AC Main spindle drives with regulated 2AD main spindle motor

AC Main spindle drives with regulated 2AD mainspindle motor

DOK-DIAX01-MAIN+2AD***-AUS1-EN-P

Selection guide

mannesmannRexroth

engineering

Indramat241629

2• DOK-DIAX01-MAIN+2AD***-AUS1-EN-E1,44 • 06.97

About this documentation

AC main spindle drives with regulated 2AD main spindle motor

Selection data

DOK-DIAX01-MAIN+2AD***-AUS1-EN-E1,44

• Mappe 7• HSPAD-AW.pdf• 9.567.013.4-04

This electronic document is based on the hardcopy document with documentdesig.: 9.567.013.4-04 EN / April 1994

The purpose of this document is

• to familiarize with the A.C. main spindle drive system,

• to define available power ratings,

• to demonstrate the use of standard and optional functions in machine toolapplications, and,

• to select a main spindle drive.

This document makes it easy to

• record the performance-related details of the main spindle drive,

• work out and record the necessary motor and drive options, and,

• make rapid and effective contact with our Sales Department.

This symbol serves to remind you that an entry has to be made in the "selectionlist". It corresponds to the word "option" in bold in the respective paragraphto the right or in the adjacent diagram.

Titel

Type of documentation:

Documenttype

Internal file reference

Reference

This documentationis used:

© INDRAMAT GmbH, 1994Copying of this document, and giving it to others and the use or communicationof the contents thereof, are forbidden without express authority. Offenders areliable to the payment of damages.All rights are reserved in the event of the grant of a patent or the registrationof a utility model or design. (DIN 34-1)

The electronic documentation (E-doc) may be copied as often as needed ifsuch are to be used by the consumer for the purpose intended.

All rights reserved with respect to the content of this documentation and theavailability of the products.

INDRAMAT GmbH • Bgm.-Dr.-Nebel-Straße 2 • D-97816 LohrTelefon 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- Comentsup to present edition date

9.567.013.4-04 EN/05.94 Apr./94 P-Dok Edition

DOK-DIAX01-MAIN+2AD***-AUS1-EN-E1,44 Jun./97 First E-Dok

Change procedures


Angebot erstellenAngebot anfordern

The selectionprocess

About this documentation

Electrical connections selection protocol

KDA 3AC-Hauptspinndelantriebe

Projektierungsunterlagen

Projektierungsunterlagen

The need for a main spindle drive

Selecting the requireddrive functions per

Section 3

Motor size and windings,drive and current,

and programming modulehave been selected

Drivefunctions havebeen selected

The motor versionhas been selected

Uncoded recording ofthe drive options

Drive selection protocol

Motor selection protocol

INDRAMAT salesconsults on the order

Independent selection withthe assistance of the documentation

Supplementarydocumentation

Type coding the motor and driveoptions and the

electrical connections

Putting an offer together

Offer

from INDRAMAT Sales

Requesting an offer

AuswBest2ADH

The electrical connections have

been selected

Selecting the constructivedesign of the motor per

Section 4

Selecting the electricalconnections per

Section 5

Main spindle drive order data

Item 1: main spindle motor type designationItem 2: main spindle motor order listItem 3: order matrix • power connections • feedback and NC connectionsItem 4: spindle feedback order list

Selecting the motor-drive combination

Section 2

Uncoded recordingof the motor options

Uncoded recording ofthe electrical connections

Recording thepower-determining

data

7. Orderdata

8. Available versions

These sections can be found inthe documentation you are looking at

Figure 1: Schematic overview of the selection process

Requesting an offerPutting an offer togetherGuidelines on the selecting process


Table of Contents

Table of Contents

1. Introduction to the A.C. main spindle drive system 6

1.1. Speed characteristics .......................................................................6

1.2. Modular main spindle drives ............................................................7

1.3. Main spindle drives for direct mains connection ................................8

2.2. Selection lists ...................................................................................9

2. Power ratings 9

2.1. Nominal power ratings .....................................................................9

2.2 selection list .................................................................................... 11

2.3. Performance curves .......................................................................12

3. Functions and features of main spindle drives 33

3.1. Functions allocated to operating mode ..........................................333.1.1. Changing the operating mode during operation ............................343.1.2. Functions for main spindle drive mode ..........................................343.1.3. Functions for C-axis mode .............................................................383.1.4. Functions for master/slave mode ...................................................40

3.2. Functions independent of the operating mode ..............................413.2.1. Speed command ............................................................................413.2.2. Direct mains connection (for RAC) ................................................413.2.3. Emergency-stop (E-stop) / mains off function ................................413.2.4. Two-motor changeover ..................................................................433.2.5. AS programming module ...............................................................43

3.3. Messages / Signals ........................................................................44

3.4. Control unit cooling ........................................................................463.4.1. Modular main spindle drives ..........................................................463.4.2. Main spindle drives for direct connection to the mains (RAC) .......47

3.5. Mechanical accessories .................................................................48

4. 2AD main spindle motor options 49

4.1. Mounting ........................................................................................49

4.2. Power connection...........................................................................49

4.3. Cooling methods ............................................................................49

4.4. Holding brake .................................................................................49

4.5. Output shaft ....................................................................................49

4.6. Shaft sealing ring ...........................................................................49


Table of Contents

4.7. Non-drive shaft end ........................................................................50

4.8. Shaft bearings ................................................................................50

4.9. Vibration severity grade .................................................................50

5. Electrical connections 51

6. Selection records 53

7. Ordering details 56

7.1. Main spindle motor .........................................................................57

7.2. Main spindle drive ..........................................................................577.2.1. Main spindle drive TDA 1.3 ............................................................577.2.3. Main spindle drive RAC 2.3 ...........................................................587.2.2. Main spindle drive KDA 3.3 ............................................................587.2.4. Main spindle drive RAC 3.5 ...........................................................597.2.5. Main spindle drive RAC 4.3 ...........................................................59

7.3. Electrical connections ....................................................................60

7.4. Spindle feedback............................................................................62

8. Available versions 63

8.1. Modular main spindle drive TDA 1 .................................................63

8.2. Modular main spindle drive KDA 3 .................................................64

8.3. Main spindle drive RAC 3 ..............................................................65



8.6. Main spindle motor 2AD100 ...........................................................68







8.13. Programming module AS ...............................................................75

9. Index 76

10. Summary of additional documentation 80


Depending upon the power requirements, a technical distinction is madebetween the two versions of the A.C. main spindle drive system:

• modular main spindle drives up to 22 kW rated output for bus connectionand incorporation in a drive package with common power supply unit, or,

• main spindle drives up to 93 kW rated output for direct connection to themains.

Figure 1.1: Speed characteristics of INDRAMAT A.C. main spindle drives

Speed

Power

Torque

Dreh2ADH

5

1

3 4

3 4

6

2

Speed

1 rated power2 rated torque3 rated speed

4 maximum speed5 maximum power6 maximum torque

1. Introduction to the A.C. main spindle drive system

1. Introduction to the A.C. mainspindle drive system

1.1. Speed characteristics

The A.C. main spindle drives with 2AD controlled main spindle motor operatein the four-quadrant mode, are microprocessor-controlled and have positioningcapability. They offer constant torque from standstill to rated speed andconstant power up to maximum speed in the field-weakening range.


Versorgungseinheitmodulares Hauptspin-delregelgerät TDA

1.2. Modular main spindle drives

mod2ADH

Mains

Power supply unit modular main spindle drive

TDAorKDA

Modular-type main spindle drives with TDA and KDA are available for a powerrange of 3.5 kW to 22 kW rated motor output. They can be combined withmodular A.C. servo drives to form compact, multi-axis drive packages operatingfrom a common power supply unit.

Figure 1.3: Motors for modular main spindle drives

Maintenance-free main spindle motors, sizes 2AD100 to 2AD132, with ratedoutputs from 3.5 to 22 kW, are used in conjunction with the TDA and KDAmodular main spindle drives.

1. Introduction to the A.C. main spindle drive system

klein2ADH

2AD100PN = 3.5/5.5/7.5 kW

2AD101

2AD132

PN = 9.5 kW

PN = 10/15/22 kW

Figure 1.2: Modular main spindle drives with TDA/KDA


1. Introduction to the a.c. main spindle drive system

1.3. Main spindle drives for direct mains connection

Mains

Main spindle driveRAC 3orRAC 2orRAC 4

RAC2ADH

Figure 1.4: Main spindle drive with RAC main spindle drive

RAC 2, RAC 3 and RAC 4 main spindle drives with power regeneration anddirect mains connection capability are available for the power range 10 to 93kW.

groß2ADH

2AD132

2AD160

2AD225

2AD180

2AD200

PN = 10/15/22 kW

PN = 30/37 kW

PN = 52/63 kW

PN = 79 kW

PN = 93 kW

Figure 1.5: Motors for main spindle drives with direct mains connection capability

Maintenance-free spindle motors, sizes 2AD132 to 2AD225, with ratedoutputs from 10 to 93 kW, are used in conjunction with RAC main spindledrives.


2. Power ratings

2. Power ratings

2.1. Nominal power ratings

Figure 2.1: Nominal power ratings of an A.C main spindle drives

2.2. Selection lists

The selection lists below are classified according to "modular main spindledrives" and "main spindle drives for direct mains connection", and are sortedaccording to nominal power within the table.

The data from the performance curves are reproduced in tabular form.

According to column "%ED", the given torque, Mmax

, or power, Pmax

, can beused during intermittent operation with the indicated percentual ON-time.(Operating mode S6 per DIN 57530/VDE 0530, duty cycle time as indicatedin column "(S6)"). For lower torque requirements, M

KB , or power, P

KB , ON-time

can be calculated as follows:

ED

ED

= ×

= ×

M

M

P

P

N

KB

N

KB

2

2

100

100

%

%

ED = On-time (%) of indicated duty cycle time listed in "(S6)"MN = rated torqueMKB = short-time operating torquePN = rated powerPKB = short-time operating power

(applies to speed range of MN)

(applied to speed range of PN)

Calculating ON-time(%ED)

2AD

100

B

2AD

100

C

2AD

100

D

2AD

101

D

2AD

132

B

2AD

132

C

2AD

132

D

2AD

160

B

2AD

160

C

2AD

180

C

2AD

180

D

2AD

200

C

2AD

225

C

3,5 5,5 7,5 9,5 1015

2230

37

52

63

79

93

0

10

20

30

40

50

60

70

80

90

100

2AD

100

B

2AD

100

C

2AD

100

D

2AD

101

D

2AD

132

B

2AD

132

C

2AD

132

D

2AD

160

B

2AD

160

C

2AD

180

C

2AD

180

D

2AD

200

C

2AD

225

C

Nen

nle

istu

ng

in

kW

Nom

inal

pow

er in

kW


2. Power ratings

Mod

ular

mai

n sp

indl

e dr

ives

(3.

