electrical connections of main spindle drives connections of main spindle drives...

Electrical Connectionsof Main Spindle Drives

DOK-GENERL-MAIN*EL*CON-PRJ1-EN-P

Project Planning Manual

mannesmannRexroth

engineering

Indramat258653

2• DOK-GENERL-MAIN*EL*CON-PRJ1-EN-E1,44 • 07.97

About this documentation

Electrical Connections of Main Spindle Drives

Project Planning Manual

DOK-GENERL-MAIN*EL*CON-PRJ1-EN-E1,44

• 209-0042-4111-00

This electronic document is based on the hardcopy document with documentdesig.: 209-0042-4111-00 EN/04.94

This documentation serves:

– to introduce and categorize the connections of the main spindle drives,

– as a source for the circuit diagrams for not only the power connections butalso the feedback and CNC connections when developing the machinecircuit diagrams,

– to offer a table summary of assembled cables and their construction,

– to make customer-specific cables possible,

– to identify the plugs and cables supplied.

This documentation

– applies to all main spindle drives,

– correlates with the „Project Planning Notes“ for main spindle controllers andmain spindle motors. This documentation can be referenced via text strings.

Titel

Type of documentation:

Documenttype

Internal file reference

Reference

This documentationis used:

© INDRAMAT GmbH, 1994Copying of this document, and giving it to others and the use or communicationof the contents thereof, are forbidden without express authority. Offenders areliable to the payment of damages.All rights are reserved in the event of the grant of a patent or the registrationof a utility model or design. (DIN 34-1)

The electronic documentation (E-doc) may be copied as often as needed ifsuch are to be used by the consumer for the purpose intended.

All rights reserved with respect to the content of this documentation and theavailability of the products.

INDRAMAT GmbH • Bgm.-Dr.-Nebel-Straße 2 • D-97816 LohrTelefon 0 93 52 / 40-0 • Tx 689421 • Fax 0 93 52 / 40-48 85

Dept ENA (MR, FS)

Copyright

Validity

Publisher

Designation of documentation Release- Comentsup to present edition date

209-0042-4111-00 EN/04.94 Apr/94 First Edition

DOK-GENERL-MAIN*EL*CON-PRJ1-EN-E1,44 Jul./97 First E-Dok

Change procedures


Table of Contents

1. Electrical Connections 7

1.1. Standardization ......................................................................7

1.2. Types ...................................................................................10

1.3. Determination of Size and Guidelines ..................................13

2. Power Connections 15

2.1. Motor-Controller Power Connections ...................................15

2.1.1. Breakdown of the Types of Connections ..........................16

2.1.2. Connection Plans for Direct Connections .........................19

2.1.3. Assembled Data List .........................................................29

2.1.4. Line Specifications ............................................................45

2.2. Power connections of the RAC three-phase mains .............46

2.2.1. Three-Phase Mains Requirements ...................................47

2.2.2. Connection Plans ..............................................................49

2.2.3. Connecting Components Data List ...................................52

3. Feedback and CNC Connections 56

3.1. Types of feedback and CNC connections ............................57

3.2. Connecting plans for direct connections ..............................60

3.2.1. Motor feedback, high-resolution ........................................61

3.2.2. Motor feedback, incremental encoder ...............................63

3.2.3. Spindle Feedback, high-resolution ....................................64

3.2.4. Spindle Feedback, incremental encoder ...........................66

3.2.5. Lead Spindle Feedback ....................................................67

3.2.6. Control input, signal and analogue outputs, Bb-contact ...68

3.2.7. Speed set-point, analogue +/- 10V ...................................69

3.2.8. Speed set-point, digital, 16 bit parallel ..............................70

Page

Table of Contents


Table of Contents

3.2.9. SERCOS Interface ............................................................71

3.2.10. Position set-point, digital, 16 bit parallel ..........................72

3.2.11. Serial interface RS 232C ................................................73

3.2.12. Incremental encoder output ............................................74

3.2.13. Control of the mains contactor integrated into the RACcontroller .........................................................................75

3.3. Assembled Cable Specifications ..........................................76

3.4. Line Specifications List ........................................................84

4. Installation Guidelines 85

5. Delivery, Identification, Storage 88

6. Customizing Specifications 91

7. Index 94

8. Supplementary Documentation 99


Table of Contents


1. ElectricalConnections

1.1. Standardization

1. Electrical Connections

The electrical connections in the entire INDRAMAT main spindledrive program have been standardized with the goal of reducing therange of cables available.

There are three categories of electrical connections:

– power connections

– feedback and CNC connections

– controller-specific connections

The motor connections to the main spindle controller always have thesame terminal assignment, regardless of the controller implemented.The cable cross sectional area is dependent on the motor powerrequirements.

The RAC controller is connected directly to the three-phase mains.The terminal assignments of the different RAC’s are always thesame. The cable cross sectional area is dependent on the currenttype of the respective RAC.

Plug assignment is the same regardless of controller and motor type.

The KDA/TDA controllers used in modular drive packages havecontroller-specific electrical connections. This documentation doesnot deal with their connection. It is dealt with in the documentation onmain spindle controllers KDA 3.2, or TDA 1.1, „Project PlanningNotes“. The cables needed are part of the electrical connectingaccessories E...-.DA.

The mains contactor and the respective control circuits are integratedinto the RAC controllers for direct mains connection. The facilitycontrol system must operate this control circuit. The controller-specific connections are outlined in the mains connection plans inSection 2.2.

Power connections

Feedback andCNC connections

Controller-specific connections


Spe

ed s

et-p

oint

Control

Con

trol

ler"

Rea

dy"

cont

act

Add

ition

al c

ontr

olle

r in

terf

ace

- In

crem

enta

l enc

oder

out

put

- S

eria

l int

erfa

ce R

S 2

32 C

- P

ositi

on s

et-p

oint

Con

trol

inpu

t and

sig

nal o

utpu

ts

of th

e co

ntro

ller

Motor fan connection

Motor connections

Motor feedback

connection

Spindle feedback

Lead spindle feedback

Feedback and CNC

connections

Katelvem

Mains

Controller-specificconnections

Power connections

Mains

Supplyunit

KDA/TDA

(only with KDA)

Figure 1.2: Categories of electrical connections for main spindle drives with KDA/TDA



X 4

X 2 X 3

X 5X 1 3

Prog. Modul AS nicht unter Spannung wechseln

ASSWITCH OFF VOLTAGE BEFORE

CHANGING MODULE AS

X 1

Q 1

X 6

AC-MAINSPINDLE DRIVE RAC 2

L -

L +

DANGER HIGH VOLTAGEDISCHARGE TIMEEntladezeit 1Min.

Mains

Spe

ed s

et-p

oint

Mai

ns c

onta

ctor

ON

Mai

ns c

onta

ctor

OF

F

Control

Mai

ns c

onta

ctor

m

onito

ring

Con

trol

ler

"rea

dy"

cont

act

Add

ition

al c

ontr

olle

r in

terf

ace

- In

crem

enta

l enc

oder

out

put

- S

eria

l int

erfa

ce R

S 2

32 C

- P

ositi

on s

et-p

oint

Con

trol

inpu

t and

sig

nal o

utpu

ts

of th

e co

ntro

ller

Mains connections

Powerconnections

Motor fan connections

Motor connections

Motorfeedback

connections

Spindlefeedback

Lead spindle feedback

Controller-specific

connections

Feedbackand CNC

connections

Katelvek

Internal control

circuit and mains

contactor

RAC

Figure 1.3: Categories of electrical connections for main spindle drives with RAC(here RAC 2.2)

Motor fans cannot be connected to the controller in main spindledrives with RAC3 and RAC4! They are connected directly to the three-phase mains via appropriate protective motor switches!


Holding brake


1.2. Types The electrical connections of all categories are available as

– assembled (ready to use), or,

– components (individual parts, not ready to use).

Assembled cables are supplied in the lengths ordered and guaranteea quick and easy assembly of control cabinet and machine. If onlyassembled cables are used, then no addditional cable and plugaccessories are needed.

Component electrical connections are made up of individual, assem-bled parts. The specifications of these parts are listed in the table.These must then be assembled in accordance with the guidelinesoutlined in Section 5.

Power connections

Assembled Components

To the motorNo additional plugor cable accessoriesneeded!

To the three-phase mainsNot available

To the motor- Power plug/compression cable

shoe on the motor- Wire-end ferrule/crimping cable

lug on the controller- CableTo the three-phase mains(with RAC)- Wire-end ferrule/crimping cable

lug- Cable


Figure 1.4: Specifications of the power connections with accessories referenced.



Feedback and CNC Connections

Partiallyassembled

ComponentsExclusivelyassembled

Additional plugconnectors andcables for the non-assembled connec-tions.

Figure 1.5: Specifications of the feedback and CNC connections withaccessories referenced.

Required:- Plug accessory

(for the controller)S1- ••• with KDA/TDAS2- ••• with RAC

- Lines- Individual plug connectors

(for feedback and CNC)

No additional plugor cable accesso-ries needed!

Should only component cables be used with the feedback and CNCconnections, then the plug accessory sets offered guarantee acomplete connection to the controller by means of appropriate plugconnectors.


Componentsfor RAC

Connections onlyobtainable fromINDRAMAT as part of themodular drive package(part of the electricalconnecting accessoriesE•• - KDA orE•• - TDA)

Assembled forKDA/TDA

Controller Connections

Figure 1.6: Construction of controller-specific connections with electricalconnecting accessories referenced.


Plug connector withoutcable to contact RACinternal control circuit(part of electricalconnecting accessoriesE1-RAC).

The controller-specific connections are always required! The electri-cal connection accesssories within the KDA/TDA modular drivepackage are dependent upon the adjacent controller in the drivepackage (see documentation main spindle controller; „Project Plan-ning Notes“).


1.3. Determinationof Size and Guidelines

The conductor cross sections of the assembled INDRAMAT cablesare sized in accordance with guidelines EN 60 204, Section 1/ 2/86.

The cross sections of the power connections to the main spindlemotor have been selected in acc. with the respective rated current ofthe motor (see tables listing assembly specifications beginning withFig. 2.19).

The cross sections of the power connections to the three-phasemains are dimensioned according to the continuous output of themain spindle motor used in the main spindle controllers for directmains connection (see Section 2.2.3).

Sizing theconductor cross sections

Load Capacity Table Conversion table for ambient temperaturesgreater than 30 degrees C.

Rated conductor Load capacity of thecross sections conductors in the machines,

normal applicationin busway Ambient Conversion

temperature factormm2 A oC

0,75 9 30 11 12 35 0,93

1,5 15,5 40 0,872,5 21 45 0,794 28 50 0,716 36 55 0,61

10 50 60 0,5016 6825 8935 111503) 134

3)actual cross section equals 47 mm2


Figure 1.7: Load capacity and conversion factor table for ambient temperaturesgreater than 30 degrees C., in acc. with EN 60 204-1/ 2/86.

The permissible operating temperature on the surface of the cableequals 70 degrees C. For allocation rated conductor cross section -load capacity, ambient air temperature is based on 30 degrees C.

Load capacity must be converted in accordance with EN 60 204-1/ 2/86 (Figure 1.7) for ambient temperatures higher than those in theexample.

See EN 60 204 Section 1 / 2/86 for further details.


Sizing maximum cable lengths Maximum cable length is limited by the electro-magnetic distortionsand the loss of voltage along the cable. Transit time effects in themotor power cable cause cable-length dependent voltage increasesat the motor terminals. This also limits cable lengths.

The maximum cable lengths given reference the direct connectionbetween controller and motor, or feedback, in those cases whereassembled INDRAMAT cables are used, and an ambient tempera-ture of 30 degrees C is maintained in accordance with VDE 0113.

Terminal points and intermediate couplings can reduce maximumcable length.

– Power connection to motor: 75 m

– Feedback connection: 75 m



2. Power Connections


INDRAMAT main spindle drives have power connections betweenthe controller and motor and between the RAC controller and thethree-phase mains.

The power connections between motor and controller are brokendown into Sections:

Section 2.1.1: Division of the types of connections

– direct connection motor-controller

– connection with intermediate terminal

– connection with plug design

– connection with plugin testing points

Section 2.1.2: Connection plans for direct connection of motor andmotor fan of

– 2AD 100 and 2AD 101 with air flow A->B

– 2AD 100 and 2AD 101 with air flow B->A

– 2AD 132 with power connector

– 2AD 132, 2D 160, 2AD 180, 2AD 200 and 2AD 225 with terminal box

– 1MB frameless spindle motor (water cooled)

Section 2.1.3: Table of assembled cable specifications for

– motor-controller direct connection and connection with intermedi-ate terminal



Section 2.1.4: Table of cable specifications such as

– type designation,

– conductor cross section,

– cable construction,

– cable diameter,

– bending radii, and,

– length-related weight.

2.1. Motor-ControllerPower Connections


There are four types of assembled power connections betweenmotor and controller.

2.1.1. Breakdown of theTypes of Connections

Motor-controllerdirect connection

direct with intermediate terminal plug withplugin

to terminal strip design testing points

Types of power connectionsmotor-controller

Power plugconnector (plug)

Symbols:

wire end ferrulefor line-up terminals

crimping cable lug for stay bolts

Flange connector

Power plugconnector (coupling)

On the motor Cable On the controller

(2AD main spindle motor, 1MB frameless spindle motor)


(Controller KDA/TDA or RAC4)

(Controllers RAC2/RAC3)

st_verb1


Figure 2.2: Assembled power cables for direct connections(also see Figs. 2.19 and 2.20 for 2AD, and for 1MB see Figs. 2.25 through2.27).

This type of connection is characterized by the lowest number ofimperfections and the lowest drop in voltage in comparison to theother types of connections.

A terminal point for the strand pair of the holding brake must belocated close to the motor power connection on the controller in thecontrol cabinet, if main spindle drives with holding brakes are used!

Figure 2.1: The four types of power connections


Motor-controller connection withintermediate terminal

With this type of connection it is easy for the CNC control to takecharge of the electrical holding brake, or to be integrated into thecontrol circuit.

The intermediate terminal at a terminal strip also makes it possible toreroute a space-saving, sheathless cable into the cable conduits ofthe control cabinet!

