Fagor DDS Series Hardware Manual

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Hardware manual

Ref.1912

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Summary of Contents for Fagor DDS Series

Page 1 DRIVE Hardware manual Ref.1912...
Page 2: Registered Trademarks
· type of file: EC Declaration of Conformity · Fagor Automation S. Coop. will not be held responsible for any losses or damage, direct, indirect or by chance that could result from that Registered trademarks information and it will be the user's responsibility to use it.
Page 3 G E N E R A L I N D E X EC DECLARATION OF CONFORMITY ....................5 TÜV SÜD FUNCTIONAL SAFETY CERTIFICATE ................9 ABOUT THIS MANUAL ........................13 ABOUT THE PRODUCT ........................14 SHIPPING CONDITIONS, STORAGE, DECOMMISSION AND DISPOSAL ........15 VERSION HISTORY ..........................
Page 4 CABLES ........................... 235 Mains connection cable. Power supply - mains connection ............236 Power cable. Motor-drive connection ..................238 Motor feedback cables ......................240 CA-D1-D4 adapter cable ......................242 Direct feedback cable ....................... 243 Signal cables for control and communications ................245 RS232/RS422 BE adapter ......................
Page 5 Modular drives .......................... 363 Compact drives ......................... 369 Bus Protection Module, BPM ....................372 Capacitor Module, CM-1.75 ...................... 372 Mains filters ..........................373 XPS CHOKES ........................... 374 RPS CHOKES .......................... 375 External Ballast resistors with external thermostat ..............375 External Ballast resistors with internal thermostat ..............376 External Ballast resistors with external thermostat &...
Page 6 This page intentionally left blank HARDWARE Ref.1912 · 6 ·...
Page 7: Ec Declaration Of Conformity
EC DECLARATION OF CONFORMITY Manufacturer Fagor Automation S. Coop. B.º San Andrés 19; C.P. 20500, Mondragón, Gipuzkoa - Spain. We hereby declare, under our own responsibility that the product: DESIGNATION: DRIVE BRAND: FAGOR PRODUCT: SAFETY COMPONENT (acc. 2006/42/EC) consisting of the following modules and accessories:...
Page 8: Machinery Directive
MACHINERY DIRECTIVE Safe Torque Off function satisfies the requirements: IEC 61800-5-1 Ed.2.0 IEC 61800-5-2 Ed.2.0 (SIL 2) IEC 61508-1 Ed.2.0 (SIL 2) IEC 61508-2 Ed.2.0 (SIL 2) IEC 61508-4 Ed.2.0 (SIL 2) EN ISO 13849-1:2015 (Cat. 3, PL d) which are certified in: Z10 17 09 80353 007 Certificate No.: TÜV SÜD, Notified Body 0123...
Page 13: About This Manual
Warning WARNING. The information described in this manual may be subject to changes due to technical modifications. FAGOR AUTOMATION, S. Coop. reserves the right to change the contents of this manual without prior notice. Headquarters Fagor Automation, S. Coop.
Page 14: Software Options
A B O U T T H E P R O D U C T Software options Bear in mind that some of the features or applications described in this manual depend on the software version installed. These considerations are reflected in the “man_dds_soft.pdf” manual supplied with this one.
Page 15 S H I P P I N G C O N D I T I O N S , S T O R AG E , D E C O M M I S S I O N A N D D I S P O SA L Shipping When shipping the unit, do it protected against blows and pack it in its original cardboard box with its original packing material.
Page 16 HARDWARE Ref.1912 · 16 ·...
Page 17: Version History
From February of 2004 on, compact drives ACD 2.50, SCD 2.50, ACD 2.75, SCD 2.75, CMC 2.50, CMC 2.75 and the programming module DDS PROG MODULE will no longer be in Fagor Automation’ catalog. However, all the documentation regarding them is kept in this manual just in case the user has already purchased any of these modules.
Page 18 Manual reference Events 0706 New VECON-3 board Sales models of the glass fiber optic cable SF0-V-FLEX New ER-18/1000+FAN resistor with fan. 0710 No new hardware has been implemented. 0802 New compact drives: ACD/SCD/CMC 2.50. There are now 3 switches for selecting the ballast resistor on PS-25B4 power supplies.
Page 19 Manual reference Events 1905 Equipment for working in industrial graphite environments: Drives: AXD 1.15-S0-0-C, AXD 1.25-S0-0-C, AXD 1.35-S0-0-C AXD 2.50-S0-0-C, AXD 2.50-S0-2-C AXD 2.75-S0-0-C, AXD 2.75-S0-2-C Removing the X5 connector on all RPS power supplies. 1910 ACD/SCD compact drives; 3-ph at 200/240 V AC. HARDWARE Ref.1912 ·...
Page 20 HARDWARE Ref.1912 · 20 ·...
Page 21: Safety Conditions
They must also know the current regulations and standards for preventing accidents that must be borne in mind when handling these units. Fagor Automation shall not be held responsible of any physical or material damage originated from not complying with these basic safety rules.
Page 22 This unit is ready to be used in industrial environments and comply with the current directives and regulations of the European Community. Fagor Automation shall not be held responsible for any damage that could suffer or cause when installed under other conditions (residential or domestic environments).
Page 23: Precautions During Maintenance
Precautions during repairs  Do not access the inside of this unit. Only personnel authorized by Fagor Automation may access the interior of this unit. Therefore, in case of a malfunction or product failure, disconnect it and call the technical service department.
Page 24 E C D E C L A R AT I O N O F C O N F O R M I T Y A N D WA R R A N T Y T E R M S The EC Declaration of Conformity is available in the downloads section of FAGOR’S corporate website at http://www.fagorautomation.com. · type of file: EC Declaration of Conformity ·...
Page 25: R E C O M M E N D E D D O C U M E N Tat I O N
R E C O M M E N D E D D O C U M E N TAT I O N Available manuals Manual available in electronic format Manual available on paper http://www.fagorautomation.com Product selection guides Document Description Format It describes the products that make up the DDS man_drive_ord_hand.pdf system and allows selecting each element according...
Page 26 Document Description Format They describe the FM7/FM9 families of asynchronous man_fm7_fm9_motors.pdf motors of the FAGOR catalog and how to install them spanish/english with the DDS system. They describe the FXM/FKM families of synchronous man_fxm_fkm_motors.pdf motors of the FAGOR catalog and how to install them spanish/english with the DDS system.
Page 27 DESCRIPTION The DDS system is an "adjustable speed electrical ·Power Drive System· as defined in IEC 61800-5-1. The DDS system is ready to be used in industrial environments. It may be used with the CNC to control the movements and devices of the machine.
Page 28   Description 1.1 Description Fagor Automation's DDS system has a modular stackable design. It may be connected directly to a TN type three-phase mains with a frequency of 50/60 Hz and with a rated voltage between 400-10 % and 460+10 % V AC.
Page 29: General Diagram
  Description 1.2 General diagram See the schematic description of all the elements that make up the DDS system: Mains connection. Non-regenerative PS-65A Three phase 50/60 Hz.TN mains power supplies + modular drives: 400 (1-10 %) to 460 (1+10 %) V AC for axes: AXD, MMC Mains filters: for spindle: SPD...
Page 30: Example Procedure
The following steps are a reference to configure and install the DDS system. NOTE. This DDS system configuration process assumes that the motors of the system are known motors. All the motors of the FAGOR catalog are described in their corresponding manuals: • Manual of synchronous servo motors. FXM, FKM families.
Page 31   Description 1.4 Insulation diagram of a machine system System · CN Numeric Control - AXD/SPD Drive - FKM Servomotor · 3x460 VAC F. H1/3 Insulation diagram of a system · CN + AXD/SPD + FKM · in a machine. HARDWARE Ref.1912 ·...
Page 32: Environmental Conditions
  Description 1.5 Environmental conditions Conditions Standard Test reference Mechanical specifications Transport Vibration Acc. to Class 2M1, vibration sinusoidal 2 Hz < f  9 Hz, 3.5 mm amplitude IEC 60721-3-2 9 Hz < f  200 Hz, 1 g 200 Hz <...
Page 33: Power Supplies
POWER SUPPLIES The FAGOR power supplies are connected after the filter to mains (see figure F. H1/1) with a line voltage between 400 and 460 V AC at a line frequency of 50/60 Hz and its functions are:  Provide a DC voltage output that will supply the modular drives through the power DC BUS.
Page 34   Power supplies 2.1 Non-regenerative power supplies When referring to non-regenerative power supplies, we'll use PS-25B4 and PS-65A. They all admit a voltage range between 400 to 460 V AC. They are: L1 L2 L+ Re Ri Re L+ F.
Page 35   Power supplies PS-65A module Technical data T. H2/1 Technical characteristics. PS-65A Line voltage 3-ph, from 400 (1-10 %) V AC to 460 (1+10 %) V AC Line frequency 48 ... 62 Hz Mains power consumption (400 V AC) 95 A Minimum connection cable section 50 mm²...
Page 36: Block Diagram
  Power supplies Power diagram 65 kW 1.9 kW 2x ER+TH-18/1100 2x ER+TH-18/1800 2.6 kW Power 2x ER+TH-18/2200 4.0 kW 600 W Internal Ballast Always install the two resistors (2x) in parallel, never in series. F. H2/2 Non-regenerative power supply, PS-65A. Power diagram. Block diagram HARDWARE Ref.1912...
Page 37: Connector Description
  Power supplies Connector description The non-regenerative power supply PS-65A has the following connectors: L1 L2 L3 CAUTION. AC touch current greater than 3.5 mA. Install ground wire of at least 10 mm² (Cu) or 16 mm² (Al). NOTE. POWER BUS Currently pin 4 ·...
Page 38 WARNING. When installing a NON-FAGOR resistor, only use this switch setting when the power of your resistor is greater than any of the ones shown in this cell of the tables provided by FAGOR. Ignoring this warning MAY CAUSE THE DESTRUCTION of the resistor WITHOUT PRIOR WARNING.
Page 39   Power supplies PS-25B4 module Technical data T. H2/4 Technical characteristics. PS-25B4 Line voltage 3-ph, from 400 (1-10 %) V AC to 460 (1+10 %) V AC Line frequency 48 ... 62 Hz Mains power consumption (400 V AC) 36 A Minimum connection cable section ·1·...
Page 40   Power supplies Power diagram 25 kW ER+TH-18/1100 950 W ER+TH-18/1800 1.3 kW ER+TH-18/2200 2.0 kW Power ER+TH-18/1000+FAN 2.0 kW ER+TH-18/1500+FAN 3.0 kW ER+TH-18/2000+FAN 4.0 kW Internal Ballast 500 W F. H2/5 Non-regenerative power supply, PS-25B4. Power diagram. Block diagram HARDWARE Ref.1912 F.
Page 41   Power supplies Connector description The non-regenerative power supply PS-25B4 has the following connectors: CAUTION. AC touch current greater than 3.5 mA. Install ground wire of at least 10 mm² (Cu) or 16 mm² (Al). Re L+ F. H2/7 Non-regenerative power supply, PS-25B4.
Page 42   Power supplies Lights indicating the status of the main power supply The non-regenerative power supply PS-25B4 has the following lights on the front panel to indicate the status of the main power supply.  FAULT BLINKING. The blinking red led indicates that there are no errors and that one or several mains phases are missing.
Page 43 WARNING. When installing a NON-FAGOR resistor, only use this switch setting when the power of your resistor is greater than any of the ones shown in this cell of the tables provided by FAGOR. Ignoring this warning MAY CAUSE THE DESTRUCTION of the resistor WITHOUT PRIOR WARNING.
Page 44: Power Connectors
  Power supplies Power connectors Terminal strip for mains connection When connecting the power supplies to mains through terminals L1, L2 and L3, the phases may be connected in any order. Fr om ma i ns N ote. R S T, cl assi c nomencl atur e L1 L2 L3 L 1 L 2 L 3, cur r ent nomencl atur e (R) (S) (T)
Page 45   Power supplies Terminal strip to connect the Ballast resistor The power supply is supplied from factory with a wire jumper between terminals Ri and L+. This configuration of the power supply means that it comes from the factory with its internal Ballast resistor. However, if with this internal resistor it is not possible to dissipate enough power (e.g.
Page 46: Derating Curves
2.3 and 2.8 N·m. This point is very important to ensure good electrical contact between modules. FAGOR power supplies have a Soft Start for charging the power DC BUS. The soft start begins when two necessary and sufficient conditions are verified: ...
Page 47   Power supplies WARNING. Before handling these leads, proceed in the following order:  Stop the motors.  Disconnect the line voltage at the electrical cabinet.  Wait, before handling these leads. The power supply module needs time to decrease the voltage of the power DC BUS down to safe values (<...
Page 48: Other Connectors
  Power supplies Other connectors X1 connector The communication between all the modules that make up the DDS system is established through connector X1. F. H2/11 Connection of the internal bus between modules through connector X1. A ribbon cable is provided with each power supply or drive for the connection.
Page 49   Power supplies The internal circuits of the non-regenerative power supplies PS-65A require an external 24 V DC supply. This is why its connector X2 has three more pins than for the PS-25B4 power supply that integrates an auxiliary power supply. The internal circuits are protected with a 1.25 A fuse.
Page 50   Power supplies PS-25B4 X3 CONNECTOR 400/460 V AC 400/460 V AC Phoenix 7.62 mm PS-25B4 X4|X5|X6 CONNECTORS +24 V DC Phoenix 5.00 mm F. H2/13 Connectors X3|X4|X5|X6 of the auxiliary power supply integrated into the PS-25B4. The gap and tightening torque and sections of the screws of the plug-in connectors for X3 and X4|X5|X6 are given by the table: T.
Page 51: Module Power-Up
  Power supplies Module power-up 1. For: PS-65A power supply Supply 24 V DC to the control circuits of the power supply through pins 9 and 10 of connector X2. PS-25B4 power supply Apply power to the Auxiliary Power Supply from mains through pins 2 and 3 of connector X3;...
Page 52   Power supplies 2.2 Regenerative power supplies When referring to regenerative power supplies, we'll use XPS-25 and XPS- 65. They all admit a line voltage between 400 (1-10 %) V AC and 460 (1+10 %) V AC and can return power back to mains. They are: Ri Re L+ Ri Re L+ F.
Page 53   Power supplies XPS modules Technical data T. H2/14 Technical characteristics. XPS-25 XPS-65 Line voltage 3-ph,from 400 (1-10 %) V AC to 460 (1+10 %) V AC Line frequency 48 ... 62 Hz Mains power consumption (400 V AC) 36 A 95 A Minimum power cable section ·1·...
