Ref.

0607

ORDERING HANDBOOK

Digital Servo Drive System

Fagor Automation S.Coop

Digital Servo Drive System

Modular system
> Modular drives system
It is configured with power supply modules that are connected directly to mains and with specific drive modules to govern axis and spindle motors.

Non regenerative power supplies (PS) Regenerative power supplies (XPS, RPS) Axis drives (AXD) Spindle drives (SPD) Other modules

Range of Fagor Power Supplies

> Models
NON REGENERATIVE Output 24 V DC for drive control signals 24 V DC / 192 W 24 V DC / 240 W Output 24 V DC for drive control signals 24 V DC / 192 W 24 V DC / 192 W Output 24 V DC for drive control signals 24 V DC / 192 W 24 V DC / 192 W 24 V DC / 192 W

Model PS-25B4 PS-65A

Output power 25 kW 65 kW Output power 25 kW 65 kW S1 / S6-40% output power 75/97 kW 45/59 kW 20/26 kW

Input voltage 400 - 460 V AC 400 - 460 V AC Input voltage 400 - 460 V AC 400 - 460 V AC Input voltage 400 - 460 V AC 400 - 460 V AC 400 - 460 V AC

REGENERATIVE

Model XPS-25 XPS-65 Model RPS-75 RPS-45 RPS-20

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Digital Servo Drive System

> Connection to mains

Input Voltage

The Fagor DDS servo drive system requires a mains voltage between 400 V AC 10% and 460 V AC + 10%

Fuses

Module receiving mains power Reference

Recommended Siemens fuse Reference

PS-25B4 XPS-25 RPS-20 PS-65A XPS-65 RPS-45 RPS-75

3NE8 003 3NE8 021 3NC8423-3

Fuses MUST be included to protect the Fagor Servo Drive System

Transformer / Auto-transformer

It should be used when the mains voltage must be isolated or adapted to the levels required by the DDS system in order to ensure maximum motor power.

A power transformer or auto-transformer must be used

[
1 2

1
-----

* 1,05

kVA

=
-----

kVA

Sum of axes powers (kW) Sum of spindle powers (kW)

See in page 11 See in page 12

Very important: When using an isolating transformer, the secondary must have a star connection and its mid point must be accessible so it can be connected to ground. This means that the output voltage of the transformer/autotransformer is maintained for the indicated apparent power. Note that if the system has an XPS power supply , the rated power Pm of cell (2) of the previous expression corresponds to the sum of the Pn's of all the asynchronous spindle motors of the system, whose value is the result of applying the expression Pn = 1.4 Pmax for each of them and then adding them all. Pmax will be the motor's maximum braking power and it may be, in general, close to the power of the asynchronous spindle motor in S6. If it is a PS power supply, cell (2) will register the value obtained from the table in page 3 of the FM7 Ordering Handbook.

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Digital Servo Drive System

Mains filter against electromagnetic interference.

Module receiving mains power Reference

Mains filter EMC Reference

Rated current A

Weight kg

XPS-25, RPS-20 PS-25B4 ACD / SCD / CMC 1.08 / 1.15 / 1.25A ACD / SCD / CMC 2.35 PS-65A , XPS-65,RPS-45, RPS-75
MAIN FILTER 130A 130 MAIN FILTER 42A 42

2.8

7.5

In order for Fagor Servo drive system to meet the European Directives on Electromagnetic Compatibility (EMC) this mains filter must be included in the servo system.

Choke inductance

Choke inductance for foltering the current returned to mains by the XPS Power Supplies. These chakes are a must for the proper operation of the Regenerative Power Supplies XPS.

Recoverig Power Supply XPS-25 XPS-65 RPS-20 RPS-45 RPS-75

Choke inductance CHOKE XPS-25 CHOKE XPS-65 CHOKE RPS-20 CHOKE RPS-45 CHOKE RPS-75

Cable section 10mm 2 50mm 2 10mm 2 35mm 2 70mm 2

> Cables
POWER CABLE FOR MAINS CONNECTION Vmains from 400 - 460 V AC Rated current through the mains cable

MAINS POWER

( kW * 1000 / (sqrt3 Vmains)

Power cable In Amperes if C < 12.5 if C < 16.5 if C < 23 if C < 29 if C < 40 Reference MPC - 4 x 1.5 MPC - 4 x 2.5 MPC - 4 x 4 MPC - 4 x 6 MPC - 4 x 10

The purchase order must indicate the length of the cables.