On the motor Cable Terminal strip Cable On the controller



(Controllers KDA/TDA or RAC4)


st_verb2


Symbols:

wire-end ferrulefor line-up terminals

crimping cable lug for stay bolts

Flangeconnector

Power plug connector (coupling)

Motor-controller connectionwith plug design

On the motor Cable Plug Cable On the controller





design

ST_VERB3


Symbols:

Wire-end ferrule forline-up terminals

Crimping cable lug for stay bolts

Flangeconnector



Figure 2.3: Assembled power cable with intermediate terminal at terminal strip(also see Figs. 2.19 and 2.20 for 2AD, Figs. 2.25 through 2.27 for 1MB).

This type of connection makes it possible to finish the control cabinetentirely independent of the machines.

In addition, damaged cables can be very quickly and reliably ex-changed.

Figure 2.4: Assembled power cable with plug design (also see Figs. 2.21and2.22 for 2AD, see Figs. 2.28 through 2.30) for 1MB.


Motor-controller connectionwith plugin testing points

This connection type is advantageous for larger facilities because itis possible to quickly and reliably exchange the damaged section ofa cable.

The mounting of assembled cables of this type is particularly simpleand quick.

Figure 2.5: Assembled power cable with plugin testing points (also see figure2.23, 2.24 for 2AD, see Figs. 2.31 through 2.33 for 1MB) .

The assembled cable with the power plug connectors at both ends(plug/coupling) can be added as an extension piece between theplugin testing points.

On the motor Cable Plug Cable On the controller





design

ST_VERB4


Symbols:

Wire-end ferrulefor line-up terminals

Crimping cable lug for stay bolts

Flangeconnector




2.1.2. Connection Plans forDirect Connections

Only the connection plans for the direct connection of the motor-controller power connections are depicted. They also, however,apply to all other connections types. The respective testing points donot alter the arrangement of motor and controller connections.

The connection plans assist in constructing the facility wiring dia-grams. The facility circuit diagrams of the machine manufacturershould be used when wiring the facility!

The technical specifications for the motor, the holding brake (op-tional) and the motor fan are dealt with in the documentation on therespective main spindle motor - project planning notes. The docu-mentation also includes a recommendation for the selection of theprotective motor switch for the motor fan.

If a main spindle motor with holding brake is used, then the controlcabinet must supply it with +24V +/-10%. The facility control systemcontrols the holding brake.

The criteria for the holding brake control system are –

– the operating principle of the holding brake, and,

– monitors the powering down of the motor (N<Nmin).

The respective application determines all other criteria.

Monitoring of motor shutdown (N<Nmin) is explained in the documententitled „AC Main Spindle Drives with Controlled AsynchronousMotors or Frameless Spindle Motors; Description of Application“.


Technical Data

Motor with Holding Brake



Figure 2.6: Connection of 2AD 100 motor with air flow from A->B and 2AD 101with terminal box to motor fan.

APMOT001

Motor fan connection:

M

31

2

3

L

N

PE

0,75 … 1,5 mm2

0,75 … 1,5 mm2

terminal box

Identifying the rated connection voltage of the motor fan in the motor type designation2AD 100 • - • • • • • • - • • • • - • • • •2AD 101 • - • • • • • • - • • • • - • • • •

Permissible mains voltage:AC 220 V ±10%, 50...60 Hz : 2 (1 only with 2AD101)AC 115 V ±10%, 50...60 Hz : 5

7 0,75 … 1,5 mm2

8 0,75 … 1,5 mm2

6 0,75 … 1,5 mm2

5 0,75 … 1,5 mm2

gn/yel cross section motor type

1 dep. (see table

2 assembled specifications)

3

KDA / TDAcontroller

2

1

3

A1

A2

A3

X8

X12

E

D

A

B

C

H

Jϑ

U

F

G0V

+24V

Crimping cable lug for stay bolts M6

Plug terminal part of elec. connectionE • • - • DA

Power plug connectorCable(numbering of strands as per INDRAMAT standard)

operated by control circuit

2AD 100 • - • • • • • • - . . .2AD 101 • - • • • • • • - . . .

2AD 100 motor connection (cooling air flow A => B) and 2AD 101 (motor fan with terminal box)

motor fan

M

3

NL

I>>

capacitor

motor fanwindings

1 2 3

I>>

ge/gr

Shield

7856

12

3

200140 approx. 130

50

3030Tightening

length

IN 172/••

(Assembled power cable IKL•••/IKF•••)

Dimension as per tech. specs of motor fan (see doc. 2AD•••, project planning notes)

Mains connection 5...8 mm

A, B, R or L 2 or 5


APMOT002


M

1

2

3

L

N

PE

0,75 … 1,5 mm2

0,75 … 1,5 mm2

Plug connector

Identifying the rated connection voltage of the motor fan in the motor type designation2AD 100 • - • • • • • • - • • • • - • • • •

Permissible mains voltage:AC 220 V ±10%, 50...60 Hz : 1AC 115 V ±10%, 50...60 Hz : 4

7 0,75 … 1,5 mm2

8 0,75 … 1,5 mm2

6 0,75 … 1,5 mm2

5 0,75 … 1,5 mm2


1 dep. (see table


3

KDA / TDAcontroller

2

1

3

A1

A2

A3

X8

X12

E

D

A

B

C

H

Jϑ

U

F

G0V

+24V

operated bycontrol circuit

main spindle motor 2AD 100 • - • • • • • • - . . .

2AD 100 motor connection (cooling air flow B => A)

motor fan

M

3

NL

I>>

I>>


approx. 50 untightened

40

26,5

26,5

15,5


Plug terminal, part of elec. connectionE • • - • DA


ge/gr

Shield

7856

12

3

200140approx. 130

50

3030Tightening

length

IN 172/••

(assembled power cable IKL•••/IKF•••)


1 or 4


Figure 2.7: Connection of 2AD 100 motor with air flow from B->A.


Figure 2.8: Connection of 2AD 101 motor with plug connector to motor fan.

APMOT005


M

1

2

L

N

PE

0,75 … 1,5 mm2

0,75 … 1,5 mm2

Plug connector

Identifying rated connection voltage of the motor fan in the motor type designation2AD 101 • - • • • • • • - • • • • - • • • •

Permissible mains voltage:AC 220 V ±10%, 50...60 Hz : 1 or 2AC 115 V ±10%, 50...60 Hz : 5

7 0,75 … 1,5 mm2

8 0,75 … 1,5 mm2

6 0,75 … 1,5 mm2

5 0,75 … 1,5 mm2


1 dep. (see table


3

KDA / TDAcontroller

2

1

3

A1

A2

A3

X8

X12

E

D

A

B

C

H

Jϑ

U

F

G0V

+24V


main spindle motor 2AD 101 • - • • • • • • - . . .

2AD 101 motor connection (motor fan with plug connector)

motor fan

M

3

NL

I>>

I>>


Crimping cable lugfor stay bolts M6

Plug terminal, part of elec. connection acc.E • • - • DA


ge/gr

Shield

7856

12

3

200140approx. 130

50

3030Tightening

length

IN 172/••

(Assembled power cable IKL•••/IKF•••)

56,5 max.71 max.9

28

Height approx. 21mm

3

4

3


C, D, E or F



Figure 2.9: Connection of 2AD 132 motor with power plug to KDA/TDA controller.

APMOT003


M

31

2

3

PE

0,75 … 1,5 mm2

0,75 … 1,5 mm2

Plug connector

Permissible mains voltage:3x400V ±15%, 50...60Hz3x460V ±10%, 60Hz

7 0,75 … 1,5 mm2

8 0,75 … 1,5 mm2

6 0,75 … 1,5 mm2

5 0,75 … 1,5 mm2


1 dep. (see table


3

KDA / TDAcontroller

2

1

3

A1

A2

A3

X8

X12

E

D

A

B

C

H

Jϑ

U

F

G0V

+24V


main spindle motor 2AD 132• - ••••••-....

2AD 132 motor connection (power plug connector) to KDA/TDA

motor fan

M

3

L2L1

I>>

I>>


I>> 0,75 … 1,5 mm2

L3

56,5 max.71 max.9

28

Height approx. 21mm




ge/gr

Shield

7856

12

3

200140approx. 130

50

3030Tightening

length

IN 172/••



C, E or F



Figure 2.10: Connection of 2AD 132 motor with power plug to RAC controller.

APMOT004


M

31

2

3

PE

0,75 … 1,5 mm2

0,75 … 1,5 mm2

Plug connector

7 0,75 … 1,5 mm2

8 0,75 … 1,5 mm2

6 0,75 … 1,5 mm2

5 0,75 … 1,5 mm2


1 dep. (see table


3

RACcontroller

2

3

1

A1

A2

A3

X14

X16

E

D

A

B

C

H

Jϑ

U

F

G0V

+24V

Wire-end ferrulein RAC2/RAC3


2AD 132 motor connection (power plug connector) to RAC

motor fan

M

3

L2L1

I>>

I>>


I>> 0,75 … 1,5 mm2

L3

56,5 max.71 max.9

28

Height approx. 21mm

Plug terminal, part of elec. connection acc.E1 - RAC


Schirm

7856

200ca. 130

50

Tightening length

IN 172/••

(assembled power cable IKL•••/IKF•••)ge/gr123

250

Permissible mains voltage:3xAC400V ±15%, 50...60Hz3xAC460V ±10%, 60Hz

RAC2.2 motor power connection(protective motor circuit breaker is integrated into RAC2.2!)

X14

U2 V2 W2

(only with RAC2.2 )


main spindle motor 2AD 132• - ••••••-....C, E or F



Figure 2.11: Connection of 2AD 132 motor with terminal box to KDA/TDA controller.

U

V

W

sw gn

bn ge

wsbl

APMOT007


PE

0,75 … 1,5 mm2

0,75 … 1,5 mm2

terminal box

Permissible mains voltage is dependent upon windings connection of motor fan!

7 0,75 … 1,5 mm2

8 0,75 … 1,5 mm2

6 0,75 … 1,5 mm2

5 0,75 … 1,5 mm2


1 dep. (see table


3

KDA / TDAcontroller

2

1

3

A1

A2

A3

X8

X12

U1

V1

W1

3

4ϑ

U

1

20V

+24V


2AD 132 motor connection (terminal box) to KDA/TDA

motor fan

M

3

L2L1

I>>

I>>


I>> 0,75 … 1,5 mm2

L3



Crimping cable lug for stay bolts, see table on preassembled specifications

Cable(numbering of strands as per INDRAMAT standard)

ge/gr

Shield

7856

12

3

200140approx. 150

3030Tightening

length


M

3

bnge

wsbl

gnsw

U

V

W

sw gn

bn ge

wsbl

3xAC400V ±15%, 50...60Hz3xAC460V ±10%, 60Hz

(Condition at delivery)

3xAC220V ±10%, 50...60Hz

terminal block

motor fanwindings

win-dings connec-tion

terminalblock

Windings connection for:

terminal block


main spindle motor 2AD 132• - ••••••-....A, B, R or L

U

V

W

U

V

W



Figure 2.12: Connection of 2AD 132, 2AD 160, 2AD 180 and 2AD 200 motors(all have terminal box)

APMOT008


PE

0,75 … 1,5 mm2

0,75 … 1,5 mm2

Motor fan windings

Permissible mains voltage:

7 0,75 … 1,5 mm2

8 0,75 … 1,5 mm2

6 0,75 … 1,5 mm2

5 0,75 … 1,5 mm2


1 dep. (see table


3

RACcontroller

2

1

3

A1

A2

A3

X14

X16

U1

V1

W1

3

4ϑ

U

1

20V

+24V


2AD 160, 2AD 180, 2AD 200 2AD 132 • - • • • • • • - . . .

2AD 132 motor connection (terminal box), 2AD 160, 2AD 180 and 2AD 200 to RAC

motor fan

M

3

L2L1

I>>

I>>

Dimension of the motor protective switch as per tech. specs on motor fan (see doc. 2AD•••, project planning notes)

I>> 0,75 … 1,5 mm2

L3

Plug terminal, part of elec. connection acc.E1-RAC

Crimping cable lug for stay bolts, see table for assembled specifications


Shield

7856

200approx. 150Tightening

length


M

3

3xAC400V ±15%, 50...60Hz3xAC460V ±10%, 60Hz

Motor fanwindings

terminalblock


ge/gr123

250

RAC2.2 motor fan connection(protective motor switch is integrated into RAC 2.2!)

X14

U2 V2 W2

(only with RAC2.2)


U

V

W

U

V

W

A, B, R or L



Figure 2.14: Connection of 1MB frameless spindle motors to KDA/TDAcontrollers via power plug connectors.

APMOT012

6 0,75 … 1,5 mm2

5 0,75 … 1,5 mm2


1 dep. (see table


3

KDA / TDAconnector

2

1

3

A1

A2

A3

X8

X12

E

D

A

B

C

H

Jϑ

F

G

1MBframeless spindle motor

1MB motor connection (power plug connector) to KDA/TDA

M

3




ge/gr

Shield

7856

12

3

200140ca. 130

503030

Tightening length

IN 172/••

(assembled power cable IKL•••/IKF•••) 25 20

FlangeconnectorIN 192/••

ϑ

(Substitute NTC-resistor, function not guaranteed!)

Fig. 2.13: Connection via terminal box of 1MB frameless spindle motors to KDA/TDA controllers

Motor connection 1MB (terminal box) to KDA/TDA

Cable(numbering of cores ad per INDRAMAT standard)

Shield

7856


length


6 0,75 … 1,5 mm2

5 0,75 … 1,5 mm2


1 dep. (see table


3

U1V1W1

ϑ


M

3

apmot009

0,75...1,5 mm2

0,75...1,5 mm2

Terminal box

ϑ

(Substitute NTC-resistor,function not guaranteed!)KDA / TDA

controller

2

1

3

A1

A2

A3

X8

X12


ge/gr1

23

1403030


Crimping cable lugs forstay bolts, see table

assembled specs



Fig. 2.16: 1MB frameless spindle motor connection to RAC controller via powerplug connector.

