INSTALLATION

&
OPERATION MANUAL

Model SMB9675-1A-1-7700

FADAL REPLACEMENT
SPINDLE DRIVE

MANUAL#: 9675-1035-000
REVISION: (B)
DATE: 4 Jan 2018

Fadal is a trademark of Fadal Machining Centers, we have no affiliation with Fadal or Mag IAS
 www.glentek.com

2 MANUAL # 9675-1035-000-B
www.glentek.com Table of Contents

TABLE OF CONTENTS
TABLE OF CONTENTS .........................................................................................................................................................................3

CHAPTER ONE: GENERAL ...................................................................................................................................................................5

1.1 OVERVIEW ......................................................................................................................................................................................... 5

1.2 INTENDED APPLICATION ........................................................................................................................................................................ 5
1.3 MODE OF OPERATION .......................................................................................................................................................................... 6

CHAPTER TWO: INSTALLING A GLENTEK SPINDLE DRIVE INTO A FADAL VMC ....................................................................................7

2.1 REMOVING THE OLD DRIVE .................................................................................................................................................................... 7

2.2 MECHANICAL INSTALLATION .................................................................................................................................................................. 7
2.3 ELECTRICAL INSTALLATION ..................................................................................................................................................................... 7

CHAPTER THREE: INITIALIZATION AND POWER UP ............................................................................................................................9

3.1 BEFORE ANY INITIALIZATION .................................................................................................................................................................. 9

3.2 TURNING THE POWER ON ..................................................................................................................................................................... 9
3.4 OPERATING THE SPINDLE....................................................................................................................................................................... 9
3.5 POT ADJUSTMENTS .............................................................................................................................................................................. 9
3.6 RIGID TAP TEST (OPTIONAL) .................................................................................................................................................................. 9

CHAPTER FOUR: TROUBLESHOOTING AND MAINTENANCE ............................................................................................................. 11

4.1 STATUS DISPLAY CODES ...................................................................................................................................................................... 11

4.2 MAINTENANCE .................................................................................................................................................................................. 11

CHAPTER FIVE: WARRANTY, FACTORY REPAIR, AND SAFETY ........................................................................................................... 12

5.1 WARRANTY ...................................................................................................................................................................................... 12

5.2 FACTORY REPAIR ............................................................................................................................................................................... 12
5.3 SAFETY ............................................................................................................................................................................................ 13

APPENDIX A - SPINDLE DRIVE CONNECTIONS .................................................................................................................................. 14

A-1 MOTOR POWER CONNECTORS............................................................................................................................................................. 14

A-2 CONTROLLER I/O CONNECTORS ........................................................................................................................................................... 14
A-3 ENCODER INPUT CONNECTOR .............................................................................................................................................................. 15
A-4 ENCODER OUTPUT CONNECTOR ........................................................................................................................................................... 16
A-5 HOST (SERIAL COMMUNICATION) CONNECTOR ....................................................................................................................................... 16
A-6 POWER AND SIGNAL WIRING............................................................................................................................................................... 16

APPENDIX B - SPINDLE DRIVE CONNECTION INTERFACE .................................................................................................................. 17

B-1 STATUS AND RPM DISPLAY ................................................................................................................................................................. 17

B-2 CONTROLLER INPUT AND OUTPUT SIGNALS ............................................................................................................................................ 17
B-3 ANALOG INPUT, COMMAND SIGNAL ..................................................................................................................................................... 18
B-5 ENCODER FEEDBACK .......................................................................................................................................................................... 20
B-6 ENCODER OUTPUT ............................................................................................................................................................................ 20
B-7 LOAD METER OUTPUT ....................................................................................................................................................................... 20
B-8 PC INTERFACE .................................................................................................................................................................................. 21
B-9 POWER INPUT AND MOTOR OUTPUT .................................................................................................................................................... 22

APPENDIX C - APPLICATION SOFTWARE .......................................................................................................................................... 23

C-1 MOTIONMAESTRO© ......................................................................................................................................................................... 23

C-2 INSTALLING MOTIONMAESTRO ............................................................................................................................................................ 23

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C-3 COMMUNICATING WITH THE SPINDLE DRIVE OR VFD DRIVE ..................................................................................................................... 24

APPENDIX D - DRAWINGS & DIAGRAMS .......................................................................................................................................... 25

D-1 VECTOR DRIVE INSTALLATION DRAWING 1 ............................................................................................................................................. 26

D-2 VECTOR DRIVE INSTALLATION DRAWING 2 ............................................................................................................................................. 27
D-3 VECTOR DRIVE CONNECTION DIAGRAM PAGE 1 ...................................................................................................................................... 28
D-4 VECTOR DRIVE CONNECTION DIAGRAM PAGE 2 ...................................................................................................................................... 29
D-5 SENSORED VECTOR COMMAND INPUT CONTROL DIAGRAM....................................................................................................................... 30
D-6 SENSORED VECTOR VELOCITY CONTROL LOOP DIAGRAM .......................................................................................................................... 31
D-7 SENSORED VECTOR CURRENT CONTROL LOOP DIAGRAM .......................................................................................................................... 32

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www.glentek.com Chapter One

Chapter One: General

1.1 Overview

The Glentek Inc. SMB9675-1A-1-7700 spindle drive uses flux vector technology to close a torque
(current) feedback loop. When applied to a three phase induction motor, the result is servo motor like
performance from a standard three phase induction motor. The Digital Signal Processor (DSP) based
spindle drive uses its high speed math processing capability to continuously calculate flux and torque
vectors and to maintain a constant 90 degree phase difference between the vectors. This technique
allows torque control from zero speed to base speed and above. Encoder feedback provides the
shaft position data needed to calculate the vectors and velocity data, thus, Vector Control allows
precise speed control down to and including zero speed of an induction motor.