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Digital Servo Drive System

Axis and Spindle drives

> References of synchronous servo motors
FXM

FXM
MOTOR SERIES SIZE LENGTH RATED SPEED WINDING 1, 3, 5, 7 1, 2, 3, 4, 5, 6, 7, 8 12 1200 rpm 20 2000 rpm A F E1 R0 A1 I0 400 V AC 220 V AC Sinusoidal Sincoder Resolver Absolute multi-turn Sincos Incremental TTL 0 1 With standard keyway Without keyway 30 3000 rpm 40 4000 rpm

-X

FEEDBACK TYPE

FLANGE AND SHAFT BRAKE OPTION

0 Without brake 1 With standard brake (24 V DC) 9 With special brake 0 1 Without fan With fan X 01 ? ZZ

VENTILATION

SPECIAL CONFIGURATION SPECIFICATION OF THE SPECIAL CONFIGURATION A1 E1 R0 I0

TM

Sincos Stegmann SRM 50, 1,024 pulses/turn Sincoder Stegmann TM SNS 50, 1,024 pulses/turn TamagawaTM resolver TamagawaT M encoder OIH48 TS5214N510, 2500 pulses/turn

NO LONGER SOLD S0 Sincoder StegmannT M SNS 60 A0 Sincos Stegmann TM SCM 70 E0 Sincos Stegmann TM SCS 70

FKM

FKM
MOTOR SERIES SIZE LENGTH RATED SPEED 2, 4, 6 1, 2, 4 60 50 45 A F E3 R0 A3 I0 6000 rpm 5000 rpm 4500 rpm 400 V AC 220 V AC Sinusoidal Sincos Resolver Absolute multi-turn Sincos Incremental TTL 40 4000 rpm 30 3000 rpm

-K

WINDING

FEEDBACK TYPE

FLANGE AND SHAFT BRAKE OPTION CONNECTION

0 With keyway 1 Cilyndrical (with no keyway) 0 Without brake 1 With standard brake (24 V DC) 0 1 Rotating angled connectors Cable exit without connectors K

SPECIAL CONFIGURATION SPECIFICATION OF THE SPECIAL CONFIGURATION A3 E3 R0 I0

01 ? ZZ

Sincos StegmannTM SRM (multi-turn) (with taper shaft), 1024 pulses/turn Sincos StegmannTM SRS 50 (taper, sheet metal), 1024 pulses/turn Tamagawa TM reslver TamagawaTM encder OIH48 TS5214N510, 2500 pulses/turn

NO LONGER SOLD A1 Sincos StegmannTM (multi-turn) SRM, 1024 pulses/turn E 3 Sincos StegmannTM SRS (taper, rubber flange), 1024 pulses/turn

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Digital Servo Drive System

> Technical data

Currents on modular axis drives for synchronous motors. fc = 4 kHz.

With internal fan Currents at fc = 4 kHz (Arms) I S1 ( = IN ) (Arms) Imax (Arms) (S3-5) Dissipated power (W) AXD 1.08 4 8 33 AXD 1.15 7.5 15 69 AXD 1.25 12.5 25 115

Drive for synchronous motor (as axis) AXD 1.35 17.5 35 156 AXD 2.50 23.5 47 225 AXD 2.75 31.5 63 285 AXD 3.100 50 100 513 AXD 3.150 62 124 617

Currents on modular axis drives for synchronous motors. fc = 8 kHz.

With internal fan Currents at fc = 8 kHz (Arms) I S1 ( = IN ) (Arms) Imax (Arms) (S3-5) Dissipated power (W) AXD 1.08 4 8 44 AXD 1.15 7.5 15 89 AXD 1.25 12.5 25 148 Drive for synchronous motor (as axis) AXD 1.35 17.5 35 195 AXD 2.50 23.5 47 305 AXD 2.75 31.5 63 395 AXD 3.100 50 100 695 AXD 3.150 62 124 847

Current in modular spindle drives for synchronous or asynchronous motors. fc = 4 kHz.