5 kW

... 2

2 kW

)

Con

tinuo

us d

uty

(S1)

Sho

rt tim

e du

tyM

axim

um d

ata

3)M

ain

spin

dle

Mai

n sp

indl

eP

rogr

amm

ing-

(S2)

1) 2

)(S

6)m

otor

driv

em

odul

e

Rat

edR

ated

Rat

edM

axim

umP

ower

Torq

ueE

DTo

rque

ED

pow

erto

rque

spee

dsp

eed

PN

MN

n Nn m

axP

KB

MK

BM

max

kWN

mm

in-1

min

-1kW

Nm

%N

m%

3.5

22.0

1500

9000

532

.049

50.0

152A

D10

0B-B

• • •

• • -

AS

• 3…

TDA

1.3

-050

-3…

AS

17 •

/005

-000

5.5

35.0

1500

9000

8.3

53.0

4410

5,0

112A

D10

0C-B

• • •

• • -

AS

• 3…

TDA

1.3

-100

-3…

AS

17 •

/006

-000

7.5

48.0

1500

9000

11.3

72.0

4410

5.0

212A

D10

0D-B

• • •

• • -

AS

• 3…

TDA

1.3

-100

-3…

AS

17 •

/007

-000

7.5

48.0

1500

9000

11.3

72.0

4410

5.,0

212A

D10

0D-B

• • •

• • -

AS

• 3…

KD

A 3

.3-1

00-3

…A

S13

• /0

07-0

00

9.5

60.0

1500

9000

1489

.044

108

312A

D10

1D-B

• • •

• • -

BD

• 3…

TDA

1.3

-100

-3…

AS

17 •

/024

-000

9.5

60.0

1500

9000

1489

.044

108,

031

2AD

101D

-B •

• • •

• -B

D •

3…K

DA

3.3

-100

-3…

AS

13 •

/024

-000

1064

.015

0075

0015

96.0

4496

,044

2AD

132B

-B •

• • •

• -B

S •

3…K

DA

3.3

-100

-3…

AS

13 •

/009

-000

1064

.015

0075

0015

96.0

4416

5,0

152A

D13

2B-B

• • •

• • -

BS

• 3…

KD

A 3

.3-1

50-3

…A

S13

• /0

19-0

00

1596

.015

0075

0022

.514

3.0

4414

3,0

442A

D13

2C-B

• • •

• • -

BS

• 3…

KD

A 3

.3-1

50-3

…A

S13

• /0

10-0

00

2214

0.0

1500

7500

2415

3.0

8417

6,0

632A

D13

2D-B

• • •

• • -

BD

• 3…

KD

A 3

.3-1

50-3

…A

S13

• /0

12-0

00

1) T

hese

dat

a ap

ply

to 3

0 m

in. s

hort

-tim

e du

ty (

S2)

and

inte

rmitt

ent d

uty

(S6)

with

the

perc

enta

ge c

yclic

dur

atio

n fa

ctor

in th

e as

soci

ated

col

umn

"ED

" at

a d

uty

c

yle

time

of te

n m

inut

es.

2) T

he s

hort

-tim

e du

ty d

ata

can

be li

mite

d by

the

pow

er s

uppl

y un

it.3)

Inte

rmitt

ent d

uty

(S6)

with

cyc

lic d

urat

ion

of te

n m

inut

es a

nd a

ssoc

iate

d O

N-t

ime.

Figure 2.2: TDA/KDA selection list

TDA/KDA Selection list


Mai

n sp

indl

e dr

ives

for

dire

ct c

onne

tion

to th

e m

ains

(10

kW

... 9

3 kW

)

Con

tinuo

us d

uty

(S1)

Sho

rt-tim

e du

tyM

axim

um d

ata

Mai

n sp

indl

eM

ain

spin

dle

Pro

gram

min

g (S

2) 1)

(S6)

mot

ordr

ive

mod

ule

Rat

edR

ated

Rat

edM

axim

umP

ower

Torq

ueE

DTo

rque

ED

pow

erto

rque

spee

dsp

eed

PN

MN

n Nn m

axP

KB

MK

BM

max

kWN

mm

in-1

min

-1kW

Nm

%N

m%

1064

.015

0075

0015

96.0

4412

725

4)2A

D13

2B-B

•••

•• -D

S •

3…R

AC

3.5

-100

…A

S16

• /0

26-0

00

1596

.015

0075

0022

.514

444

200

234)

2AD

132C

-B •

••••

-CS

• 3…

RA

C 3

.5-1

00…

AS

16 •

/011

-000

2214

0.0

1500

7500

3321

044

255

335)

2AD

132D

-B •

••••

-AS

• 3…

RA

C 3

.5-1

50…

AS

16 •

/006

-000

3019

115

0060

0035

223

735)

255

565)

2AD

160B

-B •

••••

-BS

• 3…

RA

C 3

.5-1

50…

AS

16 •

/007

-000

3019

115

0060

0045

286

4428

644

4)2A

D16

0B-B

•••

•• -B

S •

3…R

AC

2.3

-200

…A

S15

• /0

02-0

00

3723

615

0060

0053

337

4933

749

4)2A

D16

0C-B

•••

•• -B

S •

3…R

AC

2.3

-200

…A

S15

• /0

03-0

00

5233

115

0060

0065

414

6447

733

2)2A

D18

0C-B

•••

•• -B

S •

3…R

AC

2.3

-250

…A

S15

• /0

04-0

00

6340

115

0060

0093

592

4659

246

4)2A

D18

0D-B

•••

•• -B

S •

3…R

AC

4.3

-300

…A

S18

• /0

01-0

00

7950

315

0050

0093

592

7276

443

3)2A

D20

0C-B

•••

•• -A

S •

3…R

AC

4.3

-400

…A

S18

• /0

49-0

00

9359

215

0050

0093

592

100

764

503)

2AD

225C

-B •

••••

-AS

• 3…

RA

C 4

.3-4

00…

AS

18 •

/051

-000

1) T

hese

dat

a ap

ply

to 3

0-m

inut

e sh

ort-

time

duty

(S

2) a

nd in

term

itten

t dut

y (S

6) w

ith th

e pe

rcen

tage

cyc

lic d

urat

ion

fact

or in

the

asso

ciat

ed c

olum

n "E

D"

at a

duty

cyl

e tim

e of

ten

min

utes

.2)

Inte

rmitt

ent d

uty

(S6)

with

30

seco

nds

ON

-tim

e an

d gi

ven

duty

cyc

le ti

me

(%E

D)

3) In

term

itten

t dut

y (S

6) w

ith 2

min

utes

ON

-tim

e an

d gi

ven

duty

cyc

le ti

me

(%E

D)

4) In

term

itten

t dut

y (S

6) w

ith 1

0 m

inut

es O

N-t

ime

and

give

n du

ty c

ycle

tim

e (%

ED

)5)

Inte

rmitt

ent d

uty

(S6)

with

5 m

inut

es O

N-t

ime

and

give

n du

ty d

uty

cycl

e tim

e (%

ED

)

2. Power ratings

Figure 2.3: RAC selection lists

RAC selection list


2. Power ratings

2.3. Performance curves

Kenn2ADH

Rated speed n Maximum speed n

Maximum power P

Pow

er in

kW

Torq

ue in

Nm

Speed in min -1

Short-time duty power P

Rated power P

Maximum torque M

Short-time duty torque M

Rated torque M

N max

max

KB

N

max

KB

N

Continuous duty (S1)Short-time duty (S2)Intermittent duty (S6)

Figure 2.4: Performance curves of A.C main spindle drives


2. Power ratings

1000 2000 3000 4000 5000 6000 7000 8000 9000

5

10

50

K52TDA2ADH

nN=1500 nmax=9000

25

3,5

1.72.6

2.71.8

32

7,8

3.5 kW rated power

Main spindle motor:

Modular main spindle drive:

Programming module:

Requirements of power supply unit:D.C bus continuous power:D.C. bus peak power:Energy content n

max (without load moment of inertia):

2AD100B- • • • • • -AS • 3- • • • •

TDA 1.3-050-3- • • •

AS17 • /005-000

5.5 kW8.6 kW

6.2 kWs

Po

we

r in

kW

Torq

ue

in N

m

Torque in min -1Continuous duty (S1)30 min. short-time duty (S2), or intermittent duty (S6)with 10 minutes duty cycle time at 44% cyclic duration factorIntermittent duty (S6) with 10 minutes duty cycle time at 20% cyclic duration factor

5

50

22

Figure 2.5: 3.5 kW performance curves with TDA 1


2. Power ratings

1000 2000 3000 4000 5000 6000 7000 8000 9000

10

20

50

100

105

K51TDA2ADH

nN=1500 nmax=9000

5.5

8,3

15

53

34

4.23.2

5.5 kW rated power

35

Main spindle motor:


Programming module:

Requirements of power supply unit:D.C. bus continuous power:D.C. bus peak power:Energy content n


2AD100C- • • • • • -AS • 3 - • • • •

TDA 1.3-100-3- • • •

AS17 • /006-000

9.1 kW16.5 kW9.3 kWs

Continuous duty (S1)30 minute short-time duty (S2), or intermittent duty (S6)with10 minutes duty cycle time at 44% cyclic duration factorIntermittent duty (S6)with duty cycle time of 10 min. at 11% cyclic duration factor

Po

we

r in

kW

Torq

ue

in N

m

Speed in min -1

Figure 2.6: 5.5 kW performance curves with a TDA 1


2. Power ratings

Figure 2.7: 7.5 kW performance curves with a TDA 1

1000 2000 3000 4000 5000 6000 7000 8000 9000

10

20

50

100

105

K50TDA2ADH

nN=1500 nmax=9000

7.5

11,3

16.5

72

7.5 kW rated power

3.55

5.33.8

48

Main spindle motor:


Programming module:

Requirements of power supply unit:D.C. bus continuous power:D.C. bus peak power:Energy content at

nmax (without load moment of inertia):

2AD100D- • • • • • -AS • 3- • • • •

TDA 1.3-100-3- • • •

AS17 • /007-000

12.5 kW18 kW

12.4 kWs

Continuous duty (S1)30 minute short-time duty (S2), or intermittent duty (S6)with 10 minutes duty cycle time at 44% cyclic duration factorIntermittent duty (S6) with 10 minutes duty cycle time at 21% cyclic duration factor

Po

we

r in

kW

Torq

ue

in N

m

Speed in min -1


2. Power ratings

Figure 2.8: 7.5 kW performance curves with KDA 3

1000 2000 3000 4000 5000 6000 7000 8000 9000

10

20

50

100

105

5.33.8

nN=1500 nmax=9000

7.5

11.3

16.5

72

7.5 kW rated power

3.55

K63KDA2ADH

48

Main spindle motor:


Programming module:


max without load moment of inertia):

2AD100D- • • • • • -AS • 3- • • • •

KDA 3.3-100-3- • • • - • •

AS13 • /007-000

12.5 kW18 kW

12.4 kWs

Continuous duty (S1)30 minutes short-time duty (S2), or intermittent duty (S6)with10 minutes duty cycle time at 44% cyclic duration factorIntermittent duty (S6) with 10 minutes duty cycle time at 21% cyclic duration factor

Po

we

r in

kW

Torq

ue

in N

m

Speed in min -1


2. Power ratings

Figure 2.9: 9.5 kW performance curves with TDA 1

1000 2000 3000 4000 5000 6000 7000 8000 9000

K72TDA2ADH

nN=1500 nmax=9000

50

100

108

10

20

17

14

9.5

7.4

89

60

11.6

9.5 kW rated power

11

7

Main spindle motor:


Programming module:



2AD101D- • • • • • -BD • 3- • • • •

TDA 1.3-100-3-• • •

AS17 • /024-000

15.4 kW18.7 kW

12.4 kWs

Continuous duty (S1)30 minutes short-time duty (S2), or intermittent duty (S6)with 10 minutes duty cycle time at 44% cyclic duty factorIntermittent duty (S6) with 10 minutes duty cycle time at 31% cyclic duty factor

