FANUC SERVO AMPLIFIER ai User Manual
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FANUC SERVO AMPLIF IER
DESCRIPTIONS
* series
B-65282EN/06
- No part of this manual may be reproduced in any form.
- All specifications and designs are subject to change without notice.
The products in this manual are controlled based on Japan’s “Foreign Exchange and
Foreign Trade Law”. The export from Japan may be subject to an export license by the
government of Japan.
Further, re-export to another country may be subject to the license of the government of
the country from where the product is re-exported. Furthermore, the product may also be
controlled by re-export regulations of the United States government.
Should you wish to export or re-export these products, please contact FANUC for advice.
In this manual we have tried as much as possible to describe all the various matters.
However, we cannot describe all the matters which must not be done, or which cannot be
done, because there are so many possibilities.
Therefore, matters which are not especially described as possible in this manual should be
regarded as ”impossible”.
General Safety Precautions
- When an abnormality such as an alarm or a hardware failure occurs, the operations
described in the specifications are not guaranteed unless otherwise specifically noted.
When action corresponding to the abnormality is specifically described, take the action.
When no action is described, please contact FANUC.
- The signals and functions described in the specifications cannot be used separately for
safety functions unless otherwise described as being usable for the safety functions.
Their specifications are not assumed to be used as the safety functions in this case, an
unexpected danger may be caused. For information about the safety functions, please
contact FANUC.
Generally, the safety functions represent functions that protect the operators from
machine danger.
- A wrong device connection or setting can lead to unpredictable operation. When
starting to operate the machine for the first time after assembling the machine, replacing
components, or modifying parameter settings, exercise the greater care by, for example,
reducing the torque limit value, error detection level, or operating speed or by operating
the machine in such a way that an emergency stop can be made quickly.
B-65282EN/06 SAFETY PRECAUTIONS
SAFETY PRECAUTIONS
This "Safety Precautions" section describes the precautions which
must be observed to ensure safety when using FANUC servo
amplifiers (including spindle amplifiers). Users of any control motor
amplifier model are requested to read the "Safety Precautions"
carefully before first using the amplifier. Users should also read the
relevant description in this manual to become fully familiar with the
functions of the servo amplifier.
The users are basically forbidden to do any behavior or action not
mentioned in the "Safety Precautions." They are invited to ask
FANUC previously about what behavior or action is prohibited.
Contents
DEFINITION OF WARNING, CAUTION, AND NOTE ................s-2
WARNINGS AND CAUTIONS RELATING TO MOUNTING .....s-3
Warning...................................................................................... s-3
Caution ....................................................................................... s-5
Note............................................................................................s-7
WARNINGS AND CAUTIONS RELATING TO A PILOT RUN ..s-8
Warning...................................................................................... s-8
Caution ....................................................................................... s-9
WARNINGS AND CAUTIONS RELATING TO
MAINTENANCE ............................................................................s-10
Warning.................................................................................... s-10
Caution ..................................................................................... s-12
Note..........................................................................................s-13
s-1
SAFETY PRECAUTIONS B-65282EN/06
DEFINITION OF WARNING, CAUTION, AND NOTE
This manual includes safety precautions for protecting the user and
preventing damage to the machine. Precautions are classified into
Warning and Caution according to their bearing on safety. Also,
supplementary information is described as a Note. Read the Warning,
Caution, and Note thoroughly before attempting to use the machine.
WARNING
Applied when there is a danger of the user being
injured or when there is a danger of both the user
being injured and the equipment being damaged if
the approved procedure is not observed.
CAUTION
Applied when there is a danger of the equipment
being damaged, if the approved procedure is not
observed.
NOTE
The Note is used to indicate supplementary
information other than Warning and Caution.
- Read this manual carefully, and store it in a safe place.
s-2
B-65282EN/06 SAFETY PRECAUTIONS
WARNINGS AND CAUTIONS RELATING TO MOUNTING
Warning
WARNING
- Check the specification code of the amplifier.
Check that the delivered amplifier is as originally ordered.
- Mount a ground fault interrupter.
To guard against fire and electric shock, fit the factory power
supply or machine with a ground fault interrupter (designed for
use with an inverter).
- Securely ground the amplifier.
Securely connect the ground terminal and metal frame of the
amplifier and motor to a common ground plate of the power
magnetic cabinet.
- Be aware of the weight of the amplifier and other
components.
Control motor amplifiers and AC reactors are heavy. When
transporting them or mounting them in the cabinet, therefore, be
careful not to injured yourself or damage the equipment. Be
particularly carefull not to jam your fingers between the cabinet
and amplifier.
- Never ground or short-circuit either the power supply lines
or power lines.
Protect the lines from any stress such as bending. Handle the
ends appropriately.
- Ensure that the power supply lines, power lines, and signal
lines are securely connected.
A loose screw, loose connection, or the like will cause a motor
malfunction or overheating, or a ground fault.
Be extremely careful with power supply lines, motor power lines,
and DC link connections through which a large amount of
current passes, because a loose screw (or poor contact in a
connector or poor connection between a connector terminal and a
cable) may cause a fire.
- Insulate all exposed parts that are charged.
- Never touch the regenerative discharge resistor or radiator
directly.
The surface of the radiator and regenerative discharge unit
become extremely hot. Never touch them directly. An
appropriate structure should also be considered.
s-3
SAFETY PRECAUTIONS B-65282EN/06
WARNING
- Close the amplifier cover after completing the wiring.
Leaving the cover open presents a danger of electric shock.
