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9182 Independence Ave. Chatsworth, California 91311Toll Free: 1.888.727.1887

BALDOR H2 VECTOR DRIVE INSTALLATION For your ease and convenience, this Baldor H2 drive is preconfigured prior to shipment for a standard Rigid Tap Fadal machine. One Drive Is All You Need:This drive is capable of performing all the various combinations of Fadal machine configurations by simply changing the appropriate parameters outlined in these instructions, such as:♦ Rigid Tap♦ Non Rigid Tap♦ Closed Loop Vector♦ Open Loop Inverter (V/F)♦ Wye/Delta Switching♦ All Spindle RPMs♦ Single or Three Phase Input Power (Automatic Detection)♦ Internal or External Braking (Regenerative) resistor(s)

Drive Configuration at Shipping: Fadal VMC - Standard Torque-□ High Torque-□ Very High Torque-□ Other _______________

Motor HP - 10-□ 15-□ 20-□ (Continuous Duty on Motor Label) Other _______________ Closed Loop Vector-□ Inverter: NCL-□ Max Motor Speed 5000-□ 7500-□ WYE/Delta - All Drives are configured for WYE/Delta Switching Rigid Tap YES-□ NO-□ 13 Ohms (default)

Note: After reading these instructions, call VMC Electric at 406-763-9073 if you need help or information on specific parameter changes, the common parameter adjustments are listed in this documentation.

TABLE OF CONTENTS--------------------------------------------------------------------------------------------DISCLAIMER 2

------------------------------------------------------------------------------SAFTEY PRECAUTION 2---------------------------------------------------------------------------GENERAL SAFEGUARDS 3

--------------------------------------------------------------UNPACKING THE SPINDLE DRIVE 3------------------------------------------------------GENERAL SPINDLE DRIVE OPERATION 4

STEP BY STEP -----------------------------------------------INSTALLATION PROCEDURE 5-----------------------COMMON PARAMETER MODIFICATIONS FOR YOUR CONFIG 11

H2 DRIVE -----------------------------------------------------------------TROUBLESHOOTING 12MACHINE TROUBLESHOOTING ----------------------------------------------------------------- 15

----------------------------------------------------------------------------------WIRING DIAGRAMS 18---------------------------------------------------------------------------------LIMITED WARRANTY 19

POLICY INFORMATION

Publication No. D-9812-10-V11 July 2012Copyright © 2012 ITS Inc. All rights reserved.

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DISCLAIMER:In no event shall Independent Technology Service Inc., VMC Electric llc. or any of our affiliates be liable for any damages whatsoever, and in particular shall not be liable for special, indirect, consequential, or incidental damages, or damages for lost profits, loss of revenue, or loss of use arising out of use or attempted use of this product, whether such damages arise in contract, negligence, tort, under statute, in equity, at law, or otherwise. This document is based on information available at the time of its publication. While efforts have been made to be accurate, the information contained herein does not intend to cover all details or variations of the products, nor to provide for every possible contingency in connection with handling, installation, operation, or maintenance. Features may be described herein, which are not present in or on all products. We assume no obligation of notice to holders of this document with respect to changes subsequently made and make no representation or warranty, expressed, implied, or statutory with respect to, and assume no responsibility for the accuracy, completeness, sufficiency, or usefulness of the information contained herein. No warranties of merchantability or fitness for purposes shall apply

SAFTEY PRECAUTION:WARNING: DISCONNECT ELECTRICAL POWER WHEN PERFORMING MAINTENANCE OR SERVICE ON EQUIPMENT! THIS INCLUDES:

♦ WHEN ADJUSTING OR CHANGING TOOLS♦ WHEN MAKING MECHANICAL ADJUSTMENTS♦ WHEN PERFORMING MAINTENANCE WORK OR PERFORMING ANY SERVICE TO THE SPINDLE♦ WHEN REMOVING ANY GUARD♦ WHEN REMOVING ANY BELTS OR PULLEYS

TO AVOID INJURY, ELECTRICAL POWER MUST BE OFF WHEN PERFORMING MAINTENANCE OR SERVICE ON EQUIPMENT!

SERIOUS PERSONAL INJURY IS ALWAYS A HAZARD IN AN INDUSTRIAL ENVIRONMENT. EXTREME CAUTION, IN ALL FACETS OF SAFETY, SHALL BE MAINTAINED. ALL COMPANY SAFETY STANDARDS, PRECAUTIONS AND REGULATIONS OF O.S.H.A. SHALL BE MAINTAINED DURING TRAINING, INSTALLATION, AND REMOVAL OF THE SPINDLE DRIVE.


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WARNING: This equipment contains High Voltages; up to 500 DC Volts. Improper use can cause serious or fatal injury. Only qualified personnel should attempt the installation and start-up procedure after reading Chapters 1 and 4 in the VS1GV Baldor Installation Manual included with this drive.