Pow

er in

kW

Torq

ue in

Nm

Speed in min -1


2. Power ratings

Figure 2.10: 9.5 kW performance curves with KDA 3

1000 2000 3000 4000 5000 6000 7000 8000 9000

nN=1500 nmax=9000

50

100

108

10

20

17

14

9.5

7.4

89

60

11.6

K68KDA2ADH

9.5 kW rated power

11

7

Main spindle motor:


Programming module:



2AD101D- • • • • • -BD • 3- • • • •

KDA 3.3-100-3- • • • - • •

AS13 • /024-000

15.4 kW18.7 kW

12.4 kWs

Continuous duty (S1)30 minutes short-time duty (S2), or intermittent duty (S6)with 10 minutes duty cycle time at 44% cyclic duration factorIntermittent duty (S6) with 10 minutes duty cycle time at 31% cyclic duration factor

Po

we

r in

kW

Torq

ue

in N

m

Speed in min -1


2. Power ratings

Figure 2.11: 10 kW performance curves with KDA 3

Main spindle motor:


Programming module:



2AD132B- • • • • • -BS • 3- • • • •

KDA 3.3-100-3- • • • - • •

AS13 • /009-000

16.5 kW16.5 kW

14.2 kWs

Continuous duty (S1)30 minutes short-time duty (S2), or intermittent duty (S6)with 10 minutes duty cycle time at 44% cyclic duration factor

1000 2000 3000 4000 5000 6000 7000 8000

10

20

nmax=7500nN=1500

50

100

12.79.5

10

7.5

K64KDA2ADH

10 kW rated power

15

10

96

64

Pow

er in

kW

Torq

ue in

Nm

Speed in min -1


2. Power ratings

1000 2000 3000 4000 5000 6000 7000 8000

10

20

nmax=7500nN=1500

50

100

150

165

64

12.79.5

10

7.5

K67KDA2ADH

10 kW rated power

20

15

10

96

Main spindle motor:


Programming module:



2AD132B- • • • • • -BS • 3- • • • •

KDA 3.3-150-3- • • • - • •

AS13 • /019-000

16.5 kW22 kW

14.2 kWs

Continuous duty (S1)30 minutes short-time duty (S2), or intermittent duty (S6)with 10 minutes duty cycle time at 44% cyclic duration factor.Intermittent duty (S6) with 10 minutes duty cycle time at 15% cyclic duration factor

Po

we

r in

kW

To

rqu

e in

Nm

Speed in min -1



2. Power ratings

1000 2000 3000 4000 5000 6000 7000 8000

K16RAC2ADH

nN=1500 nmax=7500

10

20

50

100 96

64

127

15

1913

10 kW rated power

10

20

Main spindle motor:

Main spindle drive:

Programming module:

Connected load:

2AD132B- • • • • • -DS • 3- • • • •

RAC 3.5-100- • • • - • • • - • •

AS16 • /026-000

13.2 kVA (mains connected voltage 3 x AC 400 V)

Continuous duty (S1)30 minutes short-time duty (S2), or intermittent duty (S6)with 10 minutes duty cycle time at 44% cycle duration factorIntermittent duty (S6) with 10 minutes duty cycle time at 25% cyclic duration factor

Po

we

r in

kW

To

rqu

e in

Nm

Speed in min -1

Figure 2.13: 10 kW performance curves with RAC 3


2. Power ratings


1000 2000 3000 4000 5000 6000 7000 8000

10

20

nmax=7500nN=1500

200

100

143

19.114

11

K65KDA2ADH

15

22.5

15 kW rated power

96

15

Main spindle motor:


Programming module:


max (with load moment of inertia):

2AD132C- • • • • • -BS • 3- • • • •

KDA 3.3-150-3- • • • - • •

AS13 • /010-000

25 kW25 kW

19.7 kWs


Pow

er in

kW

Torq

ue in

Nm

Speed in min -1


2. Power ratings


1000 2000 3000 4000 5000 6000 7000 8000

K12RAC2ADH

nN=1500 nmax=7500

10

30

15

11

15

22.5

31

1911

100

200200

144

96

20

15 kW rated power

Main spindle motor:

Main spindle drive:

Programming module:

Connected load:

2AD132C- • • • • • -CS • 3- • • • •

RAC 3.5-100- • • • - • • • - • •

AS16 • /011-000

20 kVA (mains connected voltage 3 x AC 400 V)

Continuous duty (S1)30 minutes short-time duty (S2), or intermittent duty (S6)with 10 minutes duty cycl time at 44% cyclic duration factorIntermittent duty (S6) with 10 min. duty cycle time at 23% cyclic duration factor

Po

we

r in

kW

To

rqu

e in

Nm

Speed in min -1


2. Power ratings


1000 2000 3000 4000 5000 6000 7000 8000

10

20

nmax=7500nN=1500

100

200

20

16

176

153

140

K66KDA2ADH

22 kW rated power

24

22

Main spindle motor:


Programming module:



2AD132D- • • • • • -BD • 3- • • • •

KDA 3.3-150-3- • • • - • •

AS13 • /012-000

26.4 kW26.4 kW

30.8 kWs

Continuous duty (S1)30 minutes short-time duty (S2), or intermittent duty (S6)with 10 minutes duty cycle time at 84% cyclic duration factorIntermittent duty (S6) with 10 minutes duty cycle time at 63% cyclic duty factor

Po

we

r in

kW

To

rqu

e in

Nm

Speed in min -1


2. Power ratings


1000 2000 3000 4000 5000 6000 7000 8000

nN=1500 nmax=7500

50

25 25

17

22

33

40

3322

100

200

255

210

140

K13RAC2ADH

22 kW rated power

Main spindle motor:

Main spindle drive:

Programming module:

Connected load:

2AD132D- • • • • • -AS • 3- • • • •

RAC 3.5-150- • • • - • • • - • •

AS16 • /006-000


Continuous duty (S1)30 minutes short-time duty (S2), or intermittent duty (S6)with 10 minutes duty cycle time at 44% cyclic duty factorIntermittent duty (S6) with 10 minutes duty cycle time at 30% cyclic duty factor

Po

we

r in

kW

To

rqu

e in

Nm

Speed in min -1


2. Power ratings


1000 2000 3000 4000 5000 6000

nN=1500 nmax=6000

25

50

645648

200

255

191

100

K14RAC2ADH

30 kW rated power

30

40

Main spindle motor:

Main spindle drive:

Programming module:

Connected load:

2AD160B- • • • • • -BS • 3- • • • •

RAC 3.5-150- • • • - • • • - • • •

AS16 • /007-000


Continous duty (S1)30 minutes short-time duty (S2), or intermittent duty (S6)with five minutes duty cycle time at 73% cyclic duty factorIntermittent duty (S6)with five minutes duty cycle time at 56% cyclic duty factor

35

223

Po

we

r in

kW

To

rqu

e in

Nm

Speed in min -1


2. Power ratings


1000 2000 3000 4000 5000 6000

K9RAC2ADH

nN=1500 nmax=6000

25

50

7248

200

300 286

191

100

30 kW rated power

45

30

Main spindle motor:

Main spindle drive:

Programming module:

Connected load:

2AD160B- • • • • • -BS • 3- • • • •

RAC 2.3-200- • • • - • • • - • •

AS15 • /002-000


Continuous duty (S1)30 minutes short-time duty (S2), or intermittent duty (S6)with 10 minutes duty cycle time at 44% cyclic duty factor

Pow

er in

kW

Torq

ue in

Nm

Speed in min -1


2. Power ratings


1000 2000 3000 4000 5000 6000

K10RAC2ADH

nN=1500 nmax=6000

25

50

8459

200

300

337

236

100

37

37 kW rated power

53

Main spindle motor:

Main spindle drive:

Programming module:

Connected load:

2AD160C- • • • • • -BS • 3- • • • •

RAC 2.3-200- • • • - • • • - • •

AS15 • /003-000



Pow

er in

kW

Torq

ue in

Nm

Speed in min -1


2. Power ratings

1000 2000 3000 4000 5000 6000

K11RAC2ADH

nN=1500 nmax=6000

50

100

52

65

75

119103

83

250

500 477

414

331

52 kW rated power

Main spindle motor:

Main spindle drive:

Programming module:

Connected load:

2AD180C- • • • • • -BS • 3- • • • •

RAC 2.3-250- • • • - • • • - • •

AS15 • /004-000


Continuous duty (S1)30 minutes short-time duty (S2), or intermittent duty (S6)with 10 minutes duty cycle time at 64% cyclic duration factorIntermittent duty (S6) with 30 secs duty cycle time at 33% cyclic duration factor

Po

we

r in

kW

To

rqu

e in

Nm

Speed in min -1



2. Power ratings


200

1000 2000 3000 4000 5000 6000

K32RAC

nN=1500 nmax=6000

50

25

93

63

600

400

75

100

148

100

401

592

63 kW rated power

Main spindle motor:

Main spindle drive:

Programming module:

Connected load:

2AD180D- • • • • • -BS • 3- • • • •

RAC 4.3-300- • • • - • • • - • •

AS18 • /001-000


Continuous duty (S1)30 minutes short-time duty (S2), or intermittent duty (S6)with 10 min. duty cycle time at 46% cyclic duration factor

Pow

er in

kW

Torq

ue in

Nm

Speed in min -1


2. Power ratings

300

1000 2000 3000 4000 5000 6000

K31RAC2ADH

nN=1500 nmax=5000

100

50

120

79

900

600

764

503

229178151

79 kW rated power

93

592

Main spindle motor:

Main spindle drive:

Programming module:

Connected load:

2AD200C- • • • • • -AS • 3- • • • •

RAC 4.3-400- • • • - • • • - • •

AS18 • /049-000


Continuous duty (S1)30 min. short-time duty (S2), or intermittent duty (S6)with 10 min. duty cycle time at 72% cyclic duty factorIntermittent duty (S6) with 2 min.duty cycle time at 44% cyclic duty factor

Po

we

r in

kW

Torq

ue

in N

m

Speed in min -1



2. Power ratings

Figure 2.24: 93 kW performance curve with RAC 4

300

1000 2000 3000 4000 5000 6000

K41RAC2ADH

nN=1500 nmax=5000

100

50

120

93

900

600

229178

93 kW rated power

Main spindle motor:

Main spindle drive:

Programming module:

Connected load:

2AD225C- • • • • • -AS • 3- • • • •

RAC 4.3-400- • • • - • • • - • •

AS18 • /051-000


Continuous duty (S1)Intermittent duty (S6) with 2 min.duty cycle time at 50% cyclic duty factor

764

592

Po

we

r in

kW

Torq

ue

in N

m

Speed in min -1


3. Functions and features of main spindle drives

Figure 3.1: Operating modes with allocated functions of an A.C. main spindle drive

for each drive stage

• speed commandramp

• speed commandsmoothing

• speed drive matching• automatic gear

changes• spindle positioning• messages

for C-axis

• velocity loop scaling• second command

input evaluations• second command

input• high-resolution motor

feedback evaluation• incremental encoder

output• messages

for master-slaveoperation

• torque control• torque output• second command

input• messages

Main spindle drive(different drive

stages)

Master-slave drive

Operating modes(can be switched during operation)

C-axis drive

3. Functions and features ofmain spindle drives

The functions of the drives are only briefly discussed at this point. Thedocumentation entitled "AC Main Spindle Drives with Regulated AsynchronousMotors or Frameless Spindle Motors, Applications", discusses the topic in full.

If the selected function is labelled "Option" , then it should be written down inthe selection records.

