Fagor DDS User manual

DRIVE DDS
Hardware manual
Ref.1310

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 oth-
erwise, 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 guaran-
teed. 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 in-
formation 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 warn-
ings 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 influ-
ence of other nearby equipment.
Warranty
The warranty terms may be requested from your Fagor Automation
representative or through the usual commercial channels.
Registered trademarks
All registered trade marks, even those not indicated are also acknowl-
edged. When some are not indicated, it does not mean that they are
free.
October 2013 / Ref.1310
All rights reserved. No part of this documentation may be copied,
transmitted, transcribed, stored in a backup device or translated into
another language without Fagor Automation’s permission.
ORIGINAL INSTRUCTIONS

3
GENERAL INDEX
DDS
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1 DESCRIPTION ............................................................................................................. 25
Description................................................................................................................................... 26
General diagram .......................................................................................................................... 27
Stages of the system configuration..............................................................................................28
Environmental and operating conditions...................................................................................... 29
Electrical conditions ..................................................................................................................... 29
2 POWER SUPPLIES ..................................................................................................... 31
Non-regenerative power supplies ................................................................................................ 32
Regenerative power supplies....................................................................................................... 50
Regenerative regulated power supplies....................................................................................... 66
3 DRIVE MODULES........................................................................................................ 95
Modular drives ............................................................................................................................. 96
Compact drives.......................................................................................................................... 145
Turning a drive on...................................................................................................................... 186
4 AUXILIARY MODULES ............................................................................................. 189
Mains filters................................................................................................................................ 190
Chokes....................................................................................................................................... 191
External Ballast resistors ........................................................................................................... 193
Capacitor module....................................................................................................................... 199
Auxiliary power supply ............................................................................................................... 200
5 SELECTING CRITERIA ............................................................................................. 205
Selection of the synchronous motor and its associated drive.................................................... 205
Asynchronous spindle motor and servo drive selection............................................................. 211
Drive selection ........................................................................................................................... 217
Power supply selection .............................................................................................................. 218
Capacitor module selection guide.............................................................................................. 228
Ballast resistor selection guide .................................................................................................. 229
6 POWER LINE CONNECTION....................................................................................233
Mains connection....................................................................................................................... 233
Protection fuses ......................................................................................................................... 235
Differential breaker..................................................................................................................... 237
Isolating transformer or autotransformer.................................................................................... 238
Mains filter.................................................................................................................................. 240
Line inductance.......................................................................................................................... 241
Types of mains........................................................................................................................... 242
Mains connection cables............................................................................................................ 246
7 CABLES ..................................................................................................................... 247
Mains connection cable. Power supply - mains connection....................................................... 248
Power cable. Motor-drive connection......................................................................................... 249
Motor feedback cables............................................................................................................... 251
Direct feedback cable ................................................................................................................ 253
Signal cables for control and communications........................................................................... 255
RS232/RS422 BE adapter......................................................................................................... 259
RS-232 serial line....................................................................................................................... 260
RS-422 serial line....................................................................................................................... 264
8 INSTALLATION ......................................................................................................... 267
Location ..................................................................................................................................... 267
Inductive components................................................................................................................ 276
System installation..................................................................................................................... 277

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Connection between modules.................................................................................................... 279
Power supply connections ......................................................................................................... 291
Connection of the control and communications signals............................................................. 293
Check the installation................................................................................................................. 311
9 FUNCTIONAL SAFETY ............................................................................................. 313
STO safety function ................................................................................................................... 314
Interface..................................................................................................................................... 315
Examples ................................................................................................................................... 316
Precautions................................................................................................................................ 318
Risk analysis.............................................................................................................................. 319
Technical data of the safety function ......................................................................................... 320
Response time........................................................................................................................... 321
Cabling and grounding............................................................................................................... 322
Commissioning .......................................................................................................................... 323
Maintenance, repair and analyze hazardous events ................................................................. 324
Decommission and disposal ...................................................................................................... 325
10 CONNECTION DIAGRAMS....................................................................................... 327
SPD modular drive with FM7 asynchronous spindle motor ....................................................... 327
AXD modular drive with FKM synchronous axis servo motor.................................................... 328
AXD modular drive with FXM synchronous axis servo motor.................................................... 328
SCD compact drive with FM7 asynchronous spindle motor ...................................................... 329
ACD compact drive with FKM synchronous axis servo motor ................................................... 330
ACD compact drive with FXM synchronous axis servo motor ................................................... 331
Electrical cabinet. Diagrams ...................................................................................................... 332
Diagrams with a PS-65A power supply...................................................................................... 338
Diagrams with a PS-25B4 power supply.................................................................................... 340
Diagrams with a XPS power supply........................................................................................... 342
Diagrams with an RPS-XX power supply................................................................................... 344
Compact system diagrams with SERCOS connection .............................................................. 346
Compact system diagrams with CAN connection ...................................................................... 347
Diagrams of a mixed (combined) system with SERCOS connection......................................... 349
Diagrams of a mixed (combined) system with CAN connection ................................................ 350
Brake connection diagram for synchronous axis servo motors ................................................. 352
On-the-fly start/delta connection switching on FM7 spindles, E03 & HS3 series ...................... 353
11 DIMENSIONS............................................................................................................. 355
Main modules............................................................................................................................. 355
Power supply modules............................................................................................................... 356
Modular drive modules............................................................................................................... 357
Compact drive modules ............................................................................................................. 358
Mains filter.................................................................................................................................. 359
XPS chokes ............................................................................................................................... 360
RPS chokes ............................................................................................................................... 361
External Ballast resistors with external thermostat .................................................................... 362
External Ballast resistors with internal thermostat ..................................................................... 363
External Ballast resistors with external thermostat & cooling fan .............................................. 364
12 SALES REFERENCES .............................................................................................. 365
References of synchronous servo motors ................................................................................. 366
References of asynchronous motors ......................................................................................... 368
References of modular drives....................................................................................................369
References of compact drives ................................................................................................... 370
References of positioning drives................................................................................................371
Power supply references ........................................................................................................... 372
References of other elements....................................................................................................373
Cable references........................................................................................................................ 374