GENERAL SAFEGUARDS:• DO NOT OPERATE THE SPINDLE ASSEMBLY AND/OR ITS COMPONENTS UNLESS YOU HAVE READ

THIS DOCUMENT.• RETAIN FOR FUTURE REFERENCE. • FOLLOW ALL WARNINGS AND INSTRUCTIONS IN THIS DOCUMENT AND/OR THE FADAL MANUALS.

1. Read and Follow InstructionsRead all the safety and operating instructions supplied by Fadal prior to operating the spindle and/or its components

2. Attachments and EquipmentNever add any attachments and/or equipment to the spindle assembly without approval of the manufacturer as such additions may result in spindle failure, personal injury and/or voiding of the warranty.

3. ServicingDo not attempt to service the spindle drive and/or its components yourself as opening or removing covers and/or guards may expose you to dangerous hazards. Refer all servicing to qualified service personnel.

4. PowerDisconnect all power to the machine before any maintenance.

5. ProtectionAlways wear proper eye, foot and head protection when lifting, transporting and/or operating any machinery.

6. Water and MoistureDo not use the spindle drive and/or its components where they become exposed to water (coolant).

7. AccessoriesAny mounting of the spindle assembly and/or its components should follow the manufacturer’s instructions, and should use a mounting accessory recommended by Fadal, if applicable.

8. Handling the Spindle DriveDo not place the spindle drive and/or its components on an unstable cart, stand, tripod, bracket or table. The spindle drive and/or its components may fall, causing serious personal injury and serious damage to the spindle drive and/or its components.

9. Damage Requiring ServiceDisconnect all power to the spindle assembly and/or its components and refer servicing to qualified service personnel under the following conditions:

a. If the spindle assembly and/or its components do not operate normally by following the operating instructions.b. If the spindle drive and/or its components have been dropped or the shipping crate has been damaged.c. When the spindle assembly and/or its components exhibit a distinct change in performance.d. If the spindle assembly and/or its components have been crashed and exhibit a distinct change in performance.e. If the spindle assembly exhibits a rapid change in operating temperature.f. If the spindle assembly exhibits a rapid change in vibration level.g. If the spindle assembly exhibits a distinct audible change.h. If the spindle assembly locks-up and cannot rotate.

UNPACKING THE SPINDLE DRIVE:Each spindle drive ships in a highly stable shipping container to prevent damage to the spindle drive during shipment. Prior to opening do the following:

1. Inspect the shipping container for damage.2. Document any damage with photographs. 3. Report any damage to the trucking company and to your distributor, supplier or the ITS Service Team.


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General Spindle Drive OperationKeypad:The new drive operates using the same basic key stokes as the older Baldor drive. However there have been some changes over time. Review chapter 6 in the Baldor manual for keypad usage.

Drive Operation:Two modes of operation are selected from the Drive Keypad:1) The REMOTE mode is to run the motor from the CNC control.2) The LOCAL mode is used to run the motor from the keypad (Manually or AUTO TUNE).Note: The mode is displayed in the upper right of the Keypad Display (Status Page).You don’t need to be in the LOCAL mode to change parameters, only to Auto Tune or run spindle from Keypad.

Change Parameter - 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 highlighted parameter number.Press ENTER to begin Edit mode. Display flashes 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: The 7500 rpm (Wye/Delta Electronic HI/LOW) motor uses two sets of windings, it’s like having two motor in one. The drive uses two sets of parameters, one for Low Range (T1) and another for High Range (T2).When viewing a parameter via the Linear List feature, the bottom line of the keypad display shows a parameter number and a T1 or T2 next to it ti indicate which parameter table is active.These machines require attention to which parameter Table # you are editing. The correct table is selected when using the S-word during AUTO or MDI. Programming S.1 in MDI will automatically shift the contractor which is read by the drive to tell it which Table to select. Programming S.1 in MDI selects Table #2 for High Range. JOG Spindle:To run the spindle from the back of the machine in the LOCAL mode using the keypad as follows:Verify “LOCAL Mode” is displayed in the upper right hand corner of the display – Press LOCAL if in REMOTE.Press JOG – the LED lights up, no motion.Hold down the FWD to rotate the motor Forward (M4 direction at 1800 rpm).Hold down the REV to rotate Reverse (M3 direction).Release the FWD or REV to stop the spindle.Press the STOP key to exit JOG and Press REMOTE to run from CNC.

Rigid Tap – Ramps:In Rigid Tap mode the drive has a small ramp value, the CNC controls the acceleration and deceleration. Running from the keypad in LOCAL mode can cause a fault if you stop the motor from 1800 rpm and above. The Keypad JOG mode has Acc/Dec ramps. You can also push the REV key (M3 direction) and then use the up or down arrows to slowly increase or decrease the RPM up to full speed. Use the down arrow to reduce the rpm before pressing the STOP key.

Drive Fault – The drive keypad blinks the Red STOP LED when a drive FAULT in active:The drive is set to automatically reset a fault condition and it will try to keep running (after a 15 sec. time out); it will do the auto reset up to 10 faults per hour. A power off/on cycle will reset the counter.