The SMB9675-1A-1-7700 spindle drive can operate in sensor-less mode (no feedback is needed).
This mode of operation is usually referred to as inverter mode or VFD (Variable Frequency Drive)
mode. With advanced mathematic algorithms and the latest DSP technology, the Glentek SMB9675-
1A-1-7700 is optimized to produce a steady starting torque from standstill right up to full speed with
high efficiency. The applied frequency and voltage are increased at a controlled rate and ramped up
to accelerate the load without drawing excessive current.

1.2 Intended Application

The SMB9675-1A-1-7700 is intended as a drop-in replacement spindle drive for FADAL

ENGINEERING VMC’s. See the part numbers listed in the Mode of Operations section (Section 1.3)
for the available configurations.

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1.3 Mode of Operation

Changing the Mode of Operation dial (SW1) (see drawing D-2 Vector Drive Installation Drawing 2 for
dial location) will modify the configuration of the spindle drive. Aligning the dial to any of the positions
listed below will alter the drive to those settings. If none of the settings below match your preferences,
please contact one of Glentek’s sales engineers for assistance. The drive is shipped with the dial at
position 0 (zero).

To change modes, rotate the dial to the desired position before installation or disable the drive with an
M5 (spindle stop) command BEFORE rotating the dial. The four rightmost seven-segment displays
will display the operation mode selected (i.e. 7700, 7701, etc.) for seven seconds, then it will revert
back to displaying motor rpm. Enable the drive to run in the new mode.

Mode of Operation Position Settings

Position Power (HP) RPM Sensor/VFD Part Number Model Number

0 15 10K Sensor 7700 SMB9675-1A-1-7700
1 15 7.5K Sensor 7701 SMB9675-1A-1-7701
2 15 10K VFD 7702 SMB9675-1A-1-7702
3 10 10K Sensor 7703 SMB9675-1A-1-7703
4 10 7.5K Sensor 7704 SMB9675-1A-1-7704
5 10 10K VFD 7705 SMB9675-1A-1-7705
6 20 10K Sensor 7707 SMB9675-1A-1-7707
7 20 7.5K Sensor 7708 SMB9675-1A-1-7708
8 20 10K VFD 7709 SMB9675-1A-1-7709
9 5 10K Sensor 7710 SMB9675-1A-1-7710
A 5 7.5K Sensor 7711 SMB9675-1A-1-7711
B 5 10K VFD 7712 SMB9675-1A-1-7712
C - - - - -
D - - - - -
E - - - - -
F - - - - -

Note: Positions C, D, E, and F are reserved for future configurations.

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Chapter Two: Installing a Glentek Spindle Drive into a Fadal VMC

2.1 Removing the old drive

Turn off the power to the VMC and wait 5 minutes before beginning removal. Disconnect all the
wires and cables. If any wires are not labeled take note of their location. Of the cables, only the
Control cable and the Delta/Wye cable can be confused, both are 6 terminal connectors. The control
cable has 6 sockets in the connector and Delta/Wye cable has 3 sockets in the connector. Unbolt the
old drive and remove.

2.2 Mechanical Installation

The new drive may be mounted with four screws, four studs and nuts, or a combination of the two,
depending on the machine. Install the drive (slots down) by first resting the drive on the lower
mounting studs or loosened screws in the cabinet and positioning the drive over the studs at the top.
Hold the drive against the cabinet and loosely install four screws or nuts, top two first. Then tighten all
four screws or nuts.

2.3 Electrical Installation

2.3.1 Power Terminal Block Connections

Begin the wiring by connecting the AC, regenerative braking, motor, and green ground wires.
Match the wire labels to the terminal block labels. Check connections for tightness. (See Appendix A
for more details.)

2.3.2 Load Meter Cable

Connect the load meter cable by connecting the black wire to P1-1 screw terminal and the red wire
to P1-2.

2.3.3 Spindle Control Cable

Connect the spindle control cable to P2. The spindle control cable has 6 sockets installed; do not
confuse it with the wye/delta connector, which only has 3 sockets installed.

2.3.4 Wye/Delta Cable

Connect the wye/delta cable to P4 (wye/delta is an option for 7500 RPM spindles; your VMC may not
have this cable).

2.3.5 Encoder Feedback Cable

Connect the encoder feedback from the motor (9 terminal connector) to P3 (VFD drives do not
need this cable).

2.3.6 Rigid Tap Cable (Encoder Output To CNC Control)

For VMC’s with the Rigid Tap option, connect the rigid tap cable from the CNC to P5 of the spindle
drive. Use the installation drawing (see Appendix D) to match the wires by color to the correct
terminal.

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Photo 1: A successful spindle drive installation.

Photo 2: Close up of a successful spindle drive installation.

