Fagor QC-PDS User manual

DRIVE QC-PDS
Hardware manual
Ref.2003

ORIGINAL INSTRUCTIONS
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·.
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.
March 2020
/
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GENERAL INDEX
EC DECLARATION OF CONFORMITY ............................................................................................ 7
TÜV SÜD FUNCTIONAL SAFETY CERTIFICATE .......................................................................... 9
COMMERCIAL MODELS ................................................................................................................ 11
RATINGS ......................................................................................................................................... 12
ABOUT THE MANUAL.................................................................................................................... 13
ABOUT THE PRODUCT.................................................................................................................. 14
SHIPPING CONDITIONS, STORAGE, DECOMMISSION AND DISPOSAL .................................. 15
VERSION HISTORY ........................................................................................................................ 17
SAFETY CONDITIONS.................................................................................................................... 19
EC DECLARATION OF CONFORMITY, WARRANTY TERMS AND QUALITY CERTIFICATES. 22
RECOMMENDED DOCUMENTATION............................................................................................ 23
1 DESCRIPTION................................................................................................................................. 25
General Diagrams ............................................................................................................................ 26
System Description .......................................................................................................................... 30
System Configuration Diagrams....................................................................................................... 31
Insulation Diagram of a Machine System......................................................................................... 35
Stages of the System Configuration................................................................................................. 36
Ambient and Operating Conditions .................................................................................................. 37
Electrical Conditions......................................................................................................................... 38
2 POWER SUPPLIES ......................................................................................................................... 39
Non-regenerative Power Supplies.................................................................................................... 40
Regenerative Power Supplies .......................................................................................................... 53
3 DRIVES ............................................................................................................................................ 81
Single-drives..................................................................................................................................... 82
Status indicator LED's .................................................................................................................... 119
Dual-drives ..................................................................................................................................... 121
Status indicator LED's .................................................................................................................... 137
4 AUXILIARY MODULES ................................................................................................................. 139
Mains Filters ................................................................................................................................... 140
Chokes ........................................................................................................................................... 142
External Braking Resistors ............................................................................................................. 146
Thermostats Associated with External Resistors ........................................................................... 149
Capacitor Module ........................................................................................................................... 150
External Auxiliary Power Supplies.................................................................................................. 152
Bus Protection Module ................................................................................................................... 166
5 SELECTING CRITERIA................................................................................................................. 175
Synchronous motor selection ......................................................................................................... 175
Axis motor-drive matching.............................................................................................................. 180
Asynchronous motor selection ....................................................................................................... 182
Spindle motor-drive matching......................................................................................................... 188
Selecting the main power supply.................................................................................................... 190
Calculation for the input transformer power and cable section ...................................................... 197
Ballast resistor selection guide....................................................................................................... 198
6 POWER LINE CONNECTION ....................................................................................................... 199
Mains connection ........................................................................................................................... 199

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Protection fuses.............................................................................................................................. 202
Differential breaker ......................................................................................................................... 204
Isolating transformer or auto-transformer.......................................................................................205
Mains filter ...................................................................................................................................... 206
Choke ............................................................................................................................................. 208
Distribution diagrams...................................................................................................................... 212
Mains connection cables ................................................................................................................ 214
7 CABLES......................................................................................................................................... 215
Mains connection cables ................................................................................................................ 216
Power cables. DRIVE|MOTOR connection .................................................................................... 218
Motor feedback cables ................................................................................................................... 221
Direct feedback cable..................................................................................................................... 225
SERCOS-III Interface Ethernet Cables .......................................................................................... 226
SERCOS-II interface fiber optics.................................................................................................... 228
RS-232 serial line cable ................................................................................................................. 230
8 INSTALLATION ............................................................................................................................. 231
Location.......................................................................................................................................... 232
Inductive components .................................................................................................................... 243
System installation ......................................................................................................................... 244
Mechanical connections ................................................................................................................. 251
Electrical connections..................................................................................................................... 253
Connection of the control and communications signals ................................................................. 285
Checking the installation ................................................................................................................ 301
9 FUNCTIONAL SAFETY................................................................................................................. 303
Main Characteristics of the Safety Functions ................................................................................. 305
Inputs/Outputs of the Safety Function Channels............................................................................ 306
Fault Detection and Reaction ......................................................................................................... 307
Design Requirements..................................................................................................................... 309
Electrical Precautions..................................................................................................................... 312
Residual Risks................................................................................................................................ 313
Technical Data of the Safety Functions..........................................................................................314
Response Time of the Safety Functions ........................................................................................ 315
Cabling and Grounding .................................................................................................................. 316
Commissioning............................................................................................................................... 317
Maintenance, Repair and Analysis of Hazardous Events .............................................................. 318
Decommission and Disposal .......................................................................................................... 319
Electrical Safety, Environmental Conditions and EMC................................................................... 320
10 CONNECTION DIAGRAMS...........................................................................................................321
11 DIMENSIONS................................................................................................................................. 323
Non-Regenerative Main Power Supplies ....................................................................................... 324
Regenerative Main Power Supplies ............................................................................................... 326
Single-Drives .................................................................................................................................. 331
Dual-Drives..................................................................................................................................... 342
Auxiliary Power Supplies................................................................................................................ 344
Bus Protection Module ................................................................................................................... 346
Capacitor Module ........................................................................................................................... 347
Mains Filters ................................................................................................................................... 348
Chokes ........................................................................................................................................... 349
Brake Resistors with External Thermostat ..................................................................................... 351