3.1. Functions allocated to operating mode

To simplify the selection process, the functions of the drives have been dividedinto the three most commonly used operating modes. These three operatingmodes are:

• main spindle drives,

• C-axis drives, and,

• master - slave drives.

The NC controller can switch these operating modes during operation.



3.1.1. Changing the operating mode during operation

The operating modes are changed during operation by means of switchableparameter sets that are changed by the NC controller.

INDRAMAT main spindle drives are fitted with six parameter sets, two of whichare permanently active and a further one of the four switchable parameter setsis always active.

The drive is matched to the respective operating mode or reduction stage bythe four switchable parameter sets. These parameter sets all contain the sameparameters. Functions for the intended operating mode are activated byindividually setting parameter values.

Parameter set M (motor parameters)

Parameter set A (general parameters)

Figure 3.2: Example of the use of parameter sets; sets P, Q, R and S can be selectedduring operation.

3.1.2. Functions for main spindle drive mode

For main spindle drives in many cases, it is sufficient to apply the speedcommand via simple control devices (PLC and so on). Sudden changes in thespeed command can be converted within the drive into a ramp waveform.

In the drive, three selectable, successive ramp slopes are available in each ofthe four switchable parameter sets. For example, they can be used forsmoothing during breakaway and for limiting acceleration in belt couplings. Inthe constant-power range the torque reduces with speed. With the third ramp,the regulation can be held in the active range (constant speed increase dueto constant accelerating torque).

When the main spindle drive is controlled along a ramp by the NC controller,or when operating in the postioning mode, step-type changes in command dueto the NC controller cause sudden changes in torque. The speed commandcan smooth these out.

Adjustable smoothing time constants in the switchable parameter sets makeit possible to match various NC cycle times and meet mechanical demands atdifferent drive speeds.

Speed commandramps

Parameter set Parameter set Parameter setParameter set

Speed commandsmoothing

P Q R S(e.g., speed 1) (e.g., speed 2) (e.g., C-axis) (e.g., master-slave)



The machine's different mechanical arrangements during gear change, orchange in the drive's operating mode, make different demands of speedregulation.

Specific values for matching the speed drive can be set in each of theswitchable parameter sets.

Due to the wide speed range, the main spindle drive operates in the constant-torque or constant-power range. Two different speed parameters per parameterset, which can be switched according to speed, are available for matching theresulting, different requirements.

Limiting the power and the torque protects the workpiece, tool and machinefrom damage in exceptional circumstances.

In A.C. main spindle drives, there is a choice between:

• limiting the maximum torque without limiting the maximum power of thedrive, or,

• simultaneously limiting the maximum torque and limiting the maximumpower of the drive.

Speed drivematching

Figure 3.3: Example of limiting the torque to 80% of the maximum torque without limitingthe maximum power

Drehm2ADH

Maximum torque (M )

Torque M

100%

80%

Maximum power (P )

power, limited

P power

100%

80%

torque, unlimited

speed N

max

max

torque, limited

Power and torquelimiting



Figure 3.4: Example of limiting the torque and power to 80% of the maximum values

DrehL2ADH

peak torque (M )

Torque M

100%

80%

peak power (P )

power, limited

P power

100%

80%

torque, unlimited

speed N

torque, limited

max

max

The limiting value can be set individually for each of the four switchableparameter sets.

To obtain a wide speed range with constant power at the spindle, differentreduction stages are used according to the different spindle speeds. In modernmachine tools, this requires automatic gear changes.

For two speeds, the drive handles the automatic changeover (triggered by aparameter set changeover). For more than two speeds, the changeover by thedrive is supported by speed oscillation.

For simple and fast tool changes on machining centers, three spindle positionscan be selected on the drive via the controller.

If more than three positions are required, e.g.,

• to set up the tool after contouring the workpiece on milling machines,

• to index the workpiece on lathes, or,

• to position workpieces for balance holes on balancing machines,

then 3600 selectable spindle positions are available (Option additionalinterface).

Position accuracy:The position commands can be set to 0.1 of an angular degree and arecorrected to a maximum of 1/1000th of an angular degree depending on thetype of feedback used.

Automatic speedchange

Spindle positioning



Spindle positioning

Number Switchable parameters Gear-dependentof positions for positioning process traversing

3 positions can be specified positioning speed positioning via motor feedbackwith solid gearing 1:1

3600 positions can be called up position control loopdigitally via the NC controller gain positioning via motor feedback(Option additional interface) and spindle reference switch

tolerance window (Option spindle referencewithin which the "in switch) or spindle feedbackposition" message (Option additional encoderappears. input) in the case of indexing

mechanisms.

positioning via spindle feedbackon gearboxes with backlash(Option additional encoderinput)

AC main spindle drives offer a comprehensive range of signals for handshaking with the NC controller (see section 3.3 for detailled explanations ofsignals):

• up to speed

• spindle stopped

• thrust achieved

• spindle in position

• overload

• temperature warning

• spindle speed limit

• mechanical coupling of motor and/or spindle

Main spindle driveoperating mode

messages

Figure 3.5: Implementing spindle positioning



3.1.3. Functions for C-axis mode

The main spindle is used as a servo axis in lathes at low speeds. Contours canbe milled into the workpiece by interpolating with the X-axis.

Figure 3.6: C-axis on a lathe

The performance of the C-axis largely depends on the stiffness of theconnection between motor and spindle. Maximum stiffness is achieved withthe 1MB frameless spindle motor.

In comparison to the pure speed mode of the main spindle, the drive requires

• a high degree of speed stiffness,

• a finely-resolved command input voltage, and,

• a second command input, which is dependent on the type of NC-controller, for the implementation of the C-axis.

Since only low speeds - in the range up to 150 rpm - are required of the mainspindle in the C-axis mode, speed stiffness can be additionally improved byoptimizing the NC speed drive parameters.

A speed command input voltage with fine resolution is required for C-axisoperation.

INDRAMAT main spindle drives meet this requirement by providing a secondcommand weighting that can be activated by the NC controller.

A few types of NC controllers use a second speed command output for the C-axis mode.

To avoid troublesome, complicated changeovers of the command lines, allA.C. main spindle drives are fitted with a second analog command input (onlywith analog +/-10V speed command Option).

Speed drivematching

CAchse2ADH

C-axis

X-axis

Second commandinput weighting

Secondcommand input



In order to obtain uniform rotary movement in the drive at slow speeds, a speeddetector which allows sufficiently accurate speed control is needed on thedrive .

INDRAMAT main spindle drives are standardly equipped with a high-resolutionmotor feedback unit. The speed commands are adjusted with high-resolutionaccuracy at 1/2 000 000th of a revolution.

Since the C-axis involves an interpolating axis, the information about theactual-position must be continuously available to the NC controller. Thisusually involves a high-resolution measuring system with 360 000 incrementsper revolution.

INDRAMAT main spindle drives can be fitted with an interface which outputsposition data in the same way as an incremental encoder. This position datais supplied by INDRAMAT'S high-resolution spindle feedback unit (Optionadditional encoder input) or the high-resolution motor feedback on the 2ADmotor (standard).

The incremental encoder output (Option additional interface) operates asdoes a conventional incremental encoder. In this case, however, with the useof switchable parameter sets, the number of lines can be set via parametervalues and selected during operation.

The incremental encoder output transmits 360 000 increments to the drive inC-axis mode up to 150 rpm.

AC main spindle drives offer a comprehensive range of signals for handshaking with the NC controller (see section 3.3 for detailled explanation ofmessages):

• thrust achieved

• overload


High-resolution motorfeedback evaluation

Incremental encoderoutput

C-axis operatingmode signals



3.1.4. Functions for master/slave mode

If either the power or the torque of a main spindle drive is insufficient to meetthe demands of the drive, then two identical drives can be coupled together.The master/slave principle is then used.

MS2ADH

motor (Slave)

motor (master)

NCcontrol

speed command X4

X2 X3

Drive(master)

X4 X3

Drive(slave)

power

power

motor supply lead

motor supply lead

Mab

Pab

motor feedback

motor feedback

torquecommand

tan

de

m g

ea

rbo

x

Figure 3.7: Arrangement for coupling two drives according to the master/slave principle

To operate as a master/slave drive, the master must transfer the torquecommand to the slave. The output of this command can be set in INDRAMATmain spindle drives via a switchable analog output.

In the master/slave mode, the slave must be operated under torque control.

Whether the drive is run with speed or torque control (slave) is specified in theswitchable parameters in INDRAMAT main spindle drives. This allowschangeover to the slave mode during operation.

Switchable operation (torque or speed control) for the drive means that thecommand comes either from the NC controller or the master drive.

In this case, the drive is fitted with a second analog command input so that thecommand does not have to be externally changed (option speed command,analog +/- 10V). Which of the two inputs is evaluated is set in the respectiveactive parameter record.

AC main spindle drives offer a comprehensive range of signals for handshaking with the NC controller (see section 3.3 for detailled explanation ofmessages):

• coincident direction of force

• thrust achieved

• overload


Torque output

Torque control

Second commandinput

Messages formaster/slave mode


3.2. Functions independent of the operating mode

In addition to mode-specific functions, INDRAMAT main spindle drives offerotherr functions that are active or valid in all operating modes.

3.2.1. Speed command

The speed command can be transmitted by the NC controller to the control unitin three different ways (Option speed command)

• analog, +/- 10 V maximum

• digital, 16-bit parallel

• SERCOS interface

A feature of the three types of speed command input is the very wide speedrange from a minimum speed of 0.005 rpm up to maximum speed.

Analog, +/- 10 V maximumThis interface is fitted with two differential inputs which can be selected duringoperation.

Digital, 16-bit parallelGuarantees high command accuracy for low-value commands and longtransmission paths.

SERCOS interfaceThe fiber-optic SERCOS interface offers the most efficient type of commandinput apart from the command (position, speed or torque command). It alsotransmits the drive's actual values and diagnostic signals.

3.2.2. Direct mains connection (for RAC)

The RAC main spindle drives are designed for direct connection to groundedthree-phase mains supply systems. They are fitted with a built-in mainscontactor that is actuated by the NC controller via potential-free contacts. Noother series switching devices are required if the mains voltage is in the 3 x AC380 to 460 V; 50/60 Hz range (Option mains supply requirements).

Direct connection is possible in ungrounded three-phase mains systems, ifexcessive overvoltages are only transient and are of a low energy content(static charges, voltage increases due to lightning, etc.). In this case, however,the RAC must be protected by surge arresters (Option mains supplyrequirements).

3.2.3. Emergency-stop (E-stop) / mains off function

The E-stop shut-down circuit is built into the RAC drive and requires noadditional circuitry for the shut-down logic.

Furthermore, energy released during braking is fed back into the mainssystem.


Emergency-stopshutdown circuit

(for RAC)



There are two facilities for stopping the drive in an E-stop situation:

• Internal disconnection of speed command, with power disconnect aftermotor has stopped. This is controller input activated.

• The NC controller externalls sets the speed command to zero and disconnectsthe power when the motor has stopped.

The RAC drive can brake the main spindle motor in this case as well to preventthe main spindle from coasting during a mains failure. The RAC must beequipped with the option "additional bleeder" for this purpose.

The braking method implemented can correspond to the circumstances:

• Internal speed command zeroing; braking at maximum torque.

• Internal speed command ramp; braking depends on slope of ramp.

• NC-controlled braking via speed command; braking depends on technologicalprocess (e.g., separation of workpiece from tool in gear-cutting machines).

