Fagor CNC 8060 for lathes Owner's manual

DRIVE

MAB

Hardware manual

Ref.1810

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

conditions 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.

October 2018 / Ref.1810

transmitted, transcribed, stored in a backup device or translated into

another language without Fagor Automation’s permission.

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.

Original manual. Any translation of the original manual (spanish or

english) will replace the phrase ORIGINAL INSTRUCTIONS with

TRANSLATION OF THE ORIGINAL INSTRUCTIONS.

ORIGINAL INSTRUCTIONS

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GENERAL INDEX

EC DECLARATION OF CONFORMITY ............................................................................................ 7

TÜV SÜD FUNCTIONAL SAFETY CERTIFICATE ........................................................................... 9

TÜV SÜD NATIONALLY RECOGNIZED TESTING LABORATORY CERTIFICATE..................... 11

RELATIONSHIP BETWEEN TYPE MODELS & COMMERCIAL MODELS ................................... 13

ABOUT THIS MANUAL................................................................................................................... 15

ABOUT THE PRODUCT.................................................................................................................. 16

Software options............................................................................................................................... 16

Shipment .......................................................................................................................................... 17

Storage............................................................................................................................................. 17

Decommissioning and eliminating.................................................................................................... 17

SHIPPING CONDITIONS, STORAGE, DECOMMISSION AND DISPOSAL .................................. 17

VERSION HISTORY ........................................................................................................................ 19

SAFETY CONDITIONS.................................................................................................................... 21

EC DECLARATION OF CONFORMITY, WARRANTY TERMS AND QUALITY CERTIFICATES. 24

RECOMMENDED DOCUMENTATION............................................................................................ 25

1 DESCRIPTION................................................................................................................................. 27

General diagrams............................................................................................................................. 28

System description ........................................................................................................................... 33

System configuration diagrams........................................................................................................ 35

Insulation diagram of a machine system ..........................................................................................37

Stages of the system configuration .................................................................................................. 38

Ambient and operating conditions .................................................................................................... 39

Electrical conditions.......................................................................................................................... 40

2 REGENERATIVE MULTI-AXIS DRIVE............................................................................................ 41

Outside look ..................................................................................................................................... 42

Technical data .................................................................................................................................. 43

Load duty cycles............................................................................................................................... 45

Derating graph.................................................................................................................................. 46

Motor-axis association...................................................................................................................... 49

Connectors ....................................................................................................................................... 51

Light indicators ................................................................................................................................. 75

Push buttons .................................................................................................................................... 79

3 NON-REGENERATIVE MULTI-AXIS DRIVE .................................................................................. 81

Outside look ..................................................................................................................................... 82

Technical data .................................................................................................................................. 83

Load duty cycles............................................................................................................................... 86

Derating graph.................................................................................................................................. 87

Motor-axis association...................................................................................................................... 91

Connectors ....................................................................................................................................... 94

Light indicators ............................................................................................................................... 119

Push buttons .................................................................................................................................. 123

4 AUXILIARY MODULES ................................................................................................................. 125

Mains filters .................................................................................................................................... 126

CHOKES ........................................................................................................................................ 127

External Ballast resistors................................................................................................................ 129

Bus protection module. BPM.......................................................................................................... 135

Additional AXD drive ...................................................................................................................... 140

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5 SELECTING CRITERIA................................................................................................................. 141

Selection of the synchronous motors .............................................................................................141

Synchronous motor association - axes A|B|C|S............................................................................. 146

Asynchronous motors selection ..................................................................................................... 149

Asynchronous motor/S-axis relation............................................................................................... 155

Power required from the main power supply of the MAB ............................................................... 156

Ballast resistor selection guide....................................................................................................... 159

6 POWER LINE CONNECTION ....................................................................................................... 161

Mains connection ........................................................................................................................... 161

Protection fuses.............................................................................................................................. 165

Differential breaker ......................................................................................................................... 167

Isolating transformer or auto-transformer.......................................................................................168

Mains filter ...................................................................................................................................... 169

Distribution diagrams...................................................................................................................... 170

Mains connection cables ................................................................................................................ 174

7 CABLES......................................................................................................................................... 175

Mains connection cable.................................................................................................................. 176

Power cable. MAB-MOTORS connection ...................................................................................... 177

Motor feedback cables ................................................................................................................... 179

Direct feedback cable..................................................................................................................... 182

SERCOS optical fiber..................................................................................................................... 183

RS-232 serial line ........................................................................................................................... 184

8 INSTALLATION ............................................................................................................................. 185

Location.......................................................................................................................................... 186

Inductive components .................................................................................................................... 191

System installation ......................................................................................................................... 192

Mechanical connections ................................................................................................................. 196

Electrical connections..................................................................................................................... 199

Connection of the control and communications signals ................................................................. 218

Checking the installation ................................................................................................................ 224

9 FUNCTIONAL SAFETY................................................................................................................. 225

Main characteristics of the safety functions....................................................................................227

Inputs/Outputs of the safety function channels .............................................................................. 228

Fault detection and reaction ........................................................................................................... 229

Design requirements ............................................................................................................