- Confirm that the input voltage meets the specifications of the
amplifier before making connection.
If the input voltage exceeds the specified value (for example, if
the input voltage for a 200-V input amplifier is 400 V), an internal
component may be damaged and burnt out.
- Prevent conductive, flammable, or corrosive foreign matters,
mists, or water droplets from entering the unit
If conductive or flammable foreign matters enter the unit,
explosion or corruption may be caused.
If corrosive or conductive mists or water droplets are attached to
an electronic circuit, unexpected operation may be caused in the
circuit.
The electronic circuit portion must be installed in an environment
of pollution level 2 specified by IEC60664-1. To achieve
pollution level 2 in a severe machine tool environment, it is
generally necessary to install the portion in a cabinet that satisfies
IP54.
s-4
B-65282EN/06 SAFETY PRECAUTIONS
Caution
CAUTION
- Do not step or sit on the amplifier.
Also, do not stack unpacked amplifiers on top of each other.
- Use the amplifier in an appropriate environment.
See the allowable ambient temperatures and other requirements,
given in the corresponding descriptions.
- Protect the amplifier from impact.
Do not place anything on the amplifier.
- Do not disassemble the amplifier.
- Do not block the air inlet to the radiator.
- Take appropriate measures to prevent coolant, oil mist, or
chips from being adhered to the radiator and fan motors that
are exposed to the outside of the power magnetics cabinet.
A deposit of coolant, oil mist, or chips on the air inlet will result
in a reduction in the cooling efficiency. In some cases, the
required efficiency cannot be achieved. The deposit may also
lead to a reduction in the useful life of the fan motors or
semiconductors. Especially, when outside air is drawn in, mount
filters on both the air inlet and outlet. These filters must be
replaced regularly.
So, an easy-to-replace type of filter should be used.
- Connect the power supply lines and power lines to the
appropriate terminals and connectors.
- Connect the signal lines to the appropriate connectors.
- Ensure that the cables used for the power supply lines and
power lines are of the appropriate diameter and temperature
ratings.
- Do not apply an excessively large force to plastic parts.
If a plastic section breaks, it may cause internal damage, thus
interfering with normal operation. The edge of a broken section
is likely to be sharp and, therefore, presents a risk of injury.
- Before connecting the power supply wiring, check the supply
voltage.
Check that the supply voltage is within the range specified in this
manual, then connect the power supply lines.
- Ensure that the combination of motor and amplifier is
appropriate.
s-5
SAFETY PRECAUTIONS B-65282EN/06
CAUTION
- Ensure that valid parameters are specified.
Specifying an invalid parameter for the combination of motor
and amplifier may not only prevent normal operation of the
motor but also result in damage to the amplifier.
- Ensure that the amplifier and peripheral equipment are
securely connected.
Check that the magnetic contactor, circuit breaker, and other
devices mounted outside the amplifier are securely connected to
each other and that those devices are securely connected to the
amplifier.
- Check that the amplifier is securely mounted in the power
magnetic cabinet.
If any clearance is left between the power magnetic cabinet and
the surface on which the amplifier is mounted, dust entering the
gap may build up and prevent the normal operation of the
amplifier.
- Apply appropriate countermeasures against noise.
Adequate countermeasures against noise are required to maintain
normal operation of the amplifier. For example, signal lines must
be routed away from power supply lines and power lines.
s-6
B-65282EN/06 SAFETY PRECAUTIONS
Note
NOTE
- Keep the nameplate clearly visible.
- Keep the legend on the nameplate clearly visible.
- After unpacking the amplifier, carefully check for any
damage.
- Mount the amplifier in a location where it can be easily
accessed periodic inspection and daily maintenance.
- Leave sufficient space around the machine to enable
maintenance to be performed easily.
Do not place any heavy objects such that they would interfere
with the opening of the doors.
- Keep the parameter table and spare parts at hand.
Also, keep the specifications at hand. These items must be stored
in a location where they can be retrieved immediately.
- Provide adequate shielding.
A cable to be shielded must be securely connected to the ground
plate, using a cable clamp or the like.
s-7
SAFETY PRECAUTIONS B-65282EN/06
WARNINGS AND CAUTIONS RELATING TO A PILOT RUN
Warning
WARNING
- Before turning on the power, check that the cables connected
to the power magnetic cabinet and amplifier, as well as the
power lines and power supply lines, are securely connected.
Also, check that no lines are slack.
- Before turning on the power, ensure that the power magnetic
cabinet is securely grounded.
- Before turning on the power, check that the door of the
power magnetic cabinet and all other doors are closed.
Ensure that the door of the power magnetic cabinet containing
the amplifier, and all other doors, are securely closed. During
operation, all doors must be closed and locked.
- Apply extreme caution if the door of the power magnetic
cabinet or another door must be opened.
Only a person trained in the maintenance of the corresponding
machine or equipment should open the door, and only after
shutting off the power supply to the power magnetic cabinet (by
opening both the input circuit breaker of the power magnetic
cabinet and the factory switch used to supply power to the
cabinet). If the machine must be operated with the door open to
enable adjustment or for some other purpose, the operator must
keep his or her hands and tools well away from any dangerous
voltages. Such work must be done only by a person trained in the
maintenance of the machine or equipment.
- When operating the machine for the first time, check that the
machine operates as instructed.
To check whether the machine operates as instructed, first
specify a small value for the motor, then increase the value
gradually. If the motor operates abnormally, perform an
emergency stop immediately.
- After turning on the power, check the operation of the
emergency stop circuit.