Page 54: Power Diagram
  Power supplies Power diagram 25 kW 20 kW 950 W ER+TH-18/1100 ER+TH-18/1000+FAN 2.0 kW Power ER+TH-18/1500+FAN 3.0 kW ER+TH-18/2000+FAN 4.0 kW Internal Ballast 520 W To dissipate more than 520 W, connect one of the external resistors indicated on the graphics depending on the power to be dissipated.
Page 55: Block Diagram
  Power supplies Block diagram F. H2/16 Regenerative power supplies, XPS-XX. Block diagram. HARDWARE Ref.1912 · 55 ·...
Page 56   Power supplies Connector description The regenerative power supply XPS-25 has the following connectors: CAUTION. AC touch current greater than 3.5 mA. Install ground wire of at least 10 mm² (Cu) or 16 mm² (Al). Ri Re L+ Ri Re L+ F.
Page 57   Power supplies Lights indicating the status of the main power supply The regenerative power supply XPS-25 has the following lights on the front panel to indicate the status of the main power supply:  FAULT BLINKING. The blinking red led indicates that there are no errors and that one or several mains phases are missing.
Page 58   Power supplies The regenerative power supply XPS-65 has the following connectors: CAUTION. AC touch current greater 3.5 mA. Install ground wire of at least 10 mm² (Cu) or 16 mm² (Al). Ri Re L+ F. H2/18 Regenerative power supply, XPS-65. Connectors. Power connector for the three-phase mains.
Page 59   Power supplies Lights indicating the status of the main power supply The regenerative power supply XPS-65 has the following lights on the front panel to indicate the status of the main power supply:  FAULT BLINKING. The blinking red led indicates that there are no errors and that one or several mains phases are missing.
Page 60: Power Connectors
  Power supplies Power connectors Terminal strip for mains connection When connecting the power supplies to mains, the phases may be connected in any order. Fr om ma i ns N ote. R S T, cl assi c nomencl atur e L1 L2 L3 L 1 L 2 L 3, cur r ent nomencl atur e (R) (S) (T)
Page 61   Power supplies Terminal strip to connect the Ballast resistor Regenerative power supplies also have a small Ballast circuit for dissipating energy in case of an emergency. This emergency is issued when there is no connection to mains and the Ballast circuit activating voltage is exceeded. See table T.
Page 62 2.3 and 2.8 N·m. This point is very important to ensure good electrical contact between modules. FAGOR power supplies have a soft-start for charging the power bus. The soft start begins when these two conditions, that are necessary and sufficient, are met: ...
Page 63 This inductive device is a must to limit the current circulating from the power bus to mains. FAGOR supplies the choke XPS-25 and choke XPS-65-A for this application. Use cables with the maximum section allowed 16 and 50 mm² y and shorter than 2 meters (6 feet).
Page 64: Error Reset
  Power supplies Other connectors X1 connector The communication between all the modules that make up the DDS system is established through connector X1. F. H2/23 Connection of the internal bus between modules through connector X1. A ribbon cable is provided with each module (power supply or drive) for this connection.
Page 65   Power supplies The next table shows the signals and other considerations related to each pin of connector X2: T. H2/20 Connector X2. Description of the pins. System error RESET input Error RESET (24 V DC; 4.5-7 mA). N. C. Not Connected 0 volts reference for digital inputs.
Page 66   Power supplies The gap and tightening torque and sections of the screws of the plug-in connectors for X3 and X4/X5/X6 are given by the table: T. H2/21 Plug-in connector for X3. Technical data. Connector data XPS-25 XPS-65 Nr of poles Gap (mm) 7.62 7.62...
Page 67   Power supplies Module power-up 1. For the XPS-25 and XPS-65 power supplies Apply power to the Auxiliary Power Supply from mains through pins 2 and 3 of connector X3; These will power the control circuits of the power supply and provide 24 V DC at connectors X4, X5 and X6.
Page 68   Power supplies 2.3 Regenerative regulated power supplies When referring to regenerative regulated power supplies (step-up or boost power supplies in RPS mode), we use models RPS-80, RPS-75, RPS-45 and RPS-20. These also offer an unregulated RB6 mode that lower the heat, stress, noise and disturbances generated in the system and, particularly, on the motors.
Page 69   Power supplies Note prior to installation Before installing an RPS power supply when using NON-FAGOR motors, remember that: MANDATORY. Any element that will be part of the drive-motor system powered by an RPS must meet the isolation requirements described in EN 61800-5-1.
Page 70   Power supplies RPS modules Technical data T. H2/23 Technical characteristics. RPS-80 RPS-75 RPS-45 RPS-20 Line voltage 3-ph, from 400 (1-10 %) V AC to 460 (1+10 %) V AC Line frequency 48 ... 62 Hz Rated mains power active consumption 81 kW 76 kW 46 kW...
Page 71   Power supplies Derating depending on ambient temperature The following graph shows the maximum rms current in continuous S1 (Pn) and intermittent S6-40% (Pmax) duty cycles for a switching frequency of the power transistors of 8 kHz in a temperature range between 5°C/41°F and 60°C/140°F.
Page 72   Power supplies RPS-45. Power derating graph T. H2/27 Power derating on RPS-45 power supply (8 kHz). Tª ambient (power in S1) (power in S6-40%) in RPS mode in RPS mode in RB6 mode °C °F 45.4 59.0 55.0 45.4 59.0 55.0...
Page 73: Operating Cycles
  Power supplies Operating cycles Load cycle S1 Continuous duty. Operation with constant load and long enough to achieve thermal balance. F. H2/31 Load cycle S1. Load cycle S6-40% Periodic uninterrupted duty cycle with intermittent load. Succession of identical duty cycles, each with a running period under constant load and another period without load.
Page 74: Block Diagram
  Power supplies Block diagram F. H2/34 Regenerative regulated power supplies, RPS-XX. Block diagram. HARDWARE Ref.1912 · 74 ·...
Page 75   Power supplies Connector description The following figure shows the regenerative regulated power supply RPS-80 and its connector layout: L1 L2 L3 view CAUTION. AC touch current greater than 3.5 mA. Install ground wire of at least 10 mm² (Cu) or 16 mm²...
Page 76   Power supplies The following figure shows the regenerative regulated power supply RPS-75 and its connector layout: L1 L2 L3 view CAUTION. AC touch current greater than 3.5 mA. Install ground wire of at least 10 mm² (Cu) or 16 mm²...
Page 77   Power supplies The following figure shows the regenerative regulated power supply RPS-45 and its connector layout: top view L1 L2 L3 CAUTION. AC touch current greater than 3.5 mA. Install ground wire of at least 10 mm² (Cu) or 16 mm² (Al). F.
Page 78   Power supplies The following figure shows the regenerative regulated power supply RPS-20 and its connector layout: view L1 L2 L3 L1 L2 L3 CAUTION. AC touch current greater than 3.5 mA. Install ground wire of at least 10 mm²...
Page 79   Power supplies Lights indicating the status of the main power supply All the RPS regenerative regulated power supplies has the following lights on the front panel to indicate the status of the main power supply:  FAULT BLINKING. Blinking red LED. It indicates that the system is ready waiting for mains to be connected.
Page 80: Chapter 14. Error Codes And Messages
  Power supplies Other elements Besides the various connectors, the front panel of these power supplies has other elements that are mentioned next. Status display The 7-segment status display shows the system start-up sequence as well as the possible errors and warnings that could come up. For further detail, STATUS see the section «turning the module on»...
Page 81   Power supplies 2. RPS operating mode. Boost to 625 V DC. The value of the bus voltage 625 VDC will be 625 V DC approx.   line Select this configuration if 420 V AC 400 V AC. If the features required by the system are not met, choose another switch configuration to obtain a higher bus voltage.
Page 82   Power supplies Power connectors Terminal strip for mains connection This connector may be used to connect the power supply to mains. When connecting the power suppliy to mains, the phases may be connected in any order L1-L2-L3, L1-L3-L2, L3-L1-L2, etc. From mains PE L1 L2 The L1-L2-L3 phases may be connected...
Page 83 Connection to an external Ballast resistor Ref.1912 RPS power supplies do not carry a Ballast circuit and, consequently, FAGOR does not have external braking resistors (Ballast) associated with them. In applications requiring a Ballast circuit, one off-the-shelf will have to be installed.
Page 84 2.3 and 2.8 N·m. This point is very important to ensure good electrical contact between modules. FAGOR power supplies have a soft-start for charging the power DC BUS. The soft start begins when these two conditions, that are necessary and sufficient, are met: ...
Page 85   Power supplies WARNING. Never install an APS-24 to the DC bus of a DDS system with a regenerative power supply RPS if the model of the APS-24 is PF 23A or older. Observe the PF version on the versions label. Depending on this version, it will be possible to connect the APS-24 or not to the DC BUS of the DDS system with RPS regenerative power supplies.
Page 86 Installing a choke with an inductance other than the one recommended for a choke may cause severe damage to the unit. FAGOR supplies the right CHOKE RPS for this application. See the relevant cable section in table T. H2/23. Note that the cable must be shielded.
Page 87: Connector Data
  Power supplies Other connectors X1|X2 connectors These connectors belong to the auxiliary power supply integrated into the main RPS power supply. This auxiliary power supply is fed through connector X1. This electrical power is received from the three-phase line to the power supply connected to a point before the power connection operation ·before - KM1 power contactor...
Page 88   Power supplies The following table shows the values for gap, tightening torque, sections of the screws and other data of the plug-in connector for X2. T. H2/33 Plug-in connector for X2. Technical data. Connector data RPS-80 | RPS-75 | RPS-45 | RPS-20 Nr of poles Gap (mm) 5.00...
Page 89   Power supplies NOTE. It is important to know that if NS1 (pin 3 de X3) and NS2 (pin 4 de X3) are not short-circuited by the user, the main internal contactor «LINE CONTACT» will stay open. The power supply will start up, but the DC BUS will not charge and, therefore, the axes cannot move.
Page 90   Power supplies A 1.25 A fuse protects the internal circuits. NOTE. Remember that the internal circuits of PS-65A non-regenerative power supplies must be powered by an auxiliary 24 V DC power supply, “APS-24”; that's why its control connector has three terminals more than connector X6 of the RPS.
Page 91   Power supplies Module power-up When turning on the RPS power supply module or doing a reset, various messages appear on its seven-segment display:  Software version, after the r with the identifying digits.  Error listing. Stages shown on the 7-segment display: PHASE 1 PHASE 2 F.
Page 92   Power supplies 1. For RPS power supplies Apply power to the auxiliary power supply and close the main internal contactor - short-circuit NS1 and NS2 (pins 3 and 4) of connector X3 -. 2. The power supply checks the system status If the status is correct The System OK contact closes (pins 6 and 7 of X6) and it stays closed while the control circuits are powered and no error comes up in any of the...
Page 93: Operating Modes
  Power supplies Operating modes Status diagram STATE 0 WITHOUT POWER STATE 1 LOADING DC BUS STATE 2 RPS MODE (BOOST) or RB6 MODE (RECTIFIER) STATE 3 GENERATOR MODE STATE 4 EMERGENCY STOP F. H2/51 RPS power supplies. Running state diagram. Running states Description of the possible running states: Status Meaning...
Page 94   Power supplies NOTE. When detecting an error, it will switch from any state 0, 1, 2 or 3 directly to state 4. From any of the states, it will switch to state 0 if a stop occurs due to the NO READY state of any of the drives connected to the power supply or because the power line has been disconnected or because the emergency stop button has been pressed or because the line voltage has dropped.
Page 95 D R I V E S The AXD/SPD and ACD/SCD drives that make up FAGOR's DDS system are modular and stackable. They are connected directly to three-phase mains with a line voltage between 400 (1-10 %) V AC and 460 (1+10 %) V AC at a line frequency between 48 ...
Page 96 2.5A(F) 2.5A(F) 2.5A(F) 2.5A(F) 2.5A(F) F. H3/1 Size-1 modular drives of the FAGOR catalog. A. AXD|SPD 1.08|1.15, B. AXD|SPD 1.25, C. AXD|SPD 1.35, D. MMC 1.08|1.15, E. MMC 1.25, F. MMC 1.35. U V W U V W STATUS STATUS...
Page 97 (250V) (250V) 2.5A(F) 2.5A(F) DANGER DANGER HIGH VOLTAGE HIGH VOLTAGE DISCHARGE TIME>4Min DISCHARGE TIME>4Min HARDWARE F. H3/3 Ref.1912 Size-3 modular drives of the FAGOR catalog. A. AXD|SPD 3.100|3.150, B. SPD 3.200|3.250, C. MMC 3.100|3.150, D. MMC 3.200. · 97 ·...
Page 98   Drives Technical data There are specific modular drives AXD/MMC to control synchronous motors (both for feed axis and spindle applications) and SPD to control asynchronous motors (in spindle applications). This chapter is common to both models because their external characteristics (dimensions, connectors, ...) are the same.
Page 99   Drives T. H3/5 Modular drives. Technical data. AXD|SPD|MMC 1.08 1.15 1.25 1.35 2.50 2.75 2.85 3.100 3.200 3.150 3.250 Power voltage input 542/800 V DC Power to control circuits 24 V DC (between 21 V DC and 28 V DC) Consumption of the control 0.90 A 1.25 A...
Page 100: Load Duty Cycles
  Drives Load duty cycles Load cycle S1 Continuous duty. Operation with constant load and long enough to achieve thermal balance. F. H3/4 Load cycle S1. Load cycle S3-5% Periodic intermittent duty. Succession of identical duty cycles each having a period at constant maximum load and a period at constant rated load.
Page 101   Drives Derating curves Drive for an synchronous motor working as an axis The following graphs show the maximum rms current in continuous S1 (l and intermittent S3-5% (Imax.) duty cycles depending on the switching frequency of the power transistors in a temperature range between 5°C/41°F and 60°C/140°F.
Page 102   Drives I (A rm s ) Im a x AXD|MMC 2.50 T ambient Imax. ° C ° F 25.0 50.0 104 25.0 50.0 25.0 50.0 122 22.2 44.4 T a m b ie n t 131 19.3 38.6 °...
Page 103   Drives  For a switching frequency fc = 8 kHz AXD|MMC 1.08 T ambient Imax. I (Arms) Imax ° C ° F Tambient °C (°F) (95) (104) (113) (122) (131) (140) F. H3/16 Current derating on ·AXD|MMC 1.08· drives for fc = 8 kHz. AXD|MMC 1.15 T ambient Imax.
Page 104   Drives AXD|MMC 2.75 I (Arms) T ambient Imax. Imax ° C ° F 37.5 75.0 104 37.5 75.0 37.1 74.2 Tambient 122 33.3 66.5 °C (°F) 131 29.3 58.6 140 25.2 50.4 (95) (104) (113) (122) (131) (140) F.
Page 105   Drives Drive for a synchronous/asynchronous motor working as a spindle The following graphs show the maximum rms current in continuous S1 (ln) and intermittent S6-40 ( IS6-40 ) duty cycles depending on the switching frequency of the power transistors in a temperature range between 5°C/41°F and 60°C/140°F.