.......... 231

Electrical precautions ..................................................................................................................... 233

Residual risks ................................................................................................................................. 234

Technical data of the safety functions ............................................................................................ 235

Response time of the safety functions ...........................................................................................236

Cabling and grounding ................................................................................................................... 237

Commissioning............................................................................................................................... 238

Maintenance, repair and analysis of hazardous events ................................................................. 239

Decommission and disposal........................................................................................................... 241

Indications regarding electrical safety, environmental conditions and EMC .................................. 242

10 CONNECTION DIAGRAMS...........................................................................................................243

SAFETY EMERGENCY STOP. CNC 8060 + MAB-R-XXX-3XX + SAFETY EMERGENCY ......... 243

11 DIMENSIONS................................................................................................................................. 245

Multi-Axis Box................................................................................................................................. 246

Additional AXD drives..................................................................................................................... 248

Bus protection module, BPM.......................................................................................................... 251

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Mains filters .................................................................................................................................... 252

Chokes ........................................................................................................................................... 253

External Ballast resistors with external thermostat......................................................................... 254

External Ballast resistor with internal thermostat ........................................................................... 255

External Ballast resistors with external thermostat and cooling fan ............................................... 256

External thermostat ........................................................................................................................ 257

12 SALES MODELS .......................................................................................................................... 259

Synchronous servomotors.............................................................................................................. 260

Asynchronous motors..................................................................................................................... 261

MAB drives ..................................................................................................................................... 262

Auxiliary units ................................................................................................................................. 263

Cables ............................................................................................................................................ 264

AXD modular drives ....................................................................................................................... 266

Unit identification ............................................................................................................................ 267

13 APPENDIX|A1 ............................................................................................................................... 269

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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: MAB

SAFETY COMPONENT (acc. 2006/42/EC)

consisting of the following types:

MABNL1001, MABNL1100, MABNL1110, MABNL1111, MABNH1100, MABNH1110,

MABNH1111, MABRL1110, MABRL1111, MABRH1110, MABRH1111, MABRL1001,

MABRL1100

and of the following modules and accessories:

ER+TH-/, ER+TH-/+FAN, CHOKE MAB-R--, BPM

MAIN FILTER 42A-A, MAIN FILTER 75A-A

FKM, FS5, FM7

Note. Some additional characters may follow the references mentioned above. They all

comply with the directives listed. Therefore, all MAB equipment bears the EC marking on

the rating plate.

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 60204-1:2005

/A1:2008

Machine safety. Electrical equipment of the machines.

Part 1: General requirements.

IEC 61800-5-1 Ed.2.0 Adjustable speed electrical power drive systems - Part 5-1:

Safety requirements - Electrical, thermal and energy.

IEC 61800-3:2004

/A1:2011

Category C3. Adjustable speed electrical power drive systems.

Part 3: EMC requirements and specific test methods.

IEC 61000-6-7:2015 In Safety Related Parts.

Electromagnetic compatibility (EMC) - Part 6-7: Generic stan-

dards - Immunity requirements for equipment intended to

perform functions in a safety-related system (functional safety)

in industrial locations.

EC DECLARATION

OF CONFORMITY

MACHINERY DIRECTIVE

The safety functions Safe Torque Off and Safe Brake Control meet the requirements

set out in:

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:

