9182 Independence Ave.

Chatsworth, California 91311

Toll Free: 1.888.727.1887

7500 WYE/DELTA SERVICE PROCEDURE

Parameter Restore, Tuning Drive and Motor (Signal Offset Trim and One Step Tuning)
An improper tuning can cause random Power Base or Over Current Drive (Inverter) Faults.
The WYE/Delta HI/Low system uses two sets of motor winding patterns, one for low (WYE) and another high range
(DELTA). Both ranges require a successful tuning procedure.
It’s similar to having two motors in one so Drives typically use two sets of parameters stored in tables. For the Baldor
H2 Drive, table one (T1) is for low range and table two (T2) is for high range winding parameters.

With the Drive in REMOTE mode (displayed in the upper right corner of the keypad), enter the code S.1 in MDI at the
CNC to set Low range and set T1 in the Drive or S.2 to set HI range and select T2. This causes the CNC to switch
the W/D contactors. The contactors have a microswitch that the Drive reads to automatically select the proper
parameter table (the Drive must be in REMOTE mode not LOCAL).

There are three steps to restore original parameters and autotune the motor, described below.

A) Parameter Recovery From Keypad Using Parameter 1312:

The keypad stores a backup copy of the original parameters that were set when we shipped the Drive.
Setting Parameter 1312 to YES will restore all the parameters in T1 and T2 to the original settings.
The V210 10 hp is restored configured as 7500 rpm, Closed Loop, Rigid Tap.
The V215 15 hp and V220 20 hp Drives are restored as 5000 rpm, Closed Loop, Rigid Tap.

B) Analog Offset Trim (ANA) Using Parameter 2901:

This adjustment is important for the Spindle Orientation and Rigid Tap. The Drive will measure the “zero” voltage
coming from the Fadal 1010 Spindle Controller card, it then uses this measured value as a Zero Speed Reference
offset (like the balance pot on an amplifier).

C) One Step Auto Tune Using Parameter 2902:

At shipping, the Drive loaded with standard motor parameters for a new spindle motor. This procedure
compensates for the various electrical and magnetic characteristics that change as the motor ages.
NOTE: This procedure has a seven step test for Closed Vector mode and one step test for V/F mode. None of the
tests should display “TEST FAILED”. A test failure typically indicates a problem with the encoder, motor,
contractors, wiring or wrong Drive size.

How To Change Parameters - Linear List:

Instead of going through the menu’s to find a setting (Level 1, Level 2...) you can select the Linear List feature and
see the parameters by a numbered display. The P## or F## or C## signify Factory or Custom, the number is all that’s
important. To change a parameter:
• Press MENU.
• Scroll down to ADVANCED PROG and press ENTER.
• Scroll down to LINEAR LIST and press ENTER.
• The Up Down arrows move through list, the Left or Right arrows move a page at a time.
• Press ENTER to select the highlighted parameter number.
• Press ENTER to begin Edit mode. The display will flash EDIT in upper left corner. During EDIT, use the Up/Down
Left/Right arrows change the parameter values.
• Press ENTER to set the new value. The EDIT will stop blinking.
• The MENU key returns back to the Parameter List, allowing you to change another parameters or to press the
• F1 STATUS key to return to the STATUS PAGE

NOTE: When viewing a parameter, the bottom line of the keypad display usually shows a parameter number and a T1
or T2 next to it that indicates which parameter table is active.
It is important to pay attention to which parameter Table # you are editing. The correct table is selected when the
Drive is in the REMOTE mode and using the S-word during AUTO or MDI.
Programming S.1 in MDI will automatically shift the contractors to T1
Programming S.2 in MDI selects T2 for High Range.

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 A) Parameter Recovery From Keypad Using Parameter 1312:
For existing Drives, needing service.
Set parameter 1312 to YES and press ENTER to download backup parameters from KEYPAD TO PARAMETERS.

Below are the three possible operational configurations, select your machine configuration after restoring original
settings.