To manually reset a drive fault: 1) Set the Drive in LOCAL Mode 2) Press the F2 key (FAULT is displayed above the F2 key) then the drive displays RESET. 3) Press F2 again to reset then press REMOTE to restore the drive for CNC operation.


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Installation Procedure

1. Disconnect and Lock-out the Supply Power. Lock-out front door access to spindle.

2. Before removing any wires from the old drive, take notice and mark them.They’ll be installed in the same appropriate orientation of the new drive.There’s basically four types that are hardwired to the drive:A) The motor connection wires - GND,T1,T2,T3B) The power input wires - GND, L1, L2, L3 (230 VAC)C) The braking resistor(s) wires - R1, R2 (Resistors are located on top of the back cabinet).D) A six pin Molex for CNC controls (signal, fault, FWD/REV)Options:1) The motor encoder 9 pin molex for Closed Vector operation (not Inverter).2) Rigid Tap encoder wires from the drive to the Fadal spindle controller (Slot #14 on 1060 board).3) A six pin Molex with 2 or 3 pins populated is for the 7500 rpm Wye/Delta winding (table) selector. Note: If only one pink wire is populated this connector isn’t used with the new drive.

3. Remove old drive and drive plate if present. The new Drive doesn’t need the old Regen fuse (if present) just the two wires directly from the actual Regen Braking resistor. It looks like a U-shaped coil(s) and is mounted on top of the cabinet. The two wires from the coil will go directly to terminal R1 and R2.

4. Mount new adapter plate, supplied in box, in rear cabinet. It’s important that the plate is grounded to the rear cabinet via the cabinet stud bolt. Remove any paint on the mount stud bolt if present.

5. Attach new Drive to the supplied adapter plate.


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6. Remove black plastic H2 cover- 4 Philips head screws.

7. Remove 9”x7” metal cover for access to power terminals by removing the 4 screws and slide the panel down past the molex connectors.

8. Connect Left Terminal: 230 VAC, 3 phase Power - GND, L1,L2,L3.

For Single Phase follow the diagram below:

The drive will display a SINGLE PHASE message when it powers up in single phase mode as a notification. It is not in the FALUT mode, the STOP key will not be blinking (Fault Condition).Note: This message will stop being displayed If you set P2110 to SINGLE PHASE.

Connect Right Terminal: Motor GND, T1,T2,T3 Motor Wires.

Note: For the drive, both the Motor and Power Input GROUND must be connected. Most machines used a common “STAR” ground terminal; one common ground point for everything. Most spindle drives had a ground wire for the power but not to the motor ground, the motor ground was attached to the common ground point. In this case, it’s best to add a ground wire from the motor ground terminal of the drive to the common ground terminal of the machine.Refer to Chapter 4, Power Wiring in the Baldor manual.

9. Connect the two wires from the Brake (Regen) Resistor to Right Terminal Strip labeled B+/R1 and R2 (see above picture).Before connecting, measure the OHM resistance of the braking resistor when it is disconnect from the old drive, note to Ohmic value for step 18 below. A zero value indicates a bad Regen resistor.

The new H2 drive is the same as all other Fadal drives in that they use Regenerative Breaking to stop the spindle motor. Depending on the


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Regen configuration, some small resistor wires might require a Pin adapter or strip wire ¾”, create loop, insert and clamp. Make sure these are tight and pass with a 1 lb pull-test. A loose connection will cause faults such as “DC BUSS HIGH” or DESAT during spindle off.

Notes: Mitsubishi Drives1) Some Mitsubishi drives used an internal Regen resistor, connect the H2 internal resistor (5 OHMs, 750 Watts); the two internal pairs of white wires that are red capped in the H2 drive to drive terminal R1 and R2.

2) Some Mitsubishi drives had the external brake resistor that was connected to a Glentek External Brake Driver, between the Drive and the Resistor(s). The new drive doesn’t need the external braking unit that was supplied with some of the Mitsubishi drives; use only the resistor(s) and wire them directly from the resistor on top of the Inverter Box to R1 and R2 of the drive, bypassing the external regen brake unit.

10. Restore the 9” x 7” metal cover plate (4 screws)..

11. Attach CNC Pendant Load Meter wires to the two connector barrier strip on the H2 Interface card marked LOAD METER, usually colored RED (+) and Black (-).Note: Do not attach any other wires than the two wires coming from the CNC Pendant Load Meter.

12. Rigid Tap Option: (proceed to the next step if option not present). If your not sure, remove the spindle controller card in the 1060 card cage, the card is located in slot #14. The eproms will be labeled as “RIGID TAP” or ACLINEAR (Non Rigid Tap).Install the encoder feedback wires to terminals 10-13 and 16 (small Baldor daughter board). This connects the encoder output of the drive to the CNC 1010 spindle card; slot #14 of the 1060 board, bottom rectangular 10 pin connector. On the New Baldor Drive, the encoder connecter is a 16 pin connector, daughter board see drawing below. The motor encoder feeds into it; already attached to terminals 1-5 and 8,9 with 10-16 as outputs to the CNC spindle card.

