FANUC SERVO AMPLIFIER a series. DESCRIPTIONS (B-65162E/03)

B-65162E/03

5. INSTALLATION

5.3

NOISE PREVENTION

Signal lines must be separated from amplifier input power lines and motor

5.3.1

power lines. The table below lists the signal types.

Separation of Signal

Lines

Group

Signal type

Action

Amplifier input power line

Separate binding (Note 1) or electro-

Motor power line

magnetic shielding (Note 2) is neces-

sary for group B cables.

Magnetic contactor driving

coil (Note 3)

Cable between CNC and

SVM

Cable between CNC and

SPM

Separate binding or electromagnetic

Cable for position feedback

shielding is necessary for group A

or velocity feedback

cables. All cables must be shielded.

Cable for position coder

Cable for magnetic sensor

Other cable related to sensor

NOTE

1 The groups must be 10 cm or more apart from one another

when binding the cables in each group.

2 The electromagnetic shield refers to shielding between

groups with grounded steel plates.

Attach a noise suppressor such as a spark killer to the

magnetic contactor driving coil.

Cabinet

Spindle

Servo

Control

amp.

unit

Cable of group B

Duct

To operator’s

panel,

motor, etc.

Cable of group A

Section

Group A

Group B

Cover

131

5. INSTALLATION

B-65162E/03

5.3.2

Perform terminal processing of the shield sheaths of the signal wires

according to the description in Section 9.2.

Cable Clamp and

The cables that run into the amplifier and which require shield processing,

Shield Processing

with the exception of K14, K15, K17, K18, K19, K31, and K33, must be

clamped as indicated in Fig. 5.3.2 (1). Clamping secures a cable and also

provides shielding. Clamping must always be performed since it is very

important for stable system operation.

Strip part of the cable jacket to expose the shield sheath, as shown in the

figure below. Secure that part of the cable to the ground plate by using

a clamp.

The ground plate must be created and installed by the user as shown in

Figs 5.3.2 (2), (3), (4), and (5).

Ground plate

Cable

Metal fittings

for clamp

40mm∼80mm

Fig.5.3.2 (a) Cable clamp (1)

132

B-65162E/03

5. INSTALLATION

5.3.3

Driving a servo motor or spindle motor may generate noise that could

affect external general electronic devices

(such as AM radios and

Protecting External

telephones).

Electronic Devices

Preventive measures against noise, including those for external electronic

from Noise

devices affected by noise, must be taken from the viewpoint of an entire

system. See Appendix G, which describes the principle of noise

generation and which provides examples of preventive measures.

5.3.4

CE marking requires compliance with the EMC Directive. FANUC’s

products have all been granted a certificate of conformity to the EMC

CE Marking

Directive (EC Directive 89/336/EEC) by a third-party certification

Requirements

organization.

For CE marking, special considerations are required to satisfy the

installation requirements described in the following guideline:

A-72937E: To satisfy the requirement of the EMC Directive

For details of the above guideline, contact your local FANUC office.

135

5. INSTALLATION

B-65162E/03

5.3.5

To satisfy the EMC Directive, the installation of a noise filter is required

in the input section of the power magnetics cabinet.

Selecting a Noise Filter

The rated current of the noise filter being used is determined according

to the type of the CNC that is connected, the type and number of motors,

and the power consumption of the other peripheral devices. Using the

expression given below, calculate the noise filter load current, and select

a noise filter so that the load current does not exceed the rated current of

the filter. Recommended noise filters are given in (12) of Section 2.2.3.

Obtaining the load current of a noise filter

The load current of a noise filter is the sum of the CNC input current, PSM

input current, and current consumption under the other loads.

Current con-

CNC input

PSM input

Load current

sumption under

current

+ Σ

current

(Arms)

other loads

(Arms)

(Note 1)

(Note 2)

NOTE

The CNC input current is determined by the number of

PSUs (power supply units). Calculate the CNC input current

from the following expression:

CNC input current (Arms) = 5 (Arms) x number of PSUs

Normally, a CNC has one PSU. The FS15 multiaxis control

system has two PSUs.

For details of how to obtain the PSM input current, see

Sections 4.1.1 or 4.2.1.