Steps for changing configuration parameters:

1) Verify the Baldor display reads REMOTE in upper right corner (LOCAL/REMOTE button switches).
2) Use MDI to set the spindle in low range by entering S.1
3) Press MENU, select ADVANCE PROG then select LINEAR LIST to access the parameters.
4) Select Parameter 52 and verify ACTIVE PARAMETER TABLE is set to T1, press MENU to return to Param list.
5) Select P1101 and verify/change Acceleration value for your machine
6) Select P1104 and verify/change Deceleration value.
7) Select P1108 and verify/change command signal type.
8) Select P1601 and verify/change motor control type (Closed Loop Vector or VF).
If your machine doesn’t have a motor encoder you’ll need to set Parameter 1601 to V/F mode to stop Encoder
Loss message. The VF mode is a typical INVERTER.
9) Select P2003 and verify/change maximum motor speed.
10) Use MDI to set the spindle in low range by entering S.1 (Leave Drive in REMOTE mode).
11) Repeat steps 4-9 for changes in T2
12) Cycle the power to the machine; OFF and ON

This completes the Drive operation configuration.

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 Steps B and C for Auto Tuning both Hi and Low ranges:
1) Low Range Tuning
Verify the Baldor display reads REMOTE in upper right corner (LOCAL/REMOTE button switches).
2) Use MDI and enter code S.1 to shift ranges and select Drive parameter table 1 (T1).
3) Press LOCAL/REMOTE key to set the Drive in the LOCAL Mode.
4) Press MENU, select ADVANCE PROG then LINEAR LIST to access the parameters.
5) Select Parameter 52 and verify ACTIVE PARAMETER TABLE is set to T1, press MENU to return to Param list.
Select Parameter 2901 to perform ANA OFFSET TRIM.
a) press ENTER to begin the EDIT mode (EDIT is displayed in the upper left hand corner of the keypad).
b) press up arrow to set it to YES
c) press ENTER to begin test
d) press ENTER when “Test Passed” message appears
e) press MENU to return to the Parameter List
6) Select Parameter 2902 to perform ONE STEP AUTO TUNE for the motor.
CAUTION - A couple of the Closed Loop Vector tests will spin the motor (slowly not full speed) be sure the
spindle is not locked.
a) press ENTER to begin EDIT mode
b) press up arrow to set it to YES
c) press ENTER to begin test
d) press ENTER when “Test Passed” message appears for the each test until Completed Message.
e) press MENU to return to the Parameter List
7) Enter Configuration Parameters P1101,P1104,P1408.
8) Press MENU then F1 (STATUS) to return to the main menu.
9) Press LOCAL/REMOTE key to set the Drive in the REMOTE Mode.
10) High Range Tuning
Use MDI and enter code S.2 to shift ranges and select Drive parameter table 2 (T2).
11) Press LOCAL/REMOTE key to set the Drive in the LOCAL Mode.
12) Press MENU, select ADVANCE PROG then LINEAR LIST to access the parameters.
13) Select Parameter 2901 to perform ANA OFFSET TRIM.
a) press ENTER to begin the EDIT mode (EDIT is displayed in the upper left hand corner of the keypad)
b) press up arrow to set it to YES
c) press ENTER to begin test
d) press ENTER when “Test Passed” message appears
e) press MENU to return to the Parameter List
14) Select Parameter 2902 to perform ONE STEP AUTO TUNE for the motor.
CAUTION - A couple of the Closed Loop Vector tests will spin the motor (slowly not full speed).
a) press ENTER to begin EDIT mode
b) press up arrow to set it to YES
c) press ENTER to begin test
d) press ENTER when “Test Passed” message appears for each test until Test Completed Message.
e) press MENU to return to the Parameter List
15) Press MENU then F1 (STATUS) to return to the main menu.
16) Press LOCAL/REMOTE key to set the Drive in the REMOTE Mode.

NOTES:
•The Drive will automatically ABORT the 2902 AUTO TUNE test if in the REMOTE mode.

•A good system will always pass the AUTOTUNE. A failure during this procedure indicates a faulty component in
the system. The W/D contactors are the most common failure components, the encoder is another common failure.
See Troubleshooting section below.

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 Complete Spindle System
Troubleshooting Guide

WARNING: This equipment contains High Voltages; up to 500 DC Volts.

Only qualified personnel should attempt servicing the machine.

Important HI/LOW Contactor Operation: The drive STOP red led must be ON before the contactors shift ranges:

1) This condition can be caused if the P1104 DECEL time is too long, reduce the parameter value.

2) The value in P1001 defines the drive disable RPM, the default value is 30 rpm. Increasing this value will cause the
drive to disable the sooner (before the shift). A value too high could cause coasting after spindle off command.