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Order example ........................................................................................................................... 376
Module identification .................................................................................................................. 377
13 COMPATIBILITY........................................................................................................379
Mains voltage............................................................................................................................. 379
Compatibility .............................................................................................................................. 379
Module replacement .................................................................................................................. 380
VECON board............................................................................................................................ 380
VECON-2 board......................................................................................................................... 380
VECON-3 board......................................................................................................................... 381
VECON-4 board......................................................................................................................... 381
Boot for VECON-2 ..................................................................................................................... 381
Boot for VECON-3 ..................................................................................................................... 381
Boot for VECON-4 ..................................................................................................................... 381
SERCOS card (16 MBd)............................................................................................................ 381
CAN board ................................................................................................................................. 382
CAPMOTOR-x boards ............................................................................................................... 382
VECON-X boards....................................................................................................................... 382
CAPMOTOR-2 board and type of feedback .............................................................................. 383
Recognizing RPS power supplies.............................................................................................. 383
APS-24 auxiliary power supply with PS, XPS or RPS ............................................................... 383
Power supplies compatible with FM9 motors............................................................................. 383

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Fagor Automation, S. Coop.
7
Manufacturer Fagor Automation S.Coop.
Bº San Andrés 19; C.P. 20500, Mondragón, Gipuzkoa - Spain.
We hereby declare, under our responsibility the conformity of the product:
FAGOR DDS SERVO DRIVE SYSTEM
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/x+FAN, CM 1.60, CHOKE
MAINS FILTER 42A, MAINS FILTER 130A, MAINS FILTER 180A
FXM, FKM, 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.
mentioned on this declaration, meet the requirements on:
LOW VOLTAGE DIRECTIVE
ELECTROMAGNETIC COMPATIBILITY
SAFETY OF MACHINERY
IEC 60204-1:2005 +A1:
2009
Machinery safety. Electrical equipment of the machines.
Part 1: General requirements.
IEC 61800-3:
2004
Category C2. Specific standard on electromagnetic compatibility for servo
drive systems.
IEC 61326-3-1:
2008
(In “Safety Related Parts”). Electrical equipment for measurement, control
and laboratory use - EMC requirements - Part 3-1: Immunity requirements for
safety-related systems and for equipment intended to perform safety-related
functions (functional safety) - General industrial applications.
STO (Safe Torque Off) function satisfies the requirements:
IEC 61800-5-1:2007
IEC 61800-5-2:2007 (SIL 2)
IEC 61508-1:1998 (SIL 2)
IEC 61508-2:2000 (SIL 2)
IEC 61508-3:1998 (SIL 2)
IEC 61508-4:1998 (SIL 2)
ISO 13849-1:2006 + Cor 1:2009: Category 3, for Performance Level PL d
EC-Type-Examination: TÜV SÜD, Notified Body 0123
Certificate No.: Z10 12 06 80353 001
In compliance with EC Directives 2006/95/EC on Low Voltage, Directive 2006/42/EC on Machinery and
2004/108/EC on Electromagnetic Compatibility.
DECLARATION OF
CONFORMITY

Fagor Automation, S. Coop.
8
Equipment with date in serial number greater than 2012-05 meets this certification. The date appears on
the version label stuck on the outside of the drive module.
Equipment included in the EC-Type-Examination: TÜV SÜD:
Are excluded from the scope of the EC-Type-Examination: TÜV SÜD equipment with CAN communica-
tion and Drives:
In Mondragón, May 2012
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
Ref.1310
Title DRIVE DDS. Hardware manual.
Type of documentation Description, installation and start-up of digital servo drives.
Electronic document man_dds_hard.pdf.
Language English.
Manual reference Ref.1310.
Web The user must always use the latest reference of this manual, available on
FAGOR'S corporate website. http://www.fagorautomation.com
Email [e-mail]
Internal code It belongs to the manual directed to the manufacturer (OEM). The manual
code is:
Startup
Warning
Headquarters Fagor Automation, S. Coop.
Bº San Andrés 19, apdo. 144
CP. 20500 - Arrasate - Mondragón
Gipuzkoa (Spain)
www.fagorautomation.com
[email protected]
- ABOUT THIS MANUAL -
MAN REGUL (IN) STAN Code 04754001
MAN REGUL (IN) AVANZ Code 04754021
DANGER. In order to comply with the EC seal indicated on the compo-
nent, verify that the machine on which the servo system is installed com-
plies with European Directive 2006/42/EC on machine safety.
Before starting the servo drive system up, read the instructions in chapter
1of 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 support + 34 943 719200
Service Department + 34 943 771118

