FAGOR AUTOMATION
Ref.2101
QC-PDS
Original instructions
FAGOR AUTOMATION
DRAFT/1
SERCOS-II
Quick Reference
QCQR-2|28
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Responsibility exemption
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.
The content of this manual and its validity for the product described
here has been verified. Nevertheless, the information, technical or
otherwise, in these manuals or in any other type of documentation is
not guaranteed to be integral, sufficient or up to date.
Involuntary errors are possible, hence the absolute match is
guaranteed. However, the contents of manuals and documents are
regularly checked and updated implementing the pertinent corrections
in later editions.
Fagor Automation S. Coop. will not be held responsible for any losses
or damage, direct, indirect or by chance that could result from that
information and it will be the user's responsibility to use it.
Responsibility and warranty claims are excluded in case of shipping
damage, wrong usage of the unit in wrong environments or when not
used for the purpose for which it has been designed, ignoring the
warnings and safety indications given in this document and/or legal
ones that may be applied to the work place, software
modifications and
/or repairs made by unauthorized personnel, damage caused by the
influence of other nearby equipment.
EC Declaration of Conformity and Warranty Terms
The warranty terms may be requested from your Fagor Automation
representative or through the usual commercial channels.
The
WARRANTY TERMS
are available in the downloads section of
FAGOR’s corporate website at,
http://www.fagorautomation.com
· type of file: General terms and conditions of purchase - warranty ·
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 ·
Registered trademarks
All registered trade marks, even those not indicated are also
acknowledged. When some are not indicated, it does not mean that they
are free.
January 2021 / Ref.2101
All rights reserved.
No part of this documentation may be copied,
transmitted, transcribed, stored in a backup device or translated into
another language without Fagor Automation’s permission.
Original instructions.
Any translation of the original manual (spanish or
english) will replace the phrase
ORIGINAL INSTRUCTIONS
with
TRANSLATION OF THE ORIGINAL INSTRUCTIONS
.
Full and detailed information.
The
man_qc_pds_ hard.pdf
manual is available in the downloads section
of FAGOR’s corporate website at
http://www.fagorautomation.com
.
DUAL-USE products.
Products manufactured by Fagor Automation S.
Coop. included on the list of dual-use products according to regulation
(UE) Nr 1382/2014. Their product identification includes the text -MDU and
require an export license depending on destination.
· 7 ·
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: QC-PDS
SAFETY COMPONENT (acc. 2006/42/EC)
consisting of the following modules and accessories:
QC-APS-15, QC-APS3-15
QC-PS-025, QC-PS-045
QC-RPS-020, QC-RPS-030, QC-RPS-045, QC-RPS-065, QC-RPS-080, QC-RPS-160
QC-DR-007, QC-DR-012, QC-DR-021, QC-DR-030, QC-DR-040, QC-DR-055
QC-DR-080, QC-DR-120, QC-DR-160, QC-DR-225, QC-DR-275
QC-DR-07+07, QC-DR-12+12, QC-DR-21+21, QC-DR-30+30
ER+TH-
/
, ER+TH-18/
+FAN, QC-CM-75, CHOKE RPS-
, QC-BPM-100-B
MAIN FILTER 42A-A, 75A-A, 130A-A, 180A-A, 275A
FXM, FKM, FS5, FM7, FM9
Note. Some additional characters may follow the model references indicated above. They
all comply with the directives listed here. However, compliance may be verified on the label
of the unit itself.
It complies with all applicable provisions of Directive 2006/42/EC from the European
Parliament and the Council of May 17, 2006, with regard to machinery.
It also complies with all applicable provisions of the following directives:
- Directive 2014/30/EU of the European Parliament and the Council of February 26,
2014, with regard to the approximation of the legislations of the Member States in the
area of electromagnetic compatibility.
- Directive 2014/35/EU of the European Parliament and the Council of February 26,
2014, with regard to the approximation of the legislations of the Member States in the
area of electrical material.
It complies with the following harmonized standards:
LOW VOLTAGE DIRECTIVE
ELECTROMAGNETIC COMPATIBILITY DIRECTIVE
IEC 60204-1:2016
Safety of machinery - Electrical equipment of machines -
Part 1: General requirements.
IEC 61800-5-1:2007
/AMD1:2016
Adjustable speed electrical power drive systems -
Part 5-1: Safety requirements - Electrical, thermal and energy.
IEC 61800-3:2017 Category C3. Adjustable speed electrical power drive systems.
Part 3: EMC requirements and specific test methods.
IEC 61800-5-2:2016 Adjustable speed electrical power drive systems -
Part 5-2: Safety requirements - Functional.
EC DECLARATION
OF CONFORMITY
· 8 ·
MACHINERY DIRECTIVE
Safe Torque Off function satisfies the requirements:
IEC 61800-5-1:2007
IEC 61800-5-1:2007/AMD1:2016
IEC 61800-5-2:2016
IEC 61508-1:2010 (SIL 2)
IEC 61508-2:2010 (SIL 2)
IEC 61508-4:2010 (SIL 2)
EN ISO 13849-1:2015 (Cat. 3, PL d)
which are certified in:
Certificate No.:
Z10 080353 0008 Rev.00
TÜV SÜD, Notified Body 0123
In Mondragón, December 2020
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1 Notes on operating safety
Carefully read the following instructions before using
the system. In these instructions, the operating safety
conditions are identified by the following symbols.
1.1
Personnel qualification
The unit can only be repaired by personnel authorized
by FAGOR AUTOMATION.
Only specialized technicians that know and understand
the contents of this manual and all the documentation
related to the units may handle any of these units.
They must be trained on safety so they can identify and
prevent any danger. Based on their technical training,
knowledge and experience, they must be able to
foresee and recognize any possible danger that may be
caused by using these units, changing their settings
and in general by the mechanical, electrical and
electronic devices that make up the whole system.
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.