1MB motor connection (terminal box) to RAC

Plug terminal, part of elec. connection acc.E 1-RAC


Shield

7856


length


6 0,75 … 1,5 mm2

5 0,75 … 1,5 mm2


1 dep. (see table


3

U1V1W1

ϑ


M

3

apmot010

0,75...1,5 mm2

0,75...1,5 mm2

terminal box

ϑ



RACcontroller

2

3

1

A1

A2

A3

X14

X16

ge/gr12

200

3

Crimping cable lug forstay bolts, see table forassembled specifications

APMOT011

6 0,75 … 1,5 mm2

5 0,75 … 1,5 mm2


1 dep. (see table


3

E

D

A

B

C

H

Jϑ

F

G

1MB frameless spindle motor

1MB motor connection (terminal box) to RAC

M

3



Shield

7856

200approx. 130

50Tightening

length

IN 172/••

(assembled power cable IKL•••/IKF•••) 25 20

FlangeconnectorIN 192/••

ϑ



RACcontroller

2

3

1

A1

A2

A3

X14

X16

ge/gr12

200

3

Fig. 2.15: Connection via terminal box of 1MB frameless spindle motor to RACcontroller



2.1.3. AssembledData List

Figure 2.17: Four types of assembled power connections

The four types of power motor-controller connections are motor-typedependent and have been summarized in a table.

AssembledSpecifications Table

....direct connection + intermediate terminal

....plug design

....plugin testing points

Table listing assembled specifications for...

....direct connection + intermediate terminal

....plug design


Table listing assembled specifications for...

2AD main spindle motor

ZuordTab

frameless spindle motor 1MB

Figure 2.18: Allocation of main spindle motors in table

The tables list the available flexible and highly flexible assembledcables and their significant components.

direct with intermediate terminal plug withplugin

at terminal strip design testing points

Types of power connectionsmotor-controller



Figure 2.19: Assembled specifications table for direct connection andintermediate terminals on terminal strips for 2AD motors - Section 1.

Cab

leA

ssem

bled

cab

les

Ass

embl

ed c

able

com

pone

nts

for

dire

ct

conn

ectio

nA

ssem

bled

cab

les

for

inte

rmed

iate

cros

sfo

r di

rect

con

nect

ion

term

inal

s on

term

inal

str

ips

sect

ion

on th

e m

otor

Cab

leon

the

on th

e m

otor

on th

e co

ntro

ller

A [m

m ]

flex.

/hig

hly

flex.

cont

rolle

rfle

x./h

ighl

y fle

x.fle

x./h

ighl

y fle

x.

2AD

100B

-B··

···-

AS

·3-·

···

4IK

L071

/IKF

071

IN17

2/25

IN20

3/IN

403

...st

ay b

olt

M6

IKL0

74/

*)

not a

vaila

ble

(KD

A /T

DA

)

2AD

100C

-B··

···-

AS

·3-·

···

4IK

L071

/IKF

071

IN17

2/25

IN20

3/IN

403

...st

ay b

olt

M6

IKL0

74/

*)

not a

vaila

ble

(KD

A /T

DA

)

2AD

100D

-B··

···-

AS

·3-·

···

6IK

L112

/IKF

112

IN17

2/06

IN20

4/IN

404

...st

ay b

olt

M6

IKL1

15/

*)

not a

vaila

ble

(KD

A /T

DA

)

2AD

101D

-B··

···-

BD

·3-·

···

10IK

L130

/IKF

130

IN17

2/10

IN20

5/IN

405

...st

ay b

olt

M6

IKL1

34/

*)

not a

vaila

ble

(KD

A /T

DA

)

2AD

132B

-B··

···-

BS

·3-·

····

10IK

L130

/IKF

130

IN17

2/10

IN20

5/IN

405

...st

ay b

olt

M6

IKL1

34/

*)

not a

vaila

ble

(KD

A /T

DA

)

2AD

132C

-B··

···-

BS

·3-·

····

16*)

IN17

2/16

IN20

6/IN

406

...st

ay b

olt

M6

IKL1

50/IK

F15

0no

t ava

ilabl

e

(KD

A /T

DA

)

2AD

132D

-B··

···-

BD

·3-·

····

25IK

L170

/IKF

170

IN17

2/25

IN20

7/IN

407

...st

ay b

olt

M6

*)no

t ava

ilabl

e

(KD

A /T

DA

)

2AD

132B

-B··

···-

DS

·3-·

····

6IK

L115

/ *

)IN

172/

06IN

204/

IN40

4...

line-

up te

rmin

als

IKL1

15/

*)

not a

vaila

ble

(RA

C2

/RA

C3)

2AD

132C

-B··

···-

CS

·3-·

····

10IK

L134

/ *

)IN

172/

10IN

205/

IN40

5IK

L134

/ *

)no

t ava

ilabl

e

2AD

132D

-B··

···-

AS

·3-·

····

16IK

L150

/IKF

150

IN17

2/16

IN20

6/IN

406

IKL1

50/IK

F15

0no

t ava

ilabl

e

For

...

For

...

...lin

e-up

term

inal

s

(RA

C2

/RA

C3)

...lin

e-up

term

inal

s

(RA

C2

/RA

C3)

flex.

/hig

hly

flex.

alka

b01

2

Pow

er p

lug

conn

ecto

r (p

lug)

Sym

bols

:

Wire

-end

ferr

ule

Crim

ping

cab

le lu

gF

lang

e co

nnec

tion

Pow

er p

lug

conn

ecto

r (c

oupl

ing)

PG

scr

ew c

onne

ctio

n

*) A

vaila

ble.

For

inqu

iries

on

type

info

rmat

ion

cont

act D

evel

opm

ent D

ept.,

IND

RA

MA

T.

Sec

tion

1: 2

AD

pow

er c

onne

ctio

ns -

dire

ct c

onne

ctio

ns a

nd in

term

edia

te te

rmin

als



Figure 2.20: Assembled specifications table for direct connections andintermediate terminals on terminal strips for 2AD motors - Section 2.

Sec

tion

2: 2

AD

pow

er c

onne

ctio

ns -

dire

ct c

onne

ctio

ns a

nd in

term

edia

te te

rmin

als


Cab

leA

ssem

bled

cab

les

Cab

le c

ompo

nent

s fo

r di

rect

con

nect

ion

Ass

embl

ed c

able

s fo

r in

term

edia

tecr

oss

for

dire

ct c

onne

ctio

nte

rmin

als

on te

rmin

al s

trip

sse

ctio

non

the

mot

orC

able

on th

eon

the

mot

oron

the

cont

rolle

rA

[mm

]fle

x./h

ighl

y fle

x.co

ntro

ller

flex.

/hig

hly

flex.

flex.

/hig

hly

flex.

6IK

L110

..sta

y bo

lt M

6IN

204/

IN40

4...

line-

up te

rmin

als

*)

(RA

C2

/RA

C3)

IKL1

36/IK

F13

6IN

205/

IN40

5IK

L136

/IKF

136

2AD

132D

-B··

···-

AS

·3-·

···

IKL1

51/IK

F15

1IN

206/

IN40

6

2AD

160B

-B··

···-

BS

·3-·

···

IKL1

71/IK

F17

1IN

207/

IN40

7

2AD

160C

-B··

···-

BS

·3-·

····

IKL1

82/

*)IK

L182

/ *)

2AD

180C

-B··

···-

BS

·3-·

····

(PG

42)

2AD

180D

-B··

···-

BS

·3-·

····

50IK

L 19

1/ *

)IN

268/

*)

...S

crew

s*)

(PG

42

)M

12 (

RA

C4)

2AD

200C

-B··

···-

AS

·3-·

····

2 x

252

x IN

207/

2 x

IN 4

07

(PG

48)

2AD

132B

-B··

···-

DS

·3-·

····

(PG

29)

2AD

132C

-B··

···-

CS

·3-·

····

(PG

29)

(PG

29)

10 16 25 35 35IK

L182

/ *)

ALK

AB

02

2 x

IKL

175/

2 x

IKF

175

(PG

42)

(PG

29)

For

...

...lin

e-up

term

inal

s

(RA

C2

/RA

C3)

...lin

e-up

term

inal

s

(RA

C2

/RA

C3)

...lin

e-up

term

inal

s

(RA

C2

/RA

C3)

...lin

e-up

term

inal

s

(RA

C2

/RA

C3)

...lin

e-up

term

inal

s

(RA

C2

/RA

C3)

M8

..sta

y bo

lt M

6

M8

..sta

y bo

lt M

8

M8

..sta

y bo

lt M

8

M8

..sta

y bo

lt M

10

M10

..sta

y bo

lt M

10M

10

IKL1

51/IK

F15

1

IKL1

71/IK

F17

1

IKL1

82/

*)

*)...

Scr

ews

M12

(R

AC

4)

..sta

y bo

lt M

10M

10

..sta

y bo

lt M

12M

12

IN26

7

IN26

7

2AD

132B

-B··

···-

BS

·3-·

····

10IK

L135

/IKF

135

IN20

5/IN

405

..sta

y bo

lt M

6IK

L136

/IKF

136

not

avai

labl

e(P

G 2

9)(K

DA

/TD

A)

2AD

132C

-B··

···-

BS

·3-·

····

16IK

L157

/IKF

157

IN20

6/IN

406

..sta

y bo

lt M

6IK

L152

/IKF

152

(PG

29)

(KD

A /T

DA

)

2AD

132D

-B··

···-

BD

·3-·

····

25IK

L174

/IKF

174

IN20

7/IN

407

..sta

y bo

lt M

6IK

L172

/IKF

172

(PG

29)

(KD

A /T

DA

)

Für

... F

or...

..sta

y bo

lt M

6

M8

..sta

y bo

lt M

6

M8

..sta

y bo

lt M

8

M8

2

For

...

not

avai

labl

e

not

avai

labl

e

not

avai

labl

e

not

avai

labl

e

not

avai

labl

e

not

avai

labl

e

not

avai

labl

e

not

avai

labl

e

not

avai

labl

e

not

avai

labl

e

Pow

er p

lug

conn

ecto

r (p

lug)

Sym

bols

:

Wire

-end

ferr

ule

Crim

ping

cab

lelu

gF

lang

e co

nnec

tion

Pow

er p

lug

conn

ecto

r (c

oupl

ing)

PG

scr

ew c

onne

ctio

n*)

Ava

ilabl

e. F

or in

quiri

es o

n ty

pe in

form

atio

n

con

tact

Dev

elop

men

t Dep

t., IN

DR

AM

AT.

For

... F

or...


Figure 2.21: Specifications table for assembled cables with plug connectors for2AD motors - Section 1.

2AD

100B

-B••

•••-

AS

•3-•

•••

4IK

L073

/IKF

073

IN17

2/25

IN20

3/IN

403

IN21

7/25

IN21

8/25

2AD

100C

-B••

•••-

AS

•3-•

•••

4IK

L073

/IKF

073

IN17

2/25

IN20

3/IN

403

IN21

7/25

IN21

8/25

2AD

100D

-B••

•••-

AS

•3-•

•••

6IK

L111

/IKF

111

IKL1

14/IK

F11

4IN

172/

06IN

204/

IN40

4IN

217/

06IN

218/

06

2AD

101D

-B••

•••-

BD

•3-•

•••

10IK

L133

/IKF

133

IN17

2/10

IN20

5/IN

405

IN21

7/10

IN21

8/10

2AD

132B

-B••

•••-

BS

•3-•

•••

10IK

L133

/IKF

133

IN17

2/10

IN20

5/IN

405

IN21

7/10

IN21

8/10

2AD

132C

-B••

•••-

BS

•3-•

•••

16IK

L154

/IKF

154

IN17

2/10

IN20

6/IN

406

IN21

7/16

IN21

8/16

2AD

132D

-B••

•••-

BD

•3-•

••25

*)IN

172/

25IN

207/

IN40

7IN

217/

25IN

218/

25

2AD

132B

-B••

•••-

DS

•3-•

•••

6IK

L111

/IKF

111

IN17

2/6

IN20

4/IN

404

IN21

7/06

IN21

8/06

2AD

132C

-B••

•••C

S•3

-•••

•10

IKL1

33/IK

F13

3IN

172/

10IN

205/

IN40

5IN

217/

10IN

218/

10

2AD

132D

-B••

•••-

AS

•3-•

•••

16IK

L154

/IKF

154

IN17

2/16

IN20

6/IN

406

IN21

7/16

IN21

8/16

Cab

lecr

oss

sect

ion

A[m

m2 ]

Ass

embl

ed c

able

s fo

r pl

ug

conn

ecto

r

on th

e m

otor

fle

x. /h

ighl

y fle

x.on

the

cont

rolle

r fle

x. /h

ighl

y fle

x.on

the

mot

orC

able

flex.

/hig

hly

flex.

Plu

g de

sign

L.on

the

cont

rolle

r

The

com

pone

nts

of a

ssem

bled

cab

les

with

plu

g de

sign

*) *) *) *) *) *) *)

For

..

For

..

..lin

e-up

term

inal

s(R

AC

2/R

AC

3)

.. lin

e-up

term

inal

s(R

AC

2/R

AC

3)

.. lin

e-up

term

inal

s(R

AC

2/R

AC

3)

..sta

y bo

lt M

6(K

DA

/TD

A)

..sta

y bo

lt M

6(K

DA

/TD

A)

..sta

y bo

lt M

6(K

DA

/TD

A)

..sta

y bo

lt M

6(K

DA

/TD

A)

..sta

y bo

lt M

6(K

DA

/TD

A)

dto.

dto.

dto.

dto.

dto.

dto.

dto.

dto.

*) *)

Alk

ab03

..sta

y bo

lt M

6(K

DA

/TD

A)

..sta

y bo

lt M

6(K

DA

/TD

A)

dto.

dto.

Pow

er p

lug

conn

ecto

r (p

lug)

Sym

bols

:

Wire

-end

fe

rrul

eC

rimpi

ng c

able

lug

Fla

nge

conn

ectio

n

Pow

er p

lug

conn

ecto

r (c

oupl

ing)

PG

scr

ew c

onne

ctio

n

*) A

vaila

ble.

For

inqu

iries

on

type

info

rmat

ion

cont

act D

evel

opm

ent D

ept.,

IND

RA

MA

T.

Atte

ntio

n!

Fla

nge

conn

ectio

n IN

218

mus

t hav

e an

insu

lato

r ca

sing

whi

ch ju

ts o

ut o

ver

the

cont

acts

on

the

sold

ered

or

crim

ped

side

by

appr

ox. 3

mm

!

Do

not u

se a

ny o

ther

type

!

see

"Atte

ntio

n"be

low

!

see

"Atte

ntio

n"be

low

!

Sec

tion

1: 2

AD

pow

er c

onne

ctio

ns -

plu

g de

sign



Figure 2.22: Specifications for connection with plug design for 2AD motors-Section2.

2A

D1

32

B-B

•••.

•-D

S•3

-•••

•6

IN2

04

/IN

40

4

IN2

17

/10

IN2

18

/10

2A

D1

32

C-B

•••.