1010 Encoder Color Codes (usually one combination shown below)

31 – Green32 – Blue33 – Red34 – Yellow

31 – Yellow32 – Brown33 – Red34 – Green

The 1010 Encoder Ground/Shield could be labeled pin #30 or #38, either way, use terminal 16.

13. Plug in the Molex Connectors: - One 6 Pin Molex for Control signals – All machines, it’s fully populated with 6 wires/pins. - One 9 Pin Molex for Motor Encoder signals – For Rigid Tap and all Closed Loop Vector (Non Inverter) - One 6 Pin Molex for 7500 RPM Wye/Delta – 6 Pin connector, populated with 2 or 3 wires/pins: Note: Some machines have a 6 Pin Molex with only a single wire, it is not for Wye/Delta and is not needed anymore, tape it up and do not use.

14. Restore black plastic H2 cover.


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15. Turn on power to machine and perform a COLD START at the CNC control.

16. Verify the Drive Mode - REMOTE should be displayed on the upper right of the keypad display.The Keypad will display the message “ENCODER LOSS” if your machine does NOT have the a motor encoder. Set Parameter 1601 to V/F mode (Inverter) to turn off the Closed Loop Vector mode. See the Common Parameter Modifications section for setting your specific configuration.

17. VERIFY MOTOR SPEED SETTING AT TOP OF PAGE – IF INCORRECT IT COULD OVER-REV THE SPINDLE. To change, see P2003 - Common Parameters

10k spindle = max 5000 motor rpm (2:1 drive ratio, two mechanical auto Hi/Low idlers) 7.5k spindle = max 7500 motor rpm (1:1 drive ratio, direct drive, Wye/Delta Hi/Low) 15k spindle = max 5000 motor rpm (3:1 drive ratio, direct drive) 15k spindle = max 7500 motor rpm (2:1 drive ratio, direct drive)* There are some custom 10k and 15k machines with Wye/Delta switching.CAUTION: If you’re not sure, check the spindle speed setting in the CNC control parameters using the SETP command or remove the machines head cover and verify the drive system and ratio.The drive parameter #2003 sets the maximum motor speed not the spindle speed!

18. Adjust the Braking Resistor parameter by the measured value from step 9 above:If the Regen resistor(s) measured between 13 and 6 ohms (not zero) then skip to next step.Note: the measured Ohm value must be made with the resistor wires disconnected from the drive. A zero ohm value indicates a bad braking resistor.

Adjust The Braking Resistor Parameters:Parameter 2501 is the Regen brake resistor Ohms rating value. Internal brake = 5.0 Ohms External brake = usually 9, 13 or 19 Ohms. (no lower than 6 ohms)Parameter 2502 is the Regen brake resistor watts rating (in watts). Internal Baldor brake: 750 watts. External brake: 1 resistor = 1000 watts, 2 resistor stack = 2000 watts, 3 resistor stack = 4000 watts.

19. Tuning Drive and Motor (Signal Offset Trim and One Step Tuning)

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).

One Step Auto Tune Using Parameter 2902:The drive has been 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.

Steps for Tuning: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.13) 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 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 YESc) press ENTER to begin testd) press ENTER when “Test Passed” message appearse) 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).a) press ENTER to begin EDIT modeb) press up arrow to set it to YESc) press ENTER to begin test


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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) Press MENU then F1 (STATUS) to return to the main menu.8) Press LOCAL/REMOTE key to set the drive in the REMOTE Mode.NOTE: The drive will automatically ABORT the AUTO TUNE test if in REMOTE mode.

This completes the set-up for VMC 20, Standard 10k and 15k machines Proceed to step 20 machines not using 7500 RPM W/D windings.

For VMC 10, VMC 15, 4020A, 5020A (all 7500 RPM machines): With the drive in the REMOTE mode.a) Use MDI and enter code S.2 to shift ranges and select drive parameter table 2.b) Repeat Steps for Tuning starting from step 3 above. This will tune the Delta windings in HI Range.

20. Testing the Spindle Drive:Once the installation is completed, the drive is ready for operation.To run from the CNC, the drive must read “REMOTE” in the upper right corner of the keypad display.

IMPORTANT NOTE: It’s important to make sure the maximum motor speed is correct for your machine configuration to avoid over speeding your spindle. Go to the SETP menu in the CNC control and verify the maximum RPM setting of the machine then verify the correct motor speed while running the spindle.The Baldor keypad displays the actual motor speed, not the spindle speed.A 10,000 rpm spindle runs the motor at 5000 rpm (2:1). That’s 2 spindle turns per motor turn.A 7,500 rpm machine runs the motor at 7500 rpm (1:1) A 15,000 rpm spindle used both (2:1 and 3:1 drive ratios) most were 3:1 so the max motor rpm is 5000 rpm.