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Chapter Three: Initialization and Power Up

3.1 Before Any Initialization

The only setup required by the end user is to select the mode of operation (see Section 1.3 for
changing the mode of operation). All the tuning has been preset at the factory, meaning the drive will
run correctly. If applying minor changes (adjusting input command offsets, etc.) to the spindle drive,
use the procedures below for reference.

3.2 Turning the Power On

Carefully recheck the wiring. Restore power to the VMC. For seven seconds the four rightmost seven-
segment displays will show the spindle drive configuration. Afterwards, those four displays will show
the rpm value of the spindle motor, not the spindle itself. Confirm the desired mode of operation has
been selected.

3.4 Operating the Spindle

From the VMC control panel operate the spindle and confirm the spindle runs at the commanded
speeds and in the correct direction (CW and CCW). It is important to note, the 4 digit display on the
drive reports the speed of the spindle motor, the speed of the spindle itself may be different
depending on the machine design and mode. The drive calculates the rpm from the encoder signals
when operating in vector mode, when the drive is used in VFD or inverter mode (no encoder) the rpm
is calculated from the input command signal voltage received from the Fadal control.

3.5 Pot Adjustments

Normally, no adjustments are needed. However, for convenience, there are 2 pots (see drawing D-2
Vector Drive Installation Drawing 2 for pot locations), the signal gain and the balance. These pots
have limited range and are only for small adjustments. The signal gain pot should always be adjusted
first. To adjust the signal gain, command 500 rpm from the control panel and take note of the motor
rpm as reported by the inverter drive digital display. Now command 1000 rpm and note the motor
rpm, it should be double the rpm noted when commanding 500 rpm. Adjust the signal gain pot as
needed.

Continue commanding 1000 rpm. Fadal VMC’s may have motor/spindle ratios of 2:1, 1:1, 1:2, and
1:3. Adjust the balance pot until the inverter drive digital display reads the calculated motor rpm
below.

2:1 = 2000 rpm 1:1 = 1000 rpm 1:2 = 500 rpm 1:3 = 333 rpm

3.6 Rigid Tap Test (Optional)

If desired you can test the rigid tap mode of your VMC by performing the following procedure. This
procedure is drawn from the FADAL maintenance manual. Install the test screw (SVT-0077) in a
toolholder and place in the spindle. The screw can be fabricated from 1.000” round stock, by

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threading a 14 TPI Acme thread. Program is for Format 1. Use test program #6000 or the following
program:

%
N1 O6000 (RIGID TAP CYCLE)
N2 G84.2
N3 G84.1 R0+0 Z-1. Q0.0714 F500.
N4 X0.0001
N5 X-0.0001
N6 M99 P4
%

Once the program is loaded, jog the z axis down to an appropriate height so that the screw can be
indicated. Type “SETZ” and press ENTER. If you moved from you home position, also type “SETX”
and press ENTER, then type “SETY” and press ENTER.

Start the test program and observe that the program is running correctly. Press the SINGLE STEP
key. Be sure the test screw returns to its original position.

Set the indicator as shown below in Photo 3. The tip of the indicator must be touching the bottom face
of the thread halfway into the thread, the second thread from the bottom.

Press start to run the program observe the indicator. The reading should not deviate from zero by
more than .002” on either side of zero. If necessary, consult the FADAL maintenance manual for your
machine.

Photo 3: Test screw in setup with dial

indicator Photo 5: Test screw in toolholder

Photo 4: Test screw

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Chapter Four: Troubleshooting and Maintenance

4.1 Status Display Codes

Display Name Description Possible Cause

Parameter EEPROM Internal problem,
1 EEPROM Fault
checksum fault contact Glentek
Improper configuration
8 Reset External reset
setting
Drive processor is in Internal problem,
8. Reset
reset contact Glentek
Motor RPM is over Mechanical linkage
A Overspeed
speed limit problem
Regenerative braking
circuit not working, regen
Bus Over DC bus exceeded
b resistor does not match
Voltage 450VDC
spindle, check fuse in
regen circuit
Clamp
C Spindle drive disabled Control is disabling the drive
(Disabled)
Encoder Encoder faulty or encoder
E Encoder fault detected
Fault wiring broken
Motor current draw Mechanical binding in
F Foldback
exceeded set point motor or spindle
Heatsink Over Heatsink exceeded
H Fan(s) failed
Temperature 65ºC
Motor RMS over Mechanical binding in
L LS/ECB
current motor or spindle
Normal
0 Drive enabled Normal when rotating
Operation
Output short circuit
S HS/ECB Motor windings shorting
detected
Bus Under DC bus below 50VDC AC input voltage to drive
U
Voltage nominal is low or off
Single Normal
Drive enabled Normal @ zero speed
segment Operation

4.2 Maintenance

The only maintenance required is to periodically inspect the fans. The blades should be turn freely
and built up dirt or dust should be removed from the blades.

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Chapter Five: Warranty, Factory Repair, and Safety

5.1 Warranty

Any product, or part thereof, manufactured by Glentek, Inc., described in this manual, which under
normal operating conditions, in the plant of the original purchaser, thereof proves defective in material
or workmanship within one year from the date of shipment by us, as determined by an inspection by
us, will be repaired or replaced free of charge, FOB our factory, El Segundo, California, U.S.A.
provided that you promptly send to us notice of the defect and establish that the product has been
properly installed, maintained, and operated within the limits of rated and normal usage, and that no
factory sealed adjustments have been tampered with. Glentek's liability is limited to repair or
replacement of defective parts.