Press the emergency stop button to check that the motor stops
immediately, and that the power being supplied to the amplifier
is shut off by the magnetic contactor.
- Before opening a door or protective cover of a machine to
enable adjustment of the machine, first place the machine in
the emergency stop state and check that the motor has
stopped.
s-8
B-65282EN/06 SAFETY PRECAUTIONS
Caution
CAUTION
- Note whether an alarm status relative to the amplifier is
displayed at power-up or during operation.
If an alarm is displayed, take appropriate action as explained in
the maintenance manual. If the work to be done requires that the
door of the power magnetic cabinet be left open, the work must
be carried out by a person trained in the maintenance of the
machine or equipment. Note that if some alarms are forcibly reset
to enable operation to continue, the amplifier may be damaged.
Take appropriate action according to the contents of the alarm.
- Before operating the motor for the first time, mount and
adjust the position and speed sensors.
Following the instructions given in the maintenance manual,
adjust the position and speed sensors for the spindle so that an
appropriate waveform is obtained.
If the sensors are not properly adjusted, the motor may not rotate
normally or the spindle may fail to stop as desired.
- If the motor makes any abnormal noise or vibration while
operating, stop it immediately.
Note that if operation is continued in spite of there being some
abnormal noise or vibration, the amplifier may be damaged. Take
appropriate corrective action, then resume operation.
- Observe the ambient temperature and output rating
requirements.
The continuous output rating or continuous operation period of
some amplifiers may fall as the ambient temperature increases. If
the amplifier is used continuously with an excessive load applied,
the amplifier may be damaged.
s-9
SAFETY PRECAUTIONS B-65282EN/06
WARNINGS AND CAUTIONS RELATING TO MAINTENANCE
Warning
WARNING
- Read the maintenance manual carefully and ensure that you
are totally familiar with its contents.
The maintenance manual describes daily maintenance and the
procedures to be followed in the event of an alarm being issued.
The operator must be familiar with these descriptions.
- Notes on replacing a fuse or circuit board
1) Before starting the replacement work, ensure that the circuit
breaker protecting the power magnetic cabinet is open.
2) Check that the red LED that indicates that charging is in
progress is not lit.
The position of the charging LED on each model of
amplifier is given in this manual. While the LED is lit,
hazardous voltages are present inside the unit, and thus
there is a danger of electric shock.
3) Some circuit board components become extremely hot. Be
careful not to touch these components.
4) Ensure that a fuse having an appropriate rating is used.
5) Check the specification code of a circuit board to be
replaced. If a modification drawing number is indicated,
contact FANUC before replacing the circuit board.
Also, before and after replacing a circuit board, check its
pin settings.
6) After replacing the fuse, ensure that the screws are firmly
tightened. For a socket-type fuse, ensure that the fuse is
inserted correctly.
7) After replacing the circuit board, ensure that it is securely
connected.
8) Ensure that all power lines, power supply lines, and
connectors are securely connected.
- Take care not to lose any screws.
When removing the case or circuit board, take care not to lose
any screws. If a screw is lost inside the nit and the power is
turned on, the machine may be damaged.
s-10
B-65282EN/06 SAFETY PRECAUTIONS
WARNING
- Notes on replacing the battery of the absolute Pulsecoder
Replace the battery only while the power is on. If the battery is
replaced while the power is turned off, the stored absolute
positioning data will be lost. Some αi series servo amplifier
modules have batteries in their servo amplifiers. To replace the
battery of any of those models, observe the following procedure:
Open the door of the power magnetic cabinet; Leave the control
power of the power supply module on; Place the machine in the
emergency stop state so that the power being input to the
amplifier is shut off; Then, replace the battery. Replacement
work should be done only by a person who is trained in the
related maintenance and safety requirements. The power
magnetic cabinet in which the servo amplifier is mounted has a
high-voltage section. This section presents a severe risk of
electric shock.
- Check the number of any alarm.
If the machine stops upon an alarm being issued, check the alarm
number. Some alarms indicate that a component must be replaced.
If the power is reconnected without first replacing the failed
component, another component may be damaged, making it
difficult to locate the original cause of the alarm.
- Before resetting an alarm, ensure that the original cause of
the alarm has been removed.
- Contact FANUC whenever a question relating to
maintenance arises.
s-11
SAFETY PRECAUTIONS B-65282EN/06
Caution
CAUTION
- Ensure that all required components are mounted.
When replacing a component or circuit board, check that all
components, including the snubber capacitor, are correctly
mounted. If the snubber capacitor is not mounted, for example,
the IPM will be damaged.
- Tighten all screws firmly.
- Check the specification code of the fuse, circuit board, and
other components.
When replacing a fuse or circuit board, first check the
specification code of the fuse or circuit board, then mount it in
the correct position. The machine will not operate normally if a
fuse or circuit board having other than the correct specification
code is mounted, or if a fuse or circuit board is mounted in the
wrong position.
- Mount the correct cover.
The cover on the front of the amplifier carries a label indicating a
specification code. When mounting a previously removed front
cover, take care to mount it on the unit from which it was
removed.
- Notes on cleaning the heat sink and fan
1) A dirty heat sink or fan results in reduced semiconductor
cooling efficiency, which degrades reliability. Periodic
cleaning is necessary.
2) Using compressed air for cleaning scatters the dust. A
deposit of conductive dust on the amplifier or peripheral
equipment will result in a failure.
3) To clean the heat sink, do so only after turning the power
off and ensuring that the heat sink has cooled to room
temperature. The heat sink becomes extremely hot, such
that touching it during operation or immediately after
power-off is likely to cause a burn. Be extremely careful
when touching the heat sink.