Attach a noise suppressor such as a spark killer to the

magnetic contactor driving coil. When more than one PSM

is connected, sum the input currents of the PSMs.

136

B-65162E/03

5. INSTALLATION

5.4

NOTES ON

AMPLIFIER

INSTALLATION

RELATED TO SAFETY

STANDARDS

5.4.1

The servo amplifier α series is designed to conform to the following

European safety standard:

Overview

DIN VDE 0160 1988/1:1989

(Electronic devices used in a power facility and their incorporation into

the facility)

To certify conformity to the standard, FANUC has obtained certification

from Tûv Rheinland, a third-party certification organization for

European standards.

In power magnetics cabinet design when the machine is to be CE-marked,

the installation conditions described in the following sections should be

considered carefully, based on the EC Machine Directives (directives

based on 89/392/EEC).

[Remarks]

CE marking requires compliance with a related EN standard [EN

60204-1] (Electric Devices in Industrial Machines, Part 1: General

Requirements).

If an EN standard (or an IEC standard if no EN standard exists) exists for

a component in the machine, the component must conform to that EN

standard.

At present, however, no EN standard (or IEC standard) is defined for

amplifiers. Based on the results of an investigation made by Tûv

Rheinland, an approved certification organization for the machine

directives, FANUC set the above VDE standard as a target standard and

designed the servo amplifier α series to conform to the standard.

Therefore, this amplifier series satisfies the amplifier requirements for CE

marking. The user can use these amplifiers without having to be

concerned about safety.

5.4.2

Standard Class of

(1) Insulation of circuits and protective ground

Insulation Design

According to DIN VDE 0160, the insulation design of this amplifier

series conforms to DIN VDE 0110 Part 1 and other related standards.

D The primary (power supply and main circuit) and the

secondary (control circuit) are separated from each other by

reinforced insulation.

D Basic insulation is used on the protective ground side.

137

5. INSTALLATION

B-65162E/03

Basic insulation is also used between the power supply main circuit

and aluminum flange (integrated with a heatsink). Connect the

protective ground wire to the ground terminal of the lower aluminum

flange as described in Section 5.2.3.

(2)

Installation category (overvoltage category)

DIN VDE 0110 [Insulation coordination of electric apparatuses]

classifies power supply facilities by the impulse voltage (relative to

ground) in the power supply to which the amplifier is connected.

This amplifier series is designed as a device of installation category

(overvoltage category) II.

The layout of this amplifier series has been designed on the

assumption that the rated impulse withstand voltage (impulse voltage

relative to ground) in the power supply to which the amplifier is

connected is 2.5 kV or lower.

If an impulse greater than 2.5 kV, relative to ground, appears in the

power supply, it must be suppressed.

Generally, this requirement is considered to be satisfied if an

insulated transformer is used in the power supply input section of a

machine.

If an insulated transformer is not used, install a surge protector

(lightning surge absorber) between the facility and ground to suppress

any impulse higher than 2.5 kV, relative to ground.

(3)

Contamination class of the installation environment and power

magnetics cabinet protection level

EN 60204-1 (13. Control devices/13.3 Protection level) requires

that, when a machine is installed in an environment equivalent to the

general plant level, the protection level against dust, coolant, chips,

and so forth be IP54 or higher.

For a power magnetics cabinet that satisfies this requirement, the

contamination class within the cabinet is considered to be class 2.

The insulation of this amplifier series has been designed on the

assumption that the amplifier is installed in an environment of

contamination class 2.

When using the amplifier in a general machine installation

environment, install the amplifier in a power magnetics cabinet that

satisfies the requirements of protection level IP54.

The IP level, however, depends on the environment (atmosphere) in

which a machine is installed. Select the protection level of the power

magnetics cabinet according to the environment.

For an external heatsink cooling type amplifier with a heatsink fin

protruding from the rear of the mounting flange, the fin section should

be in a cooling area

(duct) of about IP22 to

33, and special

considerations should be taken not to protect the fin from direct

coolant splashes or chips.

138

B-65162E/03

5. INSTALLATION

5.4.3

Protection Against

(1)

Protection against direct contact to a charged part

Electric Shock

The protection level against electric shock after the installation of this

amplifier series is equivalent to IP1X (hand protection). Thus, no live

part can be touched unconsciously or carelessly.