3) Verify the parameter is set to HIGH TORQUE/RIGID TAP. (See #1 below)

Common Failure Points Recommended To Check

1) CNC Parameter Settings
The HIGH TORQUE/RIGID TAP parameter:
Verify the CNC control parameter in SETP is set to HIGH TORQUE/RIGID TAP. This allows an approximate 1
second dwell for the Wye/Delta contactors to switch and settle before a spindle ON is commanded to the
Spindle Drive. This delay helps to avoid contactor arcing.
This parameter was also added to allow a dwell after shifting ranges and before commanding a spindle on
command. This allows time for the slower hydraulic idlers to fully engage. An incorrect setting can cause the
belts to "chirp" at spindle on.

2) Main Power Disconnect

a) Check Fuses or just replace if old, while they may carry voltage and look good with a volt meter, they might
not supply the needed current.
b) Blade Engagement Contacts – clean; remove corrosion or pitting. A bad connection can cause an
intermittent Phase Loss error or possibly DC low error message/condition (motor won’t get to full RPM) – DC
low condition.

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3) Transformer
The target input voltage to the spindle Drive is 230 VAC. An input voltage too high can cause the Drive
(inverter) to fault out as DC High error or possibly burn out the braking resistor. Too low of an input voltage can
cause DC low faults.

4) Drive Input Power Connections

At the L1 L2 L3 GND connections, a loose or bad connection can cause a Phase Loss error or possibly DC low
error message/condition (motor won’t get to full RPM).

5) Breaking Resistor
A burnt out (open connection) or Wrong/Loose Connection can cause DC High error at Spindle Off or during
deceleration. Disconnect REGEN wires and check the OHM value of resistor. Value must not be zero (open).
You can use the Drives internal braking resistor as a test. See Installation Instructions steps #9 and #18.

6) Spindle Encoder
The encoder directly affects the current output of a Vector Drive.
See Drive Troubleshooting sections in the Installations Instructions that came with your Drive:
7) PROBLEM - Random Over Current Faults – Encoder Test Using The Drive
4) PROBLEM – Drive displays message “ENCODER LOSS”

7) Motor Connections
Check connections on both ends; at the Drive's T1 T2 T3 GND and the Wye/Delta contactors, if present.
Loose or shorting connections will cause intermittent Over Current and other faults. Impedance (the opposition
to the flow of an electric current through a conductor) is one of the common causes for misdiagnosis. The
motor looses torque by not being able to receive the needed current. With a Vector Drive, the current
component is very critical to stable motor control.
While a simple ohms or a mega ohm test might pass, the complete circuit (wiring) from the Drive to the motor
must be able to supply the proper voltage and current (amperage)

8) Junction Box
Inspect the 12 motor lead connections, a loose connection will cause intermittent Over Current faults. The
motor “bolt-clamp” connector insulation has been known to wear and cause intermittent shorts to GND. Inspect
wires for any possible insulation breakdown by friction rubbing. Some Drive systems use a terminal block
inside the junction box for motor connections. These have been know to cause high impedance connections
(see #7 above).

9) Wye/Delta Contactors
For machines with Wye/Delta High/Low contactors; all 7500 rpm machines and some custom machines. If old
or pitted, consider replacing the contactors. Do not use sand paper to try and clean. The contacts are silver
plated (lightly) and sanding typically adds to additional failure. As machines get older, these should be
automatically replaced at any sign of Spindle Faults. Besides the contacts arcing/pitting, the electro magnet
system can fail after time; any slight “buss”, audible or not, will fault the Drive.
Also the micro-switch on the contactors can randomly switch the Drive table parameters while contactors do
not switch; causing the spindle Drive to use the wrong motor parameters.

10) 1100-1 CNC Board (Wye/Delta only)

The Wye/Delta contactor are directly controlled by the Solid State Relays on the board. Relay K27 – F30
(VMC 15) is the High Range solid state relay (SSR). It switches the Wye/Delta contactors and holds them in
position by energizing the coils inside the Wye/Delta specific contactor. Besides possible internal SSR
intermittent 120 VAC failure, the 5vdc logic power on the 1100-1 board to the SSR is subject to corrosion; it’s
not gold plated. Remove and reseat or replace with a new SSR or switch with K22 (spare Coolant 2).

11) Drive Troubleshooting

See H2 Drive Troubleshooting section or call us for H2 Drive specific help.