- Notes on removing the amplifier
Before removing the amplifier, first ensure that the power is shut
off. Be careful not to jam your fingers between the power
magnetic cabinet and amplifier.
- Unless otherwise specified, do not insert or remove any
connector while the power is turned on. Otherwise, the
amplifier may fail.
s-12
B-65282EN/06 SAFETY PRECAUTIONS
Note
NOTE
- Ensure that the battery connector is correctly inserted.
If the power is shut off while the battery connector is not
connected correctly, the absolute position data for the machine
will be lost.
- Store the manuals in a safe place.
The manuals should be stored in a location where they can be
accessed immediately it so required during maintenance work.
- Notes on contacting FANUC
Inform FANUC of the details of an alarm and the specification
code of the amplifier so that any components required for
maintenance can be quickly secured, and any other necessary
action can be taken without delay.
s-13
B-65282EN/06 TABLE OF CONTENTS
TABLE OF CONTENTS
SAFETY PRECAUTIONS............................................................................s-1
DEFINITION OF WARNING, CAUTION, AND NOTE ............................................. s-2
WARNINGS AND CAUTIONS RELATING TO MOUNTING ...................................s-3
Warning ...............................................................................................................................s-3
Caution ...............................................................................................................................s-5
Note ...............................................................................................................................s-7
WARNINGS AND CAUTIONS RELATING TO A PILOT RUN ................................s-8
Warning ...............................................................................................................................s-8
Caution ...............................................................................................................................s-9
WARNINGS AND CAUTIONS RELATING TO MAINTENANCE........................... s-10
Warning .............................................................................................................................s-10
Caution .............................................................................................................................s-12
Note .............................................................................................................................s-13
1 CONFIGURATION ..................................................................................1
1.1 FEATURES OF THE SERVO AMPLIFIER αi SERIES.................................. 2
1.2 CONFIGURATION......................................................................................... 3
1.2.1 200-V Input Series....................................................................................................3
1.2.2 400-V Input Series....................................................................................................6
1.3 SERVO AMPLIFIERS.................................................................................... 8
1.4 LINEUP........................................................................................................ 10
2 SPECIFICATIONS................................................................................. 11
2.1 INPUT POWER ...........................................................................................12
2.2 ENVIRONMENTAL CONDITIONS ..............................................................25
2.3 SPECIFICATIONS OF THE MODULES ...................................................... 33
2.3.1 αi PS series .............................................................................................................33
2.3.2 αi SV series ............................................................................................................37
2.3.3 αi SP series .............................................................................................................40
2.4 WEIGHT ...................................................................................................... 43
3 ORDERING INFORMATION ................................................................. 45
3.1 SERVO AMPLIFIER .................................................................................... 46
3.1.1 200-V Input Series..................................................................................................46
3.1.1.1 αi PS series ........................................................................................................ 46
3.1.1.2 αi PS
3.1.1.3 αi SV series ....................................................................................................... 47
3.1.1.4 αi SP series ........................................................................................................ 49
3.1.2 400-V Input Series..................................................................................................50
3.1.2.1 αi PS series ........................................................................................................ 50
3.1.2.2 αi SV series ....................................................................................................... 51
3.1.2.3 αi SP series ........................................................................................................ 53
3.1.3 Others .....................................................................................................................54
3.1.3.1 AC reactor.......................................................................................................... 54
3.1.3.2 AC line filter ...................................................................................................... 56
3.1.3.3 Sub module SW ................................................................................................. 57
series ......................................................................................................46
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TABLE OF CONTENTS B-65282EN/06
3.1.3.4 Sub module SM .................................................................................................57
3.1.3.5 Connectors ......................................................................................................... 58
3.1.3.6 Fuses .................................................................................................................. 64
3.1.3.7 Power transformer ............................................................................................. 65
3.1.3.8 Regenerative discharge unit............................................................................... 69
3.1.3.9 Cables ................................................................................................................ 70
3.1.3.10 Circuit breaker and magnetic contactor ............................................................. 71
3.1.3.11 Lightning surge protector .................................................................................. 74
3.1.3.12 Noise filter ......................................................................................................... 75
3.1.3.13 Sensors for servo ............................................................................................... 75
3.1.3.14 Sensors for spindle............................................................................................. 76
3.1.3.15 Power line switch unit ....................................................................................... 77
3.1.3.16 Battery for absolute Pulsecoder ......................................................................... 78
4 HOW TO SELECT THE MODULE ........................................................ 79
4.1 HOW TO SELECT THE αi SV SERIES (SERVO AMPLIFIER) ................... 80
4.1.1 200-V Input Series..................................................................................................81
4.1.2 400-V Input Series..................................................................................................82
4.1.3 How to Select the Dynamic Brake Module (DBM) ...............................................83
4.2 HOW TO SELECT THE αi SP series(SPINDLE AMPLIFIER)..................... 84
4.2.1 200-V Input Series..................................................................................................85
4.2.2 400-V Input Series..................................................................................................85
4.3 HOW TO SELECT THE αi PS series (POWER SUPPLY) ..........................86
4.3.1 How to Obtain the αi PS series rated output capability .........................................87
4.3.2 How to Obtain the αi PS series maximum output capability .................................87
4.3.3 How to Obtain the αi PS series peak maximum output capability.........................88
4.3.4 Number of Connected αi SV series and αi SP Series ............................................89