Page 106   Drives SPD 2.75 I (Arms) T ambient IS6-40 IS6-40 ° C ° F 42.0 54.6 104 42.0 54.6 42.0 54.6 Tambient 122 38.2 49.7 °C (°F) 131 34.3 44.6 140 30.2 39.2 (95) (104) (113) (122) (131) (140) F.
Page 107   Drives SPD 3.250 I (Arms) T ambient IS6-40 ° C ° F IS6-40 95 135.0 175.5 104 135.0 175.5 113 135.0 175.5 Tambient 122 122.7 159.5 °C (°F) 131 109.9 142.9 140 96.4 125.3 (95) (104) (113) (122) (131) (140) F.
Page 108   Drives SPD 2.75 I (Arms) T ambient IS6-40 IS6-40 ° C ° F 32.0 41.6 104 32.0 41.6 32.0 41.6 Tambient 122 28.9 37.7 °C (°F) 131 25.7 33.5 140 22.5 29.2 (95) (104) (113) (122) (131) (140) F.
Page 109: Block Diagram
  Drives SPD 3.250 I (Arms) T ambient IS6-40 ° C ° F 95 108.0 140.4 S6-40 104 108.0 140.4 113 108.0 140.4 Tambient 97.2 126.3 °C (°F) 85.9 111.7 74.3 96.6 (95) (104) (113) (122) (131) (140) F. H3/44 Current derating on ·SPD 3.250·...
Page 110   Drives Connectors Layout AXD|SPD 1.08|1.15 These drives have the following connectors: WARNING. AC touch current greater than 3.5 mA. Install a ground wire with a section of at least 10 mm² (Cu) or 16 mm² (Al). RESET button STATUS DISPLAY DRIVE...
Page 111   Drives AXD|SPD 1.25 These drives have the following connectors: WARNING. AC touch current greater than 3.5 mA. Install a ground wire with a section of at least 10 mm² (Cu) or 16 RESET button mm² (Al). STATUS DISPLAY DRIVE ENABLE BOOT button.
Page 112   Drives AXD|SPD 1.35 These drives have the following connectors: U V W U V W WARNING. AC touch current greater than 3.5 mA. Install a ground wire with a section RESET button of at least 10 mm² (Cu) or 16 mm² (Al). STATUS DISPLAY BOOT button.
Page 113   Drives AXD|SPD 2.50|2.75, SPD 2.85 These drives have the following connectors: U V W U V W WARNING. AC touch current greater than 3.5 mA. Install a ground wire with a RESET button section of at least 10 mm² (Cu) or 16 mm²...
Page 114   Drives AXD|SPD 3.100|3.150 These drives have the following connectors: BOOT button. Software update & SERCOS|CAN transmission speed selection. DRIVE STATUS ENABLE DISPLAY SPEED ENABLE O.K. +24Vdc DRIVE ENABLE SPEED ENABLE O.K. +24Vdc FUSE (250V) 2.5A(F) DANGER HIGH VOLTAGE DISCHARGE TIME>4Min RESET button WARNING.
Page 115   Drives SPD 3.200|3.250 These drives have the following connectors: BOOT button. Software update & SERCOS|CAN transmission speed selection. DRIVE STATUS ENABLE DISPLAY SPEED ENABLE O.K. +24Vdc DRIVE ENABLE SPEED ENABLE O.K. +24Vdc FUSE (250V) 2.5A(F) DANGER HIGH VOLTAGE DISCHARGE TIME>4Min RESET button WARNING.
Page 116   Drives MMC 1.08|1.15 These drives have the following connectors: RESET button WARNING. AC touch current greater than 3.5 mA. Install a ground wire with a section of at least 10 mm² (Cu) or 16 mm² (Al). DRIVE ENABLE BOOT button.
Page 117   Drives MMC 1.25 These drives have the following connectors: RESET button WARNING. AC touch current greater than 3.5 mA. Install a ground wire with a section of at least 10 mm² (Cu) or 16 mm² (Al). BOOT button. STATUS DISPLAY Software update &...
Page 118   Drives MMC 1.35 These drives have the following connectors: U V W U V W RESET button WARNING. AC touch current greater than 3.5 mA. Install a ground wire with a section of at least 10 mm² (Cu) or 16 mm² (Al). BOOT button.
Page 119   Drives MMC 2.50|2.75 These drives have the following connectors: U V W U V W RESET button WARNING. AC touch current greater than 3.5 mA. Install a ground wire with a section of at least 10 mm² (Cu) or 16 mm²...
Page 120   Drives MMC 3.100|3.150 These drives have the following connectors: DRIVE ENABLE SPEED ENABLE O.K. +24Vdc STATUS BOOT button. Software update & DISPLAY SERCOS|CAN transmission speed selection. Possibilities: X5. Serial line RS-232 + (X6.SERCOS or X6.CAN ) or X6. Serial line RS-232/RS-422 ·without X5·...
Page 121   Drives MMC 3.200|3.250 These drives have the following connectors: DRIVE ENABLE SPEED ENABLE O.K. +24Vdc BOOT button. Software update & STATUS DISPLAY SERCOS|CAN transmission speed selection. Possibilities: X5. Serial line RS-232 + (X6.SERCOS or X6.CAN ) or X6. Serial line RS-232/RS-422 ·without X5·...
Page 122: Status Display
  Drives Other elements Besides the various connectors, the front panel of the drive has other elements that are mentioned next. Fuse The fuse on the front panel of each modular drive is a “2.5 A (F)/250 V (fast)” fuse and it is used to protect the internal control circuits.
Page 123   Drives Function Power connector The power connectors located on top of each drive are used to connect the motor. The ground connection of the cable shields in made from the vertical plate next to the connectors. The power bus input is located at the bottom of the modules and under the screwed-on lid.
Page 124   Drives X1 connector This connector may be used to connect the modules to each other through the internal bus communicating the elements of the DDS system with each other. F. H3/58 X1 connector. Internal bus. All the modules powered with the same power supply must be connected to this bus and this condition is must to run it.
Page 125   Drives The following table shows the values for gap, tightening torque, sections and other data of the plug-in connector for X2. T. H3/7 Pins of aerial plug-in connector X2. Technical data. AXD|SPD|MMC 1.XX 2.XX 3.XX Connector data Nr of poles Gap (mm) Min./max.
Page 126   Drives Deactivation of the Speed Enable input When the Speed Enable input is set to 0 V DC, the internal velocity command follows the stop ramp set by parameter and:  Situation 1. The torque is kept active by braking the motor. When it stops, variable SV5 (S00331) is activated.
Page 127: Phase-Shift
  Drives X3 connector This connector of the modular drive offers two possible configurations:  Encoder simulator  Direct feedback X3. Encoder si mul ator Having installed the encoder simulator card, X3 is a high density (HD) 15- pin sub-D type male (M) connector whose pins are galvanically isolated from the rest of the drive.
Page 128   Drives X3. Di r ect feedback Having installed a direct feedback card, X3 is a high density (HD) 15-pin sub- D type female (F) connector. I0/DATA I0/DATA + 485/CLK - 4 8 5 / C L K + 5 V DC + 5 V DC ·SENSOR·...
Page 129   Drives W i t h ex t e r n a l a b s o l u t e f e e d b a c k d ev i c e I0/DATA I0/DATA + 485/CLK - 4 8 5 / C L K + 5 V DC + 5 V DC ·SENSOR·...
Page 130 B. If not, it will have a CAPMOTOR-1. The feedback of FAGOR motors use sinusoidal encoder, incremental TTL encoder or resolver. Refer to the corresponding motor manual for the detailed description of the pinout of the feedback devices that can go with each motor family.
Page 131: Not Connected
  Drives X5 connector X5. RS-232 serial li ne This connector of the RS-232 serial line board that may be included in a modular drive is a 9-pin male sub-D connector for RS-232 serial connection to a PC in order to set the module configuration parameters and to adjust it.
Page 132   Drives X6 connector This connector of the modular drive identified as X6 may be:  A SERCOS-II interface connector  A CAN interface connector.  An RS-232/422 serial line connector ·only on MMC drives·. X6. SERCOS-II This connector consists of a SERCOS-II signal receiver and emitter (IN, OUT) and may be used to connect the modules of the DDS system with the CNC that governs them.
Page 133   Drives The description of the pinout of this connector is: T. H3/10 Pinout of connector X6 (CAN interface). Description. 1 GNDa N.C. (Not Connected) 2 CANL CAN L bus line 3 SHIELD Overall shield 4 CANH CAN H bus line 5 SHIELD N.C.
Page 134: Connector Data
  Drives X7 connector X7. Status of the safety r elay This connector X7 of the modular drive is associated with the second contact (N.C., Normally Closed) of an internal safety relay (with guided contacts). The status of the relay (initially closed) may be acknowledged through the two pins and a CNC, PLC or control panel, i.e.
Page 135   Drives Connectors at slots SL1/SL2 Car d A1 The A1 card must always be in slot SL1. X6- DI GI TAL I /Os, digi tal inputs and outputs If offers 4 digital inputs and 4 digital outputs, all of them fully programmable. The digital inputs are optocoupled and referred to a common point (pin 5).
Page 136   Drives X7- ANALOG I/ Os, digi tal inputs and outputs It offers 2 inputs and 2 outputs, all of them fully programmable. Each input and output is associated with a parameter. See “man_dds_soft.pdf” manual. It offers a ± 15 V power supply for generating a command easily. A 1 B oar d CHA S S IS ANALOG INPUT 2 -...
Page 137   Drives Dip-switches · DS1|DS2 · F. H3/77 Factory settings of the dip-switches ·DS1|DS2·. MANDATORY. The status of the dip-switches DS1|DS2 must not be changed by the operator. Adjustment outputs With these outputs and a potentiometer, the user can obtain a variable analog voltage for adjusting the Power Drive System during setup.
Page 138   Drives A n a l o g o u t p u t s Associated with pins 8-9 and 10-11. These outputs provide an analog voltage indicating the status of the internal system variables. They are especially designed as permanent monitoring of these internal variables and also to be connected to an oscilloscope to make it easier to set the system up.
Page 139   Drives X9-DIG.OUTs, X10- DIG.OUTs, X13-DIG. OUTs, digi tal outputs They offer 8 fully programmable digital outputs. These outputs are optocoupled and of the contact type referred to a common point (pin 1). Each output is associated with a PLC resource. 8 DI- 1 6 DO B oar d 1 6 DI- 8 DO B oar d Phoenix,...
Page 140 ACD/SCD... ACD/SCD... ACD/SCD...- L ACD/SCD...- L F. H3/82 ACD/SCD... and ACD/SCD...- L compact drives of the FAGOR catalog. A. ACD|SCD 1.08|1.15, B. ACD|SCD 1.25, C. ACD|SCD 2.35|2.50, SCD 2.75. HARDWARE Ref.1912 F. H3/83 CMC compact drives of the FAGOR catalog.
Page 141: Technical Data
  Drives Technical data T. H3/14 Current in compact drives for synchronous motors. fc = 4 kHz. With internal fan Drive for synchronous motor (as axis) ACD|CMC ACD|CMC ACD|CMC ACD|CMC ACD|CMC Currents at 1.08 1.15 1.25 2.35 2.50 fc = 4 kHz (A) Rated current (A) 12.5 17.5...
Page 142   Drives The following table shows other electrical, mechanical and ambient conditions: T. H3/18 Compact drives ACD/SCD at 400/460 V AC. Technical data. ACD|CMC 1.08 1.15 1.25 2.35 2.50 1.15 1.25 2.35 2.50 2.75 Line voltage 3-ph. from 400 (1-10 %) V AC to 460 V AC (1+10 %) V AC Line frequency 48 ...
Page 143   Drives T. H3/19 Compact drives ACD/SCD... - L at 200/240 V AC. Technical data. ACD... - L SCD... - L 1.08 1.15 1.25 2.35 2.50 1.15 1.25 2.35 2.50 2.75 Line voltage 3-ph. from 200 (1-10 %) V AC to 240 V AC (1+10 %) V AC Line frequency 48 ...
Page 144   Drives Load duty cycles Load cycle S1 Continuous duty. Operation with constant load and long enough to achieve thermal balance. F. H3/84 Load cycle S1. Load cycle S3-5% Periodic intermittent duty. Succession of identical duty cycles each having a period at constant maximum load and a period at constant rated load.
Page 145   Drives Definition of currents On axes  I “Continuous duty cycle” current.   Ip Peak current, Imax.  See load duty cycles. On spindles  I “Continuous duty cycle” current.   I Current that, in an intermittent duty cycle S6 with 10 minute S6-40% ...
Page 146   Drives Derating depending on ambient temperature Drive for an synchronous motor working as an axis The following graphs show the maximum rms current in continuous duty cycle (that is, the rated one) depending on the switching frequency of the power transistors that the drives for synchronous motors can supply in a temperature range between 5°C/41°F and 60°C/140°F.
Page 147   Drives ACD|CMC 2.50 T ambient I (Arms) ° C ° F 25.0 104 25.0 25.0 Tambient °C (°F) 122 23.8 131 22.1 (95) (104) (113) (122) (131) (140) 140 20.2 F. H3/91 Current derating on ·ACD|CMC 2.50· drives for fc = 4 kHz. ...
Page 148   Drives ACD|CMC 2.50 T ambient I (Arms) ° C ° F 20.0 104 20.0 Tambient 20.0 °C (°F) 122 19.1 131 17.8 (95) (104) (113) (122) (131) (140) 140 16.4 F. H3/96 Current derating on ·ACD|CMC 2.50· drives for fc = 8 kHz. Drive for a synchronous|asynchronous motor working as a spindle The following graphs show the maximum rms current in continuous duty cycle (that is, the rated one) depending on the switching frequency of the...
Page 149   Drives SCD 2.50 T ambient Imax. I (Arms) Imax ° C ° F 38.0 38.0 38.0 Tambient 36.3 °C (°F) 34.3 32.2 (95) (104) (113) (122) (131) (140) F. H3/100 Current derating on ·SCD 2.50· drives for fc = 4 kHz. SCD 2.75 I (Arms) Imax...
Page 150   Drives SCD 2.50 T ambient Imax. ° C ° F I (Arms) 27.0 Imax 27.0 27.0 Tambient 26.3 °C (°F) 24.7 23.1 (95) (104) (113) (122) (131) (140) F. H3/105 Current derating on ·SCD 2.50· drives for fc = 8 kHz. SCD 2.75 I (Arms) T ambient...
Page 151   Drives Connectors Layout ACD|SCD 1.08/1.15 These drives have the following connectors: top view RESET button WARNING. AC touch current greater than 3.5 mA. Install a ground wire with a section of at least 10 mm² (Cu) or 16 mm² (Al). BOOT button.