12) Speed Signal

The spindle speed comes directly from the 1010 spindle controller card. Spindle speed variations from the
signal input can be tested by using the M49 code to disable the Spindle Override Potentiometer. The speed
command signal is a 10 volt DC signal with ±10 VDC for rigid tap and 0-10 VDC for non-RT machines. The
voltage is proportionate to the commanded RPM and should be very stable. See also Encoder.

13) Drive Enable

The machine uses two FWD and REV relays to enable the Drive and control the direction on the 1100-2 board.
With Rigid Tap both relays are closed to enable the Drive, the ±10 VDC signal controls rotation direction. With
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 Non Rigid tap; one is closed for Forward and the other is closed for Reverse rotation, the 0-10 VDC signal
controls rotation speed. Replace the relays or swap with known working relays.

14) Motor Rewinds

For Closed Loop Vector Drives, after a spindle motor replacement (with a rewound motor) if the motor just
rotates back and forth - switch the motor T1 and T2 (at the Drive) to re-sink the encode/motor rotation logic. For
Inverter Drives (no encoder), switch the T1 and T2 when the motor is rotating the wrong direction.

15) 1010 Spindle Controller

The spindle controller card in slot #14 of the 1060 motherboard and controls specific spindle functions:
Speed Command - The speed command signal is a 10 volt DC signal with ±10 VDC for rigid tap and 0-10
VDC for non-RT machines. The voltage is propionate to the commanded RPM and should be very stable.
Orientation Magnet – Shares the input signal with the main cpu (1400 card) and is not read with DI, DS
command. It is used for orientation (M6 and M19) and rigid tap calibration (G84.1 and G84.2). Also used for
Motor Overload error detection.
Spindle Fault – Monitors the spindle Drive fault line and declares ES condition to main CPU.

16) Motor Test

NOTE: FIRST DISCONNECT MOTOR WIRES T1, T2, T3 FROM THE DRIVE
Use a Mega Ohm Meter (1000 VDC or higher) to test the motor/wire insulation for shorts. You’re looking for
consistency for all 3 legs. Replace the motor with a reading of 100 meg or lower.
Test at two points:
a) Individually test each T1, T2 and T3 motor leads to GRD – This tests the complete path starting from the
Drive output wires (T1,T2,T3) through contactors if present (Wye/Delta), through junction box connectors and
motor windings. Repeat with T2 and T3. Test in both Hi/Low ranges if W/D configuration.
b) Motor Windings Coil to Coil short– There are six coils inside the motor (two wire pair per coil) that can be
individually tested for a short. Contact us for further instructions about testing motor coil to coil shorts.

Visually inspect the inside of the motor for shop air contamination. Consider removing the motor and have it
tested by a local repair shop.

It is common that a bad motor can damage the old Drives and simply replacing the Drive will not solve the bad
motor issue. The H2 Drive has far superior internal protection and will protect itself by faulting with an Over-
Current or Power Base message (see Event Log in Baldor Keypad). Motors that are over 10+ years old
typically need replacing. See “Steps for Tuning the Drive to the Motor” in the Trouble Shooting section.

17) Wiring
The standard service procedure was to bypass the machines internal motor wiring, and verify that the wiring
and connectors (impedance) can carry the required motor current.
An Ohm or Mega Ohm test alone won’t always find a wiring problem. A bypass test requires running an
external motor wire from the Drive motor output (T1,T2 and T3) directly to the motor leads in the Junction Box,
thus bypassing the all internal wiring. You must use the same gauge wiring that the machine is using for the
test.
With the motor running, measure the motor current using an AC amp probe to determine that each leg of the
motor has the same (balanced) current; each leg should be equal, within two amps. With the internal wiring
bypassed, an imbalance of current usually indicates a faulty motor.
Restore the internal wiring and start checking all wires and connections between the Drive and the spindle
motor if the machine runs fine with the external wiring. The 7500 Wye/Delta machine has the Hi/Low contactors
that need to be considered. Check the amperage at the beginning (Drive) and following the wiring to the motor
wire connections.

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 Motor Wiring Diagram

12 Lead Motor Wire Pairing Configuration

T1 WYE (Low Range)
T1 = 2/8 + 6/12
T2 = 1/7 + 5/11
T3 = 3/9 + 4/10

T2 DELTA (High Range)

T1 = 2/8
T2 = 1/7
T3 = 3/9

6/12 + 5/11 + 4/10 are all combined

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