4.3.5 Notes on 400-V Input αi PS series selection ..........................................................89
4.4 HOW TO SELECT THE αi PSR series (POWER SUPPLY, RESISTANCE
DISCHARGE TYPE).................................................................................... 90
4.4.1 How to Obtain the αi PSR series Rated Output Capability.....................................91
4.4.2 How to Obtain the αi PS
4.4.3 Number of Connected αi SV series and αi SP series .............................................92
4.4.4 Selecting a Regenerative Discharge Unit ...............................................................93
4.5 LIST OF MOTOR OUTPUT CAPACITIES FOR αi PS AND αi PSR series
SELECTION ................................................................................................ 96
4.5.1 Servo Motor Continuous Rated Outputs and Maximum Outputs at Acceleration .96
4.5.2 Spindle Motor Continuous Rated Outputs and Maximum Outputs at
Acceleration..........................................................................................................100
series Maximum Output Capability .............................91
R
5 INSTALLATION ..................................................................................102
5.1 LEAKAGE CURRENT ............................................................................... 103
5.2 GROUND................................................................................................... 104
5.2.1 Ground Systems ...................................................................................................104
5.2.2 Grounding Method ...............................................................................................105
5.2.3 Notes on Connecting ............................................................................................107
5.3 NOISE PREVENTION ............................................................................... 108
5.3.1 Separation of Signal Lines ...................................................................................108
5.3.2 Cable Clamp and Shield Processing .....................................................................109
5.3.3 Cabinet .................................................................................................................113
5.3.4 Others ...................................................................................................................116
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B-65282EN/06 TABLE OF CONTENTS
5.4 AMPLIFIER INSTALLATION ..................................................................... 117
5.5 AMPLIFIER INSTALLATION NOTES RELATING TO SAFETY
STANDARDS............................................................................................. 118
5.5.1 Requirements of EN and IEC Standards ..............................................................118
5.5.1.1 Classification in standards on insulation design .............................................. 118
5.5.1.2 Protection against electric shock...................................................................... 119
5.5.1.3 Protective grounding........................................................................................ 121
5.5.1.4 EMC................................................................................................................. 121
5.5.1.5 Notes on the emergency stop circuit configuration .........................................121
5.5.1.6 Reduction of load ratio to ambient temperature .............................................. 122
5.5.1.7 Overload protection ......................................................................................... 122
5.5.1.8 External overload protection device ................................................................ 122
5.5.1.9 Over-speed protection...................................................................................... 122
5.5.1.10 24-V power supply ..........................................................................................122
5.5.1.11 Screw tightening torque................................................................................... 122
5.5.2 Requirements of UL Standards ............................................................................123
5.5.2.1 Classification in standards on insulation design .............................................. 123
5.5.2.2 Protection against electric shock...................................................................... 124
5.5.2.3 Protective grounding........................................................................................ 124
5.5.2.4 Overload protection ......................................................................................... 124
5.5.2.5 External overload protection device ................................................................ 124
5.5.2.6 Short-circuit protection.................................................................................... 125
5.5.2.7 Over-speed protection...................................................................................... 125
5.5.2.8 24-V power supply .......................................................................................... 125
5.5.2.9 Screw tightening torque................................................................................... 125
5.6 NOTES ON COOLANT (REFERENCE) .................................................... 126
6 HEAT DISSIPATION ........................................................................... 127
6.1 200-V INPUT SERIES ............................................................................... 128
6.1.1 αi PS series ...........................................................................................................128
6.1.2 αi SV series ..........................................................................................................129
6.1.3 αi SP series ...........................................................................................................133
6.2 400-V INPUT SERIES ............................................................................... 134
6.2.1 αi PS series ...........................................................................................................134
6.2.2 αi SV series ..........................................................................................................135
6.2.3 αi SP series ...........................................................................................................139
7 COOLING ............................................................................................140
8 EXTERNAL DIMENSIONS AND MAINTENANCE AREA ..................141
8.1 OUTLINE DRAWINGS .............................................................................. 142
8.1.1 Outline Drawings of Amplifiers, Panel Cut-out, and Maintenance Area .............142
8.1.2 AC Reactor Unit ...................................................................................................148
8.1.3 AC Line Filter ......................................................................................................158
8.1.4 Power Transformer...............................................................................................159
8.1.5 Regenerative Discharge Unit................................................................................165
8.1.6 Dynamic Brake Module (DBM)...........................................................................168
8.1.7 Circuit Breaker .....................................................................................................170
8.1.8 Magnetic Contactors.............................................................................................172
8.1.9 Lightning Surge Protector ....................................................................................179
8.1.10 Noise Filter ...........................................................................................................182
8.2 PANEL CUT-OUT DIAGRAMS.................................................................. 185
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TABLE OF CONTENTS B-65282EN/06
9 CONNECTION..................................................................................... 192
9.1 TOTAL CONNECTION DIAGRAM ............................................................193
9.2 CONNECTOR LOCATION ........................................................................ 195
9.2.1 αi PS series ...........................................................................................................195
9.2.2 αi SV series ..........................................................................................................200
9.2.3 αi SP Series ..........................................................................................................203
9.3 CABLE CONNECTION DETAILS .............................................................. 207
9.3.1 αi PS Series Connection Diagram ........................................................................207