This amplifier series must always be installed in a power magnetics

cabinet. According to Item 6.2.1 of EN 60204-1 ”Electric Shock

Protection by Using a Cabinet,” lock the power magnetics cabinet so

that, while the amplifier is on, the cabinet cannot be opened by

persons except special maintenance personnel or a person qualified

for maintenance who has been trained in protective measures against

electric shock.

When a machine operator needs to open the power magnetics cabinet

to perform a certain operation, the operator must have received

sufficient safety education, or a protection cover must be installed to

prevent the operator from touching the amplifier.

(2)

Checking discharge of an electrolytic capacitor

This amplifier series contains a large-capacitance electrolytic

capacitor for the power supply smoothing circuit. Even after the

power supply input circuit is turned off, this capacitor remains

charged for a while.

When it proves necessary to touch the amplifier for maintenance and

so forth, do not start maintenance work immediately; wait for the

discharge time indicated on the face plate of the amplifier.

Alternatively, measure the residual voltage at the DC link section by

using a volt-ohm meter and check that the LED (red) for indicating

the charge state is off to ensure safety.

Standards define voltages exceeding 60 VDC as hazardous voltages.

(3)

Leakage current flowing to the protective ground wire

Motors are controlled by applying a voltage to the armature with the

mean amplitude and frequency of the voltage changed by pulse width

modulation. For this pulse width modulation, a chopper voltage is

applied to the power line of the motor to provide a carrier frequency

of several kilohertz.

Ground drift capacitance mainly between the motor armature

winding and case and between the power line of the motor power

cable and protective ground wire causes a leakage current to flow into

the protective ground wire of the motor power cable and the machine

ground. Part of the leakage current also flows into the protective

ground wire of the machine.

The resultant leakage current is about 1 to 2 mA per motor shaft at the

commercial power supply frequency

(50/60 Hz). With the

measurement circuit defined by EN 60950, the leakage current is

allowed to be much higher than 3.5 mA; this is because the

high-frequency component sensitivity cannot be fully reduced.

139

5. INSTALLATION

B-65162E/03

Unless a machine is grounded, touching the machine may cause

electric shock. Take one of the following protective measures against

electric shock:

(a) Use a protective ground wire with a copper wire cross-sectional

area of no less than 10 mm².

(b) Install a ground fault interrupter so that the power supply can be

disconnected immediately if a ground fault occurs.

double ground wire connection.

When using a ground fault interrupter, select an electromagnetic

ground fault interrupter with a low high-frequency component

sensitivity, or an electronic ground fault interrupter that can be used

with inverters.

Amplifiers have multiple protective grounding terminals (marked as

5.4.4

defined by 417-IEC-5019). These terminals are used to prevent electric

Protective Installation

shock in case of dielectric breakdown, and are also used for functional

grounding to prevent noise.

All protective ground terminals must be connected to the protective

ground (PE) connection terminals in the power magnetics cabinet.

For how to connect the protective ground wires and the cross-sectional

areas of these wires, see Section 5.2.3.

Note that cables from cable terminals cannot be secured together with

protective ground terminals.

5.4.5

The amplifier uses IGBT (transistors) as an internal means of turning off

the power system; it does not use an electromechanical means.

Notes on the

Therefore, when an emergency stop circuit is configured, a line contactor

Emergency Stop

enabling electromechanical disconnection must be installed on the power

Circuit Configuration

input line for feeding power to the power supply module so that a voltage

is applied to the control coil of the contactor via the contactor control

output of the power supply module.

Some amplifier failures may prevent the output relay of the power supply

module from being turned off even when the amplifier emergency stop

command input (*ESP) is driven low, thus disabling disconnection by the

line contactor.

The emergency stop circuit must disconnect power without fail. It must

have a redundant circuit configuration having a route through which the

line contactor is disconnected directly by the command generated by the

emergency stop operation switch, independent of the disconnection

function provided by the amplifier.