2 System Description
2.1 QC-RPS-045-SN0 QUERCUS system
2.2 QC-RPS-160-SN0 QUERCUS system
DANGER or prohibition symbol.
It warns about an immediate dangerous situation.
Ignoring this warning may cause serious, even fatal,
consequences.
WARNING or caution symbol.
It warns about a potentially dangerous situation.
Ignoring this warning may cause serious injuries (even
fatal) or damages to the unit.
MANDATORY symbol.
It warns about actions and operations that MUST BE
carried out. THEY ARE NOT RECOMMENDATIONS. Ignoring
this warning may mean non-compliance of some safety
regulation.
INFORMATION symbol.
Warnings, notes, advice and recommendations.
Ground protection symbol.
It indicates that that point may be under electrical
voltage.
MANDATORY.
Only qualified personnel who know and understand the
contents of this manual and all the other documentation
related to this product and have been properly trained
on aspects of safety in the recognition and prevention
of existing risks, are authorized to work with this QC-
PDS system. Only qualified personnel may install, set
up, repair and maintain this equipment.
i
MANDATORY.
The installation must be fully compliant with all the
requirements of the local and national electrical
regulations and all other applicable regulations.
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3 Product description
3.1 Auxiliary power supplies
The auxiliary power supplies are connected via the
mains filter to three-phase mains with line voltages
between 400 (1-10%) Vac and 480 (1+10%) Vac and
line frequencies between 50 (1- 4%) Hz and 60
(1+3.3%) Hz. The main purpose of the QC-APS3-15 is
to supply the +24 Vdc
required to feed the control
circuits of the QC-DR-275-SS2-
drive and other
equipment connected to the DC BUS, gently start the
QC-RPS-
-SN0 regenerative main power supplies
using its soft-start circuit and protect the motor
against
voltage spikes through its snubber circuit.
3.2 Regenerative power supplies
The regenerative QC-RPS-
-SN0 power supplies are
part of the FAGOR QuerCus-Power Drive System. They
are connected via the CHOKE to the three-phase
mains filter with line voltages between 400 (1-10%) Vac
and 480 (1+10%) Vac and line frequencies of between
5 (1-4%) Hz and 60 (1+3.3%) Hz.
These power supplies do not come with any auxiliary
power supply and, therefore, must ALWAYS be installed
with the QC-APS3-15 external auxiliary power supply.
QC-APS3-15
Status indicator LED's
Associated with the +24 Vdc voltage
Connector Function
X33
Activating the system soft-start
A17
(+/-) DC BUS terminals under lid
A18
+24 Vdc | 15 A, electric power supply output
A20
Terminals L1, L2, L3, FE (
F
unctional
E
arth)
Three-phase power input to the auxiliary power supply
Leds Color Function
Red Amber Green
D1
ON
xx
Over-voltage
D2
ON
xx
Over-current
D3
xx
ON
In the presence of +24 Vdc
WARNING.
The DC BUS discharge period may extend for up to
10 min after the equipment has been disconnected from the
electrical mains. For this reason, always ensure that there is no
voltage in the DC BUS before handling the equipment.
X33
A17
A18
A20
D1|D2|D3
characteristics
plate
RESET.
Auxiliary power supply
initialization button
Version/model
label
Opening
and closing click cover
with bottom pivot hinge
QC-APS3-15
SIZE |0.
Width: 39 mm
M5 screw to
connect the
P
rotective
E
arth.
Tightening torque:
3 N·m
A18.
+24 Vdc output
A17.
( + / - ) D C B U S
QC-RPS-045-SN0 QC-RPS-160-SN0
A17
A18
A17
A19/X11
NODE SELECT
X5
X6
Access lid
to DC BUS.
Opening and
closing click
cover tool with
bottom pivot hinge
X12
X60
Connector Function
A19/X11
U1/U, V1/V, W1/W terminals for the mains phases
derived from the CHOKE
X1
Internal communication bus
X5
RS-232 serial line
X6
SERCOS-II interface
X12
External - KM1 power contactor control.
X60
T1, T2, T3 terminals for the line voltage feedback
X35
Control signals
A17
(
+
,
-
) DC BUS terminals
A18
+24 Vdc electric power supply input
Tightening torque: 5 N·m
M6 screw to connect the
P
rotective
E
arth
X1
X35
Status led
7-segment display
RPS/RB6 switches
version/model
label
A17
A18
BOOT
RESET
QC-RPS-045-SN0
SIZE |3. width: 156 mm
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3.3 Single-drive
The QC-DR-275-SS2-
drive is part of the SERCOS-II
FAGOR QuerC us-Power D rive System. This is
stackable and modular designed single-drive that
govern the torque (or speed and position, along with
the QUERCUS CNC) of synchronous/asynchronous
motor up to 137.5/245.5 A in S1 at 4 kHz.
X12
M8 screw to connect the
P
rotective
E
arth.
Tightening torque: 8 N·m
Access lid to DC BUS.
Opening and closing
click cover tool with
bottom pivot hinge
A18
A17
Connector Function
Top bolts
U1/U, V1/V, W1/W terminals for the mains phases
derived from the CHOKE.
X1
Internal communication bus
X5
RS-232 serial line
X6
SERCOS-II interface
X12
External - KM1 power contactor control.
X60
T1, T2, T3 terminals for the line voltage feedback
X35
Control signals
A17
(
+
,
-
) DC BUS terminals
A18
+24 Vdc electric power supply input
Bottom
bolts
Bolts (
- + + -
) of the DC BUS.
Removable access cover
to DC BUS
SCHORR washers,
M10. Self-locking nuts,
M10 DIN 6923
3x
version/model
label
4x
SCHORR washers.
M10 Self-locking nuts,
M10 DIN 6923
M10 bolts (
- + + -
)
of the DC BUS
under removable
cover
QC-RPS-160-SN0
SIZE |9. width: 390 mm
X1
X6
NODE SELECT
Status led
7-segment display
RPS/RB6 switches
X5
X35
X60
QC-DR-275-SS2-
E21
E21D
X13
M8 screw to connect the
P
rotective
E
arth.