9.3.1.1 Details of cable K1 (power supply line) .......................................................... 213
9.3.1.2 Details of short bar K2..................................................................................... 220
9.3.1.3 Details of cable K3 .......................................................................................... 225
9.3.1.4 Details of cable K69 ........................................................................................ 226
9.3.1.5 Details of cable K6 .......................................................................................... 227
9.3.1.6 Details of cable K7 .......................................................................................... 228
9.3.1.7 Details of cable K70 ........................................................................................ 230
9.3.1.8 Detailed description of the connection of cables K41 (for regenerative
discharge resistance), K42 (for thermostat), and K43 (for fan motor) ............231
9.3.1.9 Details of cable K100 (for power failure detection output)............................. 233
9.3.2 αi SV series Connection Diagram ........................................................................234
9.3.2.1 Details of cable K2 .......................................................................................... 237
9.3.2.2 Details of cable K4 .......................................................................................... 237
9.3.2.3 Details of cable K69 ........................................................................................ 237
9.3.2.4 Details of cable K21 ........................................................................................ 238
9.3.2.5 Details of cable K22 ........................................................................................ 243
9.3.2.6 Details of cable K24 ........................................................................................ 248
9.3.2.7 Details of cable K25 ........................................................................................ 249
9.3.2.8 Details of cable K26 ........................................................................................ 250
9.3.2.9 Details of cable K27 ........................................................................................ 251
9.3.2.10 Connecting the battery (for the absolute Pulsecoder)...................................... 252
9.3.2.11 Details of cable K70 ........................................................................................258
9.3.3 αi SP Series Connection Diagram ........................................................................259
9.3.3.1 Details of cable K2 .......................................................................................... 260
9.3.3.2 Details of cable K69 ........................................................................................ 260
9.3.3.3 Details of cable K10 (power cable) .................................................................260
9.3.3.4 Details of cable K70 ........................................................................................ 263
9.3.3.5 Details of cable K11 ........................................................................................ 263
9.3.3.6 Details of cable K12 ........................................................................................ 264
9.3.3.7 Details of cable K14 ........................................................................................ 267
9.3.3.8 Details of cable K16 ........................................................................................ 271
9.3.3.9 Details of cable K17 ........................................................................................ 273
9.3.3.10 Details of cable K33 ........................................................................................281
9.3.3.11 Details of cable K36 ........................................................................................287
9.3.3.12 Details of cable K71 ........................................................................................290
9.3.3.13 Details of cable K86 ........................................................................................293
9.3.3.14 Details of cable K88 ........................................................................................294
9.3.3.15 Details of cable K90 ........................................................................................295
9.3.3.16 Details of cable K96 ........................................................................................296
9.3.3.17 Details of cable K97 ........................................................................................297
9.3.3.18 Spindle Motor Feedback Cable Connection .................................................... 299
9.4 DETAILS OF CONNECTORS ...................................................................301
9.4.1 20-Pin Half-Pitch Connectors ..............................................................................301
9.4.2 Tyco Electronics AMP D-5000 Series Connector................................................302
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B-65282EN/06 TABLE OF CONTENTS
10 SPINDLE-RELATED OPTIONS ..........................................................304
10.1 SPINDLE ORIENTATION.......................................................................... 305
10.2 POWER LINE SWITCH CIRCUIT.............................................................. 306
10.2.1 Overview ..............................................................................................................306
10.2.2 Switch Circuit Configuration ...............................................................................306
10.2.3 Power Line Switch Unit .......................................................................................308
10.2.3.1 Specification .................................................................................................... 308
10.2.4 Outside and Mounting Dimension Diagrams.......................................................309
10.2.5 Connection ...........................................................................................................313
10.2.6 Notes.....................................................................................................................314
10.3 SUB MODULE SW .................................................................................... 316
10.3.1 Configuration .......................................................................................................316
10.3.2 Specification.........................................................................................................317
10.3.3 External Dimensions ............................................................................................319
10.3.4 Connector Installation Diagram (for Combination with αi SP 15) ......................321
10.3.5 Connection ...........................................................................................................322
10.4 SUB MODULE SM..................................................................................... 323
10.4.1 Specifications .......................................................................................................324
10.4.2 Outline Drawing ...................................................................................................325
10.4.3 Panel Cut-out........................................................................................................326
10.4.4 Connection ...........................................................................................................326
11 SENSOR.............................................................................................. 327
11.1 SENSOR FOR THE SERVO SYSTEM...................................................... 328
11.1.1 Absolute αiCZ Sensor (Separate Sensor).............................................................328
11.1.1.1 Specifications................................................................................................... 329
11.1.1.2 Connection block diagram (common to three models).................................... 335
11.1.1.3 Connection specifications................................................................................ 336
11.1.1.4 Rotation direction of the absolute αiCZ sensor............................................... 338
11.1.1.5 Installation ....................................................................................................... 340
11.1.1.6 Notes on use..................................................................................................... 345
11.1.1.7 Output signal check method ............................................................................348
11.2 SENSOR FOR THE SPINDLE................................................................... 350
11.2.1 Position Coder ......................................................................................................350