Page 152   Drives ACD|SCD 1.25 These drives have the following connectors: top view RESET button WARNING. AC touch current greater than 3.5 mA. Install a ground wire with a section of at least 10 mm² (Cu) or 16 mm² (Al). BOOT button.
Page 153   Drives ACD|SCD 2.35|2.50, SCD 2.75 These drives have the following connectors: External Ballast resistor RESET button top view WARNING. AC touch current greater than 3.5 mA. Install a ground wire with a section of at least 10 mm² (Cu) or 16 mm² (Al). BOOT button.
Page 154   Drives CMC 1.08|1.15 These drives have the following connectors: top view RESET button WARNING. AC touch current greater than 3.5 mA. Install a ground wire with a section of at least 10 mm² (Cu) or 16 mm² (Al). Possibilities: X5.
Page 155   Drives CMC 1.25 These drives have the following connectors: RESET button top view WARNING. AC touch current greater than 3.5 mA. Install a ground wire with a section of at least 10 mm² (Cu) or 16 mm² (Al). Possibilities: X5.
Page 156   Drives CMC 2.35/2.50 These drives have the following connectors: External Ballast resistor top view RESET button WARNING. AC touch current greater than 3.5 mA. Install a ground wire with a section of at least 10 mm² (Cu) or 16 mm² (Al). Possibilities: X5.
Page 157   Drives Other elements Besides the various connectors, the front panel of the drive has other elements that are mentioned next. Status display The status display shows the information on the drive status or the STATUS DISPLAY corresponding code when an error or warning occurs. See section 3.3. Turning a drive on at the end of this chapter.
Page 158   Drives Function of the connectors Power connector The power connector on top of each drive are used to connect the drive to mains (R, S and T) and to the motor (U, V and W). The ground connection of the cable shields in made from the vertical plate next to the connectors.
Page 159: Connector Data
  Drives Ballast connector The Ballast connector located at the bottom of each compact drive allows enabling the braking resistor (Ballast resistor) and accessing the power DC BUS (L+, L-). The following table shows the values for gap, tightening torque (wire entry holes) and other data regarding the screw-on terminals and plug-in terminals of the ballast connectors according to drive model: T.
Page 160   Drives X1 connector Compact drives internally generate the 24 V DC necessary for the internal circuits. In regular operation, this voltage is obtained from the power bus and from line voltage of the mains when starting up the system. It is a three-pin connector used to supply from mains the necessary start-up energy.
Page 161   Drives X2 connector 10-pin connector of the compact drive and integrates the functions of the power supply and the modular drive. +24 V DC 0 V DC ERROR RESET DRIVE ENABLE SPEED ENABLE DRIVE OK PROG. OUT OP5 · F01411 · F.
Page 162: Other Functions
  Drives Other functions The “Prog. Out” contact (pins 8 and 9) is a user programmable output by means of an internal parameter of the drive. See parameter OP5 in chapter 13 of the “man_dds_soft.pdf” manual. The description of the pins of this connector is: T.
Page 163   Drives  Situation 2 The torque is kept active by braking the motor. When it stops, variable SV5 (S00331) is activated. The motor does not stop in a time period set by parameter GP3 (F00702). The motor stops when its kinetic energy runs out.
Page 164   Drives X3 connector This connector of the compact drive offers two possible configurations:  Encoder simulator  Direct feedback X3. Encoder simul ator Having installed the encoder simulator card, X3 is a high density (HD) 15- pin sub-D type male (M) connector whose pins are galvanically isolated from the rest of the drive.
Page 165   Drives X3. Dir ect feedback Having installed a direct feedback card, X3 is a high density (HD) 15-pin sub- D type female (F) connector. I0/DATA I0/DATA + 485/CLK - 4 8 5 / C L K + 5 V DC + 5 V DC ·SENSOR·...
Page 166   Drives W i th exter nal absolute feedback device I0/DATA I0/DATA + 485/CLK - 4 8 5 / C L K + 5 V DC + 5 V DC ·SENSOR· ·SENSOR· N. C. + 8 V DC CHASSIS F.
Page 167 B. If not, it will have a CAPMOTOR-1. The feedback of FAGOR motors use sinusoidal encoder, incremental TTL encoder or resolver. Refer to the corresponding motor manual for the detailed description of the pinout of the feedback devices that can go with each motor family.
Page 168   Drives X5 connector X 5 . R S - 2 3 2 s e r i a l l i n e Connector for the RS-232 serial line board that may come on compact drives. It is a 9-pin male sub-D connector for RS-232 serial connection to a PC in order to set the module configuration parameters and to adjust it.
Page 169   Drives X6 connector This connector of the compact drive identified as X6 may be:  A SERCOS-II interface connector.  A CAN interface connector.  An RS-232/422 serial line connector (only on CMC drives). X6. SERCOS- II This connector consists of a SERCOS-II signal receiver and emitter (IN, OUT) and may be used to connect the modules of the DDS system with the CNC that governs them.
Page 170   Drives The description of the pinout of this connector is: T. H3/27 Pinout of connector X6 (CAN interface). Description. 1 GNDa Not Connected 2 CANL CAN L bus line 3 SHIELD Overall shield 4 CANH CAN H bus line 5 SHIELD Not Connected INFORMATION.
Page 171   Drives X7 connector X7. Status of the safety r elay Connector of the compact drive associated with the second contact (N.C., Normally Closed) of an internal safety relay (with guided contacts). The status of the relay (initially closed) may be acknowledged through the two pins and a CNC, PLC or control panel, i.e.
Page 172   Drives Connectors at slots SL1/SL2 Car d A1 The A1 card must always be in slot SL1. X6- DIGITAL I/O, di gital i nputs and outputs If offers 4 digital inputs and 4 digital outputs, all of them fully programmable. The digital inputs are optocoupled and referred to a common point (pin 5).
Page 173   Drives X7-ANALOG I/O, digital inputs and outputs It offers 2 inputs and 2 outputs , all of them fully programmable. Each input and output is associated with a parameter. See “man_dds_soft.pdf” manual. It offers a ±15 V DC power supply for generating a command easily. A 1 B oar d CHAS S IS ANALOG INPUT 2 -...
Page 174   Drives Dip-switches · DS1|DS2 · F. H3/132 Factory settings of the dip-switches · DS1|DS2 ·. MANDATORY. The operator must not change the state of the dip-switches ·DS1, DS2· located on the left when looking at the front of the unit. Adj ustment outputs With these outputs and a potentiometer, the user can obtain a variable analog voltage for adjusting the Power Drive System during setup.
Page 175: Analog Outputs
  Drives Analog outputs Associated with pins 8-9 and 10-11. These outputs provide an analog voltage indicating the status of the internal system variables. They are especially designed as permanent monitoring of these internal variables and also to be connected to an oscilloscope to make it easier to set the system up.
Page 176   Drives X9- DIG. OUTs, X10- DIG. OUTs, X13-DIG. OUT, di gital outputs They offer 8 fully programmable digital outputs. These outputs are optocoupled and of the contact type referred to a common point (pin 1) . Each output is associated with a PLC resource. 8 DI- 1 6 DO B oar d 1 6 DI- 8 DO B oar d Phoenix,...
Page 177   Drives 3.3 Turning a drive on When powering up the DDS module or doing a reset, various messages appear on the seven - segment display: 1. Initialization stages: they show values of 1, 2, 3 and 4. 2. Software version, after the r with the identifying digits. 3.
Page 178   Drives 3. Final stages: They display error messages or warnings on the display when they come up. When the series ends, it begins a new sequence again repeating these messages again. F. H3/140 Final stages. Error and warning displaying STAGES. See the meaning of errors codes and warnings that may be shown on the display of the drive in chapter 14.
Page 179   Drives HARDWARE Ref.1912 · 179 ·...
Page 180   Drives HARDWARE Ref.1912 · 180 ·...
Page 181: Auxiliary Modules
AUXILIARY MODULES Besides the power supplies and the drives that make up the FAGOR DDS system, there is a set of auxiliary modules that are also part of the system and are used to perform a specific function. Hence, we refer to: ...
Page 182 IEC 61800-3 for category C3 and the standard IEC 61800-5-2 for immunity. The mains filters of the FAGOR catalog are referred to as MAIN FILTER. They are installed between mains and the DDS system (modular or compact) in order to reduce conducted disturbances caused by the drive...
Page 183   Auxiliary modules Select the mains filter to be installed according to the power supply or compact drive as per the attached table. T. H4/3 Mains filter according to the power supply or compact drive insta- lled. Module Mains filter XPS-25, RPS-20 MAIN FILTER 42A-A PS-25B4...
Page 184 The internal switching mechanism of these power supplies generates a regenerative current to mains already filtered by this choke. FAGOR provides the XPS-25 and XPS-65-A chokes that must necessarily go with the corresponding XPS power supplies and the RPS-75-3, RPS-45 and RPS-20 chokes that must go with RPS power supplies.
Page 185: Technical Data
  Auxiliary modules MANDATORY. The use of these chokes is a must for the proper operation of the XPS regenerative power supplies. The length of the cable joining the choke with the power supply must never exceed 2 meters. Chapter 6.
Page 186   Auxiliary modules 4.3 External Ballast resistors NOTE. This manual uses two synonyms “EXTERNAL BALLAST RESISTORS” and “CROWBAR RESISTORS” to refer to external braking resistors. External resistors are used to dissipate the excess of energy generated at the power bus in a braking process of electrical motors and cannot be dissipated by the internal resistor of the module (power supply or compact drive).
Page 187   Auxiliary modules T. H4/7 External Ballast resistor with internal thermostat. Technical data. With internal thermostat ER+TH-18/1800 ER+TH-18/2200 18  18  Resistor Tolerance ±5 % ±5 % RMS power 1.3 kW 2.0 kW Energy absorbed in 5" 55 kJ 83 kJ overloaded Operating room temperature...
Page 188 Thermostats associated with external resistors Outside look F. H4/6 External thermostat. Outside look. Technical data All external Ballast resistors currently available in the FAGOR catalog come with a thermostat. They are classified as: Thermostat Model of the external Ballast resistor...
Page 189 3 of this manual. ACD/CMC/SCD compact units without NR model have a particular resistor associated with them; FAGOR supplies it in an accessory bag inside the unit package and the user must install it. This is not the case for units with NR model for which the user must select the appropriate resistor model depending on the energy to be dissipated in the application.
Page 190 3.0 kW ER+TH-18/1500+FAN * 18  SCD 2.75...NR 4.0 kW ER+TH-18/2000+FAN * FAGOR supplies the resistors indicated with an asterisk (see shaded rows) as accessories with the unit. The rest of them are supplied only upon request. HARDWARE Ref.1912 · 190 ·...
Page 191: Capacitor Module
From the energy point of view, installing a capacitor module is more efficient than installing external braking resistors. Outside look Module that must be connected in parallel to the power DC BUS. FAGOR supplies with each module two plates for connecting them to the DC BUS. F. H4/7 Capacitor module, CM-1.75.
Page 192   Auxiliary modules 4.5 Auxiliary power supply. APS-24 The main purpose of the auxiliary power supply module APS-24 is to generate +24 V DC for the control circuits of the drives and of the power supplies that do not integrate the auxiliary power supply (i.e. PS-65A). This voltage is supplied through three identical connectors (X2, X3 &...
Page 193   Auxiliary modules NOTE. See chapter 1 3. COMPATIBI LI TY for the models of the compatible APS-24 auxiliary power supplies with the XPS|RPS power supplies in case it is installed. INFORMATION. In case of micro-surges or total mains power outage, this module guarantees the stability of the 24 V DC to feed the control circuits of the drives connected to the bus and maintain it for as long as the emergency stop of the motors lasts, thus stopping the axes in a controlled manner.
Page 194   Auxiliary modules Connectors The APS-24 auxiliary power supply has the following connectors: CHASSIS +24Vdc. CHASSIS +24Vdc. CHASSIS +24Vdc. CHASSIS Imax total = 10 A Pmax total = 240 W Note. The maximum current of 10 A is the total current that the power supply can provide as the sum of all the currents that may be supplied through the three 24 V DC connectors;...
Page 195: Other Considerations
  Auxiliary modules Status indicator lamps The auxiliary power supply APS-24 has the following indicator lights that inform about its running status.  OVER VOLTAGE. Red LED. Output over voltage. It has exceeded 28 V RESET DC and interrupts its operation. OVER VOLTAGE ...
Page 196   Auxiliary modules 4.6 Bus protection module. BPM Install in DDS systems having: Synchronous spindle and only when required by the application. Purpose. Protect the power semi-conductors (IGBTs) of the drive that governs it, thus preventing damage to the unit due to a very high voltage that may be generated at the power bus because the braking energy cannot be returned when a voltage drop occurs.
Page 197   Auxiliary modules T. H4/13 Bus Protection Module, BPM. Technical data. Maximum altitude 2 000 m (6 561 ft) above sea level Operating vibration Shipping vibration 1.5 g Sealing IP 2x Chapter 11. DIMENSIONS of this manual shows their dimensions. Block diagram DRIVER INTERMEDIATE...
Page 198   Auxiliary modules FAGOR supplies the aerial connector in the accessory bag. The values for pitch, tightening torque, pole section (input holes of the connector) and other data regarding the terminals of this connectors are shown in the following table.
Page 199   Auxiliary modules FAGOR supplies the aerial connector in the accessory bag. The values for pitch, tightening torque, pole section (input holes of the connector) and other data regarding the terminals of this connectors are shown in the following table.
Page 200   Auxiliary modules HARDWARE Ref.1912 · 200 ·...
Page 201 SELECTING CRITERIA 5.1 Selection of the synchronous motor and its associated drive First motor pre-selection F. H5/1 General diagram of a motor-leadscrew-table system. The motor selection will depend on the mechanical and dynamic response characteristics that it must satisfy. Hence, the motor must meet the specifications on torque (N·m), speed, duty cycles or other kind of requirements of the motor to be moved.
Page 202 --------------- - HARDWARE is the maximum linear speed the table needs. Select in the characteristics table of FAGOR synchronous motors (see “AC synchronous servo motors” manual. FXM/FKM families) a motor having: Ref.1912 • A stall torque equal to or greater than the calculated continuous torque Ms.
Page 203   Selection criteria Second motor pre-selection Calculation of inertia, J The next step is to calculate the load that the motor has to move when accelerating; that is the moment of inertia of all the elements it moves. Total inertia (from now on inertia is due to the load J and to the...
Page 204   Selection criteria Third motor pre-selection Calculation of the acceleration torque and time The required acceleration torque is determined by the total inertia to be moved and the needed acceleration. The required acceleration is determined by the acceleration time t which is the time estimated for the motor to reach its rated speed from zero rpm.
