Fagor CNC 8037 Owner's manual

Type
Owner's manual
DRIVE
DDS
Hardware manual
Ref.1912
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.
CE 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.
December 2019 / Ref.1912
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.
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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DDS
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GENERAL INDEX
I.
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 ............................................................................................................................. 17
SAFETY CONDITIONS ........................................................................................................................ 19
EC DECLARATION OF CONFORMITY AND WARRANTY TERMS .................................................. 22
RECOMMENDED DOCUMENTATION ................................................................................................ 23
1 DESCRIPTION ........................................................................................................................... 25
Description .................................................................................................................................. 26
General diagram ......................................................................................................................... 27
Stages of the system configuration .............................................................................................28
Insulation diagram of a machine system ..................................................................................... 29
Environmental conditions ............................................................................................................ 30
Electrical conditions .................................................................................................................... 30
2 POWER SUPPLIES .................................................................................................................... 31
Non-regenerative power supplies ............................................................................................... 32
Regenerative power supplies ...................................................................................................... 50
Regenerative regulated power supplies ...................................................................................... 66
3 DRIVES .......................................................................................................................
................ 95
Modular drives ............................................................................................................................ 96
Compact drives ......................................................................................................................... 140
Turning a drive on ..................................................................................................................... 176
4 AUXILIARY MODULES ............................................................................................................ 179
Mains filters ............................................................................................................................... 180
Chokes ...................................................................................................................................... 182
External Ballast resistors .......................................................................................................... 184
Capacitor module. CM-1.75 ...................................................................................................... 189
Auxiliary power supply. APS-24 ................................................................................................ 190
Bus protection module. BPM .................................................................................................... 194
5 SELECTING CRITERIA ........................................................................................................... 199
Selection of the synchronous motor and its associated drive ................................................... 199
Asynchronous spindle motor and drive selection ...................................................................... 204
Power supply selection ............................................................................................................. 210
Capacitor module selection guide ............................................................................................. 220
Ballast resistor selection guide ................................................................................................. 221
6 POWER LINE CONNECTION .................................................................................................. 223
Mains connection ...................................................................................................................... 223
Protection fuses ........................................................................................................................ 225
Differential breaker .................................................................................................................... 227
Isolating transformer or auto-transformer ................................................................................. 228
Mains filter ................................................................................................................................. 230
Line inductance ......................................................................................................................... 231
Distribution diagrams ................................................................................................................ 232
Mains connection cables ........................................................................................................... 234
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7 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 ........................................................................................................ 249
RS-232 serial line ...................................................................................................................... 250
RS-422 serial line ...................................................................................................................... 254
8 INSTALLATION ........................................................................................................................ 257
Location .................................................................................................................................... 258
Inductive components ............................................................................................................... 265
System installation .................................................................................................................... 266
Connection between modules ................................................................................................... 269
Power supply connections ........................................................................................................ 285
Connection of the control and communications signals ............................................................ 287
Check the installation ................................................................................................................ 306
9 FUNCTIONAL SAFETY ........................................................................................................... 307
Main characteristics of the safety functions .............................................................................. 309
Drive Enable input and AS1-AS2 feedback output ................................................................... 310
Fault detection and reaction ...................................................................................................... 311
Design requirements ................................................................................................................. 313
Electrical precautions ................................................................................................................ 315
Residual risks ............................................................................................................................ 316
Technical data of the safety functions ....................................................................................... 317
Response time of the safety functions ...................................................................................... 318
Cabling and grounding .............................................................................................................. 319
Commissioning ......................................................................................................................... 320
Maintenance, repair and analysis of hazardous events ............................................................ 321
Decommission and disposal ..................................................................................................... 323
Indications regarding electrical safety, environmental conditions and EMC ............................. 324
10 CONNECTION DIAGRAMS ..................................................................................................... 325
SPD modular drive with FM7 asynchronous spindle motor ...................................................... 325
AXD modular drive with FKM synchronous axis servo motor ................................................... 326
AXD modular drive with FXM synchronous axis servo motor ................................................... 326
SCD compact drive with FM7 asynchronous spindle motor ..................................................... 327
ACD compact drive with FKM synchronous axis servo motor .................................................. 328
ACD compact drive with FXM synchronous axis servo motor .................................................. 329
Electrical cabinet. Diagrams ..................................................................................................... 330
Diagrams with a PS-65A power supply ..................................................................................... 335
Diagrams with a PS-25B4 power supply ................................................................................... 337
Diagrams with a XPS power supply .......................................................................................... 339
Diagrams with an RPS power supply ........................................................................................ 341
ACD/SCD compact system diagrams, SERCOS connection ................................................... 343
ACD/SCD compact system diagrams, CAN connection ........................................................... 345
AXD/SCD diagrams of a mixed system, SERCOS connection ................................................. 347
AXD/SCD diagrams of a mixed system, CAN connection ........................................................ 348
Holding brake connection diagram ........................................................................................... 350
On-the-fly start/delta connection switching on FM7 spindles, E03|HS3 series ......................... 351
11 DIMENSIONS ........................................................................................................................... 353
Power supply modules .............................................................................................................. 354
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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 & cooling fan ............................................. 377
External thermostat 377
12 SALES MODELS ...................................................................................................................... 379
Synchronous servo motors ....................................................................................................... 380
Asynchronous motors ............................................................................................................... 382
Modular drives .......................................................................................................................... 384
Compact drives ......................................................................................................................... 385
Positioning drives ...................................................................................................................... 386
Power supplies .......................................................................................................................... 387
Auxiliary units ............................................................................................................................ 388
Cables ....................................................................................................................................... 389
Order example .......................................................................................................................... 391
Unit identification ....................................................................................................................... 392
13 COMPATIBILITY ...................................................................................................................... 393
Mains voltage ............................................................................................................................ 393
Compatibility ............................................................................................................................. 393
Module replacement ................................................................................................................. 394
VECON board ........................................................................................................................... 394
VECON-2 board ........................................................................................................................ 394
VECON-3 board ........................................................................................................................ 395
VECON-4 board .................................................................................................................