In addition to the main spindle drive with KDA or TDA, the modular constructionof the drive package also enables servo drives to be connected to the samepower supply.

Modular drive system requirements:

• Stopping the servo drives has priority over stopping the main drive.

• The total power regenerated by the drives during braking must not exceedthe regenerated power of the supply unit, otherwise the voltage in the D.C.bus rises to inadmissible levels.

• If the D.C. bus voltage reaches the permissible limit as a result of the powerregenerated when the drives are braking, then the main spindle driveinterrupts the braking of the main spindle motors. If voltage drops again, themain spindle drive returns to braking mode.

Mains off functions (forRAC)

Emergency-stop/mains off functions

(for TDA/KDA)



3.2.4. Two-motor changeover

It is possible in some systems that two drive tasks have to be carried out atdifferent points. If the two tasks are never required simultaneously, they canbe executed with the use of two motors connecterd to one drive. The driveselects the motor by changing over the parameter sets. For this to occur, thedrive must be fitted with the "additional encoder input" (Option : for connectingthe second motor feedback).

Figure 3.8: Arrangement for two-motor changeover

2MU2ADH

X5

X3

NCcontroller speed

commandand

motorselection

drive unit

motor 1

motor feedback 2

X4X2

motor feedback 1

motor 2

motor supply cable 2

motor supply cable 1

3.2.5. AS programming module

The drive is matched to the main spindle motor and the operating characteristicsof the main spindle drive are implemented by means of the AS programmingmodule which is plugged into the drive. INDRAMAT supplies an associated ASprogramming module for each main spindle drive provided (see selectionlists).

INDRAMAT main spindle drives are microprocessor controlled.

Thanks to the associated AS programming module, the main spindle drive isimmediately ready for the first start-up without the need for tuning operations.This assumes that connections and commissioning have been properlycarried out.

INDRAMAT main spindle drives can be tuned via parameters to the systemconditions and functional requirements of the application.

The AS programming module holds the operating software and the parameters.If a unit has to be replaced, the drive does not have to be retuned since it isimmediately tuned to the motor and the machine by plugging in the previouslyused (and in this case already tuned) programming module.

Tuned programming modules can be easily duplicated for other identicalmachines or for security. This is done with the parameter duplication adapter(Option: accessories) or via the serial interface (Option: additional interface)and storage device (PC or similar).

Rapid drivecommissioning

Advantages whenreplacing units

Duplication



3.3. Messages / Signals

When actual speed value reaches command value, the main spindle drivesignals "Nact = Nset" to the NC controller to enable the feed.

Changes of speed and actuation of the holding brake may only be executedby the NC controller at low speeds or with the spindle stationary. Below aselectable motor speed, the main spindle drive informs the controller that thespindle has stopped.

If the drive has reached 90% of its maximum loading during machining cycles(90% of M

max or P

max), the main spindle drive signals "overload" to the NC

controller. This allows speed reductions at the spindle feed to be reliablyavoided by reducing the feed.

Tools run the risk of damage due to unduly high machining forces. There areadjustable load thresholds in the main spindle drive above which "thrustachieved" is signalled to the NC controller. The drive can then prevent damageto tools by reducing the feed.

In master/slave mode, both drives must derive their force from a commonshaft. The direction of force of the slave drive must be identical to that of themaster drive. If not, the controller is informed of this by the overload message.This makes commissioning simpler and safer.

Due to the overload capacity of the main spindle motors, load cycles can beimplemented in considerably more than the continuous power briefly demandedby the motor. Correct drive dimensioning ensures that the temperature of themotor and drive is always within the permissible temperature range. If,however, the cooling system of the motor or drive, for example, is not workingcorrectly (contamination or similar), the drive runs the risk of being damagedby overheating.

INDRAMAT main spindle drives are protected against overheating.

If the temperature of the motor or drive approaches the limit of the permissibletemperature range, the drive generates "temperature warning" via a signaloutput.

If the motor temperature increases further, on reaching the maximumpermissible windings temperature the drive shuts down automatically. Thesame happens if the heatsink temperature of the drive continues to climb.

In machine tools, different tools or chucks can be used at different maximumspeeds on the main spindle during operation.

Adjustable speed thresholds, to which the speed of the spindle is then limited,can be activated in the main spindle drive.

With INDRAMAT main spindle drives the spindle speeds can be limited toseven different maximum speeds, and monitored.

Speed reachesspindle hold

Spindle stopped

Overload

Thrust achieved

Direction of force iscoincident

Temperature warning

Spindle speed limit



The spindle monitor detects a faulty, dangerous condition the first time themachine is started up, if this is caused by a malfunction in the mechanicaltransmission elements.

The drive detects any break in the mechanical link from the motor to the spindlefeedback by monitoring spindle speed.

Spindle monitoring requires a spindle feedback unit to be connected to thedrive. The drive must be fitted with an additional encoder input (Option ) forthis.

After initiating spindle positioning via the main spindle drive, the controllermust be informed when the end position is reached in order to execute furtherprogram steps.

Once the spindle has reached the end position, then the control unit signals"spindle in position" to the NC controller. The message appears with a fully-adjustable tolerance window. One tolerance window is available in each of thefour switchable parameter sets.

After the machine is switched on, the drive can only execute a program if it isguaranteed that all connected drives can process all commands . In INDRAMATmain spindle drives this is communicated to the controller by means of apotential-free contact and via a signal output.

INDRAMAT main spindle drives have two analog outputs: one is bipolar (-10V .... +10 V), the other is unipolar (0 ... +10 V).

To make commissioning easier, the drives transmit status variables such asmotor speed (command and actual-value), spindle speed, torque command,spindle position, as well as D.C. bus voltage, current and power, and analogvoltage -10 V ... +10 V.

Whilst the machine is running, the bipolar analog output can be permanentlyassigned via parameters in terms of speed and torque command, power ortemperature output. The unipolar analog output continuously supplies drivecapacity in the range of +10 V to a display instrument .

Spindle monitor

Spindle in position

"Ready"

Analog outputs


VerlustleistungAirflow


3.4. Control unit cooling

3.4.1. Modular main spindle drives

Depending on the construction of the heatsink for the power electronics, thereare two cooling arrangements for the modular main spindle drives:

• with air inside the control enclosure

• with air outside the control enclosure

The TDA drive is cooled with air inside the control enclosure. The heatsink forthe power electronics is built into the drive housing.

The TDA has two current ratings: 50 A and 100 A.

The KDA drive can be cooled with air outside the control enclosure. In thiscase, the heatsink for the power electronics is placed behind the KDA housing.

When installed, the heatsink projects out of the control enclosure. An add-onfan ducts the dissipated heat out of the control enclosure.

The current ratings of the KDA are 50 A, 100 A and 150 A.

fully enclosed housingor cabinet

heatsink

dissipated heat

cowl

exte

rnal

inte

rnal

KKDA2ADH

blower motor

air flow

blower

KDA 3.2

Figure 3.9: Cooling principle using air outside the control enclosure (KDA)

Cooling with the airinside the enclosure

Cooling with the airoutside the enclosure



3.4.2. Main spindle drives for direct connection to the mains (RAC)

The heatsink for the power electronics and the blower for RAC main spindledrives are built into the housing. The airflow is passed through the equipmentvia an air duct.

The RAC drives can be cooled with air inside and outside the controlenclosure. Both options are built into each RAC and the necessary conversionis simple to carry out and requires no accessories.

The cooling air is drawn in from inside the enclosure and then blown out.

The cooling air is drawn in from outside through vents in the rear panel of theenclosure. The dissipated heat is ducted to the outside of the enclosure.

Figure 3.10: RAC cooling options

KRAC2ADH

Cooling with outside air

Lufteintritt

air inlet

air outlet

air outlet

rear panelof the enclosure

air inlet

air outlet

rear panel of the enclosure

air inlet

air outlet

Cooling with inside air

RAC 3 RAC 2and

RAC 4

RAC 3 RAC 2and

RAC 4

Two possible coolingarrangements

Cooling with air insidethe enclosure

Cooling with airoutside

the enclosure


If, for technical reasons, it is not possible to provide vents in the rear panel ofthe enclosure, then the RAC drives can also be fitted with a duct coolingsystem.

Air is then drawn in from outside and blown out again outside the controlcabinet.

Hose cooling

X 6

AC-MAINSPINDLE DRIVE RAC 2

L -

L +

X 4

X 2 X 3

X 5X 1 3

Prog. Modul AS nicht unter Spannung wechseln

ASSWITCH OFF VOLTAGE BEFORE

CHANGING MODULE AS

air inlet

SRAC2ADH

AC-MAINSPINDLE DRIVE RAC 3

X 4

X 2Prog. Modul AS nicht unter Spannung wechseln

X 3

X 5X 1 3AS

SWITCH OFF VOLTAGE BEFORECHANGING MODULE AS

air inlet

air outlet

RAC 3RAC 2

(RAC 4)

Duct

duct

duct

air outlet

duct

X 14

220 VSteuerspannung

Aux. VoltageNetz/Mains

L 3L 2L 1LN

Motor

A 3A 1 A 2

DANGER HIGH VOLTAGEDISCHARGE TIMEEntladezeit 1Min.

Figure 42: Hose cooling an RAC

Mounting components are required for duct cooling (Option: cooling). Anaccessory set supplies the necessary parts. The duct itself is not included inthis set, but can also be ordered from INDRAMAT.

The RAC 3.5 drive is also available with liquid cooling (Option : cooling)!

3.5. Mechanical accessories

A mounting frame is required for attaching each KDA, RAC 2 and RAC 4 drive.It braces the rear panel of the enclosure or the mounting plate, carries themounting threads and provides a flat and rigid mounting surface.

Since the sealing elements of the drives are pressed against a flat surface bythe mounting frame, this ensures complete sealing of the control enclosure.The heatsinks can also be wet-cleaned from the outside.

The mounting frame, including all fixing screws, is included in the mechanicalaccessory kit of the drive.


Liquid cooling


4. Motor options

4. 2AD main spindle motor options

The main spindle motor options are dealt with only briefly here. A detailleddescription is given in the associated motor documentation. Each of the statedOptions requires a decision that should be written down in the selectionrecord.

4.1. MountingThe 2AD main spindle motors can be either flange or flange and foot mounted.

4.2. Power connectionBoth the position and the outlet orientation of the power connection can beselected to accommodate varying installation conditions.

4.3. Cooling methodsINDRAMAT main spindle motors have surface cooling. They are available ina slim form with an axial or radial fan fitted to the non-drive end.

With axial fan cooling, the airflow is blown from the non-drive to the drive endof the motor or drawn in from the opposite direction.

With radial fan cooling, the airflow direction is always from the non-drive to thedrive end.

4.4. Holding brakeOnce the power to the motor is switched off, the spindle can be clamped by theholding brake for a chuck or tool change.

Choose the "electrically-operated" version for main spindle applications.

Motors with electrically-released holding brakes are available for specialapplications (e.g., servo)!

4.5. Output shaftBecause of the drive's improved smooth run and the backlash-free connectionbetween the shaft and hub, the coupling of the output components (pulley,clutch, pinion) should best be a friction-locked shaft/hub connection. Themotors are constructed with cylindrical, smooth shafts for this purpose.

If for installation reasons no friction-locked shaft/hub connection is possible,then the motors can be equipped with keys.

4.6. Shaft sealing ringOil can reach the ouput shaft where the motor is flange-mounted to oil-bathgearboxes. This means that there is the risk of oil entering the motor andinterfering with operation. The motor must be fitted with a shaft sealing ring inthis case.


