Fagor DDS XPS-25 User Manual

Installation
8.
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DDS
HARDWARE
Electrical considerations
Indications regarding EMC
Electromagnetic Compatibility is covered by the following standards:
EMC instructions for equipment installation
MANDATORY.
The electrical installation my comply with standard EN 60204-1.
T. H8/2 Standards regarding Electromagnetic Compatibility.
EN 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.
* 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 meeting the EN
61800-3 standard.
*
MANDATORY. The installation that includes this DDS system may need a
harmonic suppressing filter to comply with the standard EN 61800-3:2004
which is harmonized with the EMC Directive. Otherwise, when applying
solutions to limit the harmonics in each DDS system included in the installation
(except in systems with RPS, that would not require them) could be an
expensive solution and/or would not make any technical sense. It is better to
apply a global solution.
MANDATORY. These Power Drive Systems are not meant to be used in a
low voltage public mains that supplies energy to house installations. Radio
frequency disturbances may be expected when used in this case. However,
equipment whose compliance with the essential requirements set out in item
1. General requirements of annex I of the EMC Directive that are not ensured
in residential areas will include an indication with this use restriction.
MANDATORY.
Use galvanized or chromed plates in the installation.
Make the connections with wide contact surfaces for the metal parts.
Remove the paint from contact surfaces.
Try to increase conductivity on two-dimensional contacts.
Install a protection circuit if there is a risk of over-voltage.
Electrical energy supply lines from the lines carrying the information.
Note. The electrical field which could induce voltage spikes on the information
lines decreases with distance.
Route the motor cable at a distance of at least 20 cm from the signal cable
or use shielding plates between the motor cable and signal cable.
Do not run field bus cables and signal 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.
Recommendation
. Separate the conduits where the cables are running at
least 20 cm and 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.

Fagor DDS XPS-25 Specifications

General

Brand	Fagor
Model	DDS XPS-25
Category	DC Drives
Language	English

Summary

DRIVE DDS Hardware manual

Description

General diagram

Schematic representation of the elements composing the DDS system.

Stages of the system configuration

Steps for configuring and installing the DDS system.

Environmental conditions

Conditions related to the operating environment for the DDS system.

Electrical conditions

Electrical specifications and requirements for the DDS system.

Power Supplies

Non-regenerative power supplies

Details on PS-25B4 and PS-65A non-regenerative power supplies.

Regenerative power supplies

Details on XPS-25 and XPS-65 regenerative power supplies.

Regenerative regulated power supplies

Details on RPS power supplies in RPS and RB6 modes.

Drives

Modular drives

Overview and models of AXD, SPD, and MMC modular drives.

Compact drives

Overview and models of ACD, SCD, and CMC compact drives.

Auxiliary Modules

MAIN FILTER

Description and technical data for FAGOR MAIN FILTER models.

CHOKES

Details on XPS and RPS chokes for regenerative power supplies.

Resistor modules

Information on external ballast resistors with internal or external thermostats.

Capacitor Module, CM-1.75

Details on the CM-1.75 capacitor module for DC BUS energy storage.

Auxiliary power supply module

Details on the APS-24 auxiliary power supply module.

Bus Protection Module. BPM

Description and technical data for the BPM bus protection module.

Selecting Criteria

Selection of the synchronous motor and its associated drive

Guide for selecting synchronous motors and associated drives based on torque and speed.

Asynchronous spindle motor and drive selection

Procedure for selecting asynchronous spindle motors and drives for machine tools.

Power supply selection

Criteria for selecting the appropriate power supply based on motor requirements.

Capacitor module selection guide

Guidance on selecting the CM-1.75 capacitor module for DC BUS applications.

Ballast resistor selection guide

Guidelines for selecting the correct ballast resistor for power supplies and drives.

Power Line Connection

Mains connection

Connecting the DDS system to the three-phase mains, including required protection devices.

Protection fuses

Selection and installation of fuses for DDS system protection.

Differential breaker

Requirement and selection of differential breakers for DDS systems.