Tightening torque: 8 N·m
Access lid to DC BUS.
Opening and closing click
cover tool with bottom pivot
hinge
QC-DR-275-SS2-
SIZE |9. width: 390 mm
A18
A17
Connector Function
Top bolts
U1/U, V1/V, W1/W motor power connection terminals.
X1
Internal communication bus
X5
RS-232 serial line
X6
SERCOS-II interface
X13/X34
S
afe
T
orque
O
ff (STO) for axis / Do not install
E21/E21D
Motor feedback input / Direct feedback input.
A17
(
+
,
-
) DC BUS terminals
A18
+24 Vdc electric power supply input
Bottom bolts
Bolts (
- + + -
) of the DC BUS.
Removable access cover
to DC BUS.
X34
SCHORR washers,
M10 Self-locking nuts,
M10 DIN 6923
3x
Version/model
label
4x
SCHORR washers.
M10 Self-locking nuts,
M10 DIN 6923
M10 bolts (
- + + -
)
of the DC BUS
under removable
cover
X6
X5
X1
QCQR-8/28
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Mains filters
Its purpose is to reduce any conducted disturbances
deriving from the drive at the levels indicated under IEC
61800-3 category C3 and at the same time make it
immune to voltage spikes or pulses based on IEC
61800-5-2.
Chokes
Its purpose is to modify the currents for the processes
of returning the regenerative power supply to the
mains.
MAIN FILTER 75A-A 275A
MANDATORY. In order to comply with European
Directive 2014/30/EU on Electromagnetic Compatibility,
it is mandatory to insert a mains filter.
INFORMATION.
Take note that the mains filter must be located close to
the main power supply.
Terminals Function
L1-L2-L3
Connection terminals for mains power
L1’-L2’-L3’
Connection terminals for the main power supply
Screws
to connect the
P
rotective
E
arth.
L1-L2-L3
MAINS
L1’-L2’-L3’
LOAD
M5 screw. Tightening torque: 5 N·m
M10 screw to connect the
P
rotective
E
arth.
Tightening torque: 24 N·m
L1’-L2’-L3’
LOAD
L1-L2-L3
MAINS
M10 screw to connect the
P
rotective
E
arth. Tightening torque
: 24
N·m
MAIN FILTER 275A
MAIN FILTER 75A-A
i
CHOKE RPS-45 RPS-160
MANDATORY. ALWAYS install a CHOKE when there are
regenerative power supplies. Select the CHOKE
according to table.
CHOKE RPS-45
CHOKE RPS-160
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Bus protection module
Install in QC-PDS systems having:
Synchronous spindle and only when required by the
application.
Purpose. Protect the power semi-conductors (IGBTs)
of the drive that governs it to prevent damage to the
unit due to a very high voltages that may be
generated at the power bus when the braking energy
cannot be returned during braking and/or
QC-RPS-
-SN0 power supply when only the
controlled stop is to be ensured.
Purpose
. To ensure a controlled stop of the motor
due to mains failure because the energy may be
dissipated while braking at the external Ballast
resistors installed in the QC-BPM-100-B module. Not
installing this module will result in an uncontrolled
stop (by friction) in case of a voltage failure due to an
over-voltage error of the bus because there are no
resistors to dissipate the braking energy.
Capacitor module
Used to store energy that is returned during the electric
motor braking processes. It is also useful for systems
that sporadically demand high power peaks from the
DC power BUS, which in turn increases the capacity of
the BUS.
Braking resistors
Used to dissipate any excess energy generated by the
DC power BUS during electric motor braking. They do
not need an external power supply.
QC-BPM-100-B
Equipment status LEDs
Connector Function
X54
Basic control signal connection.
X56
External braking resistor connection.
A17
(+/-) DC BUS terminals
A18
+24 Vdc, electric power supply input
D57
FAULT
There is an error. Top LED red
BALLAST
Crowbar ON. Middle LED amber
READY
Unit ready. Bottom LED green
WARNING.
The DC BUS discharge period may extend for up to
10 min after the equipment has been disconnected from the
electrical mains. For this reason, always
ensure that there is no
voltage in the DC BUS before handling the equipment.
A18.
+24 Vdc input
A17.
(+/-) DC BUS
QC-BPM-100-B
SIZE |0. width: 39 mm
X54
A17
A18
X56
M5 screw to connect the
P
rotective
E
arth. Tightening torque: 3 N·m
D1|D2|D3
RESET.
Initialization button for
the bus protection
module
Version/model
label
Opening
and closing click
cover with bottom
pivot hinge
Characteristics
plate
QC-CM-75
ER+TH-18/1100
MODULE OHM RMS POWER RESISTANCE
QC-BPM-100-B 18
950 W
ER-TH-18/1100
WARNING. HEAT DANGER. DO NOT TOUCH the surface of
these resistors. Remember that they can sometimes
exceed temperatures of 300 °C (572 °F). If it is installed
in an easily accessible location, precautions must be
taken to prevent unintentional contact. Also avoid heat
sensitive items (cables, etc.) from coming into contact
with the surface to avoid damaging or destroying these
elements and/or causing other more dangerous
situations.
Connector Function
A17
(+/-) DC BUS terminals
WARNING.
The DC BUS discharge period may extend for up to
10 min after the equipment has been disconnected from the
electrical mains. For this reason, always
ensure that there is no
voltage in the DC BUS before handling the equipment.
A17.
(+/-) DC BUS
QC-CM-75
SIZE |1. width: 78 mm
M5 screw to connect the
P
rotective
E
arth.