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Ref.1310
DDS
HARDWARE
Software options
Bear in mind that some of the features or applications described in this manual depend on the soft-
ware version installed. These considerations are reflected in the “man_dds_soft.pdf” manual supplied
with this one.
- ABOUT THE PRODUCT -

15
DDS
HARDWARE
Ref.1310
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 con-
tact, 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.
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 AND RECYCLING -

16
Ref.1310
DDS
HARDWARE

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DDS
HARDWARE
Ref.1310
- 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 drive modules ACD 2.50, SCD
2.50, ACD 2.75, SCD 2.75, CMC 2.50, CMC 2.75 and the program-
ming module DDS PROG MODULE will no longer be in Fagor Auto-
mation’ 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 MAINS
FILTER 42A and MAINS FILTER 130A.
0407 No new hardware has been implemented.
0410 New SERCOS board
(transmission speed up to 16Mbd)

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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).
0706 New VECON-3 board
Sales references 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 acces-
sory 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 sup-
plies.
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
1310 No new hardware has been implemented.
Manual reference Events

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- SAFETY CONDITIONS -
Read the following safety instructions in order to prevent harming people and damage to this product
or to the products connected to it.
Qualification of personnel
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 docu-
mentation 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.
Cumply always with the current safety standards, the indicated conditions and the technical
data.
Analyze risks related to the application before using the unit and take the proper safety measu-
res according to the results obtained.
Ensure personnel safety anywhere in the system that these units belong to.
Never use in explosive environments (dangerous areas).
The electrical equipment must only be handled by qualified personnel (installation, operation,
maintenance, service).
Precautions against personal harm
Do not use damaged products.
Use the right mains cables.
In order to avoid risks, use only the SERCOS or CAN and mains cables recommended for this
unit. Wrong cabling may cause unexpected movements and cause personal injury.
Avoid electric shocks.
To avoid electric shocks and the risk of fire, do not apply electrical voltage beyond the range indi-
cated in this manual.
Make the ground connection.
In order to avoid electric shocks, connect the ground terminal of this unit to the main ground point.
Also, before connecting the inputs and outputs, make sure that the ground connection has been
done.
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 FUNCTION-
AL SAFETY of the DDS system.

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DDS
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Make sure that the ground connection has been made.
In order to avoid electric shocks, before turning the unit on, make sure that the ground connection
has been made. It is up to the installer to comply with current regulations and standards regarding
the ground connection of the servo drive 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. Don’t touch
them.
Do not touch unshielded components or pins when under voltage.
Make sure not to work in humid environments.
To avoid electric shocks, always work in environments where relative humidity is lower than 90%
without condensation at 45 °C (113 °F).
Make sure not to work in explosive environments.
In order to avoid risks, harm or damages, do not work in explosive environments.
The motor generates voltage when turning the shaft. Before working on the servo system,
lock the motor shaft to prevent it from turning.
Do not short-circuit the terminals of the DC bus nor those of the capacitors of the DC bus.
Avoid touching the hot braking resistor.
Don’t allow flammable or heat sensitive substances near the braking resistor.
Foreign conducting elements, dust or liquids can cause the STO safety function to stop
working. Do not use the STO safety function unless the system has been protected against
pollution by conducting substances.
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 inoperative
Follow thoroughly the measures given by EMC.
Malfunctions (due to ignoring electromagnetic compatibility) can cause unexpected system behav-
ior. Do the whole wiring carefully according to the measures given by EMC. Do not adjust the unit
with unknown data. Start the system up carefully. Ignoring these warning can cause serious injury
or even death. Follow thoroughy the measures given by EMC to avoid risks and personal injury.
Precautions against damage to the product
Work environment.
This unit is ready to be used in industrial environments and comply with the current directives and
regulations of the European Community.
Fagor Automation shall not be held responsible for any damage that could suffer or cause when in-
stalled under other conditions (residential or domestic environments).
Install the unit in the right place.
We recommend that, whenever possible, the servo drive system be 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 pa-
rasite voltages.
Provide good heat dissipation.
This unit meets the European directives on electromagnetic compatibility. Nevertheless, it is recom-
mended to keep it away from sources of electromagnetic disturbance, such as:
•Powerful loads connected to the same mains as the unit.
•Portable nearby transmitters (radio-telephones, CB radio emitters).
•Nearby radio/TV transmitters.
•Nearby arc welding machines.
•Nearby high voltage lines ...
Enclosures.
It is up to the manufacturer to guarantee that the enclosure where the unit has been installed
meets all the relevant directives of the European Union.
Connecting the power supply to ground.
The zero Volt point of the external power supply must be connected to the main ground point of
the machine. Poor grounding increases the risk of electrical shock.