With internal fan Currents at fc = 4 kHz (Arms) I S1 ( = IN )(Arms) 0.7 x I N (Arms) I S6-40 (Arms) Imax (Arms) (S6-15) Dissipated power (W) Drive for synchronous or asynchronous motor (as spindle) SPD 1.25 16 11.2 20.8 22 146 SPD 1.35 23.1 16.1 30 32 195 SPD 2.50 31 21.7 40.3 45 349 SPD 2.75 42 29 54.6 65 390 SPD 2.85 50 35 65 72.5 432 SPD 3.100 70 49 91 91 724 SPD 3.150 90 63 117 140 904 SPD 3.200 121 84.7 157.3 170 1.163

Current in modular spindle drives for synchronous or asynchronous motors. fc = 8 kHz.

With internal fan Currents at fc = 8 kHz (Arms) I S1 ( = IN ) (Arms) 0.7 x I N (Arms) I S6-40 (Arms) Imax (Arms) (S6-15) Dissipated power (W)

Drive for synchronous or asynchronous motor (as spindle) SPD 1.25 13 9.1 16.9 17.8 145 SPD 1.35 18 12.6 23.4 24.9 201 SPD 2.50 27 18.9 35.1 39.1 350 SPD 2.75 32 22.4 41.6 65.0 395 SPD 2.85 37 25.9 48.1 53.6 438 SPD 3.100 56 39.2 72.8 72.8 743 SPD 3.150 71 49.7 92.3 110.4 930 SPD 3.200 97 67.9 126.1 136.5 1.187

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Digital Servo Drive System

Technical characteristics of the modular drives

AXD // SPD // MMC 1.08 Power voltage input Power to control circuits
Consumption of the control circuits (24 V DC)

1.15

1.25

1.35

2.50

2.75

2.85

3.100

3.150

3.200

542 - 800 V DC 24 V DC (between 21 V DC and 28 V DC) 0.9 A 1.25 A Encoder // Resolver PWM, AC sinewave, vector control Serial line to connect to a PC Standard analog or digital via SERCOS (in all models). Serial line RS232/RS422 (only in MMC drives) 7-segments display Over-voltage, over-current, over-speed, heat-sink temperature, ambient temperature, motor temperature, hardware error, overload. 1 : 8192 800 Hz 100 Hz (depends on the motor/drive set) 5 C / 45 C (41 F/113 F) From 40 C (104 F ). See derating curves. -20 C / +60 C (-4 F / 140 F) IP2x < 90 % ( non condensing at 113 F / 113 F ) 0.5 G 2G 5.5 (12.1) 6.0 (13.2) 6.5 (14.3) 9.0 (19.8) 9.0 (19.8) 10.0 (22.0) 16.5 (36.4) 17.0 (37.5) 19.5 (43.0) 2A

Speed feedback Controlling method Communication Interface Status display Protections Speed range with analog input Current bandwidth Speed bandwidth Operating ambient Storage temperature Sealing Maximum humidity Operating vibration Shipping vibration Approximate weight in kg (lb)

> Drives Combination

Refer to the relevant Ordering Handbook to know the drive associated with FXM and FKM motors.

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Digital Servo Drive System

> Cables
Ready made fiber cables to close the sercos interface ring.

Length Reference

1m

2m

3m

5m

7m

10m

12m

15m

20m

25m

SFO-1

SFO-2

SFO-3

SFO-5

SFO-7

SFO-10 SFO-12 SFO-15 SFO-20 SFO-25

Length Reference Length Reference

10m

15m

20m

25m

30m

SFO-FLEX-10
35m

SFO-FLEX-15
40m

SFO-FLEX-20
45m

SFO-FLEX-25
50m

SFO-FLEX-30

SFO-FLEX-35

SFO-FLEX-40

SFO-FLEX-45

SFO-FLEX-50

Each drive module having the Sercos interface option comes with a small fiber cable for connecting it to the adjacent module. Order only the cables connecting the CNC to the drives.