Spindle ON:Run the spindle in MDI, through the various RPM ranges.The M3 CNC code causes the drive keypad to light the REV key and M4 lights the FWD key.

Test M3 and M4 for correct command signal. If the Drive is setup for Rigid Tap and the Spindle card doesn’t have the RT software; the M3 will not turn the spindle but M4 will work fine. The same problem occurs if the drive is set up Non Rigid tap and the CNC control sends a rigid tap signal. – see Common Parameter Modifications below for setting up the correct speed signal (parameter 1408) in the Drive.

If the spindle will not turn and displays OVER CURRENT fault on the Drive or Error #9 at the CNC then see the motor tuning procedure in the Troubleshooting section below.An Error #10 indicates the CNC is not seeing the Spindle Hall Sensor change states or the spindle card is not receiving encoder pulses (for Rigid Tap machines).

Spindle OFF:A DC HIGH fault on the drive could indicate the braking resistor(s) is bad; remove and check the ohm value for open or the Regen braking resistor(s), connections that are loose or not connected.

Orientation:In MDI, test the spindle orientation by using the M19 code. The orientation speed is adjusted by the SETP command. The parameter to adjust is the “ORIENTATION FACTOR”, where the higher value increases the speed. The ANA offset trim (2901) in step 20 above is important to the orientation function.

V/F Inverter Mode: The low speed torque in the open loop inverter mode can be increased by adjusting parameter 1612 STATIC BOOST to a value of .1 or .2, .3 is maximum recommended setting. This parameter number will not appear if the drive is set to the Closed Vector mode (1601).

Note:If you’re having a problem, the first thing to verify is the drives basic configuration at shipping matches your machine. The most common mistake is having the drive set for the wrong Rigid Tap setting. For example having the drive set for RT and the spindle card doesn’t have the RT software.Continued Next Page.


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There are types of software for the 1010 Spindle card in slot #14 labeled:ACLINEAR – is for non Rigid TapRIGID TAP – is for Rigid Tap

Please read “Common Parameter Modifications” below before changing any parameters.7500 rpm (W/D) machines require attention to which parameter Table # you are editing (T2= high range or T1= low range). The bottom line of the keypad display shows a parameter number and a T1 or T2 next to it ti indicate which parameter table is active.

Refer to Troubleshooting section below if you are experiencing any other problems.


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Common Parameter Modifications

NOTE: DO NOT RESTORE “FACTORY PARAMETERS” - this will clear all the Parameters and PLC code which requires returning the drive for reprogramming. You can set parameter 1312 to YES which restores (Keypad to Parameters) our original parameter setup at drive shipment.

For help changing parameters review Page 4, Change Parameter - Linear List

Parameter Tables – The Baldor drive uses two sets of parameters, stored in tables. Each table contains unique settings for a specific configuration; such as windings, ramping and motor control.For standard machines – only Table 1 is used.For 7500 rpm; VMC 15 and “A” linear machines, a dual winding configuration for Low range (T1) and High range (T2) is achieved by switching a contactor that reconfigures the motor winding pairs and sets T1 or T2 to match the windings.

IMPORTANT - If Wye/Delta (7500 rpm) switching is installed:Set the rpm range before changing parameters (see note below). In MDI enter: S.1 to shift the CNC to Low range and set the drive to Table 1 (T1) parameters. S.2 to shift the CNC to Hi range and set the drive to Table 2 (T2) parameters.

Note: anytime you change a parameter, in the center, at the bottom of the keypad display usually shows the parameter number with a T1 or T2 next to it. This confirms which table you are editing. With Wye/Delta switching, if you change a parameter in Table 1, in most cases you’ll need to change the same parameter number in Table 2. Switch tables using MDI, see above.

Drive Control Parameters All Configurations:P1101 & P1104 sets Accel/Decel time.P1408 selects speed command signal.P1601 selects Closed Vector or V/F (Inverter)

1) Settings for Rigid Tap:P1101 = .1 secondsP1104 = .3 secondsP1408 = -10 to +10 voltsP1601 = Closed Vector (Encoder)Verify P1635 is not set below 5 from Auto Tune

2) Non-Rigid Tap with Closed Vector:P1101 = 3.0 seconds - 15 hp HT 3.5 seconds - 10 hp STD 4.5 seconds – all 7500 rpmP1104 = 3.0 seconds – 15 hp HT 3.5 seconds – 10 hp STD 4.5 seconds – all 7500 rpmP1408 = 0 to +10 voltsP1601 = Closed Vector (Encoder)

3) Non-Rigid Tap with Inverter Mode (no encoder):P1101 = 3.0 seconds - 15 hp HT 3.5 seconds – 10 hp STD 4.5 seconds – all 7500 rpmP1104 = 3.0 seconds – 15 hp HT 3.5 seconds – 10 hp STD 4.5 seconds – all 7500 rpmP1408 = 0 to +10 voltsP1601 = V/F mode (Inverter)P2002 = 25 (Minimum RPM)

P2003 selects Max MOTOR RPM. 6.5k spindle = 3250 motor rpm (2:1 drive ratio)7.5k spindle = 7500 motor rpm (1:1 drive ratio)10k spindle = 5000 motor rpm (2:1 drive ratio)15k spindle = 5000 motor rpm. (3:1 drive ratio)15k spindle = 7500 motor rpm. (2:1 drive ratio)Always check drive ratio before changing P2003 Caution, wrong motor speed could over-rev the spindle!