•-C

S•3

-•••

•1

0

IN2

06

/IN

40

6

no

t a

vaila

ble

IN2

18

/16

2A

D1

32

D-B

•••.

•-A

S•3

-•••

16

IN2

07

/IN

40

7

no

t a

vaila

ble

IN2

18

/25

2A

D1

60

B-B

•••.

•-B

S•3

-•••

•2

5

IN2

05

/IN

40

5

IN2

18

/06

2A

D1

60

C-B

•••.

•-B

S•3

-•••

•3

5

2A

D1

80

C-B

•••.

•-B

S•3

-•••

•3

5

IN2

17

/06

2A

D1

80

D-B

•••.

•-B

S•3

-•••

•5

0

2A

D2

00

C-B

•••.

•AS

•3-•

•••

2X

25

Cab

lecr

oss

sect

ion

A[m

m]

(PG

29

)

(PG

42

)

(PG

42

)

Ass

embl

ed c

able

s fo

r pl

ug

conn

ecto

r

on

th

e m

oto

r fle

x. /h

igh

ly fle

x.o

n th

e c

on

tro

ller

flex.

/h

igh

ly fle

x.o

n th

e m

oto

rC

ab

lefle

x./h

igh

ly fle

x.p

lug

de

sig

nL

.o

n th

e

con

tro

ller

Ass

embl

ed c

able

com

pone

nts

with

pl

ug c

onne

ctor

(PG

48

)

(PG

42

)n

ot a

vaila

ble

no

t a

vaila

ble

Fo

r..

..sc

rew

sM

12

(RA

C4

)

..lin

e-up

term

inal

s(R

AC

2/R

AC

3)

dto

.

dto

.

dto

.

dto

.

dto

.

dto

.

dto

.

dto

.

..st

ay

bo

lt M

8

M8

Fo

r..

AL

KA

B0

4

(PG

29

)

(PG

29

)

(PG

29

)

no

t a

vaila

ble

no

t a

vaila

ble

..st

ay

bo

lt M

8

M8

..st

ay

bo

lt M

6

M8

..st

ay

bo

lt M

6

M8

..st

ay

bo

lt M

10

M1

0

..st

ay

bo

lt M

10

M1

0

..st

ay

bo

lt M

10

M1

0

..st

ay

bo

lt M

12

M1

2

..lin

e-up

term

inal

s(R

AC

2/R

AC

3)

..lin

e-up

term

inal

s(R

AC

2/R

AC

3)

..lin

e-up

term

inal

s(R

AC

2/R

AC

3)

..lin

e-up

term

inal

s(R

AC

2/R

AC

3)

..lin

e-up

term

inal

s(R

AC

2/R

AC

3)

..sc

rew

sM

12

(RA

C4

)

2A

D1

32

B-B

•••.

•-B

S•3

-•••

•1

0IN

20

5/IN

40

5IN

21

7/1

0IN

21

8/1

0

2A

D1

32

C-B

•••.

•-B

S•3

-•••

•1

6IN

20

6/IN

40

6IN

21

7/1

6IN

21

8/1

6

2A

D1

32

D-B

•••.

•-B

D•3

-•••

•2

5IN

20

7/IN

40

7IN

21

7/2

5IN

21

8/2

5

(PG

29

)

(PG

29

)

(PG

29

)

*)

Fo

r..

..st

ay

bo

lt M

6(K

DA

/TD

A)

..st

ay

bo

lt M

6(K

DA

/TD

A)

..st

ay

bo

lt M

6(K

DA

/TD

A)

dto

.

dto

.

dto

.

..st

ay

bo

lt M

6

M8

..st

ay

bo

lt M

8

M8

..st

ay

bo

lt M

8

M8

Fo

r..

*) *) *)IN

21

7/2

5

IN2

17

/16

no

t a

vaila

ble

no

t a

vaila

ble

no

t a

vaila

ble

no

t a

vaila

ble

no

t a

vaila

ble

no

t a

vaila

ble

*) *) *)

*)

IKL

13

7/IK

F1

37

no

t a

vaila

ble

no

t a

vaila

ble

*) *)

no

t a

vaila

ble

no

t a

vaila

ble

IKL

13

7/IK

F1

37

IKL

15

3/IK

F1

53

IKL

17

3/IK

F1

73

Po

we

r p

lug

co

nn

ect

or

(plu

g)

Sym

bo

ls:

Wire

-en

d

ferr

ule

Crim

pin

g c

ab

lelu

gF

lan

ge

co

nn

ect

ion

Po

we

r p

lug

co

nn

ect

or

(co

up

ling

)P

G s

cre

w c

on

ne

ctio

n

*) A

vaila

ble

. F

or

inq

uirie

s o

n typ

e in

form

atio

n c

on

tact

De

velo

pm

en

t D

ep

t., IN

DR

AM

AT.

see

"a

tte

ntio

n"

be

low

!

see

"a

tte

ntio

n"

be

low

!

see

"a

tte

ntio

n"

be

low

!

Fo

r..

Fo

r..

IN2

67

IN2

67

IN2

68

2 x

IN

20

7/2

x IN

40

7

Atte

ntio

n!

Fla

ng

e c

on

ne

ctio

n I

N2

18

mu

st h

ave

an

insu

lato

r ca

sin

g w

hic

h ju

ts o

ut

ove

r th

e c

on

tact

s o

n t

he

so

lde

red

or

crim

pe

d s

ide

by

ap

pro

x. 3

mm

!

Do

no

t u

se a

ny

oth

er

typ

e!

2

Sec

tion

2: 2

AD

pow

er c

onne

ctio

ns -

plu

g de

sign



Figure 2.23: Table of assembled specifications for connections with plug testingpoints in 2AD motors - Section 1.

2AD

100B

-B••

•••-

AS

•3-•

•••

4IK

L072

/IKF

072

IN17

2/25

IN20

3/IN

403

IN21

0/25

IN17

2/25

2AD

100C

-B••

•••-

AS

•3-•

•••

4IN

172/

25IN

203/

IN40

3IN

210/

25IN

172/

25

2AD

100D

-B••

•••-

AS

•3-•

•••

6IK

L113

/IKF

113

IKL1

12/IK

F11

2IN

172/

06IN

204/

IN40

4IN

210/

06IN

172/

06

2AD

101D

-B••

•••-

BD

•3-•

•••

10IK

L138

/IKF

138

IN17

2/10

IN20

5/IN

405

IN21

0/10

IN17

2/10

2AD

132B

-B••

•••-

BS

•3-•

•••

10IK

L138

/IKF

138

IN17

2/10

IN20

5/IN

405

IN21

0/10

IN17

2/10

2AD

132C

-B••

•••-

BS

•3-•

•••

16IK

L158

/IKF

158

IN17

2/10

IN20

6/IN

406

IN21

0/16

IN17

2/16

2AD

132D

-B••

•••-

BD

•3-•

••25

IKL1

78/IK

F17

8IN

172/

25IN

207/

IN40

7IN

210/

25IN

172/

25

2AD

132B

-B••

•••-

DS

•3-•

•••

6IK

L113

/IKF

113

IN17

2/6

IN20

4/IN

404

IN21

0/06

IN17

2/06

2AD

132C

-B••

•••-

CS

•3-•

•••

10IK

L138

/IKF

138

IN17

2/10

IN20

5/IN

405

IN21

0/10

IN17

2/10

2AD

132D

-B••

•••-

AS

•3-•

•••

16IK

L158

/IKF

158

IN17

2/16

IN20

6/IN

406

IN21

0/16

IN17

2/16

*)

IKL1

34/

*)

*)

For

..

For

..

..lin

e-up

term

inal

s(R

AC

2/R

AC

3)

..lin

e-up

term

inal

s(R

AC

2/R

AC

3)

..lin

e-up

term

inal

s(R

AC

2/R

AC

3)

..sta

y bo

lt M

6(K

DA

/TD

A)

..sta

y bo

lt M

6(K

DA

/TD

A)

..sta

y bo

lt M

6(K

DA

/TD

A)

..sta

y bo

lt M

6(K

DA

/TD

A)

..sta

y bo

lt M

6(K

DA

/TD

A)

dto.

dto.

dto.

dto.

dto.

dto.

dto.

dto.

ALK

AB

05

IKL0

72/IK

F07

2

IKL0

71/IK

F07

1

IKL0

71/IK

F07

1

IKL1

30/IK

F13

0

IKL1

30/IK

F13

0

*)

IKL1

70/IK

F17

0

Cab

lecr

oss

sect

ion

A[m

m2 ]

Pre

asse

mbl

ed c

able

s fo

r pl

ugin

te

stin

g po

ints

on th

e m

otor

fle

x. /h

ighl

y fle

x.on

the

cont

rolle

r fle

x. /h

ighl

y fle

x.on

the

mot

orC

able

flex.

/hig

hly

flex.

plug

in te

stin

g po

ints

L.on

the

cont

rolle

r

Com

pone

nts

of p

reas

sem

bled

cab

les

with

plu

gin

test

ing

poin

ts

Pow

er p

lug

conn

ecto

r (p

lug)

Sym

bols

:

Mul

ti-co

re

cabl

e en

dC

ompr

essi

on

cabl

e sh

oeF

lang

e co

nnec

tion

Pow

er p

lug

conn

ecto

r (c

oupl

ing)

PG

scr

ew c

onne

ctio

n

*) A

vaila

ble.

For

inqu

iries

on

type

info

rmat

ion

cont

act D

evel

opm

ent D

ept.,

IND

RA

MA

T.

..sta

y bo

lt M

6(K

DA

/TD

A)

..sta

y bo

lt M

6(K

DA

/TD

A)

dto.

dto.

Sec

tion

1: 2

AD

pow

er c

onne

ctio

ns -

plu

gin

test

ing

poin

ts



Figure 2.24: Table of assembled specifications for connections with plugintesting points in 2AD motors - Section 2.

IN1

72

/06

IN2

17

/06

..lin

e-up

term

inal

s(R

AC

2/R

AC

3)

dto

.2

AD

13

2B

-B••

•••-

DS

•3-•

•••

6*)

IN2

04

/IN

40

4

IN2

17

/10

IN1

72

/10

2A

D1

32

C-B

••••

•-C

S•3

-•••

•1

0IK

L1

29

/IK

F1

29

IN2

06

/IN

40

6IN

21

7/1

6IN

17

2/1

62

AD

13

2D

-B••

•••-

AS

•3-•

••1

6

IN2

07

/IN

40

7IN

21

7/2

5IN

17

2/2

52

AD

16

0B

-B••

•••-

BS

•3-•

•••

25

IN2

05

/IN

40

5

2A

D1

60

C-B

••••

•-B

S•3

-•••

•3

5

2A

D1

80

C-B

••••

•-B

S•3

-•••

•3

5

2A

D1

80

D-B

••••

•-B

S•3

-•••

•5

0n

ot

ava

ilab

le

2A

D2

00

C-B

••••

•AS

•3-•

•••

2X

25

no

t a

vaila

ble

(PG

29

)

(PG

42

)

(PG

42

)

(PG

48

)

(PG

42

)n

ot

ava

ilab

le

no

t a

vaila

ble

Fo

r..

Fo

r..

..S

cre

ws

M1

2(R

AC

4)

dto

.

dto

.

dto

.

dto

.

dto

.

dto

.

dto

.

..st

ay

bo

lt M

8

M8

Fo

r..

AL

KA

B0

6

IKL

13

4/

*)

(PG

29

)

(PG

29

)

(PG

29

)

IKL

14

9/I

KF

14

9

IKL

16

9/I

KF

16

9

no

t a

vaila

ble

no

t a

vaila

ble

*) *) *)

no

t a

vaila

ble

no

t a

vaila

ble

..st

ay

bo

lt M

8

M8

..st

ay

bo

lt M

6

M8

..st

ay

bo

lt M

6

M8

Fo

r..

..st

ay

bo

lt M

10

M1

0

..st

ay

bo

lt M

10

M1

0

IN2

67

IN2

67

..st

ay

bo

lt M

10

M1

0

..st

ay

bo

lt M

12

M1

2

..lin

e-up

term

inal

s

(RA

C2

/RA

C3

)

..lin

e-up

term

inal

s(R

AC

2/R

AC

3)

..lin

e-up

term

inal

s(R

AC

2/R

AC

3)

..lin

e-up

term

inal

s(R

AC

2/R

AC

3)

..lin

e-up

term

inal

s(R

AC

2/R

AC

3)

..S

cre

ws

M1

2(R

AC

4)

2A

D1

32

B-B

••••

•-B

S•3

-•••

•1

0IK

L1

29

/IK

F1

29

IN2

05

/IN

40

5IN

21

0/1

0IN

17

2/1

0

2A

D1

32

C-B

••••

•-B

S•3

-•••

•1

6IK

L1

49

/IK

F1

49

IN2

06

/IN

40

6IN

21

0/1

6IN

17

2/1

6

2A

D1

32

D-B

••••

•-B

D•3

-•••

•2

5IK

L1

69

/IK

F1

69

IN2

07

/IN

40

7IN

21

0/2

5IN

17

2/2

5

(PG

29

)

(PG

29

)

(PG

29

)

Fo

r..

..st

ay

bo

lt M

6(K

DA

/TD

A)

..st

ay

bo

lt M

6(K

DA

/TD

A)

..st

ay

bo

lt M

6(K

DA

/TD

A)

dto

.

dto

.

dto

.

..st

ay

bo

lt M

6

M8

..st

ay

bo

lt M

8

M8

..st

ay

bo

lt M

8

M8

Fo

r..

IKL

13

0/I

KF

13

0

*)

IKL

17

0/I

KF

17

0

Po

we

r p

lug

co

nn

ect

or

(plu

g)

Sym

bo

ls:

Mu

lti-c

ore

ca

ble

en

dC

om

pre

ssio

n

cab

le s

ho

es

Fla

ng

e

con

ne

ctio

n

Po

we

r p

lug

co

nn

ect

or

(co

up

ling

)P

G s

cre

w c

on

ne

ctio

n

*) A

vaila

ble

. F

or

inq

uirie

s o

n t

ype

info

rma

tion

co

nta

ct D

eve

lop

me

nt

De

pt.

, IN

DR

AM

AT.

Ca

ble

cro

ssse

ctio

nA

[mm

2]

Pre

ass

em

ble

d c

ab

le f

or

plu

gin

te

stin

g p

oin

ts

on

th

e m

oto

r fle

x. /

hig

hly

fle

x.o

n t

he

co

ntr

olle

r fle

x. /

hig

hly

fle

x.o

n t

he

mo

tor

Ca

ble

flex.