Ready made connections for the encoder simulator.

Length Reference

1m

3m

5m

10m

15m

20m

25m

30m

35m

SEC-1

SEC-3

SEC-5

SEC-10 SEC-15 SEC-20 SEC-25 SEC-30 SFO-35

Length Reference Length Reference

1m

3m

5m

10m

15m

SEC-HD-1
20m

SEC-HD-3
25m

SEC-HD-5
30m

SEC-HD-10
35m

SEC-HD-15

SEC-HD-20

SEC-HD-25

SEC-HD-30

SEC-HD-35

This connections join the Drive module to the CNC. Reference SEC-XX includes the necessary connectors at both ends.

Ready made connections for the direct feedback.

Length Reference

1m

3m

6m

9m

12m

EC-PD 1

EC-PD 3

EC-PD 6

EC-PD 9

EC-PD 12

Length Reference

1m

3m

6m

9m

12m

15m

EC-1B-D

EC-3B-D

EC-6B-D

EC-9B-D

EC-12B-D

EC-15B-D

This connections join the Drive module to the Direct Sensor. Reference EC-PD XX includes the necessary connectors at both ends.

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Digital Servo Drive System

Other modules
> Auxiliar power supply APS 24
The control circuits of the modular Power Supply and Drives require 24 V DC. If the Power Supply doesnt offer that voltage use the Auxiliar Power Supply APS 24

Input Voltage Servo system with modular architecture APS 24 400 V AC to 460 V AC 50/60 Hz

Output Voltage 24 V DC, 10 A

Weight 4.3kg (9.4 lbf)

Compact Modules, PS-25Bx or XPS Systems DO NOT require the Auxiliary Power APS 24.

> Capacitor module for energy storage

Energy Stored in the Power Bus depending on the Vmains. Vmains: PS-65A XPS-25 XPS-65 400 69 34 61 600 63 96 172 Ws CM 1.60 +

Effect of the Capacity Module Vmains: PS-65A XPS-25 XPS-65 400 439 149 176 600 397 421 498 Ws

Capacity CM 1.60 4mF

Weight 8.6 kg (18.2 lbf)

The Capacitor module IS NOT applicable to Compact Drives.

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Digital Servo Drive System

> Ballast resistor

If the energy returned to the Drives (due to motor braking) is so large that it cannot be dissipated by the Ballast resistor of the Power Supply, it is necessary to increase the power of the resistor by means of an external module (external Ballast resistor)

1 W m = W p + - ?Jt 2 W p = m ?g ? ? h 2 Wm i ----------ti i -------------------T

2? ? n 2 -------------60

? Ws ? Wm: Energy generated by the braking of each system motor.

Pe: Rms power generated by all braking of all the motors throughout a complete duty cycle. Jt: Total inertia of the servo system (motor + mechanics) (in kgm2 ). n: Turning speed of the motor when the braking starts (in rpm). Wmi: Energy of each braking during a cycle of time T (in Ws). Wp: Potential energy lost by the machine mass while braking (only on noncompensated axes) (in Ws). ti: Braking time (in seconds) when the Wmi energy is generated. T: Time (in seconds) in a full cycle. ? h: Height (in meters) lost while braking . Wmx: Maximum energy among all the Wm. Pmx: Maximum power generated by all the braking, given by the maximum value among all the (Wmi / ti) quotients of each braking (in kW).

?
Pe =

?w ?

? Wm i ? P m x = ? ----------- ? ? kW ? ? t i ? max

PS-65A

Pmx > 36kWs / (0,6 s) = 60 kW YES

NO

Pe > 600 W YES

NO

RM-15// RM-15 ER-18/1100//ER-18/1100 ER-18/1800//ER-18/1800 ER-18/2200//ER-18/2200

PS-25B4

Pmx > 35kWs / (1 s) = 35 kW YES

NO

Pe > 400 W YES RM-15 ER-18/1100 ER-18/1800 ER-18/2200

NO

XPS-25

Pmx > 18kWs / (0,6 s) = 30 kW YES

NO

Pe > 520 W YES RM-15 ER-18/1100

NO

XPS-65

Pmx > 50kWs / (1 s) = 50 kW YES

NO

Pe > 1800 W YES

NO

RM-15 // RM-15 or ER-18/1100 // ER-18/1100

Check that the external resistor meets the Wmx and Pe requirements of the application.