....... 395
Boot for VECON-2 .................................................................................................................... 395
Boot for VECON-3 .................................................................................................................... 395
Boot for VECON-4 .................................................................................................................... 395
SERCOS card (16 MBd) ........................................................................................................... 395
CAN board ................................................................................................................................ 396
CAPMOTOR-x boards .............................................................................................................. 396
VECON-x boards ...................................................................................................................... 396
Type of feedback and CAPMOTOR-2 board ............................................................................ 397
Recognizing RPS power supplies ............................................................................................. 397
APS-24 auxiliary power supply with PS, XPS or RPS .............................................................. 397
Power supplies compatible with FM9 motors ............................................................................ 397
Transfer of « *.mot » files. Motor table ...................................................................................... 397
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· 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: DDS
SAFETY COMPONENT (acc. 2006/42/EC)
consisting of the following modules and accessories:
APS-24, PS-25B4, PS-65A, XPS-25, XPS-65
RPS-80, RPS-75, RPS-45, RPS-20
AXD/SPD 1.08, 1.15, 1.25, 1.35, 2.50, 2.75, 2.85, 3.100, 3.150, 3.200, 3.250
ER+TH-/, ER+TH-18/+FAN, CM-1.75, CHOKE XPS, CHOKE RPS, BPM
MAIN FILTER 42A-A, 75A-A, 130A-A, 180A-A
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 60204-1:2005
/A1:2008
Safety of machinery - Electrical equipment of machines -
Part 1: General requirements.
IEC 61800-5-1:2007 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 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 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 09 80353 007
TÜV SÜD, Notified Body 0123
Units whose manufacturing date is the same as or later than 2012-05 comply with this
certificate. The date appears on the version label stuck on the outside of the drive.
Equipment included:
Are excluded the equipment with CAN communication and drives:
In Mondragón, September 2017
AXD X.XXX-A1-X-X AXD X.XXX-SI-X-X SPD X.XXX-A1-X-X SPD X.XXX-SI-X-X
AXD X.XXX-S0-X-X AXD X.XXX-SD-X-X SPD X.XXX-S0-X-X
AXD X.XXX-C0-X-X ACD X-XXX-XX-X-X MMC X.XXX-XX-XX.XX-X-X-X
SPD X.XXX-C0-X-X SCD X-XXX-XX-X-X CMC X.XXX-XX-XX.XX-X-X-X
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DDS
HARDWARE
Title DRIVE DDS. Hardware manual.
Type of documentation Description, installation and start-up of FAGOR DDS system.
Electronic document man_dds_hard.pdf.
Language English.
Manual reference Ref.1912.
Web The user must always use the latest reference of this manual, available on
FAGOR'S corporate website.http://www.fagorautomation.com.
Internal code It belongs to the manual directed to the machine manufacturer (OEM).
The manual code is:
Startup
Warning
Headquarters Fagor Automation, S. Coop.
B.º San Andrés 19, apdo. 144
C. P. 20500 - Arrasate - Mondragón
Gipuzkoa (Spain)
www.fagorautomation.com
ABOUT THIS MANUAL
MAN REGUL (IN) STAN Code 04754001
DANGER. In order to comply with the EC seal indicated on the component,
verify that the machine on which the DDS system is installed complies with
European Directive 2006/42/EC on machine safety.
Before starting the DDS 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.
+34-943-039800 (customer support)
+34-943-791712 (customer support)
+34-943-795047 (SAT, headquarters)
+34-934-744375 (SAT, Catalonia)
16
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· 14 ·
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.
ABOUT THE PRODUCT
Ref.1912
· 15 ·
DDS
HARDWARE
Shipping
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. 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 and name of the person to contact,
type of unit and 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.
Decommission and disposal
The machine manufacturer must indicate the procedure to be used for decommissioning the machine.
Respect environmental regulations. Observe that the AXD/SPD drives do not carry batteries.