Isolating transformer or auto-transformer

Use of transformers for voltage adaptation and isolation in DDS systems.

Mains filter

Mandatory installation of mains filters for EMC compliance.

Line inductance

Function and selection of line inductance (chokes) for harmonic reduction.

Distribution diagrams

Types of distribution diagrams (TN, TT, IT) and their impact on cabling.

Mains connection cables

Information on FAGOR mains connection cables for power supply and compact drives.

Cables

Mains connection cable. Power supply - mains connection

Details on FAGOR mains connection cables for power supplies and compact drives.

Power cable. Motor-drive connection

Information on FAGOR power cables for connecting motors and drives.

Motor feedback cables

Range of motor encoder cables for FXM, FKM, and FM7 motors.

CA-D1-D4 adapter cable

Adapter cable for transmitting absolute signals from linear/torque motors to AXD/ACD drives.

Direct feedback cable

Cables for connecting incremental or absolute feedback devices.

Signal cables for control and communications

Cables for encoder simulation and control signals.

SERCOS-II optical fiber

Fiber optic cables for SERCOS-II communications between CNC and drives.

CAN cable

FAGOR supplied CAN cables for communication between drives and master devices.

RS232/RS422 BE adapter

Adapter for connecting RS-232 or RS-422 serial lines with VT panels.

RS-232 serial line

Connection diagrams for RS-232 serial lines between PC, VT, and drives.

RS-422 serial line

Connection diagrams for RS-422 serial lines between VT and drives.

Installation

Location

Considerations for placing the DDS system within an electrical cabinet.

Climatic considerations

Temperature limits for the electrical cabinet housing the DDS system.

Electrical considerations

Guidelines for electrical installation, EMC, and wiring practices.

Use equipotential wires in systems with:

Recommendations for equipotential wiring and cable shielding.

Cabinet heat dissipation

Strategies for cooling electrical cabinets containing the DDS system.

8.2 Inductive components

Precautions for connecting inductive components like contactors and relays.

8.3 System installation

Procedure for installing the DDS system modules in the electrical cabinet.

8.4 Connection between modules

Instructions for connecting modules via the power bus and chassis.

Joining the chassis between modules

Procedure for mechanically connecting module chassis using bolts and plates.

Ground connection

Requirements for grounding the DDS system chassis and cable shields.

Internal bus connection

Connecting modules using the internal bus via ribbon cables.

Ballast resistor connection in power supplies and compact drives

Configuration for connecting internal or external ballast resistors.

How to plug and unplug the Ballast connector

Procedure for connecting and disconnecting ballast connectors on compact drives.

How to install AN external Ballast resistor with internal thermostat and with no fan

Installation guide for external ballast resistors with internal thermostat.

How to install AN external Ballast resistor with an external thermostat and with no fan

Installation guide for external ballast resistors with external thermostat.

How to install AN external Ballast resistor with internal thermostat and fan

Installation guide for external ballast resistors with internal thermostat and fan.

How to install TWO external Ballast resistors in parallels

Procedure for installing two external ballast resistors in parallel.

Ohm values

Information on Ohm values for external ballast resistors.

Ballast resistor connection to the bus protection module, BPM

Connecting ballast resistors to the BPM module.

How to install A resistor ER+TH-18/1100 to the BPM module

Procedure for installing ER+TH-18/1100 resistor to the BPM module.

How to install TWO resistors ER+TH-18/1100 in parallel to the BPM module

Procedure for installing two ER+TH-18/1100 resistors in parallel to BPM.

How to install THREE resistors ER+TH-18/1100 in parallel to the BPM module

Procedure for installing three ER+TH-18/1100 resistors in parallel to BPM.

Heat dissipation

Considerations for heat dissipation from external ballast resistors.

8.5 Power supply connections

Connecting power supplies to modules and drives.

Power supply for the control of modules

Details on the 24 V DC supply for control circuits of modules.

Connection of the APS-24 power supply

Connecting the APS-24 to PS-65A and modular drives.