Tightening torque: 3 N·m
Version/model
label
Opening and closing click
cover with bottom pivot
hinge
characteristics
plate
A17
QCQR-10/28
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4 Dimensions
4.1
Auxiliary power supply, QC-APS3-15
4.2
Power supply, QC-RPS-045-SN0, size|3
4.3
Power supply, QC-RPS-160-SN0, size|9
Element to connect with the external
thermostat
Braking resistor connection
terminals
373
388
39
278.7
R3
7.9
19.5
39
9
R3
R6
39
19.5
7.1
25.5
Units in mm
Mass: 3.6 kg / 7.9 lb
397
39 39 39
156
265.5 373
388
R3
7.9
R3
25.5
7.1
R6
9
19.5
19.5
Units in mm
Mass: 11.0 kg/24.2 lb
491
392.5
7878 78
117
373
390
273
R3
7.9
R3
25.5
7.1
R6
9
19.5
19.5
Units in mm
Mass: 24.0 kg/52.9 lb
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4.4
Single-drive, QC-DR-275-SS2-X, size|9
4.5
Mains filters, MAIN FILTER xA-A
4.6
Chokes, CHOKE RPS-X
4.7 External braking resistor, ER+TH-18/1100
491
392.5
7878 78117
373
390
273
R3
7.9
R3
25.5
7.1
R6
9
19.5
19.5
Units in mm
Mass: 24.0 kg/52.9 lb
270
240
19 19
135
60
255
80
M6
M6
260
235
210
240
300
42
41
15
6-Ø11
60 60
392
6-Ø12
116
PE
M10
20
20
MAIN FILTER 75A-A
MAIN FILTER 275A
Units in mm
Mass: 13.8 kg / 30.4 lb
Units in mm
Mass: 4.0 kg / 8.8 lb
T1 T2 T3 U1 V1 W1
175
136
150
228
15
Ø8
330
Units in mm
Mass: 20.3 kg / 44.7 lb
CHOKE RPS-45
320
386
4-R12.5
110 110 110
455
435
R5
R5
3
4
5
420
31
188.5
8x
Units in mm
Mass: 87.0 kg / 191.8 lb
CHOKE RPS-160
y
FDEOHOHQJKW
PP
WKHUPRVZLWFK&
IDVWRQPP
with external thermostat
ER+TH-18/1100
Units in mm
Mass: 1.25 kg / 2.75 lb
QCQR-12/28
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4.8
Bus protection module, QC-BPM-100-B
4.9
Capacitor module, QC-CM-75
5 Connectors
373
388
278.7
39
R3
7.9
19.5
39
9
R3
R6
39
19.5
7.1
25.5
Units in mm
Mass: 3.4 kg / 7.5 lb
373
39
388
78
266
R3
7.9
R3
25.5
7.1
R6
9
19.5
19.5
Units in mm
Mass: 6.3 kg / 13.9 lb
QC-APS3-15
connector figure cod. pin data
X33
(only for
QC-APS3-
15)
A18
(leftmost
unit)
A18
(rightmost
unit)
A20
QC-RPS-
-SN0
connector figure cod. pin data
A19/X11
(045)
U1/U
V1/V
W1/W
(160)
X60
X12
X35
A18
QC-DR-275-SS2-
connector
figure cod. pin
data
U1/U
V1/V
W1/W
X13
X34
Section 0.5 mm²
Length of socket 10 mm
Length to strip 8 mm
Min/max
tightening torque
0.4/0.5 N·m
Section 2.5 mm²
Screwdriver flathead, 0.6x3.5 mm
Stripped length
7 mm
Min./max.
tightening torque
0.4/0.5 N·m
Section 2.5 mm²
Screwdriver flathead, 0.6x3.5 mm
Stripped length
7 mm
Min./max.
tightening torque
0.5/0.6 N·m
Section 1 mm²
Screwdriver flathead, 0.6x3.5 mm
Stripped length 8 mm
Min./max.
tightening torque
2.5/4.5 N·m
Max. section.
35 mm²
Screwdriver
flathead, 1.0x4.0 mm
Stripped length 20 mm
Screw metric M10
Size of wrench for
hexagonal head
17
Tightening torque 24 N·m
Min./max.
tightening torque
2.5 N·m
Max. section. 35 mm²
Screwdriver TX 20x80
Stripped length 20 mm
Min./max.
tightening torque
0.22/0.25 N·m
Section 1 mm²
Screwdriver flathead, 0.4x2.5 mm
Stripped length 7 mm
Section 0.5 mm²
Length of socket 10 mm
Length to strip 8 mm
Min./max.
tightening torque
0.4/0.5 N·m
Section 2.5 mm²
Screwdriver flathead, 0.6x3.5 mm
Stripped length 7 mm
Screw metric M10
Size of wrench for
hexagonal head
17
Tightening torque 24 N·m
4
Section 0.5 mm²
Length of socket 10 mm
Length to strip 8 mm
2
Section 0.5 mm²
Length of socket 10 mm
Length to strip 8 mm
Q
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eference. Ref.2101 QCQR-13/28
6 Other elements
The QC-RPS-
-SN0 main power supply front panel
houses the connectors and other elements:
Main power supply status indicator LED’s: FAULT,
REGEN, DC BUS ON.
Electronic status indicator: Error codes.
DC BUS command voltage selector swithces to
program the power under boost mode
(RPS mode)
or rectifier mode (RB6 mode).
Buttons: BOOT and RESET.