Page 205: Drive Selection
  Selection criteria Verify that the motor chosen in previous selections meets the following condition: Peak torque equal to or greater than the calculated max. torque: M PEAK  M MAX Rated torque equal to or greater than the calculated RMS value: ...
Page 206   Selection criteria 5.2 Asynchronous spindle motor and drive selection On the spindles of machine tools, it is important to maintain a constant turning speed of the spindle. To control this speed, the drive applies torque to the load according to the characteristics of this load as well as to the adjusted accelerations and decelerations.
Page 207   Selection criteria For lathe work, a cutting blade forces against the part to be machined, while this is turning. See figure F. H5/3 The power required, Pc is calculated as follows: ·d·N (m/min) 1000 ·d·L·v d·L·v (kW) · 60·1000·...
Page 208   Selection criteria In the case of a drill, the bit is mounted on the spindle itself and turns with this to drill the material. See figure F. H5/5 The power required in this case Pd may be calculated with the following formula: ·D²·f M·...
Page 209   Selection criteria The power required in this case P is calculated as follows: S p e e d L o a d ·m ·V (kW) M o t o r 6120· F. H5/7 Frictional load. Required power.  µ...
Page 210    Selection criteria  Limited acceleration and choke. Choke = (acceleration /  t). speed adjust time F. H5/10 Acceleration and choke limit. T. H5/4 Acceleration and choke limit. Method Acceleration and choke limit. Control Progressive linear acceleration, avoiding abrupt variations of transmitted torque.
Page 211    Selection criteria Calculation of acceleration and braking time After selecting the mechanical characteristics and the power of the drive, the acceleration and braking time is calculated as follows: Constant torque 2 J   ------------------------------ - s   area: ...
Page 212: Power Supply Selection
   Selection criteria 5.3 Power supply selection Calculation of the power required from the power supply by the synchronous servo motors Initially, considering the mechanical power provided by the motors: T. H5/5 Power supply selection depending on the Pa mechanical power output of the motor. SYNCHRONOUS FXM/FKM n : Max.
Page 213    Selection criteria Then, considering the peak power (S3-5% cycle) that some motors may request sometime: T. H5/6 Selection of the power supply considering the peak power (S3-5% cycle) supplied by the drive for IGBT switching frequencies of 4 kHz and 8 kHz. SYNCHRONOUS FXM/FKM Peak power P (S3-5%) P (S3-5%)
Page 214    Selection criteria Calculation of the power required from the power supply by the asynchronous motors FAGOR asynchronous spindle motor FM7 T. H5/7 Power supply selection when using an FM7 asynchronous spindle motor with E01|E02 releases. ASYNCHRONOUS FOR SPINDLE, FM7. Releases E01&E02...
Page 215    Selection criteria T. H5/8 Power supply selection when using an FM7 asynchronous spindle motor with E03 release. ASYNCHRONOUS FOR SPINDLE, FM7. Release E03 Maximum power consumed by the power supply (kW) Asynchronous for spindle (kW) SUM OF POWER: ...
Page 216    Selection criteria T. H5/9 Power supply selection when using an FM7 asynchronous spindle motor with HS3 release. ASYNCHRONOUS FOR SPINDLE, FM7. Release HS3 Maximum power consumed by the power supply (kW) Asynchronous for spindle (kW) SUM OF POWER: ...
Page 217    Selection criteria Non-FAGOR asynchronous spindle motor For non-FAGOR asynchronous spindle motors (e.g.: a high speed spindle) the previous tables for standard FAGOR motors are not available. To properly calculate the power demanded by the non-FAGOR asynchronous spindle from the power supply, it is necessary: ...
Page 218: Required Power
   Selection criteria Power supply selecting criteria MANDATORY. Note that FM9 spindle motors whose sales models are FM9-B055- C5C  -E01-A and FM9-B071-C5C  -E01 will necessarily be associated with RPS-75 and RPS-80 power supplies respectively. The power supply module must be capable of supplying the power required by the set of motors and drives connected to it.
Page 219    Selection criteria The power supply module must be capable of supplying the peak power required by the set of motors and drives connected to it. T. H5/11 Second criteria for selecting the power supply for the whole system. SECOND CRITERIA The power supply module must be capable of supplying the peak power required (depending on the duty cycles) by all the motor-drive sets connected to it.
Page 220: Mains Voltage
   Selection criteria The range of FAGOR power supplies that may be selected is: T. H5/12 Power supplies of the FAGOR catalog. They indicate: Rated power, admitted mains voltage and whether it outputs 24 V DC or not.
Page 221: Mains Power
   Selection criteria T. H5/14 Selection of the power cabling. POWER CABLE FOR MAINS CONNECTION Vmains: Line voltage AXD/SPD: 400/460 V AC ACD/SCD: 400/460 V AC ACD/SCD ... - L: 200/240 V AC Rated current through the mains cable ...
Page 222    Selection criteria 5.4 Capacitor module selection guide The CM-1.75 is a capacitor module that increases the electrical capacitance of the power bus in 7380 µF. It should be installed on machines with very short duty cycles (very repetitive accelerations and decelerations) and with low braking energy (e.g.
Page 223    Selection criteria 5.5 Ballast resistor selection guide Calculate the value of: Energy generated by the braking of each system motor. Rms power generated by all braking of all the motors throughout a complete duty cycle. Based on the following formulae: 2...
Page 224 Ohm value and greater power. On any compact drive whose model is SCD...-NR no external Ballast resistor will supplied with the unit. The user will place the order for the external resistor required by the application with a FAGOR representative. · 224 ·...
Page 225: Power Line Connection
POWER LINE CONNECTION 6.1 Mains connection The FAGOR DDS system is designed to be connected to a three-phase line voltage of between 400 (1-10 %) V AC and 460 (1+10 %) V AC and a line frequency between 48 ... 62 Hz. Furthermore, note that the ACD/SCD compact drives are also designed to be connected to a three-phase line voltage of between 200 (1-10 %) V AC and 240 (1+10 %) V AC.
Page 226 ALWAYS connect the power supply of other equipment being installed and run together with the FAGOR DDS system through a second contactor - KM2 or through auxiliary contacts of the power (main) contactor - KM1.
Page 227: Protection Fuses
DDS system to protect it properly. T. H6/1 Technical data of the fuses to be installed with the FAGOR DDS system depending on the power supplied installed.
Page 228    Power line connection T. H6/3 Fuses to be installed in mains line depending on the power supply installed. PS-25B4 PS-65A RPS-75 XPS-25 XPS-65 MANUFACTURER RPS-80 RPS-20 RPS-45 FWH45B RF00-125A XL50F-45A XL50F-125A RF-000-40A RF-000-125A BUSMANN 40FE 100FE 160FE 170M2611 170M1318 170M1319...
Page 229 INFORMATION. As an alternative, type A differential breakers may be used with selective switch-off. They are more economical than type B ones and usually valid for DDS systems with a FAGOR filter. The off current must not be < 500 mA and they will have selecting switch-off.
Page 230    Power line connection 6.4 Isolating transformer or auto-transformer When the mains voltage must be isolated or adapted to the levels required by the DDS system, it may be connected through an isolating transformer or an auto-transformer. This element will also help reduce the amount of harmonics on the line although it will not guarantee the compliance with the CE regulation.
Page 231    Power line connection It is also highly recommended to use auto-transformers instead of isolating transformers when only an adaptation of the working voltages is required. MANDATORY. For systems with XPS power supplies, install isolating transformers ONLY when the type of mains so requires. Remember that if the isolating transformer is installed, depending on its power and impedance, it may be required to install a second choke in series with the one that musts be installed with XPS power supplies.
Page 232: Mains Filter
MANDATORY. ALWAYS install mains filters from the FAGOR catalog when installing the DDS drive system. In order for the FAGOR DDS system to meet the European Directive on Electromagnetic Compatibility 2014/30/EU, a mains filter must be installed against electromagnetic disturbances. The optional filters provided by FAGOR ensure the compliance of the DDS system itself with the currently effective directive.
Page 233    Power line connection 6.6 Line inductance Line inductance means including chokes on each of the three power lines. Its function is to reduce the harmonics generated in mains. The recommended value is given by the formula: V 0.04 ...
Page 234    Power line connection 6.7 Distribution diagrams The distribution diagram being used must be taken into consideration in order to determine the characteristics of the protection means against electrical shocks, in case of failure (indirect contacts) and against over- current, as well as the specifications of the devices in charge of such functions.
Page 235    Power line connection TN diagram Distribution diagram that has a point directly connected to ground and the conductive parts of the installation are connected to this point through ground protection conductors. This type of mains admits loads between one or several phases and the neuter.
Page 236    Power line connection TT diagram Distribution diagram that has a point directly connected to ground and the conductive parts of the installation are connected to a ground point independently from the ground electrode of the power supply system. TT diagram SECONDARY WINDING OF THE...
Page 237    Power line connection IT diagram Distribution diagram that has no direct connection to ground and the conductive parts of the installation are connected to ground. IT diagram SECONDARY SECONDARY WINDING OF THE WINDING OF THE LINE TRANSFORMER LINE TRANSFORMER OF THE PLANT OF THE PLANT...
Page 238    Power line connection 6.8 Mains connection cables For further information on the mains cabling for the DDS system, see chapter 7. CABLES , section · 7.1 Mains connection cable. Power supply - mains connection ·. HARDWARE Ref.1912 ·...
Page 239 CABLES This chapter describes the cables needed to install the DDS system and the characteristics of the connectors of those cables. It also describes the mechanical characteristics of those cables. MANDATORY. The length of any cable used in the installation of the DDS system must be shorter than 30 m, except for the power (motor), feedback (encoder), fiber optic cables (SERCOS interface) and CAN bus cables, which may exceed this length.
Page 240 Refer to table T. H5/14 of chapter 5 to determine the cable needed to connect the power supply to mains. Note that compact drives have it integrated into them. The table T. H7/1 shows the mains connection cable supplied by FAGOR and their sales model: T. H7/1 Range of mains connection cables.
Page 241    Cables It determines ·for B2 installation method· the minimum section of the cable through which the maximum current allowed in continuous duty can circulate on three-phase wires in PVC hoses or installed on the machine through conduits or channels according to UNE-EN 60204-1:2007. The ambient temperature is assumed to be 40°C/104°F.
Page 242 7.2 Power cable. Motor-drive connection Table T. H7/4 and table T. H7/5 show the range of power cables supplied by FAGOR to connect a motor and a drive. They are supplied without connectors because the power connector will usually be different depending on the motor it will be connected to.
Page 243    Cables MPC-4x+ 2x cable Mechanical characteristics T. H7/7 MPC-  x  +(  x  ) cable. Mechanical characteristics. Type Shield. It ensures EMC Compatibility. High. Special to be used in cable carrying chains with a Ø...
Page 244: Motor Feedback Cables
7.3 Motor feedback cables The attached tables show the range of motor encoder cables supplied by FAGOR to connect the motor feedback and a drive. They are supplied with connectors at both ends (see note below) and their sales model is: Motor Ref.
Page 245    Cables EEC-FM7CS- cable T. H7/12 Range of EEC-FM7CS-  cables. The number indicates their length in meters including the connector. EEC-FM7CS-05 EEC-FM7CS-20 EEC-FM7CS-35 EEC-FM7CS-50 EEC-FM7CS-10 EEC-FM7CS-25 EEC-FM7CS-40 EEC-FM7CS-15 EEC-FM7CS-30 EEC-FM7CS-45 For further detail on how to connect the drive, see the manual of the corresponding motor.
Page 246: Temperature Sensor
AXD/ACD drive, the use of an CA-D1-D4 adapter cable is always required. The D1 connector of the adapter cable is directly connectable to FAGOR "EC" cables and "XC" extension cables. The D4 connector of the adapter cable will be connected to the motor feedback X4 connector of the AXD/ACD drive.
Page 247 - X3 - feedback device (on the sensor side and drive side) F. H7/3 Diagram of the direct feedback cable for an external FAGOR incremental feedback (linear or rotary) sinusoidal (1 Vpp) or square-wave (differential TTL). External absolute feedback...
Page 248 - X3 - (on the sensor side and drive side). F. H7/4 Diagram of the direct feedback cable for the FAGOR absolute linear encoder. External Stegmann sinusoidal encoder FAGOR does not supply the direct feedback cable for connecting an external Stegmann sinusoidal encoder with the drive .
Page 249 TTL encoder attached to the rotor of the motor. The attached tables show this cable supplied by FAGOR to connect the drive (X3) and the CNC 8055 (X1, X2, X3 or X4) / 8055i (X10, X11, X12 or X13) / 8065/8070 (LOCAL COUNTER 1/2).
Page 250    Cables SERCOS-II optical fiber FAGOR supplies the fiber optic cables for SERCOS-II communications between the group of drives and the CNC in a ring connection and in lengths ranging from 1 to 100 meters. The cables between drives come with the connectors for each module.
Page 251    Cables SFO-V-FLEX- cable T. H7/21 Range of SFO-V-FLEX-  cables. The number indicates their length in meters. SFO-V-FLEX-40 SFO-V-FLEX-60 SFO-V-FLEX-100 SFO-V-FLEX-50 SFO-V-FLEX-75 Its mechanical characteristics are: T. H7/22 SFO-V-FLEX-  cable. Mechanical characteristics. The minimum bending radius will be 60 mm in dynamic Flexibility conditions and 45 in static conditions.
Page 252    Cables CAN cable Cable supplied by FAGOR upon request. It is used to establish communication through a CAN field bus between drives and a master device (CNC, PC, ESA panel, etc.). It consists of a pair of twisted wires with a section of 0.25 mm², overall shield and impedance of 120 .
Page 253    Cables 7.7 RS232/RS422 BE adapter Before showing other connections, it shows the RS232/RS422 BE adapter and the pinout for each end. A port of the adapter Connect the end of the (Sub-D, M25) RS-232 or RS-422 cable to this end of the adapter Connect this end of B port of the adapter...
Page 254 RS-232 or RS-422 serial line with a VT panel from ESA. NOTE. The user is free to use this FAGOR adapter or not. But, it should be used unless indicated otherwise because it makes the connection easier.
Page 255    Cables PC-VT connection using an RS-232 cable ·without adapter· RS-232 cable 9-pin Sub-D, type female 25-pin Sub-D, connector type male to the VT to PC connector panel (ESA) F. H7/11 RS-232 serial line connection between a PC and VT from ESA (without adapter).
Page 256    Cables PC-VT connection using an RS-232 cable · with adapter · to the VT 9-pin Sub-D, 9-pin Sub-D, panel (ESA) type female type female connector connector RS422/RS232 BE RS-232 cable adapter cable F. H7/14 RS-232 serial line connection between a PC and VT from ESA (with adapter). The adapter RS232/RS422 BE has the following connectors at its ends: A port of the adapter Connect the end of the RS-...