Connection of the auxiliary power supply of the PS-25B4 and the XPS

Connecting auxiliary power supply to PS-25B4 and XPS.

Connection of the auxiliary power supply of the RPS

Connecting auxiliary power supply to RPS power supplies.

8.6 Connection of the control and communications signals

Connecting motor feedback and control signals.

Motor feedback connection

Connecting the motor feedback device (encoder) to the drive.

TSIA-1. Temperature sensor isolation adapter

Using the TSIA-1 adapter for galvanic isolation of temperature sensors.

Direct feedback connection

Connecting linear or rotary encoders for direct feedback.

Encoder simulator connection

Connecting the encoder simulator board to the CNC.

Connection for the reception of the analog command

Receiving analog velocity commands from the CNC via connector X7.

Connection for the digital outputs

Protection circuits for optocouplers when connecting inductive loads.

SERCOS ring connection

Connecting drives to CNC via SERCOS digital communication.

Interconnection

Connecting drives in the SERCOS ring and closing the ring.

Handling fiber optic cables

Proper handling procedures for fiber optic cables.

Transmission speed selection

Selecting SERCOS transmission speed using the BOOT button.

Transmission speed changing procedure

Procedure for changing the SERCOS transmission speed.

Values that may be assigned to the transmission speed

Possible values for SERCOS transmission speed.

CAN connection with an ESA Video Terminal VT

Connecting the ESA Video Terminal to FAGOR drives via CAN bus.

CAN connection with a FAGOR 8037 CNC

Connecting FAGOR 8037 CNC to drives via CAN bus.

CAN connection with a FAGOR 8055i CNC

Connecting FAGOR 8055i CNC to drives via CAN bus.

CAN BUS connection

Overview of CAN bus functions and connection.

Line terminating resistor (RT)

Ensuring RT activation for external elements connected to the CAN bus.

Transmission speed selection

Selecting CAN transmission speed using the BOOT button.

Transmission speed changing procedure

Procedure for changing CAN transmission speed.

Values that may be assigned to the transmission speed

Possible values for CAN transmission speed.

CAN connection with an ESA Video Terminal VT

Connecting the ESA Video Terminal to FAGOR drives via CAN bus.

CAN connection with a FAGOR 8037 CNC

Connecting FAGOR 8037 CNC to drives via CAN connector.

CAN connection with a FAGOR 8055i CNC

Connecting FAGOR 8055i CNC to drives via CAN connector.

CAN connection with a FAGOR 8055 UC

Connecting FAGOR UC 8055 to drives via CAN connector.

RS-422 serial line connection

Connecting drives via RS-232/422 serial line without adapter.

RS-422 serial line connection between a VT and several drives · without adapter ·

RS-422 serial line connection between ESA VT and MMC/CMC drives without adapter.

RS-422 serial line connection between a VT from ESA and several MMC or CMC drives · without adapter ·.

RS-422 serial line connection between ESA VT and MMC/CMC drives without adapter.

RS-232/422 serial line connection between PC/ESA VT

Connecting PC/ESA VT via RS-232/422 serial line for project transfer.

RS-232 serial line connection between PC/DRIVE

Connecting PC to drive via RS-232 serial line for setup.

8.7 Check the installation

Final checks after installation to ensure proper setup.

Check the installation:

List of checks for mechanical and electrical installation.

Functional Safety

Contents

Topics covered in the functional safety chapter.

Certified functional safety standards

Information on TÜV SÜD functional safety standards.

EC marking of the machine by the machine manufacturer

Requirements for EC marking of machines using drive safety functions.

9.1 Main characteristics of the safety functions

Overview of safety functions like STO, Cat. 3 PL d - SIL 2.

9.2 Drive Enable input and AS1-AS2 feedback output

Interface for STO safety function: Drive Enable input and AS1-AS2 feedback.

9.3 Fault detection and reaction

How the system detects and reacts to faults in safety functions.

9.4 Design requirements

Design requirements for safety functions, including STO and SS1.

9.5 Electrical precautions

Safety precautions for electrical installation and operation.