/h

igh

ly f

lex.

plu

gin

te

stin

g p

oin

tsL

.o

n t

he

co

ntr

olle

r

Co

mp

on

en

ts o

f p

rea

sse

mb

led

ca

ble

s w

ith p

lug

in

test

ing

po

ints

no

t a

vaila

ble

no

t a

vaila

ble

no

t a

vaila

ble

no

t a

vaila

ble

no

t a

vaila

ble

no

t a

vaila

ble

no

t a

vaila

ble

no

t a

vaila

ble

IN2

68

2 x

IN

20

7/2

x I

N 4

07

Sec

tion

2: 2

AD

pow

er c

onne

ctio

ns -

plu

gin

test

ing

poin

ts



Figure 2.25: Table of assembled specifications for direct connection and forintermediate terminals on terminals strips in 1MB motors - Section 1.

Sec

tion

1: 1

MB

pow

er c

onne

ctio

ns -

plu

gin

test

ing

poin

ts

Cab

leA

ssem

bled

cab

les

Com

pone

nts

of a

ssem

bled

cab

les

for

dire

ct

conn

ectio

nsA

ssem

bled

cab

les

for

inte

rmed

iate

cros

sfo

r di

rect

con

nect

ion

term

inal

s on

term

inal

str

ips

sect

ion

on th

e m

otor

Cab

leon

the

on th

e m

otor

on th

e co

ntro

ller

A [m

m ]

flex.

/hig

hly

flex.

cont

rolle

rfle

x./h

ighl

y fle

x.fle

x./h

ighl

y fle

x.

ALK

AB

07

2

Pow

er p

lug

conn

ecto

r (p

lug)

Sym

bols

:

Wire

-end

fe

rrul

eC

rimpi

ng c

able

lu

gF

lang

e co

nnec

tion

Pow

er p

lug

conn

ecto

r (c

oupl

ing)

PG

scr

ew c

onne

ctio

n

*) A

vaila

ble.

For

inqu

iries

on

type

info

rmat

ion

cont

act D

evel

opm

ent D

ept.,

IND

RA

MA

T.

1MB

160F

-4A

...25

IKL1

74/IK

F17

4IN

207/

IN40

7..s

tay

bolt

M6

IKL1

72/IK

F17

2

(PG

29)

(KD

A /T

DA

)

..sta

y bo

lt M

8

M8

not

avai

labl

e

1MB

200D

-4E

...25

IKL1

74/IK

F17

4IN

207/

IN40

7..s

tay

bolt

M6

IKL1

72/IK

F17

2

(PG

29)

(KD

A /T

DA

)

..sta

y bo

lt M

8

M8

not

avai

labl

e

1MB

240B

-4A

...10

IKL1

35/IK

F13

5IN

205/

IN40

5..s

tay

bolt

M6

IKL1

36/IK

F13

6no

tav

aila

ble

(PG

29)

(KD

A /T

DA

)

..sta

y bo

lt M

6

M8

1MB

240D

-4A

...10

IKL1

35/IK

F13

5IN

205/

IN40

5..s

tay

bolt

M6

IKL1

36/IK

F13

6no

tav

aila

ble

(PG

29)

(KD

A /T

DA

)

..sta

y bo

lt M

6

M8

1MB

240F

-4A

...25

IKL1

74/IK

F17

4IN

207/

IN40

7..s

tay

bolt

M6

IKL1

72/IK

F17

2

(PG

29)

(KD

A /T

DA

)

..sta

y bo

lt M

8

M8

not

avai

labl

e

1MB

240H

-4A

...25

IKL1

74/IK

F17

4IN

207/

IN40

7..s

tay

bolt

M6

IKL1

72/IK

F17

2

(PG

29)

(KD

A /T

DA

)

..sta

y bo

lt M

8

M8

not

avai

labl

e

1MB

241H

-6C

...25

IKL1

74/IK

F17

4IN

207/

IN40

7..s

tay

bolt

M6

IKL1

72/IK

F17

2

(PG

29)

(KD

A /T

DA

)

..sta

y bo

lt M

8

M8

not

avai

labl

e

1MB

160E

-4B

...

(PG

)

1MB

160B

-4A

...

(PG

29)

1MB

200D

-4C

...

(PG

)

1MB

310B

-6A

...

(PG

)

For

... F

or...

1MB

160D

-4A

...

(PG

29)

10IK

L135

/IKF

135

IN20

5/IN

405

..sta

y bo

lt M

6IK

L136

/IKF

136

not

avai

labl

e(K

DA

/TD

A)

..sta

y bo

lt M

6

M8

10IK

L135

/IKF

135

IN20

5/IN

405

..sta

y bo

lt M

6IK

L136

/IKF

136

not

avai

labl

e(K

DA

/TD

A)

..sta

y bo

lt M

6

M8



Ca

ble

Ass

em

ble

d c

ab

les

Co

mp

on

en

ts o

f th

e a

sse

mb

led

ca

ble

fo

r d

ire

ct c

on

ne

ctio

nA

sse

mb

led

ca

ble

s fo

r in

term

ed

iate

cro

ssfo

r d

ire

ct c

on

ne

ctio

nte

rmin

als

on

te

rmin

al s

trip

sse

ctio

no

n t

he

m

oto

rC

ab

leo

n t

he

on

th

e m

oto

ro

n t

he

co

ntr

olle

rA

[m

m ]

flex.

/hig

hly

fle

x.co

ntr

olle

rfle

x./h

igh

ly f

lex.

flex.

/hig

hly

fle

x.

AL

KA

B0

8

2

Po

we

r p

lug

co

nn

ect

or

(plu

g)

Sym

bo

ls:

Wire

-en

d

ferr

ule

Crim

pin

g c

ab

lelu

gF

lan

ge

co

nn

ect

ion

Po

we

r p

lug

co

nn

ect

or

(co

up

ling

)P

G s

cre

w c

on

ne

ctio

n

*) A

vaila

ble

. F

or

inq

uirie

s o

n t

ype

info

rma

tion

co

nta

ct D

eve

lop

me

nt

De

pt.

, IN

DR

AM

AT.

Fo

r...

Fo

r...

IKL

13

6/I

KF

13

6IN

20

5/I

N4

05

IKL

13

6/I

KF

13

6..

.lin

e-u

p t

erm

ina

ls

(RA

C2

/R

AC

3)

..st

ay

bo

lt M

6

M8

no

ta

vaila

ble

IKL

13

6/I

KF

13

6IN

20

5/I

N4

05

IKL

13

6/I

KF

13

6..

.lin

e-u

p t

erm

ina

ls

(RA

C2

/R

AC

3)

..st

ay

bo

lt M

6

M8

no

ta

vaila

ble

IKL

17

1/I

KF

17

1IN

20

7/I

N4

07

...li

ne

-up

te

rmin

als

(RA

C2

/R

AC

3)

..st

ay

bo

lt M

8

M8

IKL

17

1/I

KF

17

1n

ot

ava

ilab

le

IKL

18

2/

*)IN

26

7..

.lin

e-u

p t

erm

ina

ls

(RA

C2

/R

AC

3)

..st

ay

bo

lt M

10

M1

0

IKL

18

2/

*)n

ot

ava

ilab

le

IKL

15

1/I

KF

15

1IN

20

6/I

N4

06

...li

ne

-up

te

rmin

als

(RA

C2

/R

AC

3)

..st

ay

bo

lt M

8

M8

IKL

15

1/I

KF

15

1n

ot

ava

ilab

le

1M

B2

00

D-4

B..

.

(PG

29

)

10

1M

B2

41

H-6

D..

.

(PG

29

)

10

1M

B3

10

B-6

B..

.2

5

(PG

29

)

1M

B3

10

D-6

B..

.2

5

(PG

29

)

1M

B3

12

C-4

A..

.3

5(P

G 2

9)

1M

B1

60

F-4

B..

.

(PG

)

1M

B2

00

D-4

D..

.

(PG

)

1M

B2

00

E-4

B..

.

(PG

)

1M

B2

00

H-4

B..

.(P

G

)

1M

B2

40

F-4

B..

.

(PG

)

1M

B3

10

F-6

B..

.

(PG

42

)

1M

B3

12

B-4

A..

.

(PG

29

)

35

1M

B2

40

H-4

B..

.

(PG

29

)

16

1M

B F

ram

ele

ss S

pin

dle

Mo

tor

IKL

18

2/

*)

...li

ne

-up

te

rmin

als

(RA

C2

/R

AC

3)

..st

ay

bo

lt M

10

M1

0

IKL

18

2/

*)

IN2

67

no

ta

vaila

ble

IKL

17

1/I

KF

17

1IN

20

7/I

N4

07

...li

ne

-up

te

rmin

als

(RA

C2

/R

AC

3)

..st

ay

bo

lt M

8

M8

IKL

17

1/I

KF

17

1n

ot

ava

ilab

le

IKL

17

1/I

KF

17

1IN

20

7/I

N4

07

...li

ne

-up

te

rmin

als

(RA

C2

/R

AC

3)

..st

ay

bo

lt M

8

M8

IKL

17

1/I

KF

17

1n

ot

ava

ilab

le2

5

Sec

tion

2: 1

MB

pow

er c

onne

ctio

ns -

plu

gin

test

ing

poin

ts


Figure 2.26: Table of assembled specifications for direct connection and forintermediate terminals on terminals strips in 1MB motors - Section 2.


Figure 2.27: Table listing information on assembled cables for direct connectionsand for intermediate terminals on terminal strips in 1MB motors - Section 3.

Sec

tion

3: 1

MB

pow

er c

onne

ctio

ns -

dire

ct c

onne

ctio

ns a

nd in

term

edia

te te

rmin

als

Cab

leA

ssem

bled

cab

les

Com

pone

nts

of th

e as

sem

bled

cab

les

for

dire

ct c

onne

ctio

nsA

ssem

bled

cab

le fo

r in

term

edia

tecr

oss

for

dire

ct c

onne

ctio

nste

rmin

als

on te

rmin

al s

trip

sse

ctio

non

the

mot

orC

able

on th

eon

the

mot

oron

the

cont

rolle

rA

[mm

]fle

x./h

ighl

y fle

x.co

ntro

ller

flex.

/hig

hly

flex.

flex.

/hig

hly

flex.

ALK

AB

09

2

Pow

er p

lug

conn

ecto

r (p

lug)

Sym

bols

:

Wire

-end

fe

rrul

eC

rimpi

ng c

able

lug

Fla

nge

conn

ectio

n

Pow

er p

lug

conn

ecto

r (c

oupl

ing)

PG

scr

ew c

onne

ctio

n

*) A

vaila

ble.

For

inqu

iries

on

type

info

rmat

ion

cont

act D

evel

opm

ent D

ept.,

IND

RA

MA

T.

For

... F

or...

For

... F

or...

(PG

)

..Lin

e-up

term

inal

s(R

AC

2/R

AC

3)

..Scr

ews

M12

(RA

C4)

1MB

375B

-6B

...

(PG

)

1MB

375D

-6B

...



Figure 2.28: Table of specifications for assembled cables with plug design in1MB motors - Section 1.

Sec

tion

1: 1

MB

pow

er c

onne

ctio

ns -

plu

g de

sign

Ca

ble

cro

ssse

ctio

nA

[mm

2]

Ass

em

ble

d c

ab

les

for

plu

g d

esi

gn

on

th

e m

oto

r fle

x. /

hig

hly

fle

x.o

n t

he

co

ntr

olle

r fle

x. /

hig

hly

fle

x.o

n t

he

mo

tor

Ca

ble

flex.

/h

igh

ly f

lex.

plu

gd

esi

gn

L.

on

th

e

con

tro

ller

Co

mp

on

en

ts o

f a

sse

mb

led

ca

ble

sw

ith p

lug

de

sig

n

AL

KA

B1

0

Po

we

r p

lug

co

nn

ect

or

(plu

g)

Sym

bo

ls:

Wire

-en

d

ferr

ule

Crim

pin

g

cab

le lu

gF

lan

ge

con

ne

ctio

n

Po

we

r p

lug

co

nn

ect

or

(co

up

ling

)P

G s

cre

w c

on

ne

ctio

n

*) A

vaila

ble

. F

or

inq

uirie

s o

n t

ype

info

rma

tion

co

nta

ct D

eve

lop

me

nt

De

pt.

, IN

DR

AM

AT.

Atte

ntio

n!

Fla

ng

e c

on

ne

ctio

n I

N2

18

mu

st h

ave

an

insu

lato

r ca

sin

g w

hic

h ju

ts o

ut

ove

r th

e c

on

tact

s o

n t

he

so

lde

red

or

crim

pe

d s

ide

by

ap

pro

x. 3

mm

!

Do

no

t u

se a

ny

oth

er

typ

e!

Fo

r..

Fo

r..

see

"A

tte

ntio

n"

be

low

10 25

25

10 25

25

25

1M

B1

60

D-4

A..

.(P

G 2

9)

1M

B1

60

F-4

A..

.(P

G 2

9)

1M

B2

00

D-4

E..

.(P

G 2

9)

1M

B2

40

B-4

A..

.(P

G 2

9)

1M

B2

40

D-4

A..

.(P

G 2

9)

1M

B2

40

F-4

A..

.(P

G 2

9)

1M

B2

40

H-4

A..

.(P

G 2

9)

1M

B2

41

H-6

C..

.(P

G 2

9)

1M

B1

60

E-4

B..

.(P

G

)

1M

B1

60

B-4

A..

.(P

G 2

9)

1M

B2

00

D-4

C..

.(P

G

)

1M

B3

10

B-6

A..

.(P

G

)

1M

B F

ram

ele

ss S

pin

dle

Mo

tor

IN2

05

/IN

40

5IN

21

7/1

0IN

21

8/1

0

IN2

07

/IN

40

7IN

21

7/2

5IN

21

8/2

5

IN2

07

/IN

40

7IN

21

7/2

5IN

21

8/2

5

*)..

sta

y b

olt

M6

(KD

A/T

DA

)

..st

ay

bo

lt M

6(K

DA

/TD

A)

..st

ay

bo

lt M

6(K

DA

/TD

A)

dto

.

dto

.

dto

.

