housing or cabinet
Kühlart.fh3
TDA 1.1
Air flow
Power dissipation
P
V

20
• DOK-DIAX01-TDA********-PRJ1-EN-E1,44 • 07.97
The controller TDA 1 can only perform at full drive ratings up to an
ambienttemperatureof 45°C. Inorderto keepwithinthisenvironmental
limit, it may be necessary to install a system to cool the air inside the
control cabinet.
Improperly mounted cooling systems will expose installed controllers to
theriskofmoisturecondensationandtheeffectsofcondensationwater!
Hot humid air penetrating the control cabinet will condense on the
controller while cooling!
If the cooler is wrongly located in the control cabinet, the condensation
water inherent to cooling systems may drip down onto the installed
controllers or be sprayed into them along with the flow of cooling air.
– When using cooling systems, select only well sealed control cabinets
which will prevent any moisture condensing out of hot humid air
penetrating from the outside.
– If the control cabinet has to be operated with its doors open (on
commissioning or during repairs, etc.), precautions must be taken to
ensurethatthecontrollerswillneverbecoolerthantheairinthecabinet
once the doors have been shut again, as moisture will otherwise
condense on them. The cooling system must therefore always be in
operationevenwhilethemachineisshutdowntokeepthetemperature
oftheairinthecontrolcabinetandthatoftheinstalledequipmentatthe
same level.
– Cooling systems with fixed temperature settings must be set to 40 °C,
not lower!
– Coolingsystemswithtemperaturecontrollersmustbesetsuchthatthe
temperature of the air inside the control cabinet is less than 2°C below
that of the air outside the cabinet. Set the temperature limit to 40°C!
– Always arrangecooling systemssuch that condensationwater cannot
drip down onto installed controllers. If cooling systems are to be
mounted on top of control cabinets, the cabinet must be specially
designed (see Fig. 12.1)!
– Design the control cabinet such that the fan of the cooling system will
not spray condensation water which has collected while the system is
shut down onto the controllers (see Fig. 12.2)!
2.3.1. Notes on the use of
cooling power systems in
control cabinets
2. Control cabinet design
Proper mounting of cooling
systems
Avoidance of
moisture condensation
Avoidance of water drips
or spray
Moisture condensation risk
Condensation water risk