9.6 Residual Risks

Assessment and reduction of residual risks associated with safety functions.

9.7 Technical data of the safety functions

Technical data for calculating Performance Level (PL) and Safety Integrity Level (SIL).

9.8 Response time of the safety functions

Response times for machine and drive safety functions.

9.9 Cabling and grounding

Recommendations for cabling and grounding safety functions.

9.10 Commissioning

Procedures for acceptance and partial acceptance tests of safety functions.

9.11 Maintenance, repair and analysis of hazardous events

Guidelines for mission times, failure probabilities, and maintenance.

9.12 Decommission and disposal

Requirements for decommissioning and disposal of the unit.

9.13 Electrical safety, environmental conditions and EMC

Overview of safety, environmental, and EMC considerations.

Connection Diagrams

10.1 SPD modular drive with FM7 asynchronous spindle motor

Connection diagram for SPD modular drive with FM7 motor and TTL encoder.

10.2 AXD modular drive with FKM synchronous axis servomotor

Connection diagram for AXD drive with FKM servomotor and E3 encoder.

10.3 AXD modular drive with FXM synchronous axis servomotor

Connection diagram for AXD drive with FXM servomotor and E1 encoder.

10.4 SCD compact drive with FM7 asynchronous spindle motor

Connection diagram for SCD compact drive with FM7 motor and TTL encoder.

10.5 ACD compact drive with FKM synchronous axis servomotor

Connection diagram for ACD drive with FKM servomotor and encoder.

10.6 ACD compact drive with FXM synchronous axis servomotor

Connection diagram for ACD drive with FXM servomotor and encoder.

10.7 Regulador compacto ACD 1.25-S0-0-B-L con motor lineal

Connection diagram for ACD 1.25 drive with linear motor and S2AI encoder.

10.8 Electrical cabinet. Diagrams

General diagrams for power and control circuits in the electrical cabinet.

10.9 Diagrams with a PS-65A power supply

Connection diagrams for a DDS system with PS-65A power supply.

10.10 Diagrams with a PS-25B4 power supply

Connection diagrams for a DDS system with PS-25B4 power supply.

10.11 Diagrams with a XPS power supply

Connection diagrams for a DDS system with XPS power supply.

10.12 Diagrams with an RPS power supply

Connection diagrams for a DDS system with RPS power supply.

10.13 ACD/SCD compact system diagrams, SERCOS connection

Connection diagrams for ACD/SCD compact systems using SERCOS.

10.14 ACD/SCD compact system diagrams, CAN connection

Connection diagrams for ACD/SCD compact systems using CAN bus.

10.15 AXD/SCD diagrams of a mixed system, SERCOS connection

Connection diagrams for mixed AXD/SCD systems using SERCOS.

10.16 AXD/SCD diagrams of a mixed system, CAN connection

Connection diagrams for mixed AXD/SCD systems using CAN bus.

10.17 Holding brake connection diagram

Diagrams for connecting holding brakes to FXM and FKM motors.

10.18 On-the-fly start/delta connection switching on FM7 spindles, E03|HS3 series

Diagram for start/delta connection switching on FM7 spindles.

DIMENSIONS

11.1 Power supply modules

Dimensions for PS-25B4 power supply module.

PS-65A

Dimensions for PS-65A non-regenerative power supply.

XPS-25

Dimensions for XPS-25 regenerative power supply.

XPS-65

Dimensions for XPS-65 regenerative power supply.

RPS-20

Dimensions for RPS-20 regenerative regulated power supply.

RPS-45

Dimensions for RPS-45 regenerative regulated power supply.

RPS-75

Dimensions for RPS-75 regenerative regulated power supply.

RPS-80

Dimensions for RPS-80 regenerative regulated power supply.

APS-24

Dimensions for APS-24 auxiliary power supply.

11.2 Modular drives

Dimensions for AXD/SPD/MMC 1.08 and 1.15 modular drives.

AXD/SPD/MMC 1.25

Dimensions for AXD/SPD/MMC 1.25 modular drives.