If the power line is disconnected during spindle rotation when a spindle

amplifier module is used, the spindle may not be able to be stopped

immediately by the power regeneration function, and may keep rotating

by the force of inertia. Therefore, on the redundant circuit side, a delay

function must be provided which is based on an off-delay timer

considering a normal stop time.

140

B-65162E/03

5. INSTALLATION

For detailed notes on the safety circuits, refer to the following document:

A-71429-S13J : Safety Circuit Requirements and Configuration

Examples

To obtain this document, contact your local FANUC office.

Some amplifier models are certified as conforming to standards, with the

5.4.6

load reduction factors shown below being set.

Decrease in Load

If such an amplifier is used with a load factor exceeded, the allowable

Factor for Given

temperature range of a component may be exceeded, which may cause an

Ambient Temperature

overheat alarm or a decrease in the component life. Therefore, use the

amplifier within the decrease characteristic.

(1) Power supply module time rating decrease with temperature

See Fig. 5.4.6 (a).

(2) Servo amplifier module time rating decrease with temperature

See Fig. 5.4.6 (b).

(3) Spindle amplifier module time rating decrease with temperature

See Fig. 5.4.6 (c).

ÃÃ

ÃÃÃÃÃÃÃÃÃÃÃÃ

Ambient temperature (_C)

Fig.5.4.6 (a) Decreasing Curve of Power Supply Module Time

Rating Dependent on Temperature

141

B-65162E/03

5. INSTALLATION

The allowable continuous output time for

30-minute rated output

decreases depending on the ambient temperature as follows:

ÃÃ

ÃÃÃÃÃÃÃÃÃÃÃÃÃ

ÃÃ

ÃÃÃÃÃÃÃÃÃÃ

mbient temperature (_C)

Ambient temperature (_C) Ã

ÃÃ

ÃÃÃ

ÃÃ

ÃÃÃ

ÃÃ

ÃÃÃ

ÃÃ

ÃÃÃ

ÃÃ

ÃÃÃ

ÃÃ

ÃÃÃ

ÃÃ

ÃÃÃ

ÃÃ

ÃÃÃ

ÃÃÃÃÃÃÃÃÃÃÃÃÃ

ÃÃÃ

Ambient temperature (_C)

ÃÃÃÃÃÃÃÃÃÃÃ

ÃÃÃÃÃÃÃÃÃÃ

ÃÃ

Ambient temperature (_C)

Fig.5.4.6 (e) Decreasing Curve of Spindle Amplifier Module Time Rating Dependent on Temperature

145

6. HEAT DISSIPATION

B-65162E/03

The heat dissipated by each α series control motor amplifier module is as

6.1

follows:

200-V INPUT SERIES

6.1.1

Power Supply Module

Table.6.1.1 (a) PSM Heat Out Put

Remaining heat in

cabinet

Rated

Total heat

Name

Ordering number

output

dissipation

Forced air

Natural

cooling

ventilation

(Note 1)

PSM-5.5

A06B-6077-H106

5.5kW

100W

53W

(47W)

53W

PSM-11

A06B-6077-H111

11kW

158W

(Note 2)

PSM-15

A06B-6087-H115

15kW

333W

61W

PSM-26

A06B-6087-H126

26kW

597w

75W

PSM-30

A06B-6087-H130

30kW

681W

79W

PSM-37

A06B-6087-H137

37kW

706W

81W

93W

PSM-45

A06B-6081-H106

45kW

921W

(Note 3)

NOTE

1 A vaule enclosed by parentheses indicates the remaining

heat when the module is forcibly air-cooled with an air

flow of 2m/s or more.

2 Requires forced air cooling, equivalent to fan adaptor unit

A06B-6078-K001.

Forced air cooling by fan adaptor unit A06B-6078-K003 or

equivalent (2 m/s or more) is required.