Any product or part manufactured by others and merely installed by us, such as an electric motor,
etc., is specifically not warranted by us and it is agreed that such product or part shall only carry the
warranty, if any, supplied by the manufacturer of that part. It is also understood that you must look
directly to such manufacturer for any defect, failure, claim or damage caused by such product or part.

Under no circumstances shall Glentek Inc. or any of our affiliates have any liability whatsoever for
claims or damages arising out of the loss of use of any product or part sold to you. Nor shall we have
any liability to yourself or anyone for any indirect or consequential damages such as injuries to person
and property caused directly or indirectly by the product or part sold to you, and you agree in
accepting our product or part to save us harmless from any and all such claim.

5.2 Factory Repair

Should it become necessary to return a spindle drive to Glentek for repair, please follow the
procedure described below:

1. Reassemble the unit, if necessary, making certain that all the hardware is in place.
2. Tag the unit with the following information:

A. Serial number and model number

B. Company name, phone number, and name of representative returning the unit
C. A brief note explaining the malfunction
D. Date the unit is being returned

3. Repackage the unit with the same care and fashion in which it was received. Label the package
with the appropriate stickers (e.g. FRAGILE: HANDLE WITH CARE).
4. Contact a Glentek representative, confirm that the unit is being returned to the factory and obtain
an RMA (Return Material Authorization) number. The RMA number must accompany the unit
upon return to Glentek.
5. Return the unit by the best means possible. The method of freight chosen will directly affect the
timeliness of its return.

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5.3 Safety

 Serious or fatal injury can result from failure to work safely on this equipment.

 Only qualified personnel should install and maintain this spindle drive.

 The drive has capacitors that remain charged after the power is shutoff. Wait 5 minutes to allow the
capacitors to discharge before removing the cover or working on the drive.

 Be sure the system is properly grounded before applying power.

 Regenerative braking resistors can generate temperatures that ignite combustible materials
or vapors. Keep all combustible materials way from braking resistors.

 Braking resistors should be shielded to prevent burn injuries.

 The motor will rotate when autotuning, take precautions to prevent injury and damage
to equipment.

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Appendix A www.glentek.com

Appendix A - Spindle Drive Connections

A-1 Motor Power Connectors

Table A-1.1 Motor Power Designations

Pin # I/O Name Function

1 Input L1 AC LINE 1, three phase AC input
2 Input L2 AC LINE 2, three phase AC input
3 Input L3 AC LINE 3, three phase AC input
4 Rsvd N/C Reserved
5 Rsvd N/C Reserved
6 Output B- DC BUS Return output
7 Output R1 Brake/Regen resistor output
8 Output R2 Brake/Regen resistor output
9 Output B+ DC BUS + output
10 Output T1 Motor Output Phase T1
11 Output T2 Motor Output Phase T2
12 Output T3 Motor Output Phase T3

Table A-1.2 Motor Power Connectors

Connector Type/Description 12-Pin Terminal Block

Terminal Block, Barrier,
Marathon 985-GP-12
12 Position, 10-4 AWG

A-2 Controller I/O Connectors

Table A-2.1 Load Meter Designations: Labeled as P1 on spindle drive

Pin # I/O Name Function

1 Output - (BLACK) GND
2 Output + (RED) Current Monitor Output

Table A-2.2 Load Meter Connector

Connector Type/Description 2-Pin Terminal Block

Terminal Block, Single Row,2 Position,
Magnum A202202NL
22-12 AWG

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Table A-2.3 Spindle Control Designations: Labeled as P2 on spindle drive

Pin # I/O Name Function

Spindle Common (for Forward
1 Input FWD/REV COM & Reverse)
2 Input REVERSE Spindle Reverse
3 Input FORWARD Spindle Forward
CMD Common
4 Input FLT/SPEED COM (for Fault & Speed)
Input/
5 FAULT Emergency Stop/Spindle Fault
Output
6 Output SPEED CMD Spindle Speed Command

Table A-2.4 Wye/Delta Config Designations: Labeled as P4 on spindle drive

Pin # I/O Name Function

1 Input WYE / DELTA Wye or Delta modes
2 N/C Reserved Reserved
3 Input HIGH / LOW GAIN High Gain or Low Gain modes
Common for Wye/Delta and
4 Input Common
High Gain/Low Gain modes
5 N/C Reserved Reserved
6 N/C Reserved Reserved

Table A-2.5 Spindle Control and Wye/Delta Config Connectors

Connector 6-Pin Male Mating

Female Crimp Terminal
Type/Description Connector Housing
Receptacle, 6 Position,
Molex 03-09-1064 Molex 02-09-1119
22-18 AWG

A-3 Encoder Input Connector

Table A-3.1 Encoder Input Designations: Labeled as P3 on spindle drive.