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Brake Resistors with Internal Thermostat ...................................................................................... 352
Brake Resistors with External Thermostat and Fan ....................................................................... 353
External Thermostat ....................................................................................................................... 354
12 COMMERCIAL MODELS .............................................................................................................. 355
Synchronous Servomotors ............................................................................................................. 356
Asynchronous Motors..................................................................................................................... 357
Modular Drives ............................................................................................................................... 359
Power Supplies .............................................................................................................................. 360
Auxiliary Equipment........................................................................................................................ 361
Cables ............................................................................................................................................ 362
Identification of Equipment ............................................................................................................. 364
13 ANNEXES ...................................................................................................................................... 367
ANNEX A1...................................................................................................................................... 368
ANNEX A2...................................................................................................................................... 369
ANNEX A3...................................................................................................................................... 370

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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: 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-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
MAIN FILTER 42A-A, 75A-A, 130A-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, February 2020

•
Ii] .
·.
CERTIFICATE
No. Z10 080353 0008 Rev. 00
Holder
of
Certificate: Fagor Automation, S. Coop.
San Andres Auzoa, 19
20500 Arrasate -Mondragon
SPAIN
Factory(ies): 080353
Certification Mark:
Product:
Model(s):
Parameters:
Tested
according to:
Safety components
Safe Torque
Off
(STO)
QUERCUS QC-DR Servo Drives
Supply voltage:
Response.time STO:
Operating temperature:
24VDC ± 10%
<1ms
+5°C ... +45°C
The report and the userdocumentation
in
the
current valid revision are mandatory part
of
this
certificate. The product complies with the following
safety requirements only ifthe specifications documented
in
the currently valid revision
of
this report are met.
The certified components are listed in report FA94809T
in the current valid revision.
IEC 61800-5-1:2007
IEC 61800-5-1:2007/AMD1:2016
IEC 61800-5-2:2016
IEC 61508-1:2010 (SIL2)
IEC 61508-2:2010
(S1L2)
IEC 61508-4:2010
(S1L2)
EN ISO 13849-1:2015 (Cat.
3,
PL d)
~
\7
Product
Service
The product was tested on a voluntary basis and complies with the essential requirements. The
certification mark shown above can be affixed on the product. It is not permitted to alterthe
certification mark in any way.
In
addition the certification holder must not transferthe certificate to
third parties. See also notes overleaf.
Test report no.:
Valid until:
Date, 2020-02-20
Page 1
of
1
FA94777C
2025-02-19
TOV SOD Product Service GmbH • Certification Body • Ridlerstra~e 65 • 80339 Munich • Germany

•

COMMERCIAL MODELS
QC-DR-007-FS2-FS-MDU
QC
DR
QUERCUS
SINGLE-AXIS DRIVE.
COMMERCIAL MODELS Example:
275
160 | 225
080 | 120
007 | 012 | 021 | 030 | 040 | 055
SERCOS-II
S
SERCOS-III
F
NO
S1
YES
S2
DIRECT
FEEDBACK
INTERFACE
SINGLE-AXIS.
PEAK
CURRENT (A)
- FS
FUNCTIONAL
SAFETY
- MDU
DUAL-USE
DRIVE
NO
YES
NO
YES
QC-DR-07+07-FD2-FS-MDU
QC
DR
QUERCUS
DUAL-AXIS DRIVE.
COMMERCIAL MODELS Example:
21+21 | 30+30
07+07 | 12+12
SERCOS-II
S
SERCOS-III
F
NO
D2
DIRECT FEEDBACK
INTERFACE
DUAL-AXIS.
PEAK CURRENT (A)
- FS
FUNCTIONAL
SAFETY
- MDU
DUAL-USE
DRIVE
NO
YES
NO
YES