4.7. Non-drive shaft endIt is often necessary to mount an additional position actual-value encoder(absolute-value encoder) in some applications (e.g., servo).

The motors can be fitted with a second, non-drive shaft end (only available inconjunction with a radial fan) in such cases.

4.8. Shaft bearingsHigh radial loads occur at the shaft bearings in the case of belt transmissions.Heavy-duty bearings are available for such applications.

4.9. Vibration severity gradeThe main spindle motors can be supplied with various vibration severitygrades for meeting special requirements.

4. Motor options


5. Electrical connections

The electrical connections for the entire INDRAMAT main spindle drive rangeare standardized with the aim of reducing the number of cables.

There are three categories of electrical connections for main spindle drives:

• Power connections

– connections between motor and drive,

– connections between RAC drive and three-phase mains system.

• Feedback and NC connections with the same connector pin assignment,regardless of drive or motor type.

• Drive-specific connections

– within the modular drive package (TDA, KDA),

– contacts for control circuits in the RAC drives.

All categories of connections (with the exception of drive-specific connectionsin the RAC) are available as ready-made cables. They make for easy andrapid assembly of machine and control cabinet. If only ready-made cables areused, then power or connection accessories are not needed.

Electrical connectors can also be ordered. INDRAMAT supplies all thenecessary individual parts, such as leads and other accessories, if you wishto make these up yourself.

The choice of version can be recorded in the "Record of selected electricalconnections". Peculiarities such as control cabinet bushings, intermediateterminals and couplers, etc., can be noted. Otherwise, direct connection isassumed.

Standardization

Types of powerconnections

ready-made

Figure 5.1: Breakdown of the power connections

Categories

Types

to motor• power connector/crimp cable lug at motor

end• end connector sleeve/crimp cable lug at

drive end

• supply leadto three-phase mains (for RAC)• end connector sleeve/crimp cable lug

• supply lead

individual parts

Power connections

no other connection or poweraccessories required!




Types of feedbackand NC

connections

completelyready-made

individual parts

additional connectorsand leads

partiallyready-made

Feedback and NC connections

no other connection orpower accessoriesneeded!

additional:• connector kit

(at drive end)• leads• individual connectors

(at feedback andNC ends)

Figure 5.2: A breakdown of the feedback and NC connections

When individual parts for feedback and NC connections are used, theaccessory kits include appropriate connectors to the drive.

individual parts for RAC

Types of drive-specific connections

Plug-in connectors without cablefor contacts to integrated mainscontactor (included in the RACelectrical accessories).

Figure 5.3: Breakdown of the drive-specific connections

Drive-specific connections

ready-made for

KDA/TDA

Drive-specific connections are always required!

The connection diagrams are included in the associated "Project planning"documentation of the main spindle drive.

The electrical connecting accessories within the modular drive package forthe KDA and TDA are dependent upon the position of the drive within the drivepackage (see associated documentation main spindle drives - "projectplanning").

Only the connectionswithin the modular drivepackage can be obtainedfrom INDRAMAT (part ofthe KDA/TDA electricalaccessories).


6. Selection records


The selection records are used to record motor and drive options and the typesof electrical connections needed without the use of the codes.

There are three selection records:

• the main spindle drive selection record,

• the main spindle motor selection record, and,

• the electrical connections selection record

The power-related type information about the main spindle drive, programmingmodule and main spindle motor should be entered at the underlined points asper the selection list or the performance curve.

A decision is required in each block -- this should be marked with a cross. Onlyone cross per block is permitted.

The fully completed selection records are sent to INDRAMAT. These are usedto prepare a quote.

Basis for a quotation

Completion



Selection record of main spindle drive,main spindle drive rated at ____ kW

Power-related datamain spindle drive: TDA 1.3 - __ __ __ - 3 - • • •

KDA 3.3 - __ __ __ - 3 - • • • - • •RAC 2.3 - __ __ __ - • • • - • • • - • •RAC 3.5 - __ __ __ - • • • - • • • - • •RAC 4.3 - __ __ __ - • • • - • • • - • •

Power-related dataprogramming module: AS 17 • / __ __ __ - 000

AS 13 • / __ __ __ - 000AS 15 • / __ __ __ - 000AS 16 • / __ __ __ - 000AS 18 • / __ __ __ - 000

Speed command: analog (+/- 10 V)digital, (16-bit -parallel)SERCOS interface

Additional encoder input: INDRAMAT high-resolution spindle feedbackincremental encoder - spindle feedbackconnection for second motor feedbacksynchronous input for spindle synchronizationno additional encoder input

Spindle homing switch: YesNo

Additional interface: incremental encoder outputposition command for 3600 positions, digital (16 bit parallel)serial interface (RS 232 C)no additional interface

Mains voltage: 3 x AC 380 V / 50 ... 60 Hz3 x AC 380 V/50 Hz, 3 x AC 415 V/50 Hz, 3 x AC460 V/60 Hzother voltage, 3 x _____ V, ____ Hz

Mains conditions: grounded systemnon-grounded system

Additional bleeder: braking at maximum torque or controlled by NC controller(with an additional bleeder)braking not required (no additional bleeder)

Cooling: (RAC only) duct coolingnone

Accessories: parameter duplication adapterliquid cooling (RAC 3.5 only)none

Figure 6.1: Selection record of control unit



Selection record of elec. connections, main spindle drive at ____ kWPower connections ready-made special features ______________to motor: individual parts no special features

none

Power connections to the ready-made special features ______________3-phase supply (RAC only): individual parts no special features

none

Feedback and ready-made special features ______________NC connections: partially ready-made no special features

individual parts 1)

none

Drive-specific connections are always required!

Selection record of main spindle motor,Main spindle drive rated at ____ kW

Power-related datamain spindle motor: 2AD __ __ __ __ - B • • • • • - __ __ • 3 - • • • •

Mounting: Flange mountingFoot mounting (not 2AD100)

Power connections: Power connection at top 2AD132 only!: Junction boxPower connection at right PlugPower connection at left

Power connection outlet at drive end (D)Power connection outlet at non-drive end (N)Power connection outlet to rightPower connection outlet to left

Type of cooling: Axial fan with airflow B ——> A (blowing)Axial fan with airflow A ——> B (drawing in)Radial fan

Holding brake: Electrically lockingElectrically releasingElectrically releasing, heavy-dutyWithout holding brake

Drive shaft: Without keywayWith keyway

Shaft sealing ring: YesNo

Non-drive shaft end: YesNo

Shaft bearings: StandardHeavy-duty bearings

Vibration severity grade: RSOther _______

Figure 6.2: Selection record of 2AD motor

Figure 6.3: Selection record of electrical connections

1) Put a cross next to connector accessories in the order matrix!


7. Ordering details

2AD main spindle motor(type code matrix)

Figure 7.1: An overview of the individual parts of the main spindle drive

A grid of the type designations with referencing of all supplementarydocumentation (see section 7.1).

There is an order matrix with type codes for the drive, programming modulesand necessary additional components for

• TDA 1.3, (see section 7.2.1.)

• KDA 3.3, (see section 7.2.2.)

• RAC 2.3, (see section 7.2.3.)



with references for supplementary information.

main spindledrive

RAC 2.3(order parts list)

main spindledrive

KDA 3.3(order parts list)

main spindledrive

TDA 1.3(order parts list)

main spindledrive


main spindledrive


electrical connections(order matrix, power connections,

order matrix feedback + NC connections)

spindle feedback(order parts list)

Section Item Main spindle drive components

7.1 1.

7.2 2.

7.3 3.

7.4 4.

7. Ordering details

The decisions written down in the selection record must be translated into acomplete type designation (in other words, coded) for the order. This is doneusing the "Available Versions" or the "Standard Product Range" detailled inSection 8.

The following must be ordered to obtain an operational main spindle drive thatis completely ready for installation and assembly:

• a main spindle motor,

• a main spindle drive with the necessary additional components andprogramming module,

• electrical connections, and,

• spindle feedback, where applicable.

Motor

Main spindle drive


Electrical connections

7. Ordering details

There is an order matrix for the power connections, feedback and NCconnections (see section 7.3). Supplementary documentation is referenced.

To make it easier to identify the types of electrical connections, and for a clearallocation to a main spindle drive and main spindle motor, please write downthe type designations of the associated motor and drive in the correspondingorder matrix!

It is possible to type code the electrical connections by simply putting a crossor the number-to-be-ordered in the associated order matrix!

Order matrix with referencing of supplementary documentation (see section.7.4.).

7.1. Main spindle motor

For item 1.0: convert selection record –> to type designation by means of"standard product range" (sections 8.8. to 8.12.).

Item Article Supplementary documentation

2.1 Main spindle driveTDA 1.3__ __ __-3-__ __ __

2.2 Electrical connecting accessoriesE__ __-TDA

2.3 Accessories• PDA (parameter duplication adapter)(please delete if not required)

2.4 Programming moduleAS17__/__ __ __-000


1.0 Main spindle motor2AD__ __ __ __-B__ __ __ __ __-__ __ __3-__ __ __ __

1.1 Separate rating plate for item 1.0(please delete if not required)

“2AD main spindle motor;project planning manual”,doc. no.: 209-0042-4122

Figure 7.2: Type designations for a 2AD main spindle motor

Figure 7.3: Parts list for a TDA 1.3

7.2. Main spindle drive

7.2.1. Main spindle drive TDA 1.3

For item 2.1: convert selection record to –> type designation by means of"available versions of TDA 1.1" (section 8.1).

For item 2.2: see "Supplementary Documentation"

For item 2.4: convert selection record to –> type designation by means of"available version of the AS programming module" (section 8.13.).

"TDA 1 main spindle drive,project planning manual";doc. no.: 209-0042-4112

Spindle feedback


7. Ordering details

7.2.2. Main spindle drive KDA 3.3

For item 2.1: convert selection record to –> type designation by means of"available versions of KDA 3.2" (section 8.2.)

For item 2.2: see "Supplementary Documentation"

For item 2.6: convert selection record to –> type designation by means of"available versions of AS programming module" (section 8.13.)

Figure 7.5: Parts lists for an RAC 2.3

"RAC 2-Main spindle drive;Project planning"Doc. no. 209-0042-4115


2.1 Main spindle driveRAC 2.3-__ __ __-__ __ __-__ __ __-__1

2.2 Electrical connection accessoriesE1-RAC

2.3 Mechanical accessoriesM1-RAC 2

2.4 Accessories (please delete if not required)• PDA (parameter duplication adapter)• duct cooling M2-RAC 2• duct Ø 125, part no. 238 354


Item Article Supplementary documentation2.1 Main spindle drive

KDA 3.3-__ __ __-__-__ __ __-__1

2.2 Electrical connection accessoriesE__ __-KDA

2.3 Mechanical accessoriesM1-KD

2.4 BlowerLE4-__ __ __ (220 V or 115 V,corresponding to control voltage ofsupply unit)

2.5 Accessories• PDA (parameter duplication adapter)(please delete if not required)


"KDA 3-Main spindle drive;Project planning",doc. no. 209-0042-4110

Figure 7.4: Parts list for a KDA 3.3 drive

7.2.3. Main spindle drive RAC 2.3

For item 2.1: convert selection record to -> type designation by means of"available versions of an RAC 2.3" (section 8.4.)

For item 2.5: convert selection record to -> type designation by means of"available versions of an AS programming module" (section 8.13.)