E21
Motor
feedback
E21D
Direct
feedback
QC-BPM-100-B
connector figure cod. pin data
X54
X56
A18
see feedback pinout
see feedback pinout
1 A+/COS A+ signal / 1Vpp cosine signal generated by the encoder
2 A-/REFCOS A- signal / ref. level for the cosine signal 2.5 Vdc
3 B+/SIN B+ signal / 1Vpp sine signal generated by the encoder
4 B-/REFSIN B- signal / ref. level for the sine signal 2.5 Vdc
5 I0+/CLK+/RS485 I0+/I0- reference mark signals
6 I0-/CLK-/RS485 RS-485 serial line transmission signals
CLOCK+/CLOCK-
· EnDat/SSI · signals
7 DATA+
8 DATA-
9 +5 Vdc Supply voltage
10 +5 Vdc Supply voltage
11 0 Vdc Supply voltage reference
12 0 Vdc Supply voltage reference
13 TEMP- / N. C. Polarity (-) temperature thermistor / Not Connected.
14 +8 Vdc Supply voltage
15 TEMP+ / N. C. Polarity (+) temperature thermistor / Not Connected.
DIRECT FEEDBACK IN:
QC-DR-275-SS2-X
MOTOR FEEDBACK IN:
QC-DR-275-SS2-X
1
2
3
4
5
6
7
8
9
10
11
12
13
14
15
1
2
3
4
5
6
7
8
9
10
11
12
13
14
15
DATA+/DATA- · EnDat/SSI · signals
FEEDBACK PINOUT
Section 0.5 mm²
Length of socket 10 mm
Length to strip 8 mm
Min./max.
tightening torque
0.5/0.6 N·m, S < 4 mm²
0.7/0.8 N·m, S > 4mm²
Min./max. section 0.2/10 mm²
Screwdriver
flathead, 0.6x3.5 mm
Stripped length 10 mm
Min./max.
tightening torque
0.4/0.5 N·m
Section 2.5 mm²
Screwdriver flathead, 0.6x3.5 mm
Stripped length 7 mm
12
QCQR-14/28
Q
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eference. Ref.2101
7 Installation
7.1
Location
Environmental considerations
Climate and cooling considerations
The temperature inside the electrical cabinet containing
the QC-PDS system must not exceed 55°C/131°F
(60°C/140°F with derating).
Clearances in the electrical cabinet
Heat dissipation inside the cabinet
It is recommended to use the following to cool the
electrical cabinet:
Heat exchangers
to avoid the entry of contaminated
air (vapor, suspended iron dust, etc.), eliminating the
possibility of accumulating particles, condensation,
etc. throughout the ventilation pathways.
air extractors
·fans· to prevent the entry of air into the
electrical cabinet.
Place the extractor fan at the top of the cabinet
and the air intake at the bottom.
To have a filter in the air input
. It is also recom-
mended to install a filter in the fan
.
Decrease the air intake speed from the outside by
making the air input window larger than that of the
fan. The required power and air flow depends on
the power installed.
Install the QC-PDS system as far away as
possible from air inputs and outputs.
Carry out periodic maintenance
on air filters.
MANDATORY.
The QC-PDS system which usually includes the
external safety controller is identified as a fixed
installation meant to always work inside an electrical
cabinet with an IP54 protection degree or greater.
Note that the start button, the E-stop button and
other elements may be installed outside the electrical
cabinet (enclosure).
The units must be installed vertically
.
Access to the cabinet must be restricted to qualified
maintenance personnel, who must use a key or tool to
open the door or barrier, clearly marked with the
corresponding warning signs, as stipulated in section
3.5 of IEC 61800-5-1.
Terms Regulation Reference Test
Storage
Ambient
temperature
Meets:
IEC 60721-3-1
IEC 61800-2
1K4,
From -25 ºC to +60 ºC
Shipping
Damp heat
test
(stationary
state)
Meets:
IEC 60068-2-78
IEC 61800-5-1
Disconnected power supply
40ºC +/-2ºC and
93 % +2-3 % without
condensation
Ambient
temperature
Meets:
IEC 60068-2-1
CEI 61800-2
Packed
unit
-25 °C to 70 ºC.
Operation
Ambient test.
Cold
Meets:
CEI 61800-2
5 ºC in running
conditions
Ambient test.
Dry heat
Meets:
IEC 60068-2-2,
Bd test
Under nominal
conditions of 45°C.
Under running
conditions between 5ºC
and 55 ºC
with derating (see derating
characteristic).
Damp
heat test
(stationary
state)
Meets:
IEC 60068-2-78
IEC 61800-5-1
Disconnected power supply.
40 ºC +/-2 ºC
93% +2-3%
non-condensing.
Installation
altitude above
mean
sea level with-
out
Meets:
IEC 61800-5-1
IEC 60664-1
Pollution degree 2 and
altitude of 2 000 amsl
under nominal conditions.
WARNING.
For use under the following ambient and work
conditions:
Interiors without corrosive or explosive gasses.
Ventilated places without dust or metal particles.
Ambient temperature and relative humidity as
indicated in this manual.
Up to 2 000 meters above mean sea level.
Areas that are easily cleaned, maintained and can
be tested.
MANDATORY.
Never install the QC-PDS system next to a heat source.
MANDATORY.
Inside the electrical cabinet, make sure to leave a
clearance of at least 10 cm (3.93 inches) between the
equipment and the top and bottom sections and the front
panel of the cabinet and any other obstacle obstructing
the flow, thereby providing better removal of heat.
MANDATORY.
The ventilation for the electrical cabinet must be enough
to dissipate the heat generated by all the devices and
components working inside.
Module
power dissipated at maximum load
QC-APS3-15 63 W
MAIN FILTER 75A-A 20 W
MAIN FILTER 275A 42 W
QC-BPM-100-B 5 W
QC-CM-75 0 W
Module
axis
4/8 kHz
spindle
S1
spindle
S6-40%
crest/mean
QC-RPS-045-SN0
x
625 W 850/475 W
QC-RPS-160-SN0
x
1860 W 2100/1200 W
QC-DR-275-SS2-
x
1860 W 2100/1200 W
> 100 mm
AIR
AIR
AIR
AIR
> 100 mm
> 100 mm
3.93 in
3.93 in
3.93 in
> 100 mm
> 100 mm
3.93 in
3.93 in
> 100 mm
3.93 in
AIR
AIR
AIR
AIR
size | 0 | 3 size 9
Q
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eference. Ref.2101 QCQR-15/28
Mechanical considerations
Electrical considerations
Electrical conditions
Power supply input.