Page 257 MSP serial port of the VT and the drive's RS-232 serial port. NOTE. When mentioning a drive, it means any model of the FAGOR catalog, i.e. AXD, SPD, ACD, SCD, MMC and CMC models. MANDATORY. The RS-232 serial line can only be used between the ESA VT and a single drive.
Page 258 RS-232 or RS-422 serial line with a VT panel from ESA. NOTE. The user is free to use this FAGOR adapter or not. But, it should be used unless indicated otherwise because it makes the connection a lot easier.
Page 259    Cables RS-422 serial line cable between a VT and several drives · with adapter · NOTE. Only for MMC or CMC drives. Port A RS-422 cable Port B RS422/RS232 BE Adapter B port of the adapter Pin-Out of port B (Sub-D, M9) N.C.
Page 260    Cables HARDWARE Ref.1912 · 260 ·...
Page 261: Installation
INSTALLATION This chapter defines the installation process that only covers the DDS system itself. The installation procedure of the DDS system to the power lines has been already described in chapter 6. POWER LINE CONNECTION . INFORMATION. Bear in mind that some of the wiring and grounding requirements for installing the DDS system are described in other chapters of this manual, e.g.
Page 262: Environmental Considerations
   Installation 8.1 Location MANDATORY. The DDS system that will usually include the external safety controller is identified as a fixed installation meant to always work inside an electrical cabinet (enclosure) whose protection degree is IP 54 or greater. Note that the start button, the E-stop button and other elements may be installed outside the electrical cabinet (enclosure).
Page 263    Installation Climatic considerations The temperature inside the electrical cabinet containing the DDS system must not exceed 55°C/131°F (60°C/140°F with power reduction). MANDATORY. Never install the DDS system next to a heat source. The modules generate heat and when trying to decide whether the electrical cabinet containing the DDS system needs external cooling or not, one must know the power dissipated by each one of its modules.
Page 264: Electrical Considerations
   Installation Electrical considerations MANDATORY. The electrical installation my comply with standard EN 60204-1. Indications regarding EMC Electromagnetic Compatibility is covered by the following standards: T. H8/2 Standards regarding Electromagnetic Compatibility. EN 61800-3:2004 Category C3. Adjustable speed electrical power /A1:2011 drive systems.
Page 265    Installation MANDATORY . Use shielded cables for power supply and motor. On shielded cables, the unshielded portion of the cable used to connect them to the connectors must be as short as possible in order to reduce radiated emissions.
Page 266    Installation See example of electrical installation in the next figures. CHANNEL L1’ L2’ L3’ L1 L2 L3 U V W U V W MAIN AXD/ AXD/ PS-65A FILTER 130A-A DIFFERENTIAL BREAKER L1 L2 L3 CHANNEL F. H8/3 Cables for connecting the DDS system with a PS-65A power supply.
Page 267    Installation See fig. F. H11/23 for further information on RPS-75-3, RPS-45 or RPS- 20 CHOKES. F. H8/5 Cables for connecting the DDS system with an RPS power supply. HARDWARE Ref.1912 ·...
Page 268    Installation Cabinet heat dissipation MANDATORY. The ventilation for the electrical cabinet must be enough to dissipate the heat generated by all the devices and components working inside. The following should be used to cool the electrical cabinet: ...
Page 269    Installation 8.2 Inductive components Installing the DDS system requires certain precautions regarding the connection of the inductive components such as contactors, relays, electrovalves, motor brakes or, in general, any type of coil. Hence:  All inductive circuits or components must have their own interference suppressor that must be installed as close as possible to the inductive component.
Page 270: System Installation
   Installation 8.3 System installation Preparation After knowing the system's environment, the step before installing the DDS system is the following:  Preparing the mounting fixtures inside the electrical cabinet. See chapter 11. DIMENSIONS , that shows all the necessary values. ...
Page 271  Adjust the modules through the RS-232 serial line using the application for PC (WinDDSSetup). INFORMATION. In order for the FAGOR DDS system to meet the European Directive on Electromagnetic Compatibility 2014/30/EU, the modules installation rules must be strictly followed regarding: Installation of the mains filter ·MAIN FILTER·.
Page 272    Installation Before handling the terminals, proceed as indicated and in the following order: WARNING . Disconnect the mains voltage at the electrical cabinet. Wait a few minutes before handling these terminals. The power supply of the DDS requires time to decrease the voltage of the power bus to safe values (<...
Page 273    Installation 8.4 Connection between modules Power bus connection The power bus is connected through the terminals hidden under the cover at the bottom of each module. To do this, use 2 of the 3 plates and the washers and nuts supplied with each module.
Page 274: Ground Connection
   Installation Joining the chassis between modules The chassis of the modules must be connected to each other through the M6 bolt on top of each module. To do this, the irregular plate and the nut supplied as accessories with each module must be used. U V W U V W F.
Page 275    Installation When not having a separate ground point, join the plates to the terminal of the power supply module which, in turn, will be connected to mains ground. MPC- 4x... detail A MPC- 4x... MPC- 4x... U V W U V W L3 L2 L1 MAINS...
Page 276    Installation  The tightening torque must be between 2.3 2.8 N·m. MANDATORY. Take a (PE) ground cable (as short as possible) from each module to each main machine ground point. See figure F. H8/10 MANDATORY. In order to ensure compliance with the European Directive on Electromagnetic Compatibility 2014/30/EU, it is a must to: Verify that all the requirements of local and national electrical codes are met as well as all the regulations applicable regarding the grounding of the...
Page 277 See the electrical configuration in the diagrams of the figure and read the warning below. Compact modules ACD/SCD/CMC 1.25/2.35/2.50 and SCD 2.75 do not have an internal Ballast resistor. FAGOR supplies an external Ballast resistor associated with each one of these modules as an accessory with the unit. HARDWARE Always connect according to configuration (L+, Re).
Page 278    Installation See chapter 5, the section regarding the “ BALLAST RESISTOR SELECTION GUIDE ” to know whether it is necessary or not to install an external Ballast resistor or the internal one is enough. Resistor model See chapter 4, section regarding “ RESISTOR MODULES ” to know which external Ballast resistor corresponds when an external resistor is required in an ACD/SCD/CMC 1.08/1.15 module.
Page 279    Installation How to plug and unplug the Ballast connector On ACD|SCD|CMC 1.08|1.15 drives , to connect an external Ballast resistor, first insert the terminals into the poles identified as Re and L+ of the connector with plug-in terminals and tighten each screw (slotted head 0.6x3.5 mm) with a tightening torque of 0.5...
Page 280    Installation H o w t o i n s t a l l A N e x t e r n a l B a l l a s t r e s i s t o r w i t h i n t e r n a l thermostat and with no fan WARNING.
Page 281    Installation How to install AN exter nal Ballast resistor with an exter nal thermostat and with no fan WARNING. On top of the ER+TH modules, the air temperature can reach values over 120°C/248°F. Therefore, the resistor should be mounted away from the rest of the modules or even outside the electrical cabinet, always vertically and away from cables and other temperature sensitive material.
Page 282    Installation H o w t o i n s t a l l A N e x t e r n a l B a l l a s t r e s i s t o r w i t h i n t e r n a l thermostat and fan WARNING.
Page 283    Installation How to install TWO extern al Ballast resistor in parallels Always install both resistors vertically Diagram for 2 r esistors in paral lel wit h fan and i nt ernal t her mostat Take the connection terminals of each fan to an outlet of the electrical cabinet, single phase 50/60 Hz, 220/240 V AC.
Page 284 On any compact drive whose model is SCD-...-NR x.xx no external Ballast resistor will supplied with the unit. The user will place the order for the external resistor required by the application with a FAGOR representative. Remember that it must have the same Ohm value as the internal resistor of the module.
Page 285    Installation How to install A resistor ER+TH-18/1100 to the BPM module Always install it vertically ER+TH-18/1100 ER+TH-18/1100 Element to connect with the external thermostat External thermostat Ballast resistor connection terminals Diagram Connect either one of the two pins of the thermostat to + 24 V DC of the external power supply of the electrical cabinet and the other one to a PLC input.
Page 286    Installation How to install TWO resistors ER+TH-18/1100 in parallel to the BPM module Always install both resistors vertically Diagram for 2 resistors in parallel with an external thermostat Connect according to the figure the terminal labeled +24 V DC to an external 24 V DC ER+TH-18/1100 ER+TH-18/1100 power supply of the electrical cabinet and the...
Page 287    Installation How to install THREE resistors ER+TH-18/1100 in parallel to the BPM module Always install the resistors vertically Diagram for 3 resistors in parallel with an external thermostat Connect according to the figure the terminal labeled + +24 V DC to an external 24 V DC power supply of the electrical cabinet and the other PLC INPUT to a PLC input.
Page 288: Heat Dissipation
INFORMATION. If a fan is required due the conditions of the location where the resistor will be installed, remember that FAGOR offers external ballast resistors with fan. See an example with data on the temperatures reached in points of the top of the module and the effect of the fan: T.
Page 289: Power Supply Connections
WARNING. The 24 V DC can also be used in the circuit of the electrical cabinet, but NEVER TO ACTIVATE THE MOTOR BRAKE! WARNING. The 24 V DC power supply output generated in the FAGOR “POWER SUPPLY MODULE” unit must only be used for the 24 V DC control input.
Page 290    Installation Connection of the APS-24 power supply Take two mains phases and ground to the input connector X1 of the auxiliary power supply APS-24. See figure: F. H8/22 Connection of the APS-24 with the PS-65A and the modular drives. Connection of the auxiliary power supply of the PS-25B4 and the XPS Take the two mains phases and ground to the input connector X3 of the...
Page 291 It only provides HARDWARE galvanic isolation of the temperature sensor. For further detail on the cables supplied by FAGOR for connecting the motor feedback, see chapter 7. CABLES . The technical data for the motor Ref.1912 feedback device connector is shown in the corresponding motor manual.
Page 292 X3 or X4 of the 8055 CNC. For an 8055i CNC, the connectors will be X10, X11, X12 and X13. For further detail on CNC connection, see the corresponding CNC manual. See chapter 7. CABLES for further detail on the cables supplied by FAGOR for this connection. Connection for the reception of the analog command Connector X7 of the drive has two analog input to receive the analog velocity command sent out from connector X8 of the 8055 CNC.
Page 293 The different drives and the CNC are connected through SERCOS connector X6 carried by each drive of the FAGOR catalog (see their front panel) through optic fiber. See chapter 7. CABLES of this manual.
Page 294 When all these connections have been made, the ring will be closed. See figure F. H8/28. NOTE. With each drive, FAGOR supplies a fiber optic line to connect it to its adjacent module and, upon request, the rest of the required optical fiber.
Page 295: Handling Fiber Optic Cables
   Installation Handling fiber optic cables FAGOR supplies the fiber optic cables with its terminals protected with a hood. Remove the terminal protecting hood before connecting any of these cables. Either to remove the terminal protecting hood or to connect and disconnect the cable, the cable must always be held by the terminal, never pull at the cable because it could get damaged.
Page 296    Installation Transmission speed changing procedure In an initial state (0 state), the display shows the information that already showed in previous versions (errors, SERCOS phase, etc.). Keeping the “boot” button pressed for 3 seconds (long push) it switches to a new state (state 1) that is used for selecting the communication speed and the display shows the speed currently selected.
Page 297    Installation Values that may be assigned to the transmission speed The possible values, supported by the hardware, that may be selected to set the transmission speed are: T. H8/4 Transmission speed with SERCOS interface. Display at the drive. Value Speed Shown on the display...
Page 298    Installation SERCOS connection with a FAGOR UC 8055 A drive is connected to a FAGOR 8055 CNC via SERCOS through the SERCOS DRIVES connector located on the front panel of the Central Unit. See figure UC 8055 SERCOS DRIVES F.
Page 299    Installation SERCOS connection with a FAGOR 8060 CNC A drive is connected to a FAGOR 8060 CNC via SERCOS through the SERCOS DRIVES (B32) connector located on the right side of the module. See figure 8060 10V CNC B32.
Page 300: Can Bus Connection
The different drives and the CNC are connected through CAN connector (X6) carried by each drive of the FAGOR catalog (see their front panel) through the CAN cable. See chapter 7. CABLES in this manual.
Page 301    Installation If a drive is assigned the 0 identifier, the module will be ignored. Example For example, a machine has four drives identified as 1, 2, 3 and 4. To ignore the second one, another one must be renamed so they are consecutive. The easiest solution for a situation like this will be 1, 0, 3 and 2.
Page 302    Installation F. H8/40 Minimum bending radius of the CAN cable. Line terminating resistor (RT) After connecting the modules, make sure that the external elements connected to the bus have their terminating resistor RT activated. NOTE. The RT switch (located under the CAN connector) of the last drive (usually the one farthest away from the CNC) must be activated (position 1 ...
Page 303    Installation Change of transmission speed In an initial state (0 state), the display shows certain information that lacks interest for the operator, except the software version, errors and warnings if there are any. Keeping the “boot” button pressed for 3 seconds (long push) it switches to a new state (state 1) that is used for selecting the communication speed and the display shows the speed currently selected.
Page 304 12. PARAMETERS, VARIABLES AND COMMANDS of the “man_dds_soft.pdf” manual. CAN connection with an ESA Video Terminal VT The CAN connection of the ESA terminal with FAGOR drives is made through the connector located at the bottom of the VT module. See figure. Bottom view...
Page 305 For further information, see the installation manual of the FAGOR 8037 CNC. CAN connection with a FAGOR 8055i CNC The CAN DRIVES connection of a FAGOR 8055i CNC to the drives will be made through the CAN DRIVES connector on the top rear of the module. See figure.
Page 306    Installation CAN connection with a FAGOR 8055 UC The CAN connection of the FAGOR UC 8055i to the drives will be made through the CAN DRIVES connector located on the front of the Central Unit. See figure.
Page 307    Installation Identifying the axes with addresses higher than 15 requires setting QP13. See this parameter in chapter 13 of the “man_dds_soft.pdf” manual. Example How to identify an axis addressed in position 26 in the system when communicating via RS-422 serial line? When the identifier of the axis is higher than 15 (like in this case), QP13 must be set so it meets the ratio: Defined ID = ID to be selected at the rotary switch + (15 x QP13).
Page 308: Pin Signal
   Installation The pinout of the MSP connector is described in the following table: T. H8/6 Pinout of the MSP connector. * C.L. means <Current Loop>. Signal Signal Not Connected IKT OUT TxRS232 OUT IKR OUT RxRS232 IN +5 V DC (reserved) RTS RS232 OUT Not Connected...
Page 309    Installation RS-232/422 serial line connection between PC/ESA VT To make this connection is essential for transferring the communication driver and the project. The connection is made through the MSP connector at the bottom of the VT module and the RS-232 serial line connector of the PC. The connection must be made according to the diagram shown in chapter 7.