Pin # I/O Name Function

1 Input Shield Cable Shield
2 Power +5V Encoder +5VDC out, 150mA max
3 Power GND Encoder Power Return
4 Input B- Encoder Channel B -
5 Input B+ Encoder Channel B +
6 Input Z+ Encoder Index + (Channel Z +)
7 Input A- Encoder Channel A -
8 Input A+ Encoder Channel A +
9 Input Z- Encoder Index - (Channel Z -)

Table A-3.2 Encoder Input Connector

Connector 9-Pin Male Mating

Female Crimp Terminal
Type/Description Connector Housing

Receptacle, 9 Position, 22-18 AWG Molex 03-06-1092 Molex 02-06-1103

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A-4 Encoder Output Connector

Table A-4.1 Encoder Output Designations: Labeled as P5 on spindle drive.

Pin # I/O Name Function

1 Power GND Encoder Power Return
2 Output AOut + Encoder Channel A +
3 Output AOut - Encoder Channel A -
4 Output BOut + Encoder Channel B +
5 Output BOut - Encoder Channel B -

Table A-4.2 Encoder Output Connector

Connector Type/Description 5-Pin Terminal Block

Terminal Block,5 Position,
Phoenix Contact 1934890
22-12 AWG

A-5 Host (Serial Communication) Connector

Table A-5.1 Host (Serial Communication) Designations: Labeled as P6 on

spindle drive.

Pin # I/O Name Function

1 Reserved Reserved Reserved
2 Reserved Reserved Reserved
3 Reserved Reserved Reserved
4 Input/output COMMON Logic Ground
5 Output RS-232 TX RS-232 Transmit
6 Input RS-232 RX RS-232 Receive
7 Reserved Reserved Reserved
8 Reserved Reserved Reserved

Table A - 5.2. Host (Serial Communication) Connector

Connector Type/Description 8-Pin Male Mating Connector

Standard Commercial, RJ-45 Commercial, RJ45

A-6 Power and Signal Wiring

A-6.1 Recommend 3-phase input, 3-phase output, and chassis GND power wiring, 8 AWG
(8.36 mm2) or larger, 105°C rated PVC or better.

A-6.2 Recommend BUS+, BUS Return, and brake power wiring, 10 AWG (5.26 mm2) or larger,
105°C rated PVC or better.

A-6.3 Recommend all signal wiring, 22 AWG (0.326 mm2) or larger, 105°C rated PVC or better.

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Appendix B - Spindle Drive Connection Interface

This section describes the spindle drive connections and how they are used in the typical application. Refer
to the spindle drive’s installation drawings in Appendix D. This drawing indicates the location of the pins
described below along with the location of the connector they can be found on.

B-1 Status and RPM Display

Five 7-segment LED displays are provided for displaying the status and RPM of the spindle drive. (See
drawing D-2 Vector Drive Installation Drawing 2 for LED display locations.)

The left most LED is the drive status display. If the motor is properly commutated, the outermost segments
of the LED display will light up one-by-one in a sequential manner when the motor runs. If the motor
reverses direction, the LED will cycle through the segments in the opposite direction.

When the motor’s current is clamped, (i.e. held to zero), or the spindle drive is in a fault condition, one of
the fault characters will be displayed as is appropriate to the fault or state.

Note: See Chapter 4 for more information on Drive status codes.

The four LEDs on the right are the RPM display. For drives in vector control mode, the actual motor speed
is shown. For drives in VFD mode, when the drive is operating normally, the commanded motor speed is
shown.

Note: Motor speed and spindle speed will not necessarily be the same. Fadal VMC’s may have
motor/spindle ratios of 2:1, 1:1, 1:2, and 1:3.

B-2 Controller Input and Output Signals

Signals that typically are connected to an external controller are described in this section. These signals
include the primary command signal interface to the spindle drive, Forward/Reverse, Wye/Delta, Hi
Gain/Lo Gain, Estop/Fault, load meter, encoder output signal, and common.

Signal Description

SPEED CMD Command signal analog input, reference to CMD Common.

SPINDLE FORWARD Enable the motor in the CCW direction.
SPINDLE REVERSE Enable the motor in the CW direction.
WYE / DELTA Enable the motor either in WYE or DELTA mode.
HIGH / LOW GAIN Enable the motor either in HI or LO gain mode.
ESTOP / FAULT Bi-directional, functions as Emergency Stop input or Fault output.
LOAD METER Analog output, indication of the load current on the motor.
AOut Encoder A channel Output.
BOut Encoder B channel Output.
ZOut Encoder Z index Output (not used).

For the actual pin out of above signals, see Appendix A - Controller I/O Connector section

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B-3 Analog Input, Command Signal

Pins SPINDLE CMD and FLT/SPEED COM are the command input pins. The command input takes a differential
analog signal as referenced to the spindle drive’s ground. Input voltage is expected to range from -10 volts
to +10 volts (typical).

The velocity command signal will be 0 to +10 VDC in unipolar control (non-rigid tap mode), ±10 VDC for
bipolar control (rigid tap mode).

Note: CMD COMMON (AGND) is connected to Logic Common (Digital GND) inside the spindle drive.

0.022uF

TP5 1.50K

10.0K
9 TLE084
SPEED CMD -
8
TO DSP A/D CONVERTER
10
FLT/SPEED COM +
332
10.0K 0.33uF
1.50K

TP6 AGND
0.022uF AGND
Vref

Command Signal Analog Input Schematic

B-4 Controller Inputs/Outputs - Direction Control, WYE / DELTA, HIGH/LOW GAIN

Inputs, ESTOP Input, and FAULT Output

The spindle drive accepts SPINDLE FORWARD and SPINDLE REVERSE signals for operating four rotation
commands.