3 AC, from 400 (1-10 %) Vac to 480 (1+10 %) Vac
DC BUS: 500/800 Vdc
Electrical precautions
Once the installation has been completed and before
handling any of the terminals on the QC-PDS system
equipment, follow the instructions in the order below:
Indications regarding EMC
Electromagnetic Compatibility is covered by the following
standards:
Terms Regulation Reference Test
Shipping
Vibration Meets:
IEC 60721-3-2
Class 2M1, sinusoidal
vibration
2 Hz
f
9 Hz, 3.5 mm
amplitude
9 Hz
f
200 Hz, 1 g
200 Hz
f
500 Hz, 1.5 g.
Jerk limit Meets:
IEC 60721-3-2
IEC 61800-2
Class 2M1,
packed unit
Operation
Ambient
sinusoidal
vibration tests
Meets:
CEI 60068-2-6,
Fc test
Sinusoidal vibration
10 Hz
f
57 Hz,
constant 0.075 mm
amplitude
57
Hz
f
150 Hz,
1 g constant acceleration
Degrees of
sealing pro-
tection
(code IP)
Meets:
EN 60529
Open IP xx.*
Always install inside
an electrical
cabinet.
*
Open IP xx
, to be installed inside a cabinet or assembly that provides the
required access protection.
Meets:
IEC 61800-5-1
Protection
Class
Class I
(with protective conductors)
Over-voltage, category III
Pollution Degree 2
Altitude
2 000 m amsl
Distribution diagrams: TN/TT
Diagrams with grounding on a vertex
are not permitted.
MANDATORY.
The electrical installation should be carried out in
compliance with standard IEC 60204-1.
MANDATORY.
The installation must be fully compliant with all the
requirements of the local and national electrical
regulations and all other applicable regulations.
MANDATORY.
Only qualified personnel who know and understand the
contents of this manual and all the other documentation
related to this product and have been properly trained on
this safety subject to recognize and prevent existing
risks, are authorized to work with this QC-PDS system.
Only qualified personnel may install, set up, repair and
maintain this equipment.
MANDATORY.
As for possible high leak currents (3.5 mA AC or 10 mA
DC), use a protection ground wire with a cross section of
at least 10 mm² (Cu) or 16 mm² (Al) or two protection
ground wires with the same cross section as that of the
wires connected to the power supply terminals. Comply
with local regulations on grounding. Look at the
indicative warning symbol on the equipment.
WARNING.
The system must always be installed before applying
voltage according to the EN 60204-1 standard. Ignoring
it may cause serious injuries, even death.
WARNING.
Do not introduce foreign conductive objects inside the
equipment or handle damaged equipment. They can
generate parasitic tensions. Not following these
instructions may lead to death or serious injury.
WARNING.
Disconnect all power supplies, including the external
power that feeds the control board that could be
present.
Eliminate the mains voltage using an appropriate
switch to obtain a condition without voltage.
Ensure that the motor shaft cannot turn during the
event of an unexpected circumstance.
Wait at least 10 minutes · MAX DISCHARGE TIME:
10 min · until the capacitors on the DC BUS are fully
discharged. This precaution is indicated on the cover
of the DC BUS.
Make sure that the DC BUS voltage is lower than 60
Vdc. This precaution is indicated on the front of the
equipment near the DC BUS cover under the
heading · CAUTION, RISK OF ELECTRICAL
SHOCK ·
Assemble and close all covers and connect the
QC-PDS system to the ground before supplying
voltage.
MANDATORY.
The EMC directive defines equipment as any device or
fixed installation. This device is identified as a fixed
installation and is meant to work inside an electrical
cabinet according to category C3 and is IEC 61800-3
compliant.
IEC 61800-3:
2017
*note)
Category C3. Variable speed electrical power
drive systems. Part 3: EMC product standard,
including specific testing methods.
IEC 61800-5-2:
2016
Variable speed electrical power drive systems.
Part 5-2: Security requirements - Functional.
* note)
MANDATORY.
The EMC directive defines equipment as any device or
fixed installation. This device is identified as a fixed
installation and is meant to work inside an electrical
cabinet according to category C3 and is IEC 61800-3
compliant.
QCQR-16/28
Q
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EMC instructions for equipment installation
Use equipotential wires in systems with:
* note)
MANDATORY.
The installation that includes this product may need a
harmonic suppressing filter to comply with the standard
IEC 61800-3 which is harmonized with the EMC
Directive. Otherwise, when applying solutions to limit the
harmonics for each QC-PDS system included in the
installation, this could be an expensive solution and/or it
might not make any technical sense. It is better to apply a
global solution
* note)
MANDATORY.
This type of Power Drive System is not designed to be
used with a domestic low-voltage power supply mains.
Radio frequency disturbances may be expected when
used in this case. However, equipment whose
compliance with the essential requirements set out
under the heading 1. GENERAL REQUIREMENTS of ANNEX I
of the EMC Directive that are not ensured in residential
areas will include an indication with this restriction on
use.
MANDATORY.
Use the copper and aluminum plates that are
provided as accessories during mounting.
Make the connections with wide contact surfaces for
the metal parts.
Remove any paint from the contact surfaces.
Try to increase conductivity on two-dimensional
contacts.
Install a protection circuit if there is a risk of over-
voltage.
Move power lines away from signal lines. Remember
that electric fields can induce voltage peaks in signal
lines, which decreases when there is more distance
between them.
Move the motor cable at least 20 cm away from the
signal cable or use shielding plates between the
motor cable and signal cable.
Do not install field bus or signal cables through a
single conduit with DC and AC lines with voltages
over 60 V. The field bus cables, signal lines and
analog lines can be installed in a same conduit.
It is recommended to separate the cable installation
conduits by at least 20 cm, or make them as short as
possible. Do not install unnecessary cable loops and
use short cables from the central ground point for
connecting to a ground point outside the electrical
cabinet.
Avoid induction loops by choosing common routes
for power, signal and data circuit cables.
Use shielded cables for the power supply and motor.
For 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.
MANDATORY.
Installations in large areas.