RATINGS
QC-DR- 007 07+07 012 12+12 021 21+21 030 30+30 040 055
OUTPUT at X11A/X11B CONNECTORS
RATED VOLTAGE [V AC]
0-400
RATED FREQUENCY [Hz]
0-550
RATED CURRENT [Arms]
5.4 3.5/3.5 9.2 6.0/6.0 16.2 10.5/10.5 23.1 15.0/15.0 30.8 42.3
RATED POWER [kW]
3.7 2.4/2.4 6.4 4.2/4.2 11.2 7.3/7.3 16.0 10.4/10.4 21.3 29.3
RATED POWER [hp]
5.0 3.3/3.3 8.6 5.6/5.6 15.0 9.8/9.8 21.4 13.9/13.9 28.6 39.3
INPUT at A17 TERMINALS
RATED VOLTAGE [V DC]
565-800
RATED FREQUENCY [Hz]
DC
RATED CURRENT [A DC]
6.9 5.6 11.9 9.7 21.0 17.0 29.0 25.0 39.0 54.0
RATED POWER [kW]
3.9 3.0 6.0 7.0 11.0 12.0 16.0 17.0 22.0 30.0
RATED POWER [hp]
5.3 4.0 9.0 9.0 15.0 16.0 22.0 23.0 30.0 41.0
QC-DR- 080 120 160 225 275
OUTPUT at A19/X11 CONNECTOR
RATED VOLTAGE [V AC]
0-400
RATED FREQUENCY [Hz]
0-550
RATED CURRENT [Arms]
61.5 92.3 123.1 187.5 245.5
RATED POWER [kW]
42.6 64.0 85.3 129.9 170.1
RATED POWER [hp]
57.2 85.7 114.3 174.2 228.0
INPUT at A17 TERMINALS
RATED VOLTAGE [V DC]
565-800
RATED FREQUENCY [Hz]
DC
RATED CURRENT [A DC]
79.0 119.0 158.0 242.0 316.0
RATED POWER [kW]
44.0 67.0 89.0 136.0 179.0
RATED POWER [hp]
60.0 90.0 120.0 183.0 240.0

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HARDWARE
ABOUT THE MANUAL
Title DRIVE QC-PDS. Hardware manual.
Documentation type Description, installation and start-up of FAGOR QUERCUS - POWER
DRIVE SYSTEM.
Electronic document man_qc_pds_hard.pdf.
Language English.
Manual reference Ref.2003
Web The user should always use the latest reference of this manual, available on
FAGOR’s corporate website.
http://www.fagorautomation.com
Email [email protected]
Internal code Manual code.
This belongs to the manual intended for the manufacturer (OEM).
Startup
Warning
Headquarters Fagor Automation, S. Coop.
B.º San Andrés 19, apdo. 144
C. P. 20500 - Arrasate - Mondragón
Gipuzkoa (Spain)
www.fagorautomation.com
Customer Service
Technical Service
MAN QC-PDS HARD (CAS) Code XXXXXXXX
DANGER. In order to comply with the CE seal indicated on the component,
check that the machine incorporating the QC-PDS system meets the
specifications of Machine Directive 2006/42/CE.
Before starting up the QC-PDS system, 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
+34 943 791712
+34 943 795047 (head office)
+34 934 744375 (Catalonia)

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Software options
Bear in mind that some of the features or applications described in this manual are dependent on the
installed software version of the QUERCUS CNC.
These considerations are indicated in the ·man_qc_60_65_inst.pdf ·CNC 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 (5.9 inches) larger than those of
the unit itself. The cardboard used to make the box must have a resistance of 170 kg (374.8 lb).
2. Attach a label indicating the owner of the unit, 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 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. Refer to this data in chapter
1, section 1.6 AMBIENT AND OPERATING CONDITIONS of this manual. Always protect the product against
dust and dirtiness.
Decommissioning and eliminating
The machine manufacturer must indicate the procedure for shutting down the machine.
Respect environmental regulations. Keep in mind that no QC-PDS servo units of the QUERCUS system
comes with a battery.
Bear in mind the storage and shipping requirements when getting rid of QC-PDS 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 version history shows the list of hardware elements that have been added to each manual
version. Refer to the ·man_qc_60_65_inst.pdf ·CNC manual for the features included in the latest
software version.
VERSION HISTORY
Manual reference Events
2003
First version