11.2.1.1 αi position coder.............................................................................................. 350
11.2.1.2 α position coder S............................................................................................ 353
11.2.1.3 Installation conditions and notes ..................................................................... 356
11.2.2 αiBZ Sensor (A860-2150-T*** and A860-2155-T***) ......................................358
11.2.3 αiCZ Sensor (for the Spindle)..............................................................................367
11.2.3.1 Names and specification numbers ...................................................................368
11.2.3.2 Absolute maximum ratings.............................................................................. 368
11.2.3.3 Specifications................................................................................................... 368
11.2.3.4 System configuration and connection block diagram...................................... 380
11.2.3.5 Connection specifications................................................................................ 381
11.2.3.6 Rotation direction of the αiCZ sensor ............................................................. 384
11.2.3.7 Machine start-up procedure (outline) .............................................................. 385
11.2.3.8 Installation ....................................................................................................... 386
11.2.3.9 Interpolation error learning.............................................................................. 391
11.2.3.10 Notes................................................................................................................ 392
11.2.3.11 Maintenance target parts.................................................................................. 393
11.2.3.12 Output signal check method ............................................................................ 394
11.2.3.13 Spindle alarms ................................................................................................. 396
c-5
TABLE OF CONTENTS B-65282EN/06
APPENDIX
A FITTING A LIGHTNING SURGE PROTECTION DEVICE.................. 399
A.1 200-V INPUT SERIES POWER SUPPLY.................................................. 400
A.2 400-V INPUT SERIES POWER SUPPLY.................................................. 402
A.3 CAUTIONS ................................................................................................ 403
B CABLES ..............................................................................................404
B.1 10-PAIR CABLE ........................................................................................405
B.2 COMPOSITE 7-CORE CABLE .................................................................. 407
B.3 COMPOSITE 10-CORE CABLE ................................................................ 415
B.4 COMPOSITE 12-CORE CABLE ................................................................ 417
B.5 COMPOSITE 16-CORE CABLE ................................................................ 419
B.6 10-PAIR CABLE ........................................................................................420
C EXTERNAL DIMENSIONS OF EACH CONNECTOR......................... 421
D FEEDBACK CABLE LENGTH............................................................ 431
D.1 SPINDLE CABLE LENGTH
(WHEN RECOMMENDED CABLES ARE USED) ..................................... 432
D.2 SERVO CABLE LENGTH
(WHEN RECOMMENDED CABLES ARE USED) ..................................... 433
E POWER LINE FOR SERVO MOTOR AND AMPLIFIER..................... 434
E.1 SELECTING A POWER CABLE................................................................ 435
F MEASURES AGAINST NOISE FROM SERVO AMPLIFIERS ........... 438
F.1 NOISE OCCURRENCE IN SERVO AMPLIFIERS..................................... 439
F.2 NOISE TYPES........................................................................................... 440
F.3 ANTI-NOISE MEASURES......................................................................... 442
F.3.1 Pre-Installation Arrangement ...............................................................................442
F.3.2 Anti-Noise Measures ............................................................................................443
F.3.3 Concrete Examples of Anti-Noise Measures........................................................444
F.3.4 Anti-Noise Measures for Power Supply Equipment and Grounding ...................446
F.3.5 Anti-Noise Devices ..............................................................................................449
F.4 MISCELLANEOUS .................................................................................... 450
G EXAMPLES OF RECOMMENDED POWER MAGNETICS
CABINETS FOR SERVO AMPLIFIER INSTALLATION..................... 451
G.1 OVERVIEW ............................................................................................... 452
G.2 DESCRIPTIONS........................................................................................ 453
G.2.1 Power Magnetics Cabinet Seal-up........................................................................453
G.2.2 Environments for Amplifier Heat Sink Sections ..................................................458
G.2.3 Environments for Amplifier Installation ..............................................................460
H DC LINK TERMINAL BOARD SECTION PROTECTIVE COVER ......462
H.1 OVERVIEW ............................................................................................... 463
H.2 HOW TO MOUNT......................................................................................464
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B-65282EN/06 TABLE OF CONTENTS
I POWER FAILURE DETECTION FUNCTION ..................................... 465
I.1 OVERVIEW ............................................................................................... 466
I.2 POWER FAILURE DETECTION SPECIFICATION ................................... 467
I.3 APPLICATION TO PREVENTION OF VERTICAL AXES FROM FALLING
AT POWER FAILURE ...............................................................................469
I.3.1 Procedure..............................................................................................................469
I.3.2 Brake Circuit ........................................................................................................470
I.3.3 Method for Keeping Vertical Axis Motors Energized .........................................473
I.3.4 Cautions................................................................................................................476
I.3.5 Confirming Effect.................................................................................................477
I.3.6 Method for Supplying External Power to the Amplifier......................................479
I.4 USE IN COMBINATION WITH THE DUAL CHECK SAFETY FUNCTION 481
J SENSOR (OLD SPECIFICATIONS)....................................................482
J.1 SENSOR FOR THE SYNCHRONOUS BUILT-IN SERVO MOTOR AND
SEPARATE SENSOR ............................................................................... 483
J.1.1 Absolute αiCZ Sensor (Serial Output, A860-2142-T***)...................................483
J.2 SENSOR FOR THE SPINDLE................................................................... 498
J.2.1.1 αiBZ Sensor (Conventional Dimensions, A860-2120-T***)..........................498
J.2.2 αiCZ Sensor (Analog Output, A860-2140-T***)................................................503
K MAGNETIC SENSOR SIGNAL CONVERSION ADAPTER................515
K.1 ORDERING INFORMATION ..................................................................... 516
K.2 SPECIFICATIONS..................................................................................... 516
K.3 DIMENSIONS............................................................................................ 517
K.4 CONNECTION........................................................................................... 518
K.5 METHOD OF ADJUSTMENT .................................................................... 520
L HARMONIC LEAKAGE CURRENT ....................................................521
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B-65282EN/06 1.CONFIGURATION
1 CONFIGURATION
Chapter 1, "CONFIGURATION", consists of the following sections:
1.1 FEATURES OF THE SERVO AMPLIFIER αi SERIES.............2
1.2 CONFIGURATION......................................................................3
1.3 SERVO AMPLIFIERS .................................................................8
1.4 LINEUP ......................................................................................10
- 1 -
1.CONFIGURATION B-65282EN/06
1.1 FEATURES OF THE SERVO AMPLIFIER αi SERIES
The servo amplifier αi series employs a modular structure, and is
thinner, conserves more space, outputs less heat, and saves more
energy.