ER-43/350 Wmx Pe 20kJ

ER-24/750 40kJ

ER-18/1100 60kJ

ER-18/1800 55kJ

ER-18/2200 83kJ

NO External Ballast

NO External Ballast

NO External Ballast

NO External Ballast

ER-33/550 3kJ

ER-18/900 4kJ

300W

650W

950W

1300W

2000W

250W

450W

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Digital Servo Drive System

Power Suppy for modular drives

> First criteria
The power supply module must be capable of supplying the power required by the all the motor-drive sets connected to it.

> Second criteria

The power supply module must be capable of supplying the peak power required (depending on the duty cycles) by the all the motor-drive sets connected to it.

> Power required for axis motors: FXM and FKM

Follow the calculating to determine which Power Suplly module is needed for the set of mudular drives.

Power (characteristics table)

n : Maximum axis speed in the application (rpm) nN: Rated motor speed (rpm) Pa= Pcal1,17 [n/nN] : Axis power (kW) See FXM or FKM Ordering Handbook

Axes

Pcal kW

n rpm

nN rpm

Pa kW

GROUP I From 0 to 2 kW Synchronous

1 2 3 Sum of GROUP I: 1 2 3 Sum of GROUP II: GROUP III From 8.5 to 27 kW Synchronous 1 2 3 Sum of GROUP III:

Ki

GROUP II From 2 to 8.5 kW Synchronous

+ *
Kii

+ *
Kiii

=
SUM OF POWER: ( kW )

Synchronous motors per group 1 2 3 4 5 6

K factor 1 0.63 0.50 0.38 0.33 0.28

...where:
Pcal: motor power (kW) according to the motor characteristics 1,17: coefficient that stores the efficiency of the motor (0.9 ) and that of the drive (0.95). The servo set is divided in groups depending on their power by applying to each one a simultaneity factor Ki, Kii, Kiii.

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Digital Servo Drive System

> Peak Power required for axis motors: FXM and FKM
Power P (S3-5% cycle)
P (S3-5%) (kW) 1 GROUP I From 0 to 2 kW Synchronous 2 3 Sum of GROUP I:

Ki

+
GROUP II From 2 to 8.5 kW Synchronous 1 2 3 Sum of GROUP II:

Kii

+
GROUP III From 8.5 to 27 kW Synchronous 1 2 3 Sum of GROUP III:

Kiii

=
SUM OF POWER: (kW)

Synchronous motors per group 1 2 3 4 5 6

k factor 1 0.63 0.50 0.38 0.33 0.28

Drive AXD 1.08 AXD 1.15 AXD 1.25 AXD 1.35 AXD 2.50 AXD 2.75 AXD 3.100 AXD 3.150

P (S3-5%) 6 12 19 27 36 48 77 95 kW.

> Power required for Spindle motors: FM7

Maximum power consumed by the power supply (kW)
See FM7 Ordering Handbook

Asynchronous for spindle ASYNCHRONOUS 1 2

Pm

SUM OF POWER: (kW)

Pm: Required power obtained for the asynchronous spindle drive in S6-40% cycles. This data includes the internal losses of the drive.

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Digital Servo Drive System

> First Criteria

The power supply module must be capable of supplying the power required by the all the motordrive sets connected to it.

REQUIRED POWER:

1
Power supply module Reference RPS-20 PS-25B4, XPS-25 RPS-45 PS-65A, XPS-65 RPS-75 ?

kW

Rated power (in duty cycle S1) In kW If A < 20 If 20 < A < 25 If 25 < A < 45 If 45 < A < 65 If 65 < A < 75 If A > 75

? Until reaching the rated power demanded from the power supply. All the required power cannot be supplied, thus 2 power supplies will be needed.