Table.6.1.1 (b) PSMR Heat Output

Remaining heat in

cabinet

Rated

Total heat

Name

Ordering number

output

dissipation

Natural

Forced air

ventilation

cooling

PSMR-3

A06B-6081-H103

3.0kW

60W

5.5kW

105W

55W

PSMR-5.5

A06B-6081-H106

7.5kW

130W

60W

147

6. HEAT DISSIPATION

B-65162E/03

Table.6.1.1 (c) AC Reactor

Name

Ordering number

Total heat dissipation

Remarks

When PSM-5.5 is used

For PSM-5.5, 11

A81L-0001-0122

23W

When PSM-11 is used

For PSM-15

A81L-0001-0123

33W

For PSM-26

A81L-0001-0120

42W

For PSM-30

A81L-0001-0124

42W

For PSM-37

A81L-0001-0147

72W

For PSM-45

A81L-0001-0133

67W

Table.6.1.1 (d) AC Line Filter

Name

Ordering number

Total heat dissipation

Remarks

10W

At 2.0kW output

For PSMR-3

A81L-0001-0083#3C

15W

At 3.0kW output

40W

At 5.5kW output

For PSMR-5.5

A81L-0001-0101#C

50W

At 7.5kW output

148

6. HEAT DISSIPATION

B-65162E/03

6.1.2

When a motor other than those listed below is used, its heat output should

be assumed to be that of a listed motor with a higher rated current.

Servo Amplifier

Module

Table.6.1.2 (a) SVM1 (1-AXIS)

Motor used

Remaining heat in cabinet

Ordering

Total heat

Name

Forced air

number

dissipation

Natural

L axis

M axis

N axis

cooling

ventilation

(Note 1)

A06B-6079-H101

SVM1-12

α2/3000

31W

A06B-6096-H101

A06B-6079-H102

SVM1-20

αC6/2000

34W

A06B-6096-H102

A06B-6079-H103

SVM1-40S

α6/2000

47W

32W

(30W)

A06B-6096-H103

A06B-6079-H104

SVM1-40L

α22/1500

80W

45W

(41W)

A06B-6096-H104

α6/3000

70W

39W

(36W)

A06B-6079-H105

SVM1-80

α12/3000

91W

47W

(42W)

A06B-6096-H105

α22/2000

106W

54W

(47W)

A06B-6079-H106

α40/2000

144W

66W

(56W)

A06B-6096-H106

α30/3000

167W

62W (Note 2)

SVM1-130

A06B-6079-H106

A06B-6096-H106

α40/2000

198W

72W (Note 2)

(with a fan)

A06B–6078–K002

αL50/2000

229W

81W (Note 2)

A06B-6079-H107

SVM1-240

α6/3000

553W

134W

(56W)

A06B-6096-H107

α100/2000

643W

152W

(56W)

A06B-6079-H108

SVM1-360

A06B-6096-

H108

α150/2000

643W

152W

(60W)

NOTE

1 A vaule enclosed by parentheses indicates the remaining heat when the module is forcibly

air-cooled with an air flow of 2m/s or more.

2 Requires forced air cooling equivalent to fan adaptor unit A06B-6078-K002.

149

6. HEAT DISSIPATION

B-65162E/03

Table.6.1.2 (b) SVM2 (2-AXES)

Motor used

Remaining heat in cabinet

Ordering

Total heat

Name

Forced air

number

dissipation

Natural

L axis

M axis

N axis

cooling

ventilation

(Note)

A06B-6079-H201

SVM2-12/12

α2/3000

54W

A06B-6096-H201

A06B-6079-H202

SVM2-12/20

α2/3000

αC12/2000

68W

A06B-6096-H202

A06B-6079-H203

SVM2-20/20

αC12/2000

82W

A06B-6096-H203

α2/3000

α6/2000

64W

41W

(38W)

A06B-6079-H204

SVM2-12/40

A06B-6096-H204

α2/3000

αC22/1500

97W

54W

(49W)

αC12/2000

α6/2000

77W

45W

(41W)

A06B-6079-H205

SVM2-20/40

A06B-6096-H205

αC12/2000

αC22/1500

111W

60W

(53W)

α6/2000

73W

43W

(39W)

A06B-6079-H206

SVM2-40/40

α6/2000

αC22/1500

107W

57W

(51W)

A06B-6096-H206

αC22/1500

141W

72W

(63W)

α6/2000

α6/3000

96W

50W

(45W)

α6/2000

α12/3000

118W

59W

(52W)

α6/2000

α22/2000

133W

65W

(57W)

A06B-6079-H207

SVM2-40/80

A06B-6096-H207

αC22/1500

α6/3000

130W

65W

(57W)