Motor Parameters Settings:Below are the settings for the standard 10 HP and 15 HP (non WYE/DELTA) motor settings.

Parameter Name 10 HP Motor Values 15 HP Motor Values2402 Motor Rated AMP 25.7 38.02405 Motor Magnetic AMP 8 102412 Slip Frequency 1.333 Hz 1.333 Hz2416 Motor Rated HP 10 HP 15 HP

The only reason to change the motor values would be if a 15 HP drive was needed to run a 10 HP motor.Give us a call at (406) 763-9073 and we’ll step you through the DELTA (T2) parameters if required. All drives ship with the Table 2 parameters loaded for the Delta windings and are ready for Wye/Delta switching.


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H2 Drive Troubleshooting

IMPORTANT: DO NOT RESTORE “FACTORY PARAMETERS” - this will clear all the Parameters and PLC code which requires returning the drive for reprogramming. You can set parameter 1312 to YES which restores (Keypad to Parameters) all our original parameters setup at drive shipment.DO NOT CHANGE ANY PLC SETTINGS - the PLC code (P3400-P3430) is protected and once modified requires returning the drive for reprogramming.

ERROR LOG - The drive retains the last 10 faults in the EVENT LOG, to view press the MENU key and select EVENT LOG. The errors have a date stamp to show the latest fault. Select the fault then press the HELP key to read suggestions to solving the problem.

1) PROBLEM – CNC Error #2 with M3 and M4The RT software in the 1010 spindle card is not reading encoder pulses. The encoder is fine if the drive runs smooth when running in LOCAL mode from the Baldor keypad. Verify the encoder connections from the Baldor drive to the spindle controller card. The ground/shield wire attached at terminal J16 of the Baldor encoder output board is critical to the axis card receiving pulses. A loose connection will cause this problem.

2) PROBLEM – Spindle turns M3 but not M4Change P1408 to setting 0 to +10 volts. This is caused because the drive expects a -10 to +10 volt signal (RT mode) and the Spindle card is not RT. The 1010 spindle card is in slot #14. The Eproms will read either ACLINEAR for a non-rigid tap machine or RIGID TAP. 3) PROBLEM – Spindle turns back and forth or slowly in one direction using 30+ Amps (normal is 8-12 amps) and/or the Drive displays OVER CURRENT Fault.Switch the T1 and T2 motor wires. This happens when the motor rotation is backwards to the encoder, usually because of a rewound motor. If problem persists, perform Encoder test below. 4) PROBLEM – Drive displays message “ENCODER LOSS” The Drive is not sensing the encoder channels while in the Closed Loop mode. Usually because of a bad encoder or a faulty connection between the Baldor drive and the spindle motor encoder.The encoder has 4 channels: Wires 2-5 with wire 8 is supply voltage (+5 VDC) and wire 9 as common.The encoder signal is a square wave the alternates between 0 and 3.5 VDC as you slightly rotate and stop the spindle. The state relationship between the channels will always be displayed as below, depending where the spindle is stopped. Measure the DC voltage from each wire and use wire #9 as signal common.States A+ High A+ Low Wire 2 = A+ 3.5 0Wire 3 = A- 0 3.5Wire 4 = B+ 3.5 0Wire 5 = B- 0 3.5The point of the test is to see the states changing at the drive input. Possible problems would be with the encoder or the wiring from encoder to the drive. If wires #1 (shield) and #9 (power common) are backwards the encoder output remains high at approximately 4.8 VDC for all encoder outputs. To solve this condition; swap wires #1 and #9 or install both wires #1 and #9 in terminal #9 (power common) and verify wires #2 - #5 state changes as described above.


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5) PROBLEM – OVER CURRENT and POWER BASE FAULT: Either random or at spindle on.The Over Current protection fault is displayed anytime the drive exceeds its maximum output current. This could happen during a heavy cut that exceeds the continuous or peak current duty cycle of the drive.

Follow the procedures below if this is occurring while not taking a heavy cut.First, verify the encoder coupler is not loose on the spindle motor shaft. Check the motor pin and coupler.Second, verify the encoder is working as in the described test for problem #7 below.The standard spindle motor electrical and magnet properties can change over time as well as with rewound motors. These changes can be outside of the normal Vector parameters of a standard Fadal spindle motor.The H2 Drive has a “One Step Auto Tune” procedure that will automatically adjust Inverter/Vector parameters.