Very important: When using two power supplies on the same machine, they must make up two independent groups with their own drives. Only the SERCOS ring (if there is one) may be common to both groups.

Note that: If the power required by the set is greater than 75 kW, the set of motors and drives must be divided into groups and powered by different power supplies.

> Second Criteria

The power supply module must be capable of supplying the peak power required (depending on the duty cycles) by the all the motor-drive sets connected to it.

REQUIRED PEAK POWER:

kW

Peak power (depending on the duty cycle) In kW If B < 75

Power supply module Reference PS-25B4 PS-65A ? XPS-25 XPS-65 ? RPS-20 RPS-45 RPS-75 ? Until reaching the peak power demanded from the power supply. All the required power cannot be supplied and a second power supply will be needed.

NON-REGENERATIVE POWER SUPPLIES

If 75 < B < 195 If B > 195 If B < 55 If 55 < B < 108 If B > 108 If B < 26 If 26 < B < 59 If 59 < B < 97

REGENERATIVE POWER SUPPLIES

REGENERATIVE REGULATED POWER SUPPLIES

Very important: When using two power supplies on the same machine, they must make up two independent groups with their own drives. Only the SERCOS ring (if there is one) may be common to both groups.

??If the peak power required by the set is greater than 108 kW for XPS power supplies or greater than 97 kW for RPS power supplies , the set of motors and drives must be divided into groups and powered by different power supplies.

WARNING: Never connect the power supplies in parallel !

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Digital Servo Drive System

Dimensions
Dimensions of the Drive modules in mm (in inches).

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Digital Servo Drive System

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Digital Servo Drive System

External Resistor - ER -

ER-43/350
mm ln L 60 110 inches 2.36 4.33

ER-24/750
mm 140 220 inches 5.51 8.66

ER-18/1100
mm 240 320 inches 9.44 12.59

ER-18/1800
mm A B L I P 120 40 380 107 300 inches 4.72 1.57 14.96 4.21 11.81

ER-18/2200
mm 190 67 380 107 300 inches 7.48 2.63 14.96 4.21 11.81

2.5 mm 2

4,8

57

300

68

13

ER-33/550
mm P L 81 102 inches 3.18 4.01

ER-18/900
mm 124 145 inches 4.88 5.701

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Digital Servo Drive System

Chokes - for XPS power supplies -

CHOKE XPS-25
H

CHOKE XPS-65
mm 156 150 9 9 230 230 inches 6.14 5.90 0.35 0.35 9.05 9.05

CHOKE XPS-25 CHOKE XPS-65

mm A B C D H F
A F

inches 4.52 4.13 0.39 0.35 6.49 7.08

115 105 10 9 165 180

Chokes - for RPS power supplies -

CHOKE RPS-20 CHOKE RPS-45 CHOKE RPS-75

CHOKE RPS-20
mm A B C D E F G 330 175 136 150 8 15 162 inches 12.99 6.88 5.35 5.90 0.31 0.59 6.37

CHOKE RPS-45
mm 330 175 136 150 8 15 228 inches 12.99 6.88 5.35 5.90 0.31 0.59 8.97

CHOKE RPS-75
mm 380 235 152 170 9 18 271 inches 14.96 9.25 5.98 6.69 0.35 0.70 10.66

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Digital Servo Drive System

Mains filter - DLC -

MAIN FILTER 42A

PS-25B4, RPS-20 XPS-25, ACD/SCD/CMC 1.xx H

MAIN FILTER 130A

PS-65A, RPS-45, RPS-75 XPS-65, ACD/SCD/CMC 2.xx L

MAIN FILTER 42A

mm L W H X Y 330 70 185 314 45 inches 12.99 2.75 7.28 12.36 1.77

MAIN FILTER 130A

mm 440 110 240 414 80 inches 17.32 4.33 9.44 16.29 3.14

Fagor Automation S.Coop. B San Andrs s/n, Apdo. 144 E-20500 Arrasate - Mondragn, Spain
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www.fagorautomation.com E-mail: info@fagorautomation.es Tel. 34-943 71 92 00 / Fax. 34-943 79 17 12

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Digital Servo Drive System

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