αC22/1500

α12/3000

151W

73W

(63W)

αC22/1500

α22/2000

166W

79W

(68W)

α6/3000

119W

58W

(50W)

α6/3000

α12/3000

141W

67W

(57W)

α6/3000

α22/2000

156W

73W

(63W)

A06B-6079-H208

SVM2-80/80

A06B-6096-H208

α12/3000

162W

75W

(64W)

α12/3000

α22/2000

177W

81W

(69W)

α22/2000

192W

87W

(74W)

α6/2000

α22/1500

107W

57W

(51W)

SVM2-40L/

A06B-6079-H209

α12/2000

α22/1500

123W

63W

(56W)

40L

A06B-6096-H209

α22/1500

141W

72W

(63W)

NOTE

A vaule enclosed by parentheses indicates the remaining heat when the module is forcibly

air-cooled with an air flow of 2m/s or more.

150

6. HEAT DISSIPATION

B-65162E/03

Table.6.1.2 (c) SVM3 (3-AXES)

Motor used

Remaining heat in cabinet

Total heat

Ordering

Name

dissipa-

Forced air

number

Natural

L axis

M axis

N axis

tion

cooling

ventilation

(Note)

A06B-6079-H301

SVM3-12/12/12

α2/3000

79W

A06B-6096-H301

A06B-6079-H302

SVM3-12/12/20

α2/3000

αC12/2000

93W

A06B-6096-H302

A06B-6079-H303

SVM3-12/20/20

α2/3000

αC12/2000

106W

A06B-6096-H303

A06B-6079-H304

SVM3-12/20/20

αC12/2000

120W

A06B-6096-H304

α2/3000

α6/2000

89W

58W

(54W)

A06B-6079-H305

SVM3-20/20/20

A06B-6096-H305

α2/3000

αC22/1500

122W

71W

(65W)

α2/3000

αC12/2000

α6/2000

102W

62W

(57W)

A06B-6079-H306

SVM3-12/20/40

A06B-6096-H306

α2/3000

αC12/2000

αC22/1500

136W

77W

(69W)

αC12/2000

α6/2000

116W

68W

(62W)

A06B-6079-H307

SVM3-20/20/40

A06B-6096-

H307

αC12/2000

αC22/1500

150W

82W

(74W)

NOTE

A vaule enclosed by parentheses indicates the remaining heat when the module is forcibly

air-cooled with an air flow of 2m/s or more.

151

6. HEAT DISSIPATION

B-65162E/03

6.1.3

Spindle Amplifier

Module

Table.6.1.3 (a) SPM

Remaining heat in cabinet

Continuous rated

Total heat

Name

Ordering number

output of motor

dissipation

Natural

Forced air cooling

(Note 4)

ventilation

(Note 1)

SPM-2.2

A06B-6078-H202#H500

1.5kW

75W

37W

(32W)

2.2kW

112W

44W

(36W)

SPM-5.5

A06B-6078-H206#H500

3.7kW

120W

46W

(36W)

5.5kW

171W

41W (Note 2)

SPM-11

A06B-6078-H211#H500

7.5kW

218W

46W (Note 2)

SPM-15

A06B-6088-H215#H500

11kW

273W

45W

15kW

435W

53W

SPM-22

A06B-6088-H222#H500

18.5kW

515W

57W

SPM-26

A06B-6088-H226#H500

22kW

684W

62W

SPM-30

A06B-6088-H230#H500

26kW

739W

65W

30kW

911W

75W (Note 3)

SPM-45

A06B-6088-H245#H500

37kW

1123W

85W (Note 3)

NOTE

1 A vaule enclosed by parentheses indicates the remaining heat when the module is forcibly

air-cooled with an air flow of 2m/s or more.

2 Requires forced air cooling equivalent to fan adaptor unit A06B-6078-K001 (with air flow of

2 m/s or greater).

Forced air cooling by fan adaptor unit A06B-6078-K003 or equivalent (2 m/s or more) is

required.

The rated output is the continuous rated output of the motor.

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FANUC SERVO AMPLIFIER a series. DESCRIPTIONS (B-65162E/03) - page 5