Page 310: Check The Installation
   Installation 8.7 Check the installation Check the installation:  Mechanical fixtures for the whole system  Distances  Tighten all the mounting screws with their corresponding tightening torque.  Electrical connections and wiring:  Connection of protection wires ...
Page 311: Functional Safety
FUNCTIONAL SAFETY The DDS system is an adjustable speed electrical P ower D rive S ystem that is suitable for use in safety-related applications P ower D rive S ystem · S afety- R elated· as defined in IEC 61800-5-2. Contents This chapter contains information regarding the functional safety required in: ...
Page 312    Functional safety EN ISO 13849  EN ISO 13849-1 Safety of machinery - Safety-related parts of control systems - Part.1: General principles for design.  EN ISO 13849-2 For validation purposes, the standard EN ISO 13849-2 should be used. ...
Page 313: Safe State
   Functional safety 9.1 Main characteristics of the safety functions These drives have the following safety functions:  S afe T orque O ff (STO) Definition. Safe torque off. Drive Enable safety input that works together with the - KM1 contactor to eliminate the motor torque safely. STO correspond to an uncontrolled stop according to stop category 0 of standard IEC 60204-1.
Page 314    Functional safety 9.2 Drive Enable input and AS1-AS2 feedback output The interface for the integrated channel (Drive Enable) of the STO safety function consists of the DRIVE ENABLE input and its associated contact of the AS1-AS2 feedback. S AFE T ORQUE O FF DRIVE ENABLE...
Page 315    Functional safety 9.3 Fault detection and reaction Fault detection in the safety functions  plausibility check After a demand of the safety functions, the safety controller must check that the feedback has been closed. This check should not be made until the response time of the safety function has elapsed.
Page 316: Other Monitoring
   Functional safety Reaction time of the safety function to a fault Given that the feedback verification must not be carried out until the response time for the safety function has elapsed, the effective reaction time of the system when a failure occurs can be considered to be precisely the response time of the safety function.
Page 317: Design Requirements
SS1, set GP9 To execute the SS1, the safety controller activates the SPEED ENABLE input or a FAGOR PLC input that activates the SERCOS SPENA. In response, the drive will stop the motor and wait for GP9 before removing the motor torque.
Page 318    Functional safety Example 2. SS1 application that meets with Cat. 3, PL d - SIL 2 This safety function corresponds to a controlled stop in accordance with stop category 1 of IEC 60204-1. The safety function SS1 referred to in this examples corresponds to type "c) safe stop 1 time controlled ·SS1-t·”...
Page 319: Electrical Precautions
   Functional safety 9.5 Electrical precautions Safety functions DANGER.  The activation of the safety function STO neither isolates the mains nor discharges the power DC BUS.  Opening the main external contactor - KM1 isolates the system from mains, but the DC BUS is still alive for the time period indicated on the front plate of the unit.
Page 320: Residual Risks
STO is applied. In this case, additional protection measures are required against axis drop (e.g. a holding brake FAGOR’S FKM motors contain the integrated holding brake option). A risk analysis of the machine will determine whether this measure is needed or not.
Page 321    Functional safety 9.7 Technical data of the safety functions To calculate the machine's P erformance L evel (PL of EN ISO 13849-1) and/or S afety I ntegrated L evel (SIL of IEC 62061), use the drive data provided in the following tables: T.
Page 322 Consider that the actual response time of the holding brake is the sum of the response time of its control and the response time of the brake itself which for FAGOR brakes varies between 5 and 30 ms. HARDWARE Ref.1912...
Page 323    Functional safety 9.9 Cabling and grounding Safety functions The following recommendations must be taken into account when designing the safety functions:  See · Drive Enable electrical protections ·.  Try keeping power cables and signal cables apart from each other. ...
Page 324: Acceptance Test
   Functional safety 9.10 Commissioning Staff members are forbidden to access the danger zone until the safety functions have been validated. Acceptance test The scope of this section are the machine safety functions that use safety functions of the drive. An example of this would be an SS1 function that is demanded when the emergency button is pressed, and that in turn demands the STO function from the drive.
Page 325 HARDWARE plausibility check . Analysis of hazardous events of the drive in the field Ref.1912 Fagor Automation monitors that field MTTFd are less than the theoretical ones. · 325 ·...
Page 326    Functional safety Tools for diagnosis, maintenance and repair in case of failure See Fault detection in the safety functions .  Conventional error display See section 3.3 Turning a drive on of this manual that describes how the errors are displayed: - On the 7-segment display for drives with SERCOS connection and with analog connection...
Page 327    Functional safety 9.12 Decommission and disposal There are no specific requirements for the safety related part. See the requirements for the whole unit in SHIPPING CONDITIONS, STORAGE, DECOMMISSION AND DISPOSAL at the beginning of this manual. HARDWARE Ref.1912 ·...
Page 328    Functional safety 9.13 Electrical safety, environmental conditions and EMC See the following sections of this manual:  SAFETY CONDITIONS  Qualification of personnel  1.5 Environmental conditions  1.6 Electrical conditions  8. INSTALLATION , sub-section · Electrical precautions · ...
Page 329: Connection Diagrams
CONNECTION DIAGRAMS 10.1 SPD modular drive with FM7 asynchronous spindle motor Connection diagram of an SPD modular drive with an FM7 asynchronous spindle motor that has TTL encoder feedback. Digital Spindle Modular Drive Ready made cable to 8055/55i CNC, SEC-HD 1/3/5/10/15/20/25/30/35 SPD 2.50-SI-1 Length in meters;...
Page 330    Connection diagrams 10.2 AXD modular drive with FKM synchronous axis servomotor R e a d y m a d e c a b l e E E C - S P - 3 / 5 / 6 / 7 / 8 / 9 / 1 0 / 1 1 / 1 2 / 1 5 / 2 0 / 2 5 / 3 0 / 3 5 / 4 0 / 4 5 / 5 0 / 6 0 L e n g t h i n m e t e r s ;...
Page 331    Connection diagrams 10.4 SCD compact drive with FM7 asynchronous spindle motor Connection diagram of an SCD compact Digital Spindle Compact Drive drive with an FM7 asynchronous spindle N ote. SCD 1.25-A ... motor that has encoder feedback. R S T, cl assi c nomencl ature L 1 L 2 L 3, cur r ent nomencl atur e Line voltage: 400/460 V AC.
Page 332    Connection diagrams 10.5 ACD compact drive with FKM synchronous axis servomotor C o n n e c t i o n d i a g r a m o f a n A C D 1 . 1 5 D i g i t a l A x i s C o m p a c t D r i v e compact drive with an FKM synchronous A C D...
Page 333    Connection diagrams 10.6 ACD compact drive with FXM synchronous axis servomotor C o n n e c t i o n d i a g r a m o f a n A C D 1 . 1 5 D i g i t a l A x i s C o m p a c t D r i v e compact drive with an FXM synchronous A C D...
Page 334    Connection diagrams 10.7 Regulador compacto ACD 1.25-S0-0-B-L con motor lineal Connection diagram of an ACD 1.15 D i g i t a l A x i s C o m p a c t D r i v e compact drive with a linear motor and A C D 1 .
Page 335    Connection diagrams 10.8 Electrical cabinet. Diagrams DANGER. The diagrams of this chapter do not meet the European Machinery Directive 2006/42/EC. Complying with the European Machinery Directive usually requires PL d or SIL 2 (milling machines and lathes). The AXD/SPD reaches PL d or SIL 2 (see models in the Declaration of Conformity).
Page 336    Connection diagrams Error Reset When an error appears at any drive, its “Drive OK” and, therefore, the “System OK” contact of the power supply that feeds it will be open. The relay - KA1 will be deactivated and its associated contact open and will not be possible to supply power to the power supply until the cause of the error is eliminated, as long as it is a non-resettable error.
Page 337 Z axis to keep it from falling due to gravity. NOTE. The reaction time of a brake integrated into an axis feeding FAGOR motor may vary between 7 ms and 97 ms depending on the model.
Page 338    Connection diagrams Closing the main power switch - S1 must take two phases to connector X1 when using compact drives or an APS-24 as auxiliary power supply of the PS-65A and to connector X3 when using XPS or PS-25B4 power supplies. In the case of RPS power supplies, there are three phases instead of two and they must go to connector X1.
Page 339    Connection diagrams Start-up of the DDS with PS power supplies. Block diagram HARDWARE Ref.1912 F. H10/8 Start-up of the DDS with PS power supplies. Block diagram. · 339 ·...
Page 340    Connection diagrams Start-up of the DDS with XPS or RPS power supplies. Block diagram HARDWARE Ref.1912 F. H10/9 Start-up of the DDS with XPS or RPS power supplies. Block diagram. · 340 ·...
Page 341    Connection diagrams 10.9 Diagrams with a PS-65A power supply +24 V DC ER+TH-xx+FAN RESISTOR MODULE +t° 0.15/0.20 A, 23/20 W ER+TH-xx+FAN PLC INPUT RESISTOR +24 V DC MODULE 0.15/0.20 A, 23/20 W +t° +24 V DC Power PS-65A POWER Error Reset...
Page 342    Connection diagrams Diagram for general connection to mains WARNING. When using an isolating transformer, the secondary must be connected in star and its middle point must be connected to GND. - F3 - F4 - F5 IT A MUST TO USE FUSES - S1 - Q1 MAIN FILTER 130A-A...
Page 343    Connection diagrams 10.10 Diagrams with a PS-25B4 power supply +24 V DC ER+TH-xx+FAN RESISTOR PLC INPUT +24 V DC MODULE 0.15/0.20 A, 23/20 W +t° +24 V DC PS-25B4 Error Reset POWER System Speed Enable SUPPLY SYSTEM POWER (Phoenix, 5.08 mm)
Page 344    Connection diagrams Diagram for general connection to mains WARNING. When using an isolating transformer, the secondary must be connected in star and its middle point must be connected to GND. - F3 - F4 - F5 IT A MUST TO USE FUSES - S1 - Q1 MAIN FILTER 42A-A...
Page 345    Connection diagrams 10.11 Diagrams with a XPS power supply 10 mm² (XPS-25) 50 mm² (XPS-65) +24 V DC CHOKE XPS-XX +24 V DC Error Reset System Speed Enable (Only in XPS) POWER SYSTEM SUPPLY POWER (Phoenix, 5.08 mm) +24 V DC 3x400/460 V AC X4 X5 X6...
Page 346    Connection diagrams Diagram for general connection to mains EARLY OPEN EARLY OPEN +24VDC CONTACT CONTACT see fig.a fig.a - F3 - F4 -KA3 - F5 OFF DELAY CONTACT IT A MUST TO USE FUSES POWER MAINS - S1 - Q1 MAIN FILTER - Q1...
Page 347    Connection diagrams 10.12 Diagrams with an RPS power supply IMPORTANT. N o t e . It is absolutely necessary to short-circuit pins NS1 and NS2 externally R S T , c l a s s i c n o m e n c l a t u r e with a wire of at least 1 mm²...
Page 348    Connection diagrams Diagram for general connection to mains EARLY OPEN EARLY OPEN CONTACT CONTACT see fig.a - F1 - F2 - F3 IT A MUST TO USE FUSES POWER MAINS fig.a - S1 - Q1 MAIN FILTER A-A MECHANICAL DIFFERENTIAL +24VDC...
Page 349    Connection diagrams 10.13 ACD/SCD compact system diagrams, SERCOS connection C O M P A C T D R I V E + 2 4 V D C M O D U L E S C D 1 . 1 5 + 2 4 V D C K A 3 + 2 4 V D C...
Page 350    Connection diagrams Diagram for general connection to mains Line voltage: 200 (1-10 %) V AC / 240 (1+10 %) V AC Line frequency: 48 ... 62 Hz WARNING. When using an isolating transformer, the secondary must be connected in star and its middle point must be connected to GND.
Page 351    Connection diagrams Diagram of the maneuver +24 V DC EMERG. STOP DR.X ENABLE ENABLE Green DR.Z BRAKE I1 PLC DELAY OFF CONTROL t (s) -KM1 -KA3 -BRK DRIVE CNC EMERG. ENABLES O1 PLC -KA4 -KA6 -KA1 EMERGENCY LINE TO SPEED ENABLES Important.
Page 352 2x400/460 V AC (Phoenix, 5.08mm) Chassis FAGOR CNC Notes. Compact modules do not have the System_Speed_Enable signals. In this diagram, in spite of having CAN interface, electrical signals are used to activate the enables. F. H10/25 Compact system with CAN connection.
Page 353    Connection diagrams Diagram for general connection to mains WARNING. When using an isolating transformer, the secondary must be connected in star and its middle point must be connected to GND. - F3 - F4 - F5 IT A MUST TO USE FUSES - S1 - Q1 MAIN FILTER 42A-A...
Page 354 OUT2 2.5 A OUT2 (F) Fuse +24 V DC Error Reset COMPACT Drive Enable DRIVE Speed Enable 3x400/460 V AC MODULE DR.S 2x400/460 V AC Chassis FAGOR CNC F. H10/28 AXD/SCD mixed system, SERCOS connection. HARDWARE Ref.1912 · 354 ·...
Page 355 DR.Z OUT2 2.5 A AXIS OUT2 (F) Fuse DRIVE +24 Vdc COMPACT DRIVE MODULE Error Reset Drive Enable Speed Enable 3x400/460 VAC DR.S 2x400/460 VAC Chassis FAGOR CNC F. H10/29 HARDWARE AXD/SCD mixed system, CAN connection. Ref.1912 · 355 ·...
Page 356    Connection diagrams Diagram of the maneuver +24VDC Important. - KA3 is a relay for a delayed deactivation of contactor - KM1 (t seconds) in order to be able to keep it closed long enough to return to mains (with XPS power supply) t he excess ene rgy gener ated while braking the motor.
Page 357    Connection diagrams 10.17 Holding brake connection diagram FXM synchronous motor - S1 MECHANICAL MAIN SWITCH 230 VAC FXM MOTOR 24 VAC +24 VDC 0 VDC BRAKE F. H10/31 Connection diagram for the holding brake of an FXM synchronous servo motor. FKM synchronous motor 400 VAC - S1...
Page 358 Important warnings 1. Either an external auxiliary power supply or a FAGOR power supply may be used to supply the 24 V DC. Never connect both at the same time ! 2. To brake the motor in a controlled way during a power failure, make sure that 24 V DC will be supplied to contactors - KM1 and - KM2 and relays - KA3 and - KA4.
Page 359 INFORMATION. Be aware that the room required for the top and bottom connectors of the units may even be up to 50 mm. NOTE. The user can also get 3D CAD drawing of the units from FAGOR's corporate website, http://www.fagorautomation.com. Go to the «download»...