FORWARD REVERSE ACTION

closed open drive on, CCW rotation, unipolar speed control
open closed drive on, CW rotation, unipolar speed control
closed closed drive on, bipolar speed and direction control
open open drive off, no voltage or flux to the motor

SPINDLE FORWARD and SPINDLE REVERSE are enable and direction control signals. That is, each signal
enables motor movement in one direction. If both signals are closed (the signals are pulled low), motor
movement in both directions is enabled. When only one enable is closed (FORWARD or REVERSE on), the
velocity command is unipolar, and when both enables are closed (FORWARD and REVERSE on), the velocity
command is bipolar.

When both FORWARD and REVERSE are closed, the spindle drive is in rigid tap mode. When only FORWARD
or REVERSE is closed, the spindle drive is in non-rigid tap mode (sometimes called “inverter” mode). Both
rigid tap mode and non-rigid tap (“inverter”) mode are used with vector drives. Inverters or VFD drives use
non-rigid tap mode only.

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+5V

1.00K +3.3V

3 1
10.0K
+10V MMBD7000

IRLL014
FROM DSP

1.00K

10.0K
13 12
TO DSP
+5V +5V 40106

HMA124 4.99K

3
1 4
40106 2.00K
MMBD7000 1 2
TO DSP
1.21K 2 3 10.0K
10.0K 0.33uF
1

FAULT

+5V
HMA124 4.99K
3

1 4 AGND
40106
MMBD7000 9 8
TO DSP
1.21K 2 3 10.0K
1

FORWARD
+5V
HMA124 4.99K
3

1 4
40106
MMBD7000 5 6
TO DSP
1.21K 2 3 10.0K
1

REVERSE
+5V
HMA124 4.99K
3

1 4
40106
MMBD7000 3 4
TO DSP
1.21K 2 3 10.0K
1

WY E/DELTA
+5V
HMA124 4.99K
3

1 4
40106
MMBD7000 1 2
TO DSP
1.21K 2 3 10.0K
1

HIGH/LOW GAIN

Controller I/O Schematic

When FORWARD and REVERSE are both open (signals are left floating) the spindle is off and spins freely.
However, the change from closed to open (FORWARD and/or REVERSE on to both off) is also a signal to stop
(just like Emergency Stop); the drive is never supposed to coast to a stop.

The change from WYE to DELTA or vice versa occurs only when the drive is off (FORWARD and REVERSE
open) and the motor is stopped or below 50 rpm. When the CNC wants DELTA mode, the signal WYE /
DELTA is pulled low.

When the CNC wants LOW GAIN, the signal HIGH / LOW GAIN is pulled low.

ESTOP and FAULT share the same I/O pin at the spindle drive. A spindle FAULT is declared by the spindle
drive. Status good is 10 VDC thru a 1K pull-up resistor. 0 VDC indicates a fault condition to the CNC. The
Fault output is open collector that can sink 500 mA max. When ESTOP is asserted (signal is pulled low),
drive is to totally ignore FORWARD, REVERSE, and the velocity command, and ramp down to a stop.

MANUAL# 9675-1035-000-B 19
Appendix B www.glentek.com

B-5 Encoder Feedback

The following pin description defines the main encoder feedback input port.

Signal Description
---------- ----------------------------------
+5V Drive supplied 5 volt source (output)
A+ / A - Encoder A channel input
B+/B- Encoder B channel input
Z+/Z- Encoder Z channel input (not used)

The spindle drive can supply 5 volts of encoder power. The source is rated at 150 mA.

The encoder input uses a DS26LV32 differential line receiver. By default, the encoder feedback is
configured for receiving differential signals (single-ended configuration is available upon request). The
spindle drive accepts nominal encoder frequency of 5 MHz (maximum frequency of up to 10 MHz is
possible, but is system dependent). The Z channel is edge sensitive such that swapping Z + and Z - does
not change the behavior of the spindle drive.

B-6 Encoder Output

The encoder out signals are differential output signals. The encoder output pins are buffered
representation of the motor encoder feedback. The encoder output uses a 26C31 differential line driver.

Encoder channels A and B are available as pins AOut +, AOut -, BOut +, BOut - on P5.

B-7 Load Meter Output

This is an indication of the load on the motor. The output ranges from -10 volts to +10 volts and has
16-bit resolution.

2.5 VDC = 100% absolute motor current (100% of continuous current)

3.75 VDC = 150% absolute motor current (150% of continuous current)
3.01K 20.0K
LOAD METER + (RED)
220pF

TP1 (AN0)

2 TLE084 150
-
1
3
Vref +
+3Vref
3.01K 20.0K
DAC8532 +3.3VA
LOAD METER - (BLACK)
8 1 0.0022uF
7 GND Vdd 2 TP7 (AGND)
FROM DSP (SI) DIN VREF AGND
6 3
FROM DSP (SCLK) SCLK VFB
5 4
FROM DSP (D/A_0) SY NC Vo 3.01K 20.0K
AUX. ANALOG OUT
0.1uF 1uF
AGND 220pF
0.1uF
TP2 (AN1)

6 TLE084 150
-
AGND AGND 7
5
Vref +
3.01K 20.0K

0.0022uF
AGND

Load Meter Output Schematic

20 MANUAL # 9675-1035-000-B
www.glentek.com Appendix B

B-8 PC Interface

The PC interface can be found at the HOST connector. A RS-232 interface is on the external of the spindle
drive. This port is the primary means of communication with the spindle drive for setup and control. The
port utilizes an RJ-45 type connector.