Bear in mind the storage and shipping requirements when disposing of the AXD/SPD 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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· 17 ·
DDS
HARDWARE
VERSION HISTORY
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 the
“man_dds_soft.pdf” manual that is supplied with this one.
Manual reference Events
9702
First version
9707
PS-65, RM-15, CM-60, APS-24, AXD/SPD 3.xx
9802
Compact 8, 25, 50, 75, DDS PROG MODULE
9810
XPS-25, XPS-65.
9904
New fanned motors FXM.
New SPM 180M motor.
New products (mains voltage 460 V AC).
Description and installation of the XPS.
New drive AXD/SPD 1.35
EMK filters
0002
only in CD Rom
SPMxx.1 Motors
PS-25B3 and PS-25B4
ER resistors
WinDDSSetup
Improved AXD/SPD 1.15.
Digital I/O boards
0103
No new hardware has been implemented
0112
FXM motors at 400-15 % V AC
MMC and CMC drives
ACD/SCD 1.08/1.15 drive (compact)
Crowbar resistor: ER-18/1800 and ER-18/2200
RS-422 interface for MMC and CMC drives
0303
New drive SPD 2.85
New drive SPD 3.200
New capacitor module CM 1.60 (replaces the previous CM 60)
New spindle motors FM7 (E01 and E02 versions)
0305
New encoder E3 (similar to E2 but with tapered shaft).
0310
No new hardware has been implemented
0403
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.
0405
From this version on, our catalogs show the mains filter model “MAIN
FILTER 42A” and “MAIN FILTER 130A”.
0407
No new hardware has been implemented.
0410
New SERCOS board
(transmission speed up to 16Mbd)
0602
New compact drives: ACD/SCD/CMC 1.25A
New compact drives: ACD/SCD/CMC 2.35
New resistors: ER-33/550 and ER-18/900 (as accessory)
Regenerative regulated power supplies. Boost (step-up) power
supplies: RPS-75, RPS-45 and RPS-20.
CHOKE RPS-75, CHOKE RPS-45 and CHOKE RPS-20.
0606
No new hardware has been implemented.
0612
New choke XPS-65 (smaller and lighter).
20
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· 18 ·
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.
New CAPMOTOR-2 board.
0806
The choke RPS-75-3 replaces the choke RPS-75.
There are now 3 switches for selecting the ballast resistor on PS-65A
power supplies.
0811
The following are being replaced:
External 18/1800 W Ballast resistor that is supplied as an accessory
in certain units for 18/1800W with internal thermostat.
External Ballast resistor ER-18/2200 by ER+TH-18/2200 with internal
thermostat.
0905
External 24/750W Ballast resistor that is supplied as an accessory in
certain units for 24/750W with external thermostat.
Changing the power connector for motor connection at SPD 3.200
drives.
1003
The external ballast resistor with fan ER-18/1000+FAN has been
replaced with the new ER+TH-18/1000+FAN with fan and external
thermostat.
The auxiliary APS 24 power supply has been modified and it can now
be connected to the DC bus of the PS, XPS and RPS power supplies.
New regenerative regulated power supply RPS-80.
New modular spindle drive SPD 3.250.
1107
No new hardware has been implemented.
1109
No new hardware has been implemented.
1209
Functional safety. STO safety function.
New spindle compact drive SCD 2.75.
1305
New CHOKE XPS-65-A that replaces the CHOKE XPS-65.
1307
New VECON-4 board.
1406
The Ballast aerial connector has been changed on all compact drives.
New capacitor module ·CM-1.75· (replaces the ·CM-1.60·).
RPS power supplies. RPS mode (boost) and RB6 mode (rectifier).
Mains filter. MAIN FILTER 75A” for RPS-45.
Temperature sensor isolation adapter ·TSIA-1·.
1502
Bus Protection Module ·BPM·.
1601 Reorganization of texts for electrical safety and functional safety.
New mains filter: ·MAIN FILTER 130A-A· for PS-65A.
New commercial models -MDU (dual-use).
1605
Mains filter ·MAIN FILTER 42A-A· for PS-25B4, XPS-25, RPS-20, and
ACD/SCD x.x replacing MAIN FILTER 42A.
Mains filter ·MAIN FILTER 130A-A· for XPS-65 and RPS-75 replacing
MAIN FILTER 130A.
1702
Mains filter ·MAIN FILTER 75A-A· for RPS-45
1710
TÜV SÜD FUNCTIONAL SAFETY certificate update.
1711
No new hardware has been implemented.
1807 Changing the sensor position of the thermostat for the braking resistors
ER+TH-...+ FAN.
Equipment for working in industrial graphite environments:
Power supplies: PS-25B4-C, RPS-20-C,
Drives: AXD 1.15-S0-2-C, AXD 1.25-S0-2-C, AXD 1.35-S0-2-C
CA-D1-D4 adapter cable for the connection of the linear motor or
torque motor feedback to the motor feedback board of the drive.
Manual reference Events
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DDS
HARDWARE
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.
Manual reference Events
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Fagor CNC 8037 Owner's manual

Type
Owner's manual

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