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Read the following safety instructions in order to prevent harming people and damage to this product
or to the products connected to it.
Bear in mind that besides the safety conditions indicated in this section, more conditions are described
throughout this manual either as requirements or marked with ·SAFETY SYMBOLS ·.
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.
Forseen usage
Destine the units to an industrial environment as instructed in this manual.
Always comply with the safety standard in force at the location where the machine will be used, as
well as the environmental conditions specified and the technical data. See chapter 1. DESCRIPTION,
sections 1.6. AMBIENT AND OPERATING CONDITIONS and 1.7. ELECTRICAL CONDITIONS.
Analyze risks related to the application before using the unit and take the proper safety
measures according to the results obtained.
Ensure personnel safety anywhere in the system that these units belong to.
Never use in explosive environments (dangerous areas).
Precautions against personal harm
Never use damaged units.
Use proper mains AC power cables.
To avoid risks, we advise using only the SERCOS and mains cables recommended for this unit.
Wrong wiring may cause unexpected movements in the system and cause personal injury.
Avoid electrical overloads.
To avoid electric shocks and the risk of fire, do not apply electrical voltage beyond the range
indicated in this manual.
Make the ground connection.
In order to avoid electric shocks, connect the ground bolt of this unit to the main ground terminal.
Also, before connecting the inputs and outputs, make sure that the ground connection has been
done.
Make sure that the ground connection has been made.
In order to avoid electric shocks, make sure that the ground connections have been properly made
before turning the unit on.
SAFETY CONDITIONS
MANDATORY Always use the latest reference (version) of this manual. It is available
on FAGOR's corporate website. http://www.fagorautomation.com.
MANDATORY Refer to chapter 9 of this manual for any information on FUNCTIONAL
SAFETY of the QC-PDS system.

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See chapter 8. INSTALLATION in this manual. It is up to the installer to comply with current
regulations and standards regarding the ground connection of the QC-PDS system. Do not use the
conduit as ground protection, use the protection ground wire inside the conduit.
Only use tools with electrical insulation.
Many components of the product, including the pc board, work with mains voltage. Do not touch.
Do not touch unshielded components or pins when under voltage.
Take proper precautions in humid environments.
To avoid electric shocks, always work in environments where the relative humidity is lower than 90%
and with no condensation at 45°C/113°F. See chapter 1. DESCRIPTION, section 1.6. AMBIENT AND
OPERATING CONDITIONS.
Do not work in explosive environments.
In order to avoid risks, harm or damages, do not work in explosive environments.
Lock the motor shaft to prevent it from turning.
The motor generates voltage when the shaft is turned. Lock the motor shaft before performing any
work on the QC-PDS system.
Do not short-circuit the DC BUS bolts or the capacitor pins.
Avoid touching the hot braking resistor (BALLAST).
Don’t allow flammable or heat sensitive substances near the braking resistor.
Make sure that any conducting element, no matter how small, cannot get inside the unit -
pollution degree 2 - because it could render the safety function (STO) inoperative.
Foreign conducting elements, dust or liquids can cause the STO safety function to stop working.
Therefore, do not use the STO safety function unless the system has been protected against
pollution by conducting substances.
Follow thoroughly the measures given by EMC.
Malfunctions (due to ignoring Electromagnetic Compatibility) can cause unexpected system
behavior. Carefully install the cables in accordance with the EMC standards. Do not adjust the unit
with unknown data. Start the system up carefully. Ignoring these warning can cause serious injury
and even death. Follow thoroughly the measures given by EMC to avoid risks and personal injury.
See chapter 8. INSTALLATION, ·ELECTRICAL CONSIDERATIONS · and · EMC INSTRUCTIONS FOR
EQUIPMENT INSTALLATION · of section · ELECTRICAL CONSIDERATIONS ·.
Precautions against damage to the product
Working environment conditions.
This unit is ready to be used in industrial environments and comply with the current directives and
regulations of the European Community.
FAGOR AUTOMATION is not responsible for any damages incurred or damages to any installations
carried out under other conditions (residential or domestic environments).
Appropriate installation site.
Whenever possible, we recommend that the QC-PDS system is installed away from coolants,
chemicals, blows, etc. that could damage it. Keep foreign elements such as chips, screws or wire
pieces away from the units. Foreign conducting elements may damage the product or generate
parasite voltages. Ensure there is a sufficient heat dissipation system.
This unit meets the European Directives on Electromagnetic Compatibility. Nevertheless, it is
recommended to keep it away from sources of electromagnetic disturbance, such as:
Powerful loads connected to the same mains as the unit.
Nearby portable transmitters (radio-telephones, ham radio transmitters).
Nearby radio / TC transmitters.
Nearby arc welding machines.
Nearby high voltage lines....
Enclosures.
It is up to the machine manufacturer to guarantee that the enclosure of the unit meets all the relevant
directives of the European Union.
Ground connection of the power supply
The ground (or zero volt) point of the auxiliary power supply must be connected to the main ground
point of the machine. Poor grounding increases the risk of electric shock.
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