+3.3V MAX3232EIDR

16 1
Vcc C1+
2 0.1uF
V+ 3
0.1uF 6 C1-
V- 4
RJ45SHLD 0.1uF 0.1uF C2+ +3.3V
15 0.1uF
H1 10.0K GND 5
C2-
1 14 11
2 T1OUT T1IN 10.0K
3 13 12
4 R1IN R1OUT
5 TX232 7 10
T2OUT T2IN FROM DSP (SCITX)
6
7 RX232 8 9
R2IN R2OUT TO DSP (SCIRX)
8

H2

RS-232 Input Schematic

The serial cable can be made or purchased for communicating with a PC by configuring a cable with one
end being a male RJ-45 plug and the other end being a DB-9 female connector.

Note: If required, Glentek can customize a serial port digital interface to adapt to your controller as
required to meet your protocols. We are currently doing this for high speed Ethernet ports.

MANUAL# 9675-1035-000-B 21
Appendix B www.glentek.com

B-9 Power Input and Motor Output

The signal names for power are listed below:

Pin Name Description

-------------- ----------------------------------
L1, L2, L3 Input - AC voltage (line 1, line 2, and line 3, respectively).
PE Protective Earthing, Chassis GND.
B+ Output - DC BUS +.
B- Output - DC BUS Return.
R1 Output - Brake/Regen resistor.
R2 Output - Brake/Regen resistor.
PHASE T1 Output - Motor phase T1.
PHASE T2 Output - Motor phase T2.
PHASE T3 Output - Motor phase T3.

L1, L2, and L3 are 3-phase, 208-240 VAC, 50/60 Hz AC inputs. The maximum inrush current at power
up is 510 A @ 240 VAC.

B+ and B- are unregulated DC BUS output (derived from 3-phase inputs). Total DC BUS capacitance is
4,080 uF. BUS under-voltage trips nominally at 50 VDC ± 5%. BUS overvoltage trips nominally at
450 VDC ± 5%.

R1 and R2 are external Regen resistor (brake) outputs. Acceptable resistance range is 12 - 30 Ohms.
Regen turns on at 395 VDC ± 5%. Regen circuit uses a Ferraz Shawmut TRS10R time delay fuse.

Motor power is delivered at pins PHASE T1, T2 and T3. The motor power is Pulse Width Modulated
signals used to drive the motor.

It is recommended that the wire size for 3-phase AC inputs and motor outputs is 8 AWG (8.36 mm2)
or larger, 105°C rated PVC or better.

It is recommended that the wire size for DC BUS, and Brake/Regen resistor inputs is 10 AWG (5.26 mm²)
or larger, 105°C rated PVC or better.

Note: It is best not to connect the motor power pins until it is established that the logic section is working
and operational. This means that with the AC input pins connected, one should be able to communicate
with the spindle drive via a serial cable and the motor encoder feedback should be functioning properly.

22 MANUAL # 9675-1035-000-B
www.glentek.com Appendix C

Appendix C - Application Software

C-1 MotionMaestro©

MotionMaestro is Glentek's Windows based application software that you will need to setup and tune
the spindle drive. MotionMaestro has many features that allow users to easily configure and tune the
entire Glentek digital product line. However, for the Fadal VMC replacement spindle drive most of the
setup has been done at the factory. The installer only needs go through a quick tuning procedure to
get the spindle drive up and running. But first, MotionMaestro needs to be installed.

C-2 Installing MotionMaestro

C-2.1 Requirements
MotionMaestro requires either Windows 95, Windows NT 4.0, Windows 98 SE, Windows 2000,
Windows ME, Windows XP, Windows 7, or the Windows 8 operating system. A computer with a serial
port or a USB port is also required. It is suggested that you have a minimum of 3 megabytes of
application program disk space available prior to installation.

C-2.2 MotionMaestro v1.37

Only MotionMaestro v1.37 or later will work with Glentek Inc. spindle drives, earlier versions are not
compatible.

C-2.3 Installation
The MotionMaestro install disk is set up to utilize Install Shield to simplify installation.There are only a
few setup options offered. In general you can press NEXT or YES until installation is complete. When
installation is complete, you will find a MotionMaestro icon in the Windows Start\Programs menu. The
MotionMaestro installation program is named Setup.exe. It is found in the MotionMaestro \disk1
directory of the distribution CD, included with the spindle drive. The installation will also create a
Glentek folder in the Program Files folder.

A MotionMaestro 1.37 folder is created when 1.37 installed. You can have multiple versions
of MotionMaestro installed, if you wish, and they will be placed into their own directories. When
MotionMaestro is directed to establish communications with the spindle drive, the spindle drive is
queried for a model ID and Firmware version. MotionMaestro will configure itself and select the
appropriate configuration files based on the spindle drive’s returned values.

MANUAL# 9675-1035-000-B 23
Appendix C www.glentek.com

C-3 Communicating With the Spindle Drive or VFD Drive

C-3.1 Serial Port

If your PC has a serial port (RS-232), you can connect to the spindle drive with Glentek cable (GTK #
GC2400-AL005AM-000). This cable has a female DB-9 (computer) on one end and an RJ-45 (spindle
drive) on the other.