Different voltage sources.
Mains through several buildings reducing the current
in the cable shield and the emissions. Connect to
ground the electrical cabinet, the door, the mounting
plate, with ground straps or cables with a cross
section larger than 10 mm² (AWG 6).
The digital signal wire shielding must be connected
at both ends to a large surface or through a
conductive housing of the connector. This reduces
disturbances that affect the signal cables and also
the emissions.
The analog signal wire shielding must be connected
directly to the device (signal input), reducing the
ground loops due to low frequency disturbances.
Make shield connection on the grounded side of the
equipment when a device does not have a ground
connection.
Do not use the conduits as grounding conductors;
use the ground protection conductor inside the
conduits.
Use cable and ground clamps to connect large areas
of cable shield.
Install a single uncut shielded cable. If a cable must
necessary be cut for the installation, connect it with
the shield connections and through a metal cover at
the cut (joint) point. In the worst case, if it is not
possible to use shielded connectors, keep the
shortest length possible of cable exposed to
interferences, so as to ensure a sound connection
between the shields.
Install switching devices such as contactors, relays
or electro-valves with interference suppression
elements or arc suppressors (e.g. diodes, varistors,
RC circuits).
Install power and control components separately.
Use equipotential cables when having long lines to
reduce the current through the cable shield.
When connecting power cables, the shield of this
cable should be connected to a ground bar.
MANDATORY.
Run a single shielded cable, in one piece, without
joints. If a cable must necessary be cut for the
installation, connect it with the shield connections
and through a metal cover at the cut (joint) point. In
the worst case, if it is not possible to use shielded
connectors, keep a minimum length of cable
exposed to disturbances guaranteeing a good
connection between the shields. See figure ·A·.
When connecting the single-pole power cables to
the motor, the shield for this cable should be
connected to a chassis support. See figure ·B·.
When connecting power cables to the motor
feedback and direct feedback, the shield for these
cables should be connected to a ground bar
(Grounding Plate-2). See figure ·C·.
Q
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uick
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eference. Ref.2101 QCQR-17/28
Inductive components
Installing the QC-PDS 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. Thus:
All inductive circuits or components must have their
own interference suppressor that must be installed
as close as possible to the inductive component.
The mentioned interference suppressors will be RC
circuits, varystors or suppressor diodes.
Do not install the excitation cables of the inductive
components and the signal cables in the same
channel, especially when shielded cables are not
available for these signals.
Note: A typical scenario is when using inductive
proximity switches or similar usually connected with
an unshielded cable.
In extreme situations, and if the sensors on the
machine are very sensitive to interference being
carried along the 24 Vdc power cables, it may be
necessary to isolate or decouple their power supply
from that of the power supply of the other system
elements (inductive components, drives, etc.).
MANDATORY.
Do not
use fly diodes as interference suppression
elements for inductive components. These diodes can
only serve as interference suppressor of the inductance
due to the cabling itself.
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QCQR-18/28
Q
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C
us - Power Drive System.
Q
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R
eference. Ref.2101
7.2 Mechanical installation
Preparing the fasteners
Use the holes and slots prepared for the purpose of fastening the equipment. It is essential to avoid vibrations. Where necessary,
use shock-absorbing lanyards. ALWAYS use the clamp provided as an accessory for the size|0 modules. The reason for installing
this clamp is to join the size|0 module with the adjacent module in order to avoid or minimize vibrations. See figures below.
QC-CM-75 / QC-RPS-045-SN0 / QC-DR-275-SS2-X
QC-APS3-15 / QC-BPM-100-B
3 N·m
M5
RECOMMENDED
WASHER
DIN 125, M5
3 N·m
M5
RECOMMENDED
WASHER
DIN 125, M5
R3
25.5
7.1
R6
9
19.5
R3
7.9
19.5
M5
3 N·m
RECOMMENDED
WASHER
DIN 125, M5
RECOMMENDED
WASHER
DIN 125, M5
3 N·m
M5
R3
7.9
19.5
39
9
R3
R6
39
19.5
7.1
25.5
Dimensions in mm, 1 in = 25.4 mm
39 39 39
156
QC-RPS-045-SN0
QC-APS3-15
39
39
39
15
R3.15
MAIN FILTER 75A-A
5 N·m
M6
RECOMMENDED
WASHER
DIN 125 M6
A
5 N·m
M6
RECOMMENDED
WASHER
DIN 125, M6
B
INSTALL THE MAIN FILTER 75A-A
NEXT TO THE POWER SUPPLY
A
B
7.5
10
10
15
R3.15
7.5
373
7811778
QC-DR-275-SS2-X
390
78
QC-BPM-100-B
39
39
39
78
QC-CM-75
39
80
A
B
29.5
75A-A
MAINS
LOAD
60
255
QC-DR-275-SS2-X CHASSIS SUPPORT
42
277
294
thickness 1.50
111.5
4-R2.75
SHIELDS TO
CHASSIS SUPPORT
POWER BOLT PROTECTOR
PROTECTIVE EARTH
SCREW FOR THE
CHASSIS SUPPORT
METAL CLAMP
CHASSIS SUPPORT
U1/U PHASE. SINGLE-POLE
MOTOR POWER CABLE
RPS-45 CHOKE
15
Ø8
QC-CM-75 / QC-RPS-160-SN0 / QC-DR-275-SS2-X
RECOMMENDED
WASHER
DIN 125, M5
INSTALL THE MAIN FILTER 275A
NEXT TO THE POWER SUPPLY
QC-APS3-15 / QC-BPM-100-B
Dimensions in mm, 1 in = 25.4 mm
MAIN FILTER 275A
M5
3 N·m
L3'
6-Ø12
244
L2
L1'
L1
MAINS
L3
275A
LOAD
122
L2'
235
19.5
9
R3
R6
39
78
390
19.5
7.1
25.5
QC-RPS-160-SN0
M5
3 N·m
RECOMMENDED
WASHER
DIN 125, M5
373
39
QC-APS3-15
39
39
A
B
A
B
RECOMMENDED
WASHER
DIN 125, M5
3 N·m
M5
R3
7.9
A
3 N·m
RECOMMENDED
WASHER
DIN 125, M5
M5
78 78
39
7811778
RECOMMENDED
WASHER
DIN 125, M10
M10
24 N·m
QC-DR-275-SS2-X
24 N·m
B
M10
M10
390
78
122
24 N·m
117
R6
R3
7.1
9
19.5
25.5
R3
19.5
7.9
235
260
392
6-Ø12
210
244
300
60 60
RPS-160 CHOKE
R5
R5
3
8x
8 N·m
M8
RECOMMENDED
WASHER
DIN 125 M8
ALWAYS INSTALL THE RPS-160 CHOKE
INSIDE THE ELECTRICAL CABINET AND
FIXED TO THE FLOOR
42
277
294
thickness 1.50
111.5
4-R2.75
SHIELDS TO
CHASSIS SUPPORT
POWER BOLT PROTECTOR
PROTECTIVE EARTH
SCREW FOR THE
CHASSIS SUPPORT
METAL CLAMP
CHASSIS SUPPORT
U1/U PHASE. SINGLE-POLE
MOTOR POWER CABLE
QC-DR-275-SS2-X CHASSIS SUPPORT
QC-BPM-100-B
39
39
39
78
QC-CM-75
39
MAIN FILTER 275A
Q
uer
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us - Power Drive System.