..st

ay

bo

lt M

6

M8

..st

ay

bo

lt M

8

M8

..st

ay

bo

lt M

8

M8

*) *)

IKL

13

7/I

KF

13

7

IKL

17

3/I

KF

17

3

IKL

17

3/I

KF

17

3

IN2

05

/IN

40

5IN

21

7/1

0IN

21

8/1

0

IN2

07

/IN

40

7IN

21

7/2

5IN

21

8/2

5

IN2

07

/IN

40

7IN

21

7/2

5IN

21

8/2

5

*)..

sta

y b

olt

M6

(KD

A/T

DA

)

..st

ay

bo

lt M

6(K

DA

/TD

A)

..st

ay

bo

lt M

6(K

DA

/TD

A)

dto

.

dto

.

dto

.

..st

ay

bo

lt M

6

M8

..st

ay

bo

lt M

8

M8

..st

ay

bo

lt M

8

M8

*) *)

IKL

13

7/I

KF

13

7

IKL

17

3/I

KF

17

3

IKL

17

3/I

KF

17

3

IN2

07

/IN

40

7IN

21

7/2

5IN

21

8/2

5..

sta

y b

olt

M6

(KD

A/T

DA

)d

to.

..st

ay

bo

lt M

8

M8

*)IK

L1

73

/IK

F1

73

10

IN2

05

/IN

40

5IN

21

7/1

0IN

21

8/1

0*)

..st

ay

bo

lt M

6(K

DA

/TD

A)

dto

...

sta

y b

olt

M6

M8

IKL

13

7/I

KF

13

7

10

IN2

05

/IN

40

5IN

21

7/1

0IN

21

8/1

0*)

..st

ay

bo

lt M

6(K

DA

/TD

A)

dto

...

sta

y b

olt

M6

M8

IKL

13

7/I

KF

13

7



Figure 2.29: Table of specs on assembled cables with plug design for 1MBmotors - Section 2.

Sec

tion

2: 1

MB

pow

er c

onne

ctio

ns -

plu

g de

sign

Cab

lecr

oss

sect

ion

A[m

m ]

Ass

embl

ed c

able

for

plug

des

ign

on th

e m

otor

fle

x. /h

ighl

y fle

x.on

the

cont

rolle

r fle

x. /h

ighl

y fle

x.on

the

mot

orC

able

flex.

/hig

hly

flex.

Plu

g de

sign

L.on

the

cont

rolle

r

Com

pone

nts

of a

ssem

bled

cab

le w

ith p

lug

desi

gn

(PG

48)

ALK

AB

11

Pow

er p

lug

conn

ecto

r (p

lug)

Sym

bols

:

Wire

-end

fe

rrul

eC

rimpi

ng

cabl

e lu

gF

lang

e co

nnec

tion

Pow

er p

lug

conn

ecto

r (c

oupl

ing)

PG

scr

ew c

onne

ctio

n

*) A

vaila

ble.

For

inqu

iries

on

type

info

rmat

ion

cont

act D

evel

opm

ent D

ept.,

IND

RA

MA

T.

Atte

ntio

n!

Fla

nge

conn

ectio

n IN

218

mus

t hav

e an

insu

lato

r ca

sing

whi

ch ju

ts o

ut o

ver

the

cont

acts

on

the

sold

ered

or

crim

ped

side

by

appr

ox. 3

mm

!

Do

not u

se a

ny o

ther

type

s!

IN21

7/10

IN21

8/10

IN20

5/IN

405

dto.

..sta

y bo

lts M

6

M8

*)IK

L137

/IKF

137

see

"Atte

ntio

n"be

low

!F

or..

For

..

1MB

200D

-4B

...

(PG

29)

10

1MB

241H

-6D

...

(PG

29)

10

1MB

310B

-6B

...25

(PG

29)

1MB

310D

-6B

...(P

G 2

9)

1MB

312C

-4A

...35

(PG

29)

1MB

160F

-4B

...(P

G )

1MB

200D

-4D

...

(PG

)

1MB

200E

-4B

...

(PG

)

1MB

200H

-4B

...(P

G

)

1MB

240F

-4B

...

(PG

)

1MB

310F

-6B

...

(PG

42)

1MB

312B

-4A

...

(PG

29)

35

1MB

240H

-4B

...

(PG

29)

16

1M

B F

ram

ele

ss S

pin

dle

Mo

tor

IN20

6/IN

406

IN21

7/16

IN21

8/16

dto.

..sta

y bo

lts M

8

M8

*)IK

L153

/IKF

153

IN20

5/IN

405

IN21

7/10

IN21

8/10

*)dt

o...s

tay

bolts

M6

M8

IKL1

37/IK

F13

7

IN20

7/IN

407

IN21

7/25

IN21

8/25

dto.

..sta

y bo

lts M

8

M8

*)IK

L173

/IKF

173

IN26

7no

t ava

ilabl

eno

t ava

ilabl

edt

o...s

tay

bolts

M10

M10

not a

vaila

ble

not a

vaila

ble

..lin

e-up

term

inal

s(R

AC

2/R

AC

3)

..lin

e-up

term

inal

s(R

AC

2/R

AC

3)

..lin

e-up

term

inal

s(R

AC

2/R

AC

3)

..lin

e-up

term

inal

s(R

AC

2/R

AC

3)

..lin

e-up

term

inal

s(R

AC

2/R

AC

3)

2

not a

vaila

ble

dto.

not a

vaila

ble

..sta

y bo

lts M

10

M10

..lin

e-up

term

inal

s(R

AC

2/R

AC

3)no

t ava

ilabl

eno

t ava

ilabl

eIN

267

25IN

207/

IN40

7IN

217/

25IN

218/

25dt

o...s

tay

bolts

M8

M8

*)IK

L173

/IKF

173

..lin

e-up

term

inal

s(R

AC

2/R

AC

3)

25IN

207/

IN40

7IN

217/

25IN

218/

25dt

o...s

tay

bolts

M8

M8

*)IK

L173

/IKF

173

..lin

e-up

term

inal

s(R

AC

2/R

AC

3)



Figure 2.30: Specifications table on assembled cables with plug design for 1MBmotors - Section 3.

Sec

tion

3: 1

MB

pow

er c

onne

ctio

ns -

plu

g de

sign

Cab

lecr

oss

sect

ion

A[m

m ]

Ass

embl

ed c

able

for

plug

des

ign

on th

e m

otor

fle

x. /h

ighl

y fle

x.on

the

cont

rolle

r fle

x. /h

ighl

y fle

x.on

the

mot

orC

able

flex.

/hig

hly

flex.

Plu

g de

sign

L.on

the

cont

rolle

r

Com

pone

nts

of a

ssem

bled

cab

les

with

pl

ug d

esig

n

ALK

AB

12

Pow

er p

lug

conn

ecto

r (p

lug)

Sym

bols

:

Wire

-end

fe

rrul

eC

rimpi

ngca

ble

lug

Fla

nge

conn

ectio

n

Pow

er p

lug

conn

ecto

r (c

oupl

ing)

PG

scr

ew c

onne

ctio

n

*) A

vaila

ble.

For

inqu

iries

on

type

info

rmat

ion

cont

act D

evel

opm

ent D

ept.,

IND

RA

MAT

.

Atte

ntio

n!

Fla

nge

conn

ectio

n IN

218

mus

t hav

e an

insu

lato

r ca

sing

whi

ch ju

ts o

ut o

ver

the

cont

acts

on

the

sold

ered

or

crim

ped

side

by

appr

ox. 3

mm

!

Do

not u

se a

ny o

ther

type

s!

1MB

375B

-6B

...

(PG

)

1MB

375D

-6B

...

..lin

e-up

term

inal

s(R

AC

2/R

AC

3)

..scr

ews

M12

(RA

C4)

see

"Atte

ntio

n"be

low

!F

or..

For

..

2

For

..F

or..

see

"Atte

ntio

n"be

low

!

(PG

)



Figure 2.31: Specifications table on assembled cables for connection with plugintesting points in 1MB motors - Section 1.

ALK

AB

13

Pow

er p

lug

conn

ecto

r (p

lug)

Sym

bols

:

Mul

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re

cabl

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dC

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ble

lug

Fla

nge

conn

ectio

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Pow

er p

lug

conn

ecto

r (c

oupl

ing)

PG

scr

ew c

onne

ctio

n

*) A

vaila

ble.

For

inqu

iries

on

type

info

rmat

ion

cont

act D

evel

opm

ent D

ept.,

IND

RA

MA

T.

Cab

lecr

oss

sect

ion

A[m

m2 ]

Ass

embl

ed c

able

for

plug

in te

stin

g po

ints

on th

e m

otor

fle

x. /h

ighl

y fle

x.on

the

cont

rolle

r fle

x. /h

ighl

y fle

x.on

the

mot

orC

able

flex.

/hig

hly

flex.

Plu

g te

stin

g po

ints

L.on

the

cont

rolle

r

Com

pone

nts

of p

reas

sem

bled

cab

les

with

plu

gin

test

ing

poin

ts

1MB

160D

-4A

...10

(PG

29)

1MB

160F

-4A

...25

(PG

29)

1MB

200D

-4E

...25

(PG

29)

1MB

240B

-4A

...10

(PG

29)

1MB

240D

-4A

...10

(PG

29)

1MB

240F

-4A

...25

(PG

29)

1MB

240H

-4A

...25

(PG

29)

1MB

241H

-6C

...25

(PG

29)

1MB

160E

-4B

...

(PG

)

1MB

160B

-4A

...

(PG

29)

1MB

200D

-4C

...

(PG

)

1MB

310B

-6A

...(P

G

)

1M

B F

ram

ele

ss S

pin

dle

Mo

tor

For

..F

or..

IKL1

29/IK

F12

9IN

205/

IN40

5IN

210/

10IN

172/

10..s

tay

bolt

M6

(KD

A/T

DA

)dt

o...s

tay

bolt

M6

M8

IKL1

30/IK

F13

0

IKL1

69/IK

F16

9IN

207/

IN40

7IN

210/

25IN

172/

25..s

tay

bolt

M6

(KD

A/T

DA

)dt

o...s

tay

bolt

M8

M8

IKL1

70/IK

F17

0

IKL1

69/IK

F16

9IN

207/

IN40

7IN

210/

25IN

172/

25..s

tay

bolt

M6

(KD

A/T

DA

)dt

o...s

tay

bolt

M8

M8

IKL1

70/IK

F17

0

IKL1

69/IK

F16

9IN

207/

IN40

7IN

210/

25IN

172/

25..s

tay

bolt

M6

(KD

A/T

DA

)dt

o...s

tay

bolt

M8

M8

IKL1

70/IK

F17

0

IKL1

69/IK

F16

9IN

207/

IN40

7IN

210/

25IN

172/

25..s

tay

bolt

M6

(KD

A/T

DA

)dt

o...s

tay

bolt

M8

M8

IKL1

70/IK

F17

0

IKL1

69/IK

F16

9IN

207/

IN40

7IN

210/

25IN

172/

25..s

tay

bolt

M6

(KD

A/T

DA

)dt

o...s

tay

bolt

M8

M8

IKL1

70/IK

F17

0

IKL1

29/IK

F12

9IN

205/

IN40

5IN

210/

10IN

172/

10..s

tay

bolt

M6

(KD

A/T

DA

)dt

o...s

tay

bolt

M6

M8

IKL1

30/IK

F13

0

IKL1

29/IK

F12

9IN

205/

IN40

5IN

210/

10IN

172/

10..s

tay

bolt

M6

(KD

A/T

DA

)dt

o...s

tay

bolt

M6

M8

IKL1

30/IK

F13

0

10IK

L129

/IKF

129

IN20

5/IN

405

IN21

0/10

IN17

2/10

..sta

y bo

lt M

6(K

DA

/TD

A)

dto.

..sta

y bo

lt M

6

M8

IKL1

30/IK

F13

0

Sec

tion

1: 1

MB

pow

er c

onne

ctio

ns -

plu

gin

test

ing

poin

ts



Figure 2.32: Specifications table on assembled cables for connection with plugintesting points in 1MB motors - Section 2.

Sec

tion

2: 1

MB

pow

er c

onne

ctio

ns -

plu

gin

test

ing

poin

ts


ALK

AB

14

Pow

er p

lug

conn

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lug)

Sym

bols

:

Wire

-end

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lang

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Pow

er p

lug

conn

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r (c

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PG

scr

ew c

onne

ctio

n

*) A

vaila

ble.

For

inqu

iries

on

type

info

rmat

ion

cont

act D

evel

opm

ent D

ept.,

IND

RA

MA

T.

Cab

lecr

oss

sect

ion

A[m

m2 ]

Ass

embl

ed c

able

for

plug

in te

stin

g po

ints

on th

e m

otor

fle

x. /h

ighl

y fle

x.on

the

cont

rolle

r fle

x. /h

ighl

y fle

x.on

the

mot

orC

able

flex.

/hig

hly

flex.

Plu

g te

stin

g po

int

L.on

the

cont

rolle

r

Com

pone

nts

of a

ass

embl

ed c

able

s w

ith p

lugi

n te

stin

g po

ints

1MB

200D

-4B

...(P

G 2

9)

10

1MB

241H

-6D

...(P

G 2

9)10

1MB

310B

-6B

...25

(PG

29)

1MB

310D

-6B

...25

(PG

29)

1MB

312C

-4A

...35

(PG

29)

1MB

160F

-4B

...

(PG

)

1MB

200D

-4D

...(P

G

)

1MB

200E

-4B

...(P

G

)

1MB

200H

-4B

...(P

G

)

1MB

240F

-4B

...(P

G

)

1MB

310F

-6B

...

(PG

42)

1MB

312B

-4A

...(P

G 2

9)

35

1M

B F

ram

ele

ss S

pin

dle

Mo

tor

For

..F

or..

IN21

7/10

IN17

2/10

IKL1

29/IK

F12

9IN

205/

IN40

5dt

o.IK

L134

/ *)

..sta

y bo

lt M

6

M8

..lin

e-up

term

inal

s

(RA

C2/

RA

C3)

IN21

7/10

IN17

2/10

IKL1

29/IK

F12

9IN

205/

IN40

5dt

o.IK

L134

/ *)

..sta

y bo

lt M

6

M8

..lin

e-up

term

inal

s

(RA

C2/

RA

C3)

IN20

7/IN

407

IN21

0/25

IN17

2/25

dto.

IKL1

69/IK

F16

9*)

..sta

y bo

lt M

8

M8

..lin

e-up

term

inal

s(R

AC

2/R

AC

3)

IN20

7/IN

407

IN21

0/25

IN17

2/25

dto.