Photo 6: Serial port on the spindle drive Photo 7: GC2400-AL005AM-000

C-3.2 USB Port

If your PC has a USB port, a USB to serial port (RS-232) adapter (GTK # GC2410-001) is necessary
in addition to the cable above. Two known tested adapters are available: USBG-232 from USBGEAR
and US232R-10 from FUTURE TECHNOLOGY DEVICES INTERNATIONAL Ltd.

24 MANUAL # 9675-1035-000-B
www.glentek.com Drawings & Diagrams

Appendix D - Drawings & Diagrams

MANUAL# 9675-1035-000-B 25
Drawings & Diagrams www.glentek.com

D-1 Vector Drive Installation Drawing 1

26 MANUAL # 9675-1035-000-B
www.glentek.com Drawings & Diagrams

D-2 Vector Drive Installation Drawing 2

MANUAL# 9675-1035-000-B 27
Drawings & Diagrams www.glentek.com

D-3 Vector Drive Connection Diagram Page 1

28 MANUAL # 9675-1035-000-B
www.glentek.com Drawings & Diagrams

D-4 Vector Drive Connection Diagram Page 2

MANUAL# 9675-1035-000-B 29
Drawings & Diagrams www.glentek.com

D-5 Sensored Vector Command Input Control Diagram

Sensored Vector Command Input Control Diagram

Analog Input
Analog Input + Input Analog Scale
Velocity or
Current Command
Analog to Digital
Conversion  Deadband
(IAD) (IAS)
32768
+
MM Set MM Set

Input Analog
Offset
(IAO)

MM Set

Digital Bidirectional + +
Communication
Port
Serial Interface:
CanOpen, etc


Mode 1
Current To Current Control
Current
Limiter Loop Diagram
Command
(IL) Mode 1
Trajectory Slew- (SVC)
Rate Generator
Amps / Sec or MM Set MM View
RPM / Sec
(AL/DL) Mode 2
Velocity To Velocity
Velocity
Limiter Control Loop
Command
(VL) Diagram
MM Set (SVC)

MM Set MM View

30 MANUAL # 9675-1035-000-B
www.glentek.com Drawings & Diagrams

D-6 Sensored Vector Velocity Control Loop Diagram

Sensored Vector Velocity Control Loop Diagram

Proportional
Gain
(GVP)
32768 + Gain
Mode 2
Velocity Velocity
Mode 2
+ Error MM Set Velocity Loop
Velocity
Command   Command
Integer
Error Command
to Current Loop
(SVC) Settable
- Integral Gain (GVC)
(SVC)
+
View MM
Measured Motor (GVI) MM Set
Velocity with 32768
Derivative and
Tach Gain
MM Set

Gain Velocity
Derivative Gain Scale in Counts
Raw Velocity per Interrupt Velocity
Tach Gain
+ Estimate
 (GVD)
Low Pass
Feedback filter (GVF)
Power of 2
settable
From Current
Control Loop
256 32768 20=1 Diagram
28=256
+ MM Set (GVS)
MM Set MM Set
MM Set
Scaled Velocity
±32767

(SVS)

MM View

MANUAL# 9675-1035-000-B 31
Drawings & Diagrams www.glentek.com

D-7 Sensored Vector Current Control Loop Diagram

Sensored Vector Current Control Loop Diagram

Mode 1 Filter 1 Filter 2 Filter 3

Current
Command Loop Gain Programmable Programmable Programmable Current Limit
(SVC) Set at Unity Gain Biquad Filter Biquad Filter Biquad Filter
(32767) when High Pass High Pass High Pass
Mode 2 System is Properly Low Pass Low Pass Low Pass (IL )
Velocity Loop Phased Band Pass Band Pass Band Pass 32768
Error Comand (GL) Band Reject Band Reject Band Reject
from Velocity
Control Loop MM Set MM Set MM Set MM Set
(SVC) MM Set
MM View

Integral Gain
(GII)
32768 GLENTEK
DQ Current
+ 
custom Space
+ 

Command
(SID) MM Set  

Vector Modulator
conversion from
Rotor Flux (SIQ) Station Frame to
Field 
Current
Weakening - Proportional
+ 3 phase
(VFI) Gain
(GIP) R S T
MM View 32768

MM Set Current
Measured Sense
Current Park
Current
(SIA) Transform
Clarke Sense
(STD) Station Frame to
MM View Transform
(STQ) Rotation Frame Current
conversion 3  2  Sense
MM Set

Rotor Time 
Commutation
Constant Slip Estimator
Angle
(VFT)

Commutation Position 3
MM View Window for Number Data Incremental Induction
of Poles, Encoder Encoder Motor
Count, etc

Velocity GLENTEK
To Velocity Custom 16bit High
Control Loop Band Velocity
Diagram Generator
07-12-2010

32 MANUAL # 9675-1035-000-B
www.glentek.com Drawings & Diagrams

MANUAL# 9675-1035-000-B 33
 www.glentek.com

208 Standard Street, El Segundo, California 90245, USA.

Telephone: (310) 322-3026; Fax: (310) 322-7709
www.glentek.com e-mail: [email protected]

34 MANUAL # 9675-1035-000-B