Compact
(1) Use of a latest low-loss power device and a newly developed
(2) The width of the amplifier is reduced, and therefore the amplifier
(3) The shape of the cable connector is improved to reduce the
Reduction in cabling
(1) Amplifiers can be connected with one cable.
(2) A ground connection from the motor output terminal block to the
Connector attachment to power lines
(1) Connectors are attached to input power lines and motor power
Improved maintainability
(1) A fan motor can now be replaced in an instant manner, so that
(2) Connectors are attached to input power lines and motor power
(3) The need to perform reference position return operation after
highly-efficient radiator makes it possible to reduce the depth of
the fin to 100 mm, therefore reducing the depth of the amplifier.
requires an average of approximately 30% smaller installation
space in the cabinet than the conventional amplifiers.
length of cable projection into the control board.
flange is included, so external cabling for this connection is no
longer required. (A connection from the top of the flange to the
system ground on the control board is required.)
lines. (For the large-capacity models, terminal blocks are used.)
The time required for power line attachment to and detachment
from the servo amplifier cabinet is substantially reduced.
the time required to replace a fan motor is reduced substantially.
lines, so that the time required for servo amplifier replacement is
reduced substantially.
servo amplifier replacement is eliminated.
The servo amplifier αi series has a built-in backup capacitor in
the Absolute Pulsecoder as standard. The capacitor enables
absolute position detection operation for about 10 minutes, so
that reference position return operation after servo amplifier or
feedback cable replacement is unnecessary.
- 2 -
B-65282EN/06 1.CONFIGURATION
1.2 CONFIGURATION
The FANUC αi series consists of the following units and parts:
1.2.1 200-V Input Series
(1) αi PS series (Power Supply).............................................(Basic)
(2) αi PS
(3) αi SV series (Servo Amplifier).........................................(Basic)
(4) αi SP series (Spindle Amplifier).......................................(Basic)
(5) AC reactor.........................................................................(Basic)
(6) Connectors (for connection cables)..................................(Basic)
(7) Fuses ..............................................................................(Basic)
(8) Power transformer .......................................................(Optional)
(9) AC line filter.....................................................................(Basic)
(10) Regenerative discharge unit..............................................(Basic)
(11) DBM (Dynamic brake module)........................................(Basic)
series (Power Supply) [resister discharge type].... (Basic)
R
- 3 -
1.CONFIGURATION B-65282EN/06
φ
Basic configuration using αi PS (example)
Common Power
Supply
i PS
α
Spindle Amplifier
i SP
α
Servo Amplifier
i SV
α
DC link
(300VDC)
200 to 240 VAC
3φ
Circuit
breaker 2
Circuit
breaker 1
Units prepared by the machine tool builder
Magnetic
contactor
Lightning
surge
protector
NOTE
1 For how to use the αi PS together with the αi SV
and α
MODULE".
2 A magnetic contactor, AC line filter, and circuit
breakers are always required.
3 To protect the unit from surge currents caused by
lightning, connect surge absorbers between lines,
and between the lines and ground, at the power
inlet of the power magnetic cabinet. See
APPENDIX A for details.
4 When using the 3φ fan motor, breaker 2 can be
shared.
200R,200S
1φ
AC reactor
(note 4)
3φ
fan motor
3
Spindle motor
Servo motor
i SP, see Chapter 4, "HOW TO SELECT THE
- 4 -
B-65282EN/06 1.CONFIGURATION
φ
Basic configuration using αi PSR (example)
Common Power
supply
i PS
α
R
Spindle amplifier
i SP
α
Servo amplifier
i SV
α
DC link
(300VDC)
200 to 240 VAC
3φ
Circuit
breaker 2
Circuit
breaker 1
Units prepared by the machine tool builder
Magnetic
contactor
Lightning
surge
protector
(note 5)
NOTE
1 For how to use the αi PSR together with the αi SV
and α
MODULE".
2 A magnetic contactor, AC line filter, and circuit
breakers are always required.
3 To protect the unit from surge currents caused by
lightning, connect surge absorbers between lines,
and between the lines and ground, at the power
inlet of the power magnetic cabinet. See
APPENDIX A for details.
4 When an insulating transformer is installed,
high-frequency noise to the Power Supply is
reduced, so the AC line filter is not required. If the
insulating transformer is installed outside the power
magnetic cabinet, and the cable connecting the
amplifier is exposed, the cable must be covered
with a grounded metal duct, or an AC line filter
must be installed.
5 When using the 3φ fan motor, breaker 2 can be
shared.
200R,200S
1φ
AC
line
filter
Regenerative
3
φ
discharge
unit
fan motor
3
Spindle motor
Servo motor
i SP, see Chapter 4, "HOW TO SELECT THE
- 5 -
1.CONFIGURATION B-65282EN/06
1.2.2 400-V Input Series
(1) αi PS series (Power Supply).............................................(Basic)
(2) αi SV series (Servo Amplifier).........................................(Basic)
(3) αi SP series (Spindle Amplifier).......................................(Basic)
(4) AC reactor.........................................................................(Basic)
(5) Connectors (for connection cables)..................................(Basic)
(6) Fuses ..............................................................................(Basic)
(7) DBM (Dynamic brake module)........................................(Basic)
- 6 -
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