..sta

y bo

lt M

8

M8

IKL1

69/IK

F16

9*)

..lin

e-up

term

inal

s(R

AC

2/R

AC

3)

IN26

7no

t ava

ilabl

eno

t ava

ilabl

edt

o...s

tay

bolt

M10

M10

not a

vaila

ble

not a

vaila

ble

..lin

e-up

term

inal

s(R

AC

2/R

AC

3)

dto.

not a

vaila

ble

not a

vaila

ble

..sta

y bo

lt M

10

M10

IN26

7..l

ine-

up te

rmin

als

(RA

C2/

RA

C3)

not a

vaila

ble

not a

vaila

ble

IN20

7/IN

407

IN21

0/25

IN17

2/25

dto.

..sta

y bo

lt M

8

M8

IKL1

69/IK

F16

9*)

..lin

e-up

term

inal

s(R

AC

2/R

AC

3)25

1MB

240H

-4B

...16

(PG

29)

IN20

6/IN

406

IN21

0/16

IN17

2/16

dto.

IKL1

49/IK

F14

9*)

..sta

y bo

lt M

8

M8

..lin

e-up

term

inal

s(R

AC

2/R

AC

3)


Figure 2.33: Table of assembled specifications for connections using plugtesting points in 1MB motors - Section 3.

ALK

AB

15

Pow

er p

lug

conn

ecto

r (p

lug)

Sym

bols

:

Wire

-end

fe

rrul

eC

rimpi

ngca

ble

lug

Fla

nge

conn

ectio

n

Pow

er p

lug

conn

ecto

r (c

oupl

ing)

PG

scr

ew c

onne

ctio

n

*) A

vaila

ble.

For

inqu

iries

on

type

info

rmat

ion

cont

act D

evel

opm

ent D

ept.,

IND

RA

MA

T.

Cab

lecr

oss

sect

ion

A[m

m2 ]

Ass

embl

ed c

able

for

plug

in

test

ing

poin

ts

on th

e m

otor

fle

x. /h

ighl

y fle

x.on

the

cont

rolle

r fle

x. /h

ochf

lex.

on th

e m

otor

Cab

lefle

x. /h

ochf

lex.

Plu

g te

stin

g po

int

L.on

the

cont

rolle

r

Com

pone

nts

of th

e as

sem

bled

cab

le w

ith p

lugi

n te

stin

g po

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..lin

e-up

term

inal

s(R

AC

2/R

AC

3)

..Scr

ews

M12

(RA

C4)

1MB

375B

-6B

...

(PG

)

1MB

375D

-6B

...(P

G

)

For

..F

or..

For

..F

or..

Sec

tion

3: 1

MB

pow

er c

onne

ctio

ns -

plu

gin

test

ing

poin

ts



Cable Type Cable cross Cable Construction Diameter Bending Radius WeightSection in mm in mm in kg/min mm2 fixed flexible

IN 203 4 4x4,0 + 2x(2x1,5)StC mm2 18,5 ± 1,0 120 270 0,570

IN 204 6 4x6,0 + 2x(2x1,5)StC mm2 18,0 ± 1,0 120 300 0,670

IN 205 10 4x10,0 + 2x(2x1,5)StC mm2 26,0 ± 1,0 200 380 1,100

IN 206 16 4x16,0 + 2x(2x1,5)StC mm2 26,0 ± 1,0 220 390 1,330

IN 207 25 4x25,0 + 2x(2x1,5)StC mm2 28,5 ± 1,0 240 430 1,700

IN 267 35 4x35,0 + 2x(2x1,5)StC mm2 32,0 ± 1,0 150 250 2,170

IN 403 4 4x4,0 + (2x0,75)StC + 15,5 ± 1,0 95 160 0,373 (2x1,0)StC mm2

IN 404 6 4x6,0 + (2x0,75)StC + 18,0 ± 1,0 105 175 0,500 (2x1,0)StC mm2

IN 405 10 4x10,0 + (2x0,75)StC + 21,5 ± 1,0 130 220 0,740 (2x1,0)StC mm2

IN 406 16 4x16,0 + 2x(2x1,0)StC mm2 25,0 ± 1,0 150 250 1,100

IN 407 25 4x25,0 + (2x0,75)StC mm2 26,0 ± 1,0 140 200 0,500

Figure 2.34: Cable specifications for power connections


2.1.4. Cable Specifications


2.2. Power connections of theRAC three-phase mains

The power connections between the RAC main spindle controller andthe three-phase mains are arranged in ...

Section 2.2.1: Three-phase mains requirements for direct connectionof RAC controllers to

– grounded three-phase mains, and,

– ungrounded three-phase mains.

Section 2.2.2: Connecting diagrams for

– grounded three-phase mains, and,

– ungrounded three-phase mains.

Section 2.2.3: Tabulated specifications of connecting components,such as,

– required connection cross sections,

– fuses for cable protection,

– power transformers, if needed,

– surge protector type designations, if needed,

– design of connections on the controller.

The power connections of the RAC controller three-phase mains aregenerally internal control cabinet cables which are, for the sake ofexpediency, constructed with single strands. Motor connectioncables from INDRAMAT can, however, also be used.


Types


Dependent upon the „AC supply voltage“ option, the following mainsvoltages are permissible for RAC controllers:

Figure 2.35: Permissible mains voltage for RAC controllers.

Voltage at the RAC should not be permitted to periodically exceed1000 V (peak value) between the outer wire (terminal L1, L2, L3) andthe housing!

Non-periodic overvoltages between the outer wire and housing aretolerable for RAC controllers, if these are in accordance with VDE0160 (see Fig. 2.36)!

Type key field no. 5, Voltage permitted „Rated connection voltage“ for.. at X14/L1,L2,L3 ..RAC2.2 ..RAC 4.1 ..RAC 3.1

380 / 3xAC 400V, -15%/+10%, 50..60 Hz

3xAC 400V, -15%/+15%, 50 Hz460 460 / 3xAC 460V, -10%/+10%, 60 Hz

/ 460 3xAC 380 ... 460V/ ±10%, 50..60 Hz

Type key field no. 11, Voltage permitted„Rated connection voltage at X14/L,Nfor control electronics.“Only in RAC 3.1

220 AC 220V, ±10%, 50..60 Hz, 200VA

2.2.1. Three-Phase MainsRequirements

Permissible mains voltage

Non-periodic overvoltage

Periodic voltages

0,1 0,2 0,4 0,6 1 1,3 2 4 6 10 20T (ms)

T

UN+∆U

UN

3

2,6

2,42,32,2

2

1,8

1,6

1,4

1,21,151,11

UN

∆U

∆U 2

Figure 2.36: Non-periodic overvoltages as per VDE 0160.



Grounded Three-Phase Mains

The peak value of the rated voltage equals UN = 460V* square root

of 2=650V. Maximum tolerable, non-periodic voltage peak equals1500 V for T<1.3 ms.

RAC controllers can be directly connected to Wye-point and three-phase mains grounded on the outer wire. Should the mains voltagenot agree with the RAC rated connection voltage, then anautotransformer is needed to equalize the voltage (see Figure 2.37)!

Ungrounded Three-Phase Mains Ungrounded three-phase mains run increased danger of unsafeovervoltages occurring between the outer wire and the housing. RACcontrollers can only be operated on these mains

– if the drive is connected via an isolating transformer, or,

– if surge arresters safeguard the facility.

The RAC controller is most protected against damage from overvoltagewhen it is connected via an isolating transformer. The drive operateswith the greatest possible safety. The use of an isolating transformeris recommended in that case where an ungrounded three-phasemains also requires voltage to be matched to the permissible connec-tion voltage of the unit (see Figure 2.38).

RAC controllers may only then be operated with ungrounded three-phase mains if the facility is secured with a surge arrester. Anautotransformer can be used in the event that voltage must bematched to the permissible rated connection voltage of the unit.

The recommended surge arrester safeguards upto a leakage currentof l2t=750A2s. For thermal reasons, greater leakage currents evokea response from the signal contact of the surge arrester.

The signal contact expediently triggers the separation of the machinefrom the mains (see Figure 2.39). Should this not be possible, thenthe signal contact is switched into the control system of the mainscontactor of the RAC (see Figure 2.40).

The operational safety of the drives is greater if an isolating trans-former is used, than if a surge arrester is used. The initial expensewith larger loads is, however, significantly smaller. The surge arrest-ers are destroyed after one use and must be exchanged!


Connection via anIsolating Transformer

Surge Arresters as Safeguards


Figure 2.37: Connecting RAC2, RAC3 and RAC4 to a grounded three-phase mains.

L1 L2 L3L3

RAC2, RAC4

Permissible voltages see Sec. 2.2.1, "Three-Phase Mains Requirements"

For information on connection cross sections, rated fuse currents and transformers (if needed), see Sec. 2.2.3, "List of Connecting Components Specifications".

X14

L1

L2

L3

PE

L1 L2 L3L3

RAC3

X14

APRAC001

Does not apply if voltage matching not needed!

TT-Mains

L N

Does not apply to AC 220 V!

0,75

...2,

5mm

2

0,75

...2,

5mm

2

F1 F1 200VA220V ±10%50...60Hz

An earth leakage circuit breaker (FI) should not be built intothe RAC controllers!

Figure 2.38: Connecting RAC2, RAC3 and RAC4 to an ungrounded three-phasemains using an isolating transformer.

Ungrounded Three-Phase Mains

L1 L2 L3L3

RAC2, RAC4

X14

L1

L2

L3

L1 L2 L3L3

RAC3

X14

APRAC002

IT-Mains

L N


0,75

...2,

5mm

2

0,75

...2,

5mm

2

F1F1

Ungrounded Three-Phase Mains

N

Permissible voltages see Sec. 2.2.1, "Three-Phase Mains Requirements"


200VA220V ±10%50...60Hz


2.2.2. Connection Plans

Grounded Three-Phase Mains


L1 L2 L3L3

RAC2, RAC4


X14

L1

L2

L3

L1 L2 L3L3

RAC3

APRAC003

IT-Mains

L N


0,75

...2,

5mm

2

0,75

...2,

5mm

2

Remote control

F2

X14

F1F1

F3

F2

Control cabinet - earth potential.

Machine master switch

Does not apply if voltage matching not

needed! Permissible voltage see Sec. 2.2.1, "Three-Phase Mains Requirements"

200VA220V ±10%50...60Hz

Figure 2.39: Connecting RAC2, RAC3 and RAC4 to ungrounded three-phasemains, actuation of surge arrester triggers mains separation.



L1 L2 L3

RAC2, RAC4


X14

L1

L2

L3

L1 L2 L3

RAC3

APRAC004

IT-Mains

L N

Does not apply toAC 220 V!

0,75

...2,

5mm

2

0,75

...2,

5mm

2

X14

F1F1

F3

F2

Control cabinet -earth potential

Does not apply if voltage matching not

needed!

43X15

OF

F

Control

43X15

OF

F

Permissible voltage, see Sec. 2.2.1, "Three-Phase Mains Requirements".

Relay Relay Relay Relay

Control

Response from F2triggers break.

F2

200VA220V ±10%50...60Hz

For thermal reasons, the surge arresters disconnect at l2t=750A2s(30s at 5A) once they are actuated (leakage current). They are thenno longer functional and must be exchanged!

Figure 2.40: Connecting RAC2, RAC3 and RAC4 to ungrounded three-phasemains, actuation of surge arrester triggers release of mains contactor in theRAC.

An earth leakage circuit breaker (Fl) must not be built into theRAC controller!



Main spindle PRated

IMains RAC

Fuse Cable cross motor in kW in A F1, Type section in mm2

2AD132B-...-DS 10 191MB200E-4B-... 11 21 3xNH25gl 41MB240F-4B-... 11 26

2AD132C-..-CS 15 291MB240H-4B-... 15 291MB241H-6D-... 16 30 3xNH35gl 61MB200D-4D-... 19 361MB310B-6B-... 19 36

1MB200H-4B-... 19,5 371MB312B-4A-... 20 382AD132D-...-AS 22 42 3xNH50gl 101MB310D-6B-... 25 481MB312C-4A-... 25 48

2AD160B-...-BS 30 57 3xNH63gl 161MB310F-6B-... 35 66

2AD160C-...-BS 37 70 3xNM80gl 251MB375B-6B-... 40 76

2AD180C-...-BS 52 99 3xNH100gl 351MB375B-6B-... 55 105

2AD180D-...-BS 63 120 3xNH125gl 50

2AD200C-...-AS 79 150 3xNH160gl 2x25

2AD225C-...-AS 93 176 3xNH200gl 2x35

2.2.3. Connecting Compo-nents Data List

The dimensions of the mains fuse and the mains connection cableare dependent upon the rated output of the main spindle motoroperated on the RAC controller.

If the rated output of the main spindle motor is fully utilized during aprocessing cycle, then the following values are achieved:

Figure 2.41: Mains connection specifications with rated service of main spindlemotors, or frameless spindle motors (valid for 3 x AC 380 V ... 3 X AC 460 V).

Appropriate circuit breakers can be used instead of NH-fuses!


Connection cross section,type of fuse


Should the rated power of the main spindle motor not be completelyutilized during the duty cycle, including acceleration and braking, thenthe RAC mains connection can be engineered lower. The minimumvalues for the connecting components must, however, be adhered to!Wiring and overload problems could occcur (with load peak current),if these minimum values are not achieved!

Controller Type Min. Fuse Min. conductor CrossF1, Type Section in mm2

RAC3.1-100-... 3xNH25gl 4

RAC3.1-150-... 3xNH35gl 6

RAC2.2-200-... 3xNH50gl 10

RAC2.2-250-... 3xNH63gl 16

RAC4.1-300-... 3xNH80gl 25

RAC4.1-400-... 3xNH25gl 25

Figure 2.42: Minimum values of the connecting components

(Formula applies to 3 x AC 380 V ... 3 x AC 460 V).

Using the load capacity table in Fig. 1.7, the calculated mains current,lmainsRAC, is allocated to a cable cross section. The selected crosssection and its corresponding fuse must not fall short of the minimumvalues listed in Figure 2.42!

The output, Smains, of a possibly needed autotransformer, corre-sponds to the rated output, or the actually required continuous outputof the main spindle motor. The inductive components of the relativeshort-circuit voltage, Ukx, must be smaller than 4%!