7. Ordering details


2.1 Main spindle driveRAC 3.5-__ __ __-460-__ __ __-__1-220


2.3 Accessories (please delete if not required)• PDA (parameter duplication adapter)• duct cooling M1-RAC3• duct Ø 80, part no. 239 312,• duct Ø 125, part no. 238 354


Figure 7.6: Parts list for an RAC 3.5


For item 2.1: convert selection record to -> type designation by meansof "available versions of drive RAC 4.3" (section 8.5.)

For item 2.5: convert selection record to -> type designation by meansof "available version of AS programming module" (section 8.13.)


2.1 Main spindle driveRAC 4.3-__ __ __-460-__ __ __-W__


2.3 Mechanical accessoriesM1-RAC 4

2.4 Accessories (please delete if not required)

• PDA (parameter duplication adapter)

• duct cooling M2-RAC 4

• duct Ø 125, part no. 238 354


Figure 7.7: Parts list for an RAC 4.3


For item 2.1: convert selection record to -> type designation by means of"available version of a RAC 3.5 drive " (section 8.3.)

For item 2.4: convert selection record to -> type designation by means of "aavailable versions of an AS programming module" (section 8.13.)

"RAC 4-Main spindle drive;Project planning",doc. no. 209-0042-4113

"RAC 3-Main spindle drive;Project planning",doc. no. 209-0042-4116


2AD100B-.-AS.3 IKL 071/… crimp cable lug IN 203/… plug IN 172/25

2AD100C-.-AS.3 IKL 071/… crimp cable lug IN 203/… plug IN 172/25

2AD100D-.-AS.3 IKL 112/… crimp cable lug IN 204/… plug IN 172/06

2AD101D-.-BD.3 IKL 130/… crimp cable lug IN 205/… plug IN 172/10

Power connector IKL 130/… crimp cable lug IN 205/… plug IN 172/102AD132B-.-BS.3

terminal box IKL 135/… crimp cable lug IN 205/… crimp cable lug

2AD132B-.-DS.3terminal box IKL 110/... connector sleeves IN 204/... crimp cable lug

Power connector upon request crimp cable lug IN 206/… plug IN 172/162AD132C-.-BS.3


2AD132C-.-CS.3terminal box IKL 136/… connector sleeves IN 205/… crimp cable lug

2AD132D-.-AS.3terminal box IKL 151/… connector sleeves IN 206/… crimp cable lug

Power connector IKL 170/… crimp cable lug IN 207/… plug IN 172/252AD132D-.-BD.3


2AD160B-.-BS.3 IKL 172/… connector sleeves IN 207/… crimp cable lug

2AD160C-.-BS.3 IKL 182/… connector sleeves IN 267/… crimp cable lug

2AD180C-.-BS.3 IKL 182/… connector sleeves IN 267/… crimp cable lug

2AD180D-.-BS.3 IKL 191 crimp cable lug IN 268/... crimp cable lug

2AD200C-.-BS.3 2 x IKL 175 crimp cable lug 2 x IN 207/... crimp cable lug

2AD225C-.-BS.3 2 x IKL 183 crimp cable lug 2 x IN 267/… crimp cable lug

Particular electrical design features such as bushings, isolating points, etc. and environmental conditions not

complying with VDE 0113 standards should be noted in the "Remarks" column!Supplementary documentation: "Electrical connections of main spindle drives, project planning", no. 209-0042-4111

ready-madecable / (length)

for directconnection

Order matrix - power connections

2AD__ __ __ __-__ __ __ __ __-__ __ __ __-__ __ __ __

KDA 3 . 3-__ __ __-__-__ __ __-__ __

TDA 1 . 3-__ __ __-__-__ __ __

RAC__ __-__ __ __-__ __ __-__ __ __-__ __

Ready-made cables or individual parts should be ordered according

to motor type by placing, in the left-hand edge of the relevant field,

an "x" or a quantity 1

Selected motor

Selected drive

Procedure

Constructing ready-made cables for direct connection

Rem

arks

drive end cable / (length) motor endMotor

7. Ordering details

Figure 7.8: Ordering guide for power connections

7.3. Electrical connections


Selected drive

Selected motor

functional options

Procedure

Particular electrical design features such as bushings, angle connections, etc. should be noted in the "Remarks" column!Supplementary documentation: "Electrical connections for main spindle drives; Project planning" no. 209-0042-4111

Drive interfaces

to NC IN 293

Individual parts of ready-made cables

Feedback orNC conn.

to feedback Motor feedbackconnection

IKS 315/. . . .

IN 290 IN 401

A analog IKS 045/. . . .

IN 287

D digital16-bit parallel

IKS 612/. . . . IN 291

L SERCOSinterface

IKO 984/. . . .

O

Add.encoder

inputfor

IKS 314/. . . .

IN 289 IN 209 IN 401Phigh-resolution

INDRAMATspindle

feedback

IKS 327/. . . .

IN 289 IN 209

incrementalencoderspindle

feedback

IN 301

Y Synchronousinput

IKS 331/. . . . IN 290 IN 209 IN 301

O None

D

IN 209/. . . .

I incrementalencoder output

SIN 234/

. . . . IN 291

withoutadditional

encoder input

Sta

ndar

d

digitalposition

command

for

the

func

tiona

l opt

ions

215 896. . . .

Speedcommand

additionalencoderinput

additio-nalinterfaces

connectorsleeves

connectorsleees

connectorsleeves

connectorsleeves

S1-

IKS620/. . . .

IKS618/. . . .

IKS015/. . . .

IKS016/. . . .

IKS614/. . . .

IKS612/. . . .

S2-

IN 289

IN 292IN 296

IN 328

IN 295 IN 291

IN 271/. . . .

IN 209/. . . .

IN 233/. . . .

215 896. . . .

Connectoraccess. kits

Remarks

connectorsleeves

serial interfaceRS 232-C

7. Ordering details

Figure 7.9: Ordering guide for feedback and NC connections

Ready-madecable

(length)to drive

D-Sub connector

(corresponds tofunctional options)

KDA/TDA RAC

IKS 610/. . . .

. . . .

Control input,monitoring andanalog outputs

KDA/TDA RAC

Lead/(length)

Order matrix - feeedback and NC connections

2AD_ __ __ __-B__ __ __ __-__ __ __ __-__ __ __ __

KDA 3 . 3-__ __ __-__- -__1

TDA 1 . 3 -__ __ __-__-

RAC__ __-__ __ __-__ __ __- -__ __

• Ready-made cables or individual parts should be ordered according to the

functional options of the drive by placing an "x"

or quanity 1 at the left hand edge of the relevant field!

• Should only individual parts be ordered, then

connection accessories kit S • - • • • will reduce the number of parts to be ordered.


7.4. Spindle feedback

For item 4.1 ... 4.3: see "Supplementary documentation"


4.1 Measuring wheelMH2-__ __ __-5-__ __ __A

4.2 SensorSH2-__ __ __-5-__R

4.3 Sensor connecting cableIN 356/__ __ __

High-resolution main spindleencoder for KDA and RAC mainspindle drives; applications,doc. no. 9.552.247.4-02

Figure 7.10: Parts list for INDRAMAT high-resolution spindle feedback

7. Ordering details




8.1. Modular main spindle drive TDA 1

1. Designation: TDA

2. Series: 1

3. Version: 13

4. Current rating:50 A 050100 A 100

5. D.C. bus rated voltage:DC 300V: 3

6. Speed command:analog (+/- 10 V) Adigital (16 bit parallel) DSERCOS interface L

7. Additional encoder input:without additional encoder input Oadditional encoder input für spindle feedback or 2nd motor feedbackP

Additional encoder input and synchronous input Y(for TDA 1.1: requires speed command = A and AS 75/… for TDA 1.3: requires speed command = A)

8. Additional interface:without additional interface Oposition command, digital (16 bit parallel) Dserial interface (RS 232 C) Sincremental encoder output I

Type code fields: Example: TDA 1.3 - 100 - 3 - A00

Quellverweis: INN 07.02

Figure 8.1: TDA 1 standard product range


1. Designation: KDA

2. Series: 3

3. Version: 23

4. Current rating:50 A 050100 A 100150 A 150

5. D.C. bus rated voltage:DC 300V: 3


7. Additional encoder input:without additional encoder input Oadditional encoder input for spindle feedback or 2nd motor feedbackP

Additional encoder input and synchronous input Y(for KDA 3.2: requires speed command = A und AS 35/… for KDA 3.3: requires speed command = A)

8. Additional interface:without additional interface OPosition command, digital (16 bit parallel) DSerial interface (RS 232 C) SIncremental encoder output I

9. Rated connection voltage for attached blower:AC 115 V/50…60 Hz UAC 220 V/50…60 Hz W

10.Cooling mode:mounted blower 1

Type code fields: KDA 3.3 - 150 - 3 - A00 - W1Example:


8.2. Modular main spindle drive KDA 3


Figure 8.2: Available versions of the KDA 3


1. Designation: RAC

2. Series: 3

3. Version: 15


5. Rated connection voltage for power electronics:3 x 380V…460V; 50…60 Hz 460



Additional encoder input and synchronous input Y(for RAC 3.1: requires speed command = A and AS 65/… for RAC 3.5: requires speed command = A)

8. Additional interface:without additional interface Opositionssollwert, digital (16 bit parallel) Dserial interface (RS 232 C) Sincremental encoder output I

9. Additional bleeder:without additional bleeder Wadditional bleeder (for braking during mains failure) Z

10.Cooling mode:mounted blower 1liquid coolant F

11. Rated connection voltage for control electronics: AC 230 V/ 50…60 Hz 220

Type code fields: Example:


8.3. Main spindle drive RAC 3

RAC 3.5 - 150 - 460 - A00 - W1 - 220


Figure 8.3: Available versions of the RAC 3




1. Designation: RAC

2. Series: 2

3. Version: 23

4. Current rating:150 A 150200 A 200250 A 250

5. Rated connection voltage:3 x AC 400V/50…60 Hz 3803 x AC 400V/50 Hz, 3 x AC 460V/60 Hz 460



additional encoder input und synchronous input Y(for RAC 2.2: requires speed command = A and AS 55/… for RAC 2.3: requires speed command = A)


9. Additional bleederwithout additional bleeder WAdditional bleeder (for braking during mains failure) Z


Type code fields: Example: RAC 2.3 - 200 - 460 - A00 - W1






RAC 4.3 - 400 - 460 - A00 - W1

1. Designation: RAC

2. Series: 4

3. Version: 13


5. Rated connection voltage:3 x AC 400V/50Hz, 3 x AC 460V/60Hz 460


7. Additional encoder input:without additional encoder input Oadditional encoder input for spindle feedback or 2nd motor feedbackPadditional encoder input and synchronous input Y(requires speed command = A)


9. Additional bleeder:without additional bleeder W


Type code fields: Example:




1. Designation: 2AD

2. Series: 100

3. Length: B, C, D

4. Version:Flange mounting B05

5. Power connection position:top O

6. Power connection output direction:At drive end AAt non-drive end BTo the right * RTo the left * L

7. Cooling mode:Axial blower (airflow B --> A), AC 220 V 1Axial blower (airflow A --> B), AC 220 V 2Axial blower (airflow B --> A), AC 115 V 4Axial blower (airflow A --> B), AC 115 V 5Radial blower, (airflow B --> A), AC 220 V, blower right 6Radial blower, (airflow B --> A), AC 220 V, blower below 7Radial blower, (airflow B --> A), AC 220 V, blower left 8Radial blower, (airflow B --> A), AC 115 V, blower right ARadial blower, (airflow B --> A), AC 115 V, blower below BRadial blower, (airflow B --> A), AC 115 V, blower left C