Steps for Tuning the Drive to the Motor:1) For 7500 rpm Wye/Delta machines: set the machine in the range having the problem. In MDI, enter S.2 for High range or S.1 for Low range. It does’t matter which range for standard 10K machines.2) The drive must be in the LOCAL mode, press the REMOTE/LOCAL key on the Baldor Keypad. The upper right of the drive display must read LOCAL not REMOTE.3) Press: MENU, select ADVANCE PROG, LINEAR LIST to access the parameters. 4) Select Parameter 2902, set it to YES to perform ONE STEP AUTO TUNE (it takes about 6 minutes)5) The drive will begin a series of motor tests; press ENTER at the completion of each test. Call if the drive displays the message “TEST ABORTED”. After a successful auto tune, the Drive will display the completed message. Press ENTER to return to the initial parameter 2902 screen.6) Press MENU then F1 (STATUS) to return to the main status menu and Set REMOTE mode by pressing the REMOTE/LOCAL key.

6) PROBLEM – Spindle Not Turning, CNC displays “MOTOR OVERLOAD” Error #10 and No Drive faultsVerify the drive is in the REMOTE mode. See Problem #2. Verify the 1100-2 FWD/REV relays are working. The drive REV or FWD should light up when enabled by the CNC.

7) PROBLEM – Random Over Current Faults – Encoder Test Using The DriveAny missing encoder pulses will cause improper calculated motor speed and this creates problems in the Vector calculations which results in high current output to the motor. This test procedure will run the motor in open loop mode and allows the verification of what rpm the encoder is showing.

To perform an Encoder Test:1) Press Menu, select BASIC PARAM and press ENTER to begin EDIT. Press the up arrow to change Control Type to V/F Control and press ENTER to accept the change.2) Press MENU and press the down arrow, select DIAGNOSTICS and press ENTER.3) Press the right arrow 11 times to view the POSITION COUNTER display.4) The third line down display SPEED MEAS. This line will be used to view the rpm that the drive is calculating from the encoder input.5) Start the spindle running from the CNC pendant at 1800 rpm or at an rpm range that fails. Be sure to use an M49 code to disable the spindle override pot.6) Observe the rpm displayed at the SPEED MEAS of the Baldor keypad. The motor is running at a constant speed in V/F (inverter) open loop mode; it’s not following the encoder. The speed measured should be fairly constant ± 15 rpm or better. A bad encoder will not be stable and occasionally jump a couple of hundred rpm or give an rpm value that is way off what it should be. We’ve seen it read 15000 rpm on one occasion. Change the rpm speed and monitor it a various speeds.Check all connections and replace the encoder if necessary.You can continue running the machine in the V/F mode while you wait for a replacement encoder. The only limitation is the machine will not be able to do rigid tapping.7) End Encoder Test – Two Options: A) Press F1 for STATUS, to exit and continue running the machine in the V/F mode. B) To Restore Close Loop Vector:

Press MENUSelect BASIC PARAM, press ENTER to editPress up arrow, select CLOSED VECTOR and press ENTER to change.Press MENU and select STATUS


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8) PROBLEM – Spindle Orientation Retries or Rigid Tap fails at doing G84.2The Spindle orientation is slow or goes past orientation position then locks after one or two rotations or Rigid Tap pre-cycle (G84.2) failures.1) Review the installation step 19 above “Perform Analog Offset Trim Adjustment”.2) Reduce DECEL time P1104 in T2 For 7500 rpm spindles with problems in Hi Range.3) For Closed Vector mode, verify P1635 is not set below 5 from Auto Tune.4) Adjust the control ORIENTATION FACTOR using the SETP command of the CNC. A factor to low will cause little or no motion and a factor to high causes overshoot and instability. With 10k Hi/Low drives you need to balance both the high range and the low range i.e. the low range will be a little slow and the high range is on the fast side.

9) PROBLEM – Drive displays message DC HIGH faults during spindle offIf the spindle won’t stop at all:

Check for loose Regen connections at R1 and R2.Check the Regen resistor Ohm value, first remove resistor wires at R1 and R2 from the drive before testing.

A zero ohm value indicates the braking resistor (Regen) is burnt out and needs replacing.If the spindle stops but not a high speeds:

Check the AC input voltage, retap transformer if above 240 VAC, closer to 230 VAC.For Non Rigid Tap machines you can increase the deceleration time by changing parameter number 1104.For Rigid Tap machines you can increase the Ohm value of parameter 2501. This will increase the deceleration time without impacting rigid tapping. Start at a value of 30 ohms and increase up to 45 ohms. Above 45 ohms can start to degrade the high speed (3000 rpm) rigid tapping.