Page 360: Power Supply Modules
   Dimensions 11.1 Power supply modules PS-25B4 Dimensions in mm. 1 in = 25.4 mm R3.5 R3.5 R6.5 F. H11/1 Non regenerative power supply, PS-25B4. Dimensions. HARDWARE Ref.1912 · 360 ·...
Page 361    Dimensions PS-65A Dimensions in mm. 1 in = 25.4 mm R3.5 R3.5 R6.5 F. H11/2 Non regenerative power supply, PS-65A. Dimensions. HARDWARE Ref.1912 · 361 ·...
Page 362    Dimensions XPS-25 Dimensions in mm. 1 in = 25.4 mm R3.5 R3.5 R6.5 F. H11/3 Regenerative power supply, X PS-25. Dimensions. HARDWARE Ref.1912 · 362 ·...
Page 363    Dimensions XPS-65 Dimensions in mm. 1 in = 25.4 mm R3.5 R3.5 R6.5 F. H11/4 Regenerative power supply, XPS-65. Dimensions. HARDWARE Ref.1912 · 363 ·...
Page 364    Dimensions RPS-20 Dimensions in mm. 1 in = 25.4 mm R3.5 R3.5 R6.5 F. H11/5 Regenerative regulated power supply, RPS-20. Dimensions. HARDWARE Ref.1912 · 364 ·...
Page 365    Dimensions RPS-45 Dimensions in mm. 1 in = 25.4 mm R3.5 R3.5 R6.5 F. H11/6 Regenerative regulated power supply, RPS-45. Dimensions. HARDWARE Ref.1912 · 365 ·...
Page 366    Dimensions RPS-75 Dimensions in mm. 1 in = 25.4 mm R3.5 R3.5 R6.5 F. H11/7 Regenerative regulated power supply, RPS-75. Dimensiones. HARDWARE Ref.1912 · 366 ·...
Page 367    Dimensions RPS-80 Dimensions in mm. 1 in = 25.4 mm R3.5 R3.5 R6.5 F. H11/8 Regenerative regulated power supply, RPS-80. Dimensions. HARDWARE Ref.1912 · 367 ·...
Page 368    Dimensions APS-24 Dimensions in mm. 1 in = 25.4 mm R3.5 R3.5 R6.5 F. H11/9 Auxiliary power supply, APS-24. Dimensions. HARDWARE Ref.1912 · 368 ·...
Page 369    Dimensions 11.2 Modular drives AXD/SPD/MMC 1.08, AXD/SPD/MMC 1.15 Dimensions in mm. 1 in = 25.4 mm R3.5 R3.5 R6.5 F. H11/10 Modular drives, AXD/SPD/MMC 1.08 | 1.15. Dimensions. HARDWARE Ref.1912 · 369 ·...
Page 370    Dimensions AXD/SPD/MMC 1.25 Dimensions in mm. 1 in = 25.4 mm R3.5 R3.5 R6.5 F. H11/11 Modular drives, AXD/SPD/MMC 1.25. Dimensions. HARDWARE Ref.1912 · 370 ·...
Page 371    Dimensions AXD/SPD/MMC 1.35 Dimensions in mm. 1 in = 25.4 mm R3.5 R3.5 R6.5 F. H11/12 Modular drives, AXD/SPD/MMC 1.35. Dimensions. HARDWARE Ref.1912 · 371 ·...
Page 372    Dimensions AXD/SPD/MMC 2.50, AXD/SPD/MMC 2.75, SPD 2.85 Dimensions in mm. 1 in = 25.4 mm R3.5 R3.5 R6.5 F. H11/13 Modular drives, AXD/SPD/MMC 2.50 | 2.75, SPD 2.85. Dimensions. HARDWARE Ref.1912 · 372 ·...
Page 373    Dimensions AXD/SPD/MMC 3.100, AXD/SPD/MMC 3.150 Dimensions in mm. 1 in = 25.4 mm R3.5 R3.5 R6.5 F. H11/14 Modular drives, AXD/SPD/MMC 3.100 | 3.150. Dimensions. HARDWARE Ref.1912 · 373 ·...
Page 374    Dimensions AXD/SPD/MMC 3.200, AXD/SPD/MMC 3.250 Dimensions in mm. 1 in = 25.4 mm R3.5 R3.5 R6.5 F. H11/15 Modular drives, AXD/SPD/MMC 3.200 | 3.250. Dimensions. HARDWARE Ref.1912 · 374 ·...
Page 375    Dimensions 11.3 Compact drives ACD/SCD/CMC 1.08, ACD/SCD/CMC 1.15 Dimensions in mm. 1 in = 25.4 mm R3.5 R3.5 R6.5 F. H11/16 Compact drives, ACD/SCD/CMC 1.08 | 1.15. Dimensions. HARDWARE Ref.1912 · 375 ·...
Page 376    Dimensions ACD/SCD/CMC 1.25 Dimensions in mm. 1 in = 25.4 mm R3.5 R3.5 R6.5 F. H11/17 Compact drives, ACD/SCD/CMC 1.25. Dimensions. HARDWARE Ref.1912 · 376 ·...
Page 377    Dimensions ACD/SCD/CMC 2.35, ACD/SCD/CMC 2.50, ACD/SCD/CMC 2.75 Dimensions in mm. 1 in = 25.4 mm R3.5 R3.5 R6.5 F. H11/18 Compact drives, ACD/SCD/CMC 2.35 | 2.50 | 2.75. Dimensions. HARDWARE Ref.1912 · 377 ·...
Page 378    Dimensions 11.4 Bus Protection Module, BPM Dimensions in mm. 1 in = 25.4 mm R3.5 R3.5 R6.5 F. H11/19 B us P rotection M odule, BPM. Dimensions. 11.5 Capacitor Module, CM-1.75 Dimensions in mm. 1 in = 25.4 mm R3.5 HARDWARE 263.5...
Page 379    Dimensions 11.6 Mains filters HARDWARE Ref.1912 Note. Keep in mind to also leave a minimum clearance of 50 mm in order to be able to connect the power cables to the top and bottom connectors of the filter. F.
Page 380    Dimensions 11.7 XPS CHOKES U1 U2 Ø E BASE AREA CHOKE Units XPS-25 4.13 4.52 7.08 0.31 0.39 6.49 XPS-65-A 4.72 3.34 5.98 6.69 0.35 0.35 10.47 F. H11/22 CHOKES. A. XPS-25 CHOKE. B. XPS-65-A CHOKE. Dimensions. HARDWARE Ref.1912 ·...
Page 381    Dimensions 11.8 RPS CHOKES T1 T2 T3 U1 V1 W1 ØE CHOKE Units RPS-75-3 14.96 9.25 5.98 6.69 0.35 0.70 10.66 RPS-45 12.99 6.88 5.35 5.90 0.31 0.59 8.97 RPS-20 12.99 6.88 5.35 5.90 0.31 0.59 6.37 F.
Page 382    Dimensions 11.9 External Ballast resistors with external thermostat Ø 6,2 80 84 THERMO-SWITCH 160 °C FAST ON 6.3 mm F. H11/24 External Ballast resistors with external thermostat. Dimensions. HARDWARE Ref.1912 · 382 ·...
Page 383    Dimensions 11.10 External Ballast resistors with internal thermostat Ø 12 Ø 6.5 2.5 mm² 2.5 mm² THERMOSTAT OUT CABLES F. H11/25 External Ballast resistor with internal thermostat. Dimensions. HARDWARE Ref.1912 · 383 ·...
Page 384: External Thermostat
   Dimensions 11.11 External Ballast resistors with external thermostat & cooling fan 4-ØD With external ER+TH- ER+TH- ER+TH- thermsotat 18/1000+FAN 18/1500+FAN 18/2000+FAN Units 6.88 6.88 6.88 6.49 6.49 6.49 2.99 2.99 2.99 6.06 6.06 6.06 6.69 12.95 20.86 4.76 11.02 19.68...
Page 385: Sales Models
SALES MODELS This chapter indicates the sales models of all FAGOR products. It refers to: Synchronous servomotors FXM/FKM Asynchronous motors FM7/FM9 Modular drives AXD/SPD Compact drives ACD/SCD MC drives MMC/CMC PS-25B4, PS-65, XPS-25, XPS-65, RPS-80, Power supplies RPS-75, RPS-45 and RPS-20 Mains filters ·MAIN FILTER·, auxiliary power...
Page 386: Synchronous Servo Motors
   Sales models 12.1 Synchronous servo motors Note. Encoders with reference: - I0, are only available on motors with "F" winding. - E1/A1, are only available on motors with "A" winding. F. H12/1 Synchronous servo motors, FXM. Denominations. HARDWARE Ref.1912 ·...
Page 387    Sales models MOTOR SERIES SIZE 1, 2, 4, 6, 8, 9 LENGTH 1, 2, 3, 4, 5, 6 RATED 2000 rev/min 4500 rev/min SPEED 3000 rev/min 5000 rev/min 4000 rev/min 6000 rev/min WINDING 400 V AC 220 V AC FEEDBACK TYPE A3 Multi-turn absolute sinusoidal 1Vpp encoder ·1024 ppt·...
Page 388: Asynchronous Motors
   Sales models 12.2 Asynchronous motors FM7-  -  - E0  FAGOR M7 MOTOR BASE SPEED (Single winding) 1500 rev/min 1000 rev/min 500 rev/min 1250 rev/min MOTOR POWER kW (Duty S1). Note. The kW for each model are obtained by multiplying the given value by 0.1.
Page 389    Sales models F. H12/4 Asynchronous motors, FM9. Denominations. HARDWARE Ref.1912 · 389 ·...
Page 390    Sales models 12.3 Modular drives Example: AXD 1.08-C0-0-B MODULAR AXIS DRIVE, AXD IS RIVE 77 mm (08|15|25|35) SIZE width (models) 117 mm (50|75) 234 mm (100|150) CURRENT (A) 12.5 IS1 | Imax. 17.5 for IGBT switching 25.0 frequencies of 37.5 50.0 100...
Page 391    Sales models 12.4 Compact drives ACD 1.25-S0-0-B-L Example: AXIS COMPACT DRIVE, ACD AXIS COMPACT DRIVE 77 mm (08/15/25) weidth (models) SIZE 177 mm (35/50) CURRENT (A) for fc = 4 kHz for fc = 8 kHz Irated / Ipeak 15.0 15.0 for IGBT's switching...
Page 392    Sales models 12.5 Positioning drives F. H12/9 Modular positioning drives, MMC. Denominations. HARDWARE Ref.1912 F. H12/10 Compact positioning drives, CMC. Denominations. · 392 ·...
Page 393    Sales models 12.6 Power supplies PS-65A NON REGENERATIVE Example: POWER SUPPLY, PS OWER UPPLY (mains voltage of 400/460 V AC) POWER wer rated urrent 65A (65 kW, 120 A) POWER SUPPLY WITH INTEGRATED PS-25B4-C Example: AUXILIARY 24 V POWER SUPPLY, PS OWER UPPLY (mains voltage of 400/460 V AC) POWER (power, rated current) 25B4 (25 kW, 45 A)
Page 394: Auxiliary Units
   Sales models 12.7 Auxiliary units ACCESORY MODULES MAIN FI LTER 130A-A Example: FAGOR MAINS FILTER MAIN FILTER MAX. CURRENT (A) ·discontinued· 42A-A ·discontinued· 75A-A 130A ·discontinued· 130A-A 180A ·discontinued· 180A-A UXILIARY OWER UPPLY (24 V DC) APS-24 APACITOR ODULE (7.38 mF)
Page 395    Sales models 12.8 Cables F. H12/16 Power cables. Denominations. F. H12/17 Signal cables. Denominations. HARDWARE Ref.1912 F. H12/18 SERCOS-II interface cables. Denominations. · 395 ·...
Page 396    Sales models F. H12/19 CAN interface cable. Denominations. FXM MOTOR CONNECTORS Example: MC 23 FXM POWER CONNECTOR AMC Angled Vertical 23 A MAX. CURRENT 46 A 80 A E0C 12 ENCODER FEEDBACK CONNECTOR (12 pins) Example: MC 61/6 FKM MOTOR CONNECTORS Vertical FKM POWER CONNECTOR...
Page 397: Order Example
   Sales models 12.9 Order example F. H12/21 Order example. HARDWARE Ref.1912 · 397 ·...
Page 398: Unit Identification
   Sales models 12.10 Unit identification Each electronic unit is identified by its characteristics plate. It indicates the sales model and its main technical characteristics. NOTE. The user must make sure that the sales models indicated on the packing list of the order match those supplied by each unit on its characteristics plate before making any connection to avoid any possible shipping errors.
Page 399 380 V AC (50/60 Hz). They all have been now redesigned to work with line voltage ranging between 400/460 V AC (50/60 Hz). Their identification comes on the label that each of these module has. 380 V AC 400- 460 V AC Fagor Automation S.Coop. Fagor Automation, San Andres Auzoa 19 S.Coop.(Spain) 20500 Arrasate-Mondragón...
Page 400: Module Replacement
   Compatibility 13.3 Module replacement Replacing 380 V AC module with a new 460 V AC module involves:  Drive MSC 12A or later.  Auxiliary power supply APS-24 PF 05A and later.  Capacitor module CM-1.60 (version [CAP 00A] [VAR 02A] and later). NOTE.
Page 401    Compatibility 13.6 VECON-3 board This board replaces the VECON-2 board. Version of the VECON-3 board Software version VEC 01A and later 06.18 and later NOTE. It is possible but not recommended to have the same machine with several units where one controls its motor with a 04.xx version and hardware with VECON another one that controls its motor with a 05.xx version and hardware with VECON-2 and a third one that controls its motor with 06.18 version or later and VECON-3 hardware.
Page 402 13.12 CAN board Although this board was already recognized on FAGOR drives since software version 07.0x, now when using a FAGOR drive that has a CAN communication board, always install software version 08.0x. INFORMATION. Remember that all the modules (CNC included) must be set with the same transmission speed.
Page 403    Compatibility 13.15 Type of feedback and CAPMOTOR-2 board Feedback device type Motor feedback board CAPMOTOR-1 Resolver Stegmann encóder CAPMOTOR-1, CAPMOTOR-2 Encoder with square signals U, V and W CAPMOTOR-1, CAPMOTOR-2 Encoder with C and D signals CAPMOTOR-1, CAPMOTOR-2 CAPMOTOR-2 EnDat with incremental A and B signals CAPMOTOR-2...
Page 404    Compatibility HARDWARE Ref.1912 · 404 ·...
Page 406 FAGOR AUTOMATION Fagor Automation S. Coop. Bº San Andrés, 19 - Apdo. 144 E-20500 Arrasate-Mondragón, Spain Tel: +34 943 039 800 Fax: +34 943 791 712 E-mail: info@fagorautomation.es www.fagorautomation.com...

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