AXD/SPD/MMC 1.35

Dimensions for AXD/SPD/MMC 1.35 modular drives.

AXD/SPD/MMC 2.50, AXD/SPD/MMC 2.75, SPD 2.85

Dimensions for AXD/SPD/MMC 2.50/2.75 and SPD 2.85 drives.

AXD/SPD/MMC 3.100, AXD/SPD/MMC 3.150

Dimensions for AXD/SPD/MMC 3.100/3.150 modular drives.

AXD/SPD/MMC 3.200, AXD/SPD/MMC 3.250

Dimensions for AXD/SPD/MMC 3.200/3.250 modular drives.

11.3 Compact drives

Dimensions for ACD/SCD/CMC 1.08 and 1.15 compact drives.

ACD/SCD/CMC 1.25

Dimensions for ACD/SCD/CMC 1.25 compact drives.

ACD/SCD/CMC 2.35, ACD/SCD/CMC 2.50, ACD/SCD/CMC 2.75

Dimensions for ACD/SCD/CMC 2.35/2.50 and 2.75 compact drives.

11.4 Bus Protection Module, BPM

Dimensions for the BPM bus protection module.

11.5 Capacitor Module, CM-1.75

Dimensions for the CM-1.75 capacitor module.

11.6 Mains filters

Dimensions for FAGOR MAIN FILTER models.

11.7 XPS CHOKES

Dimensions for XPS-25 and XPS-65A chokes.

11.8 RPS CHOKES

Dimensions for RPS-20, RPS-45, and RPS-75-3 chokes.

11.9 External Ballast resistors with external thermostat

Dimensions for external ballast resistors with external thermostat.

11.10 External Ballast resistors with internal thermostat

Dimensions for external ballast resistors with internal thermostat.

11.11 External Ballast resistors with external thermostat & cooling fan

Dimensions for external ballast resistors with thermostat and fan.

11.12 External thermostat

Dimensions for external thermostat.

Sales Models

Synchronous servo motors

Denominations for FAGOR FXM and FKM synchronous servo motors.

Asynchronous motors

Denominations for FAGOR FM7 and FM9 asynchronous motors.

Modular drives

Denominations for AXD, SPD, and MMC modular drives.

Compact drives

Denominations for ACD, SCD, and CMC compact drives.

Positioning drives

Denominations for MMC and CMC positioning drives.

Power supplies

Denominations for FAGOR PS, XPS, and RPS power supplies.

Auxiliary units

Denominations for FAGOR auxiliary modules like filters, chokes, etc.

Cables

Denominations for FAGOR power, signal, and interface cables.

Connectors

Denominations for connectors on FXM and FKM servo motors.

Order example

Example of how to place an order for FAGOR catalog products.

Unit identification

Information on identifying electronic units via characteristic plates.

Compatibility

13.1 Mains voltage

Line voltage ranges supported by FAGOR drives and power supplies.

13.2 Compatibility

Compatibility of elements with mains voltages and drive versions.

13.3 Module replacement

Guidelines for replacing 380 V AC modules with 460 V AC modules.

13.4 VECON board

Compatibility of VECON boards with software versions.

13.5 VECON-2 board

Information on VECON-2 board replacement and software versions.

13.6 VECON-3 board

Information on VECON-3 board replacement and software versions.

13.7 VECON-4 board

Information on VECON-4 board replacement and software versions.

13.8 Boot for VECON-2

Loading software versions on VECON-2 boards.

13.9 Boot for VECON-3

Loading software versions on VECON-3 boards.

13.10 Boot for VECON-4

Loading software versions on VECON-4 boards.

13.11 SERCOS card (16 MBd)

Compatibility of SERCOS card with software versions and transmission speeds.

13.12 CAN board

Compatibility of CAN board with FAGOR drives and software versions.

13.13 CAPMOTOR-x boards

Compatibility of CAPMOTOR-x boards with feedback types and software versions.

13.14 VECON-x boards

Compatibility of VECON-x boards with software versions.