10) PROBLEM – Spindle Orientation is slow, cogging in Inverter mode (parameter 1601 = V/F MODE)1) Adjust the ORIENTATION FACTOR using the SETP command of the CNC. A factor to low will cause little or no motion and a factor to high causes overshoot and instability. With 10k Hi/Low drives you need to balance both the high range and the low range i.e. the low range will be a little slow and the high range is on the fast side.2) The low speed torque in the open loop inverter (VF) mode can be increased by adjusting parameter 1612 STATIC BOOST to a value of .1 or .2, .3 is maximum recommended setting. This parameter number will not appear if the drive is set to the Closed Vector mode. Both T1 and T2 for Wye/Delta configuration.3) For Non Rigid tap machines; set Parameter 2002 to a minimum rpm of 25 and reduce ACCEL Parameter 1101 and DECEL Parameter 1104 to 1 second for each. Adjust both parameters T1 and T2 for Wye/Delta configuration.4) See “Steps for Tuning the Drive to the Motor” in problem number 6 above.

11) PROBLEM – Auto Tune FailureFirst verify the drive is in the LOCAL mode.The drive is shipped with the correct motor parameters for a standard new original motor.The auto tune procedure compensates for motor breakdown. The procedure should never fail unless something is wrong with the motor, encoder, contactors (Wye/Delta) or wiring. It uses resistance, voltage and current to measure and adjust for optimum settings. By doing this it also tests the motor more thoroughly then a Ohm or Mega-Ohm test can do.The drive cannot tune a motor that is really bad or out of then normal range of the drives rating; a 10 hp drive cannot tune a 15 hp motor. The V210= 10 hp motor, the V215= 15 hp and a V220= 20 hp. A lower value HP is usually successful, change P2416 to the actual motor HP before Auto Tuning.

NOTE: Failing the Auto Tune requires correcting the problem and restoring the original parameters by setting parameter 1312 to YES (Keypad to Parameters) before trying to Auto Tune the motor again.

The Wye/Delta contactors are a common failure component and should be replace when a drive is replace.Review Troubleshooting Guide in the following section.

12) PROBLEM – Spindle Stops And Coasts A Couple Of Turns (M19 and G84)Adjust Parameter P1001 to a lower value. This parameter determines when the motor is turning slow enough to disable the drive. The Mitsubishi used the FWD/REV disable to stop the motor, reducing this value will simulate the same action. The default value is 30 RPM.With INVERTER (V/F) mode reducing this value can improve Orientation and G84 Tapping.

13) PROBLEM – Spindle Runs Fine But Rotates The Wrong DirectionSwap T1 and T2 for Inverter (VF) mode. For Closed Vector swap T1 and T2 plus Motor Encoder wires #2 (A+) and #3 (A-) to reverse the encoder counting. See Problem #4 for encoder wire connections.


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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.

Common Failure Points Recommended To Check1) Parameter SettingsThe HIGH TORQUE/RIGID TAP parameter:

For machines with Wye/Delta wiring, verify the parameter 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.

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.


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4) Drive Input Power ConnectionsAt 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 steps #9 and #18.

6) Spindle EncoderThe encoder directly affects the current output of a Vector Drive. See Drive Troubleshooting sections:7) PROBLEM - Random Over Current Faults – Encoder Test Using The Drive4) PROBLEM – Drive displays message “ENCODER LOSS”

7) Motor ConnectionsCheck 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 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.


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14) Motor RewindsFor 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 TestNOTE: 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

Below is the standard (non Wye/Delta) wiring. Above is the 7.5k rpm Wye/Delta, using contactors.


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LIMITED WARRANTY:Any spindle drive, sold by Independent Technology Service Inc. or any of our affiliates, which, under normal operating conditions in the plant of the original purchaser thereof, proves defective in material or workmanship within specified time (two years) from the date of shipment by us, as determined by an inspection by us, will be repaired or replaced, at our discretion, free of charge for repair. Customer is responsible for the shipping costs.

Provided that you promptly send to us notice of the defect and establish that the spindle drive has been properly installed, maintained, and operated within the limits of rated and normal usage, and that no factory adjustments have been tampered with or damage has occurred from contamination; i.e. water, coolant, any foreign material such as chips or dust. We cannot warranty a spindle drive that has failed due to contamination, over voltage surges or lightening strikes.

Independent Technology Service Inc. or agents liability is limited to repair or replacement of defective parts as examined and determined by us. Repaired items will carry a 90-day warranty or until fulfillment of original warranty time; whichever is greater.

All expressed and implied warranties, including the implied warranties of merchantability and fitness for a particular purpose are limited in duration to the warranty period, and no warranties, whether expressed or implied, will apply after this period.

Under no circumstances shall Independent Technology Service 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 claims or damages that may be initiated against us by third parties.

POLICY INFORMATION:

RESTOCKING:We cannot receive a return part that has been damaged or in a condition that makes it unable to resale as originally sold. Parts being returned must be returned in the same packaging and in the same condition (as determined by us) as it was originally received. Spindle Drives returned to us that are not under a warranty repair will be subject to a 10% restock fee. We will contact the customer to discuss returns considered unusable or damaged for possible solutions.

SHIPPING:Customer is responsible for all shipping unless determined by us to be our fault; i.e. the wrong part was shipped.


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