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uick
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eference. Ref.2101 QCQR-19/28
Loading the DC BUS
Couple the plates that are provided as accessories and designed for the purpose of making DC BUS equipment connections
comprising the system and tighten the M5x16 DIN 7985T combined screws. See the figure.
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QC-RPS-045-SN0
DC BUS
QC-APS3-15
QC-BPM-100-B
QC-CM-75
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QC-BPM-100-B
QC-CM-75
DC BUS
QCQR-20/28
Q
uer
C
us - Power Drive System.
Q
uick
R
eference. Ref.2101
7.3 Electrical installation
Mains connection
The FAGOR QC-PDS system is designed to be
connected to a three-phase mains with line voltages
between 400 (1-10%) Vac and 480 (1+10%) Vac and
line frequencies between 48 ... 62 Hz.
Certain mandatory protection devices must be added to
the lines that extend from mains to the FAGOR QC-
PDS system. Others are optional.
Protection fuses
On the lines coming from the mains
To protect the QC-PDS system, fuses must be included
on the lines coming from the mains.
Recommended fuses
Any of the fuses in the previous table may be installed to
obtain the maximum power. In cases where it is
oversized, the fuse value should be adjusted to the actual
requirements of the machine.
For the lines that reach the A20 connector of auxiliary
power supply
The lines leading to the QC-APS3-15 auxiliary power
supply via the A20 connector require external time-lag
protection fuses or a 6.3 A circuit breaker, as this auxiliary
power supply does not have its own built-in protection
fuses.
Whether fuses or circuit breakers are installed, always
follow the local regulations in the country of destination
as well as machine safety if it has to comply with any
safety regulations
Differential breaker
On a QC-PDS system, fault DC current, practically flat,
may come up besides the AC currents and pulsating DC
currents. This requires the use of a differential breaker
.
Isolation transformer or auto-transformer
When the mains voltage must be isolated or adapted to
the levels required by the QC-PDS 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 EC regulation.
The connection may vary depending on the type of mains
and electromagnetic compatibility required by it.
If the type of mains does not require isolating
transformers and they only require a voltage adaptation;
we recomment to install auto-transformers instead of
isolating transformation.
After the transformer, so as to modify the mains to the
range of 400/480 Vac, the following are placed in the
following order: the main switch - S1, the protection
fuses, the differential breaker - Q1 and the
electromagnetic interference MAIN FILTER
A-A. Also,
if the main power supply is regenerative, the main - KM1
contactor and CHOKE.
MANDATORY.
Install the mains filter and the CHOKE in the positions
as indicated in the diagrams provided below.
INFORMATION
FAGOR does not supply the fuses, i.e., the QC-PDS
system does not include the fuses as accessories. See
recommended fuses.
QC-RPS-045-SN0 QC-RPS-160-SN0
Min. prospective
shortcircuit current
5 000 A 5 000 A
MANUFACTURER
SIBA
10 010 07.125 20 610 32.315
20 001 04.125
50 140 06.125
Semi-conductor fuses according to UL 248 to be installed in the
mains line according to the QC-PDS model. Nominal voltage in
AC, UN
500 Vac. High cut-off power
100 kA.
WARNING.
Using other protection devices instead of fuses
(magneto-thermal switches, for example) does no
guarantee proper protection of the equipment.
QC-APS3-15 external auxiliary power supply
SIBA 189020.6.3 T 6.3 A 500 Vac 80 A² s
MANDATORY.
Always install external protection fuses or circuit
breakers on the lines that feed auxiliary power supply via
the A20 connector for the QC-APS3-15.
i
MANDATORY.
Install a universal type B breaker (valid for AC, pulsating
DC and flattened DC currents) and selective switch-off
(delayed switch-off).
WARNING.
Never use AC type differential breakers. The use of
differential breakers sensitive to pulsating currents and,
overall, general purpose differential breakers can cause
undesired stops due to the high sensitivity of these
devices to pulsating currents.
INFORMATION.
As an alternative, Type A differential breakers may be
used with selective switch-off. They are more
economical than type-B ones and are usually valid for
QC-PDS systems with a FAGOR filter. The off current
must not be lower 500 mA and should have a selective
switch-off.
WARNING.
Watch out for the total leak current when several
machines share a differential breaker. All of them may
add up to a considerable value.
MANDATORY.
When installing an isolating transformer, the secondary
must a have a star (Y) configuration with access to the
mid point which must be connected to grond.
i
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Fagor CNC 8058elite M User manual
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