8. Windings type: AS

9. Holding brake:without 0electrically locked 1electrically released 2

10.Motor feedback:with high-resolution motor feedback 3

11.Output shaft: with key balanced balancedsmooth shaft with entire with half key key

without shaft sealing ring A B E with shaft sealing ring C D H

12.Second shaft extension:without 2with 2nd shaft ext. for encoder (incremental, absolute) **) 3

13.Shaft bearings:Standard N

14.Vibration severity grade:R 1S 2

*) viewed from motor shaft, direction depends on power connetion**) only with radial blower


8.6. Main spindle motor 2AD100

Type code fields: Example: 2AD100C-B05OB1-AS03-A2N1

Quellverweis: INN 6.30 Teil 1

Figure 8.6: Standard product range of the 2AD100


1. Designation: 2AD

2. Series: 101

3. Length: C, D

4. Version:Flange mounting B05

5. Power connection position:top O

6. Power connection output direction:with junction box with plug

at the blower at the blowerAt drive end A CAt non-drive end B DTo the right * R ETo the left * L F

7. Cooling mode:Axial blower (airflow B --> A), AC 220 V 1Axial blower (airflow A --> B), AC 220 V 2Axial blower (airflow A --> B), AC 115 V 5

8. Windings type:2AD101C BD2AD101D BD, BS




without shaft sealing ring A B Ewith shaft sealing ring C D H

12.Second shaft extension:without 2

13.Shaft bearings:standard N

14.Vibration severity grade:R 1S 2S1 **) 3

*) View from motor shaft, direction depends on power connection**) not available with "D" length







1. Designation: 2AD

2. Series: 132

3. Length: B, C, D

4. Version:Flange mounting B05Flange and foot mounting B35

5. Power connection position:top Oleft Lbelow R

6. Power connection output direction:Junction box connection Plug

(junction box at the blower) (plug at the blower)at drive end A Cat non-drive end B -to the right * R Eto the left * L F

7. Cooling mode:Axial blower (airflow B --> A) 1Axial blower (airflow A --> B) 2Radial blower (airflow B --> A), blower top **) 3Radial blower (airflow B --> A), blower right **) 6Radial blower (airflow B --> A), blower below **) 7Radial blower (airflow B --> A), blower left **) 8

8. Windings type:2AD132B BS, DS2AD132C BS, CS2AD132D AS, BD

9. Holding brake:without 0electrically locked 1electrically released 2electrically released, heavy-duty 3electrically released, extra heavy-duty 4




12.Second shaft extension:without 2with 2nd shaft extension for encoder (incremental, absolute) ***) 3

13.Shaft bearings:standard Nheavy-duty V

14.Vibration severity grade:R 1S 2S1 ****) 3

*) View from motor shaft, direction depends on output direction**) The position of the blower may not be the same as the position of the power connection***) Available only with radial blower and motor feedback "3".****) Not available with heavy-duty shaft bearings.



Type code fields: Example: 2AD132C-B35OB1-BS03-A2N1




1. Designation: 2AD

2. Series: 160

3. Length: B, C

4. Version:Flange mounting B05Flange and foot mounting B35


6. Power connection output direction:at drive end, junction box Aat non-drive end, junction box Bto the right, junction box *) Rto the left, junction box *) L


8. Windings type:2AD160B BS2AD160C BS

9. Holding brake:without 0electrically locked 1electrically released 2electrically released, heavy-duty 3


11.Output shaft: with key

balanced balancedsmooth shaft with entire with half key key














1. Designation: 2AD

2. Series: 180

3. Length: C, D

4. Version:Flange and foot mounting B35




8. Windings type:2AD180C BS2AD180D BS


10.Motor feedback:without 0with high-resolution motor feedback 3with incremental encoder ROD 1424, damped 5












1. Designation: 2AD

2. Series: 200

3. Length: C





8. Windings type:2AD200C AS

9. Holding brake:without 0








*) View from motor shaft, direction depends on output direction**) The position of the blower may not be the same as the position of the power connection****) Not available with heavy-duty shaft bearings.







1. Designation: 2AD

2. Series: 225

3. Length: C



6. Power connection output direction:at drive end, junction box Aat non-driveend, junction box Bto the right, junction box *) Rto the left, junction box *) L

7. Cooling mode:Axial blower (airflow B --> A) 1Axial blower (airflow A --> B) 2

8. Windings type:2AD225C AS

9. Holding brake:without 0







*) View from motor shaft, direction depends on output direction****) Not available with heavy-duty shaft bearings.







8.13. Programming module AS


1. Designation: AS

2. Main spindle drive

KDA 3.2 3RAC 2.2 5RAC 3.1 6TDA 1.1 7RAC 4.1 8KDA 3.3 13RAC 2.3 15RAC 3.5 16TDA 1.3 17RAC 4.3 18

3. Software codes

Main spindle drive (standard) 1(not all combinations are listed below)

Servo drive 2

Main spindle drive with incremental encoder output 3(not for AS1••/…)

Main spindle drive with SERCOS interface 4

Main spindle drive with optional functions 5(not for AS1••/…)

Servo drive with SERCOS interface 6

4. Motor feedback

High-resolution motor feedback 0

5. Code for motor-drive combination

Determined and documented by INDRAMAT e.g., 04

6. Version

standard 000ready-made, e.g.: 003 003

Type code fields: AS151 / 004 - 000Example:

Figure 8.13: Available versions of the AS programming module



9. Stichwortverzeichnis

9. Index

AAbsolute-value encoder 50Actuation of holding brak 44Air duct 47Airflow 46Analog outputs 45Automatic changeover 36Automatic speed change 36Axial fan cooling 49

BBacklash-free connection 49Balancing machines 36Basis for a quotation 53

CC-axis 38C-axis operating mode messages 39Changing the operating mode 34Components for main spindle drive 56Connections, drive-specific 51Constant speed increase 34Contouring 36Controller-specific connections 52Cooling airflow 47

DDifferential inputs 41Direct connection, mains 41Dissipated heat 46Drive packages 7Drive "ready" 45Drive variables 45

EEarthed three-phase mains supply system 41Earthed three-phase mains supply system messages 41Emergency-stop shutdown circuit (for RAC) 41Emergency-stop/mains off functions (for TDA/KDA) 42

FFeedback and NC connections 51Flange mounting 49Foot mounting. 49Functions allocated to operating mode 33Functions with allocated operating mode 33

GGear-cutting machines 42Guidelines on the selecting process 3



HHeat dissipation 46Heatsink 46High-resolution motor feedback evaluation 39

IIncremental encoder 39Individual cable parts 51INDRAMAT spindle feedback 39

KKDA 7KDA blower 46Key 49

MMachine tools 36Machining force obtained 44Main spindle controllers, direct mains conn. 8Main spindle controllers RAC 8Main spindle drive operating mode messages 37Main spindle motor 6Main spindle motors 7Mains contactor 41Mains system 41Mains voltage 41Master/slave 40Master/slave mode 40Maximum speeds 44Messages for master/slave mode 40Modular-type main spindle drives 7Motor 7, 8Mounting 49Mounting frame 48Mounting plate 48

NNact = Nset 44

OOil-bath gearboxes 49Operating mode main spindle drives 34Operating software 43"Option" 33Order matrix feeedback and NC connections 61Order matrix power connections 60Ordering details main spindle drive 56Overload 44

PParameter duplication adapter 43Parameter records 34Parameters 43Permissible temperature range 44Position control loop gain 37



Position information 39Position set-points 36Positioning via motor feedback 37Positioning via motor feedback and spindle ref. sw 37Positioning via spindle feedback 37Power and torque limiting 35Power connection 49Power connections 51Power limiting 35Putting an offer together 3

RRAC 8RAC selection list 11Radial fan cooling 49"Ready" 45Ready-made cables 51Replacing units 43Requesting an offer 3

SSecond set-point input 38Second set-point input weighting 38Selecting process 3Selection record - elec. conn. 54Selection record of electrical connetions 55Selection record of main spindle controller 54Selection record of main spindle motor 54, 55SERCOS interface 41Serial interface 43Simple and fast tool changes 36Speed controller matching 35, 38Speed limits 44Speed oscillation 36Speed reached 44Speed reaches spindle hold 44Speed regulation 35Speed set-point 41Speed set-point smoothing 34Speed set-point ramps 34Speed set-point to zero 42Spindle in position 45Spindle monitor 45Spindle positioning 36Spindle speed monitoring 45Spindle stopped 44Stiffness 38Supply unit. 7Switchable operating modes 34Switchable parameter records 34



TTDA 7TDA/KDA selection list 10Temperature pre-warning 44To index the workpiece 36Torque control 40Torque limiting 35Torque output 40Types of controller-specific connections 52Types of feedback and NC connections 52Types of power connections 51


10. Supplementary documentation

10. Summary of additional documentation

RAC4RAC3

RAC2TDA1

Drive KDA3

Electricalconnections for

main spindlespindle drives

Electrical connections

Project planningDoc. no. 209-0042-4111

Main spindle drive

Project planningKDA 3, Doc. no. 209-0042-4110TDA 1, Doc. no. 209-0042-4112RAC 2, Doc. no. 9.558.084.4RAC 3, Doc. no. 9.558.085.4RAC 4, Doc. no. 209-0042-4113

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with regulated asynch.motor or frameless

spindle motor

AC main spindle drive with regulatedasynchronous motor or frameless spindle motor

ApplicationsDoc. no. 209-0041-4109

Selection dataDoc. no.: 9.567.013.4

AC-Main spindle drivewith regulated main spindle motor 2AD

AC main spindle drivewith regulated

asynchronous motor

2AD

Main spindle motors 2AD

Project planningDoc. no. 209-0042-4122

Main spindlemotors 2AD


Bausatzspindel-motor

1MB 375

10. Supplementary documentation

1MB- Stator1MB

- Rotor

HGVIGS

High-resolutionmain spindle

position encoder

Frameless spindle motor

Project planning1MB160, Doc. no. 9.576.014.41MB200, Doc. no. 9.576.016.41MB240/241, Doc. no. 9.576.015.41MB310/312, Doc. no. 9.576.008.41MB375, Doc. no. 9.576.007.4

Mounting guidelinesStator, Doc. no. 9.600.063.4Rotor, Doc. no. 9.600.062.4

Supplementary documentation

• High-resolution main spindle position encoder - Applications Doc. no. 9.552.247.4 - Mounting guidelines Doc. no. 9.600.060.4• Incremental encoder output IGS Doc. no. 9.568.015.4• High-resolution encoder junction HGV Doc. no. 9.568.010.4

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AC main spindle drive withregulated spindle motor 2ADand switchable planetary gearboxes2KSelection dataDoc. no. 9.567.022.4

AC main spindle driveswith regulated frameless

spindle motorr

1MB

AC main spindle driveswith regulated frameless spindle motor 1MBSelection dataDoc. no. 9.576.012.4

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Figure 10.1: Overview of supplementary documentation on "AC main spindle driveswith main spindle motor 2AD and frameless spindle motor 1MB"

Bausatzspindel-motor

1MB 310Bausatzspindel-

motor

1MB 240Bausatzspindel-

motor

1MB 200Frameless spindlemotor

1MB 160

AC main spindledrives 2AD with

gearboxes 2K

Indramat

Documents

AC Main spindle drives with regulated 2AD main spindle motor