Certificate No.: Z10 17 03 80353 003

TÜV SÜD, Notified Body 0123

In Mondragón, April 2017

RELATIONSHIP BETWEEN TYPE

MODELS & COMMERCIAL

MODELS

TYPE MODELS COMMERCIAL MODELS

MABNL1110 MAB--075-2 / MAB--075-2-MDU / MAB-000-3-L / MAB--000-3-L-MDU

MABNL1111 MAB--075-3 / MAB--075-3-MDU / MAB--000-4-L / MAB--000-4-L-MDU

MABNH1100 MAB--000-2-H / MAB--000-2-H-MDU

MABNH1110 MAB--150-2 / MAB--150-2-MDU / MAB--000-3-H / MAB--000-3-H-MDU

MABNH1111 MAB--150-3 / MAB--150-3-MDU / MAB--000-4-H / MAB--000-4-H-MDU

MABRL1110 MAB-R-075-2 / MAB-R-075-2-MDU / MAB-R-000-3-L / MAB-R-000-3-L-MDU

MABRL1111 MAB-R-075-3 / MAB-R-075-3-MDU / MAB-R-000-4-L / MAB-R-000-4-L-MDU

MABRH1110 MAB-R-150-2 / MAB-R-150-2-MDU / MAB-R-000-3-H / MAB-R-000-3-H-MDU

MABRH1111 MAB-R-150-3 / MAB-R-150-3-MDU / MAB-R-000-4-H / MAB-R-000-4-H-MDU

M A B X Y A B C D

M A B , T Y P E M O D E L S

X

M

U L T I

- A

X I S

B

O X

N

N o n r e g e n e r a t i v e p o w e r

R

R e g e n e r a t i v e p o w e r

Y

L

H

H i g h p o w e r

L o w p o w e r

A

0

1

X 1 1 S n o n m o u n t e d

B

0

1

X 1 1 A n o n m o u n t e d

C

0

1

X 1 1 B n o n m o u n t e d

D

0

1

X 1 1 C n o n m o u n t e d

X 1 1 S m o u n t e d

X 1 1 A m o u n t e d

X 1 1 B m o u n t e d

X 1 1 C m o u n t e d

MAB, COMMERCIAL MODELS

MABULTI- XIS OX

POWER

SUPPLY

none

R

non-regenerative

regenerative

Example:

MAB - - 000 - 3 - L - MDU

DRIVE

·SPINDLE·

000

without spindle

DRIVE

·AXES·

OPTION

·AXES·

DUAL

USE

075

7.5 kW

150

15 kW

2

2 axes

3

3 axes

4

4 axes

none

standard

without spindle ·standard current·

- L

without spindle ·high current·

- H

none

no

yes

- MDU

References MAB-R-000- currently not available.

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ABOUT THIS MANUAL

Títle DRIVE MAB. Hardware manual.

Type of documentation Description, installation and start-up of FAGOR's MAB system.

Electronic document man_mab_hard.pdf.

Language English.

Manual reference Ref.1810.

Web The user must always use the latest reference (version) of this manual,

available on FAGOR'S corporate website.

http://www.fagorautomation.com

Email [email protected]

Internal code Manual code.

It belongs to the manual directed to the machine manufacturer.

Startup

Warning

Headquarters Fagor Automation, S. Coop.

B.º San Andrés 19, apdo. 144

C.P. 20500 - Arrasate - Mondragón

Gipuzkoa (Spain)

www.fagorautomation.com

[email protected]

MAN MAB HARD (IN) Código 04754101

DANGER. In order to comply with the CE seal indicated on the component,

check that the machine incorporating the MAB system meets the

specifications of Machine Directive 2006/42/CE.

Before starting the MAB system up, read the instructions in chapter 1 of this

manual.

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.

Customer

service

+ 34 943 719200

Technical

service

+ 34 943 771118

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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 indicated in the software manual.

ABOUT THE PRODUCT

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Shipment

When shipping the unit, do it protected against blows and pack it in its original cardboard box with its

original packing material. If you do not have the original packaging material, pack it as follows:

1. Get a cardboard box whose 3 inside dimensions are at least 15 cm (6 inches) larger than those of the

unit itself. The cardboard used to make the box must have a resistance of 170 kg (375 lb).

2. Attach a label to the unit indicating the owner of the unit, his address, name of the contact person, type

of device and the serial number.

3. In case of failure, also indicate the symptom and a short description of the failure.

4. Protect the unit wrapping it up with a roll of polyethylene or with similar material.

5. Pad the unit inside the cardboard box filling it with polyurethane foam on all sides.

6. Seal the cardboard box with packaging tape or with industrial staples.

Storage

Store the product only under the allowed ambient conditions indicated here. See this data in chapter 1 of

this manual. Always protect the product against dust and dirtiness.

Decommissioning and eliminating

The machine manufacturer must indicate the procedure to be used for shuting the machine down.

Respect environmental regulations. Note that none of the multi-axis MAB drives or extra AXD drives of

the MAB system carries batteries.

Bear in mind the storage and shipping requirements when getting rid of MAB and AXD units.

Recycling. The product is made of various materials that may be recycled and eliminated separately. Get

rid of the product in compliance with local regulations.

SHIPPING CONDITIONS, STORAGE,

DECOMMISSION AND DISPOSAL

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The history of versions shows the list of the hardware elements added in each manual version. To know

the features added in each software version and the version of the manual that describes them, see

software manual.

VERSION HISTORY

Manual reference Events

1704

First version

1712

SELV/PELV power supply for the STO/SBC and STOFB/SBCFB

1810

Further information on the status LEDs of each axis.

The ·MAB 4TH AXIS ACCESSORIES· bag is required for the installation,

along with the MAB for an additional AXD 1.XX drive or a second MAB.

Replace FAULT legends for the STATUS legends on the cover.

Modification of the nominal and peak current values on the S axis for MAB--

075--- models and MAB--000--L models.

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