SMains = √3*UX14/L1-L2*IMainsRAC

UX14/L1-L2

= Voltage at the RAC mains connection terminals(most favorable value: 3 x AC 400 V)

IMainsRAC (see formula above)

UKX1 = Prim. short-circuit voltage in V, inductive componentURated1= Rated voltage of the transformer in V, primary

IMainsRAC =1,9*PCont.Motor *A/kW

PCont.Motor= continuous output (kw) actuallyrequired of the motor

uKX = UKX1/URated1*100%


Sizing the Autotransformer


Controller Type Minimum Output SMains (kVA)

RAC3.1-100-... 25

RAC3.1-150-... 40

RAC2.2-200-... 50

RAC2.2-250-... 65

RAC4.1-300-... 80

RAC4.1-400-... 100

Sizing the Isolating Transformer

Figure 2.43: Minimum transformer output if the RAC controller is connected via ian isolating transformer.

The already stated formulae are used to calculate the mains current,ImainsRAC

, and the mains connection output, Smains

, of the main spindlemotor:

(Formula valid for 3 x AC 380 V ... 3 x AC 460 V.)

Pcont.Motor= continuous output (kw) actuallydemanded of motor

ImainsRAC =1,9*Pcont.Motor *A/kW

Smains = √3*UX14/L1-L2*ImainsRAC

UX14/L1-L2 = Voltage at mains connection terminals of RAC (most favorable value: 3 x AC 400 V)

ImainsRAC

(see above formula)


The output, Smains, of an isolating transformer, if needed, also de-pends upon the rated output, or the actual continuous output requiredof the main spindle motor.

The stray inductance of an isolating transformer is significantly higherthan that of an autotransformer. Depending upon the type of RAC, theminimum transformer output of the isolating transformer must, as aresult, achieve the minimum value! The inductive component of therelative short-circuit voltage, U

kx, must be smaller than 4%!


Controller Type Fuse F3 Surge arresterType F2, Type

RAC3.1-100-... ---

RAC3.1-150-... --- VM 500 FM

RAC2.2-200-... ---

RAC2.2-250-... 3x100Agl (Manufactured

RAC4.1-300-... 3x100Agl by DEHN)

RAC4.1-400-... 3x100Agl

Overvoltage Protectors

Figure 2.44: Specifications for surge arresters in an ungrounded three-phasemains.

on the mains cable on the controller

Multi-core cable end forline-up terminals (RAC2/RAC3)

Compression cable shoes forscrews M12 (RAC4)

Netzan1

Figure 2.45: Mains connection cable for RAC controllers.


Controller Lay-Out


3. Feedback andCNC Connections

Signal exchange with the CNC control takes place via the CNCconnections; feedback of position or speed of the motor shaft and thespindle to the main spindle controller via the feedback connections.

The Section on feedback and CNC connections is broken down into

Section 3.1: Division of the types of connections

– direct connection

– connection with link terminal



Section 3.2: Connection diagrams for the direct connection of

– CNC control and controller

– feedback and controller for all standard interfaces and optionalinterfaces

Section 3.3: Specifications table of the assembled cables for

– direct connection and connections using link terminals



Section 3.4: Specifications table for cables, such as,

– type designation

– conductor cross sections and cable construction

– cable diameter

– inflection radii, and,

– length-related weight

3. Feedback and CNC Connections


3.1. Types of feedback andCNC connections

There are four types of assembled feedback and CNC connections.

Figure 3.1: Four types of assembled feedback and CNC connections

This type of connection is characterized by the lowest number ofimperfections in comparison to other connection types.

Figure 3.2: Assembled cables for direct connections (also see figure 3.22).


direct with intermediate terminal with plug with plugin on terminal strip design testing points

Types of Feedback and CNCConnection

Direct connection

Plug connector(plug)for feedback connection,elbow type

Symbols:

Multi-corecable end

Wall breakthrough

on the controller Cable feedback side

CNC side

XXkab01

D-sub-plug connector

Plug connector(plug)for feedback connection, straight type


This type of connection permits an easy diagnosis of the signalexchange to the CNC control at the intermediate terminal points.

Intermediate terminals in feedback connections with incrementalencoder are not to be recommended because of increased sensitivityto interference! Intermediate terminals are not permitted with high-resolution motor and spindle feedback!

Figure 3.3: Assembled cables for intermediate terminals on the terminal strip(also see Figure 3.22).

The control cabinet can be finished entirely independent of themachine with this type of connection. The melding of machine andcontrol cabinet is quick and simple.

In addition, damaged cables on the outside of the control cabinet canbe quickly and safely exchanged.

Figure 3.4: Assembled cables for plug design (also see Figure 3.23).

Connection withIntermediate Terminals

Connection with plug design

on the controller cable Plug design cable feedback side

XXkab03

CNC side

Plug connector (plug)for feedback connection,elbow type

Symbols:

Multi-corecable ends

Wall breakthrough


Plug connector (plug)for feedback connection,straight type

on the controller cable terminal strip cable feedback side

XXkab02

CNC side

Plug connector (plug) for feedback connection, elbow type

Symbols:

Multi-corecable ends

Wall breakthrough


Plug connector (plug) for feedback connection, straight type



Connection withplugin testing point

This type of connection is advantageous with larger facilities as it ispossible to quickly and safely exchange a damaged section.

The mounting of assembled cables of this type of connection isparticularly simple and quick.

Figure 3.5: Assembled cable with plugin testing points (also see Figure 3.24)

on the controller cable Plugin testing point cable feedback side

XXkab04

CNC side

Plug connector (coupling)for feedbackconnection

Plug connector (plug)for feedback connection,elbow type

Symbols:

Multi-corecable end


Plug connector (plug)for feedback connection,straight type



3.2. Connecting plans fordirect connections

Standard interfacesand optional interfaces


Only the connection plans for the direct connection of feedback andCNC connections are depicted. They do, however, apply to all othertypes of connections. The respective testing points do not alter theallocation of the connections for feedback or CNC control and mainspindle controller.

The connection plans are to be used to develop the plant connectiondiagrams. The plant connection diagrams of the machine manufac-turer are to be used when wiring the plant!

Main spindle controllers are always equipped with motor feedbackconnection (X3, standard) and control input, signal and analogueoutputs (X2, standard). The controllers can optionally be equippedwith additional feedback and CNC interfaces.

The optional interfaces are listed in the type designations of thecontroller to be mounted. The type key is listed in the documentationabout main spindle controllers - „Project Planning Notes“.


3.2.1. Motor feedback,high-resolution

Figure 3.6: Connection plan for high-resolution motor feedback (standard)

0

SBDSUB7

X3

cable IN 209(Color coded as per INDRAMAT standards)

D-Sub-plug connector (15 way)IN 290

Controller

2

11

13

14

15

pk

gr

br

gn

0,25 mm2

0,25 mm2

0,25 mm2

0,25 mm2

0ref

B

Bref

Aref

A7

9

12

10

+ 5Vint

0Vint

1

2

3

4

5

6

9

7

8

Motor feedbackhigh-resolution

(insulated sensor attachment)

vio

bl

0,25 mm2

0,25 mm2

wh

br

1 mm2

1 mm2

plug connector (9 way)IN 401

assembled cable IKS 032

assembled cable IKS 315/..52

2661

47

45

plug connector (9 way)IN 309

IKS 315

The high-resolution motor feedback cable must not be fedover a terminal strip due to sensitivity to interference!


IKS315


0

X1

cabl

e IN

209

(col

or c

oded

as

per

IND

RA

MA

T s

tand

ards

)D

-sub

-plu

g co

nnec

tor

(15

pole

s)IN

290 2 11 13 14 15

pk gr brgn

0,25

mm

2

0,25

mm

2

0,25

mm

2

0,25

mm

2

0ref

B Bre

f

Are

f

A7 9 12 10

+ 5

Vin

t

0Vin

t

1 2 3 4 5 6 9 7 8

Mot

or fe

edba

ck

high

-reso

lutio

n (in

sula

ted

sens

or a

ttach

men

t)

vio

bl

0,25

mm

2

0,25

mm

2

wh

br

1 m

m2

1 m

m2

Plu

g co

nnec

tor

(9 w

ay)

IN 4

01

Ass

embl

ed c

able

IKS

315

/..52

26

45

grpkrdbkbngn

wh

bn

""""

0,25 mm2BB00AA

cabl

e IN

209

(col

or c

odin

g as

per

IND

RA

MA

T

stan

dard

s)

813456

910

12

0V

+ 5V

"

1 mm2

70Preassembled cable IKS 618

1 mm2

D-s

ub-p

lug

conn

ecto

r (1

5 w

ay)

IN 2

89

X3

0

X3

cabl

e IN

209

(col

or c

oded

as

per

IND

RA

MA

T s

tand

ards

)D

-sub

-plu

g co

nnec

tor

(15

way

)IN

290

Con

trol

ler

2 11 13 14 15

pk gr brgn

0,25

mm

2

0,25

mm

2

0,25

mm

2

0,25

mm

2

0ref

B Bre

f

Are

f

A7 9 12 10

+ 5

Vin

t

0Vin

t

vio

bl

0,25

mm

2

0,25

mm

2

wh

br

1 m

m2

1 m

m2

Plu

g co

nnec

tor

(15

way

)IN

289

Ass

embl

ed c

able

IKS

617

/..

45

grpkrdbkbngn

wh

bn

""""

0,25 mm2BB00AA

813456

910

12

0V

+ 5V

"

1 mm2

1 mm2

X4

2 11 13 14 157 9 12 10

0 0ref

B Bre

f

Are

f

A + 5

Vin

t

0Vin

t

X2

(mot

or ty

pe k

ey fi

eld

"mot

or fe

edba

ck =

3")

(The

out

puts

A A

, B B

, and

0 0

of X

3 an

d X

4

have

bee

n D

C-d

ecou

pled

from

the

cont

rolle

r!)

HG

V 1

45

45

512

cycl

es (

)10

24 c

ycle

s (

)

Voltage supply for A A, B B, 0 0see **)


45

HG

V1_

1

see *)

*) Gro

und

shie

ld o

nly

on o

ne e

nd o

f

set-

poin

t lin

e. If

pos

sibl

e, a

t vol

tage

sour

ce.

**)

Con

nect

the

+5V

sup

ply

only

onc

e

if bo

th in

crem

enta

l enc

oder

out

puts

(X3

and

X4)

are

con

nect

ed!

see *)

Figure 3.7: HGV1 connection plan switched into the high-resolution motorfeedback cable.



0

SBDSU1

X3

Cable IN 209(color coded as perINDRAMAT standards)

D-sub-plug connector (15 way)IN 290

Controller

3

4

8

1

6

rd

bk

pk

gr

0,25 mm2

0,25 mm2

0,25 mm2

0,25 mm2

0

B

B

A

A5

9

12

10

+ 5Vint

0Vint

3

4

8

1

5

6

9

12

10

Motor feedback incremental encoder(insulated attachment)

gn

br

0,25 mm2

0,25 mm2

wh

br

1 mm2

1 mm2

Plug connector (12 way)IN 301

Assembled cable IKS 331/..52

26

45

1

IKS 331


3.2.2. Motor feedback, incre-mental encoder

Figure 3.8: Connection plan for incremental encoder motor feedback (motor typekey field „motor feedback = 1“).

IKS 317


3.2.3. Spindle Feedback,high-resolution

IKS 314

0

SBDSU3

X5


D-sub plug connector (15 way)IN 289

Controller

3

4

8

1

6

rd

bk

pk

gr

0,25 mm2

0,25 mm2

0,25 mm2

0,25 mm2

0

B

B

A

A5

9

12

10

+ 5Vint

0Vint

3

4

8

1

5

6

9

12

10

Spindle feedback incremental encoder(insulated sensor attachment)

gn

br

0,25 mm2

0,25 mm2

wh

br

1 mm2

1 mm2



26

61

47

45


1

The cable to the high-resolution spindle feedback must notbe fed over a terminal strip because of sensitivity tointerference!


Figure 3.9: Connection plan for high-resolution main spindle position encoder asspindle feedback (controller with „additional encoder input = P“ option).

IKS314


Figure 3.10: HGV1 connection plan switched into the high-resolution mainspindle position encoder cable.

0

X2

Cab

le IN

209

(col

or c

oded

as

per

IND

RA

MA

T s

tand

ards

)D

-sub

-plu

g co

nnec

tor

(15

way

)IN

289 2 11 13 14 15

0,25

mm

2

0,25

mm

2

0,25

mm

2

0,25

mm

2

0 ref

B Bre

f

Are

f

A7 9 12 10

+ 5

Vin

t

0Vin

t

1 2 3 4 5 6 9 7 8

Spi

ndle

feed

back

hi

gh-r

esol

utio

n (in

sula

ted

sens

or a

ttach

men

t)

0,25

mm

2

0,25

mm

2

1 m

m2

1 m

m2

Plu

g co

nnec

tor

(9 w

ay)

IN 4

01

Ass

embl

ed c

able

IKS

314

/..52

26

45

1

pk gr brgn vio

bl wh

br

0

X2

Cab

le IN

209

(col

or c

oded

as

per

IND

RA

MA

T s

tand

ards

)D

-sub

-plu

g co

nnec

tor

(15

way

)IN

289 2 11 13 14 15

0,25

mm

2

0,25

mm

2

0,25

mm

2

0,25

mm

2

0 ref

B Bre

f

Are

f

A7 9 12 10

+ 5

Vin

t

0Vin

t

0,25

mm

2

0,25

mm

2

1 m

m2

1 m

m2

Plu

g co

nnec

tor

(15

way

)IN

290

Ass

embl

ed c

able

IKS

049

/..

45

1

pk gr brgn vio

bl wh

br

45

1

X1 2 11 13 14 157 9 12 10

0 0 ref

B Bre

f

Are

f

A + 5

Vin

t

0Vin

t

D-s

ub-p

lug

conn

ecto

r (1

5 w

ay)

IN 2

89

grpkrdbkbngn

wh

bn

""""

0,25 mm2BB00AA

Line

IN 2

09(c

olor

cod

ed a

cc.

to IN

DR

AM

AT

st

anda

rds)

813456

910

12

0V

+ 5V

"

1 mm2

70Preassembled cable IKS 618

1 mm2

grpkrdbkbngn

wh

bn

""""

0,25 mm2BB00AA

813456

910

12

0V

+ 5V

"

1 mm2

1 mm2

X3

X4

(The

out

puts

A A

, B B

, and

0 0

of X

3 an

d X

4 ar

e

CD

-dec

oupl

ed fr

om th

e co

ntro

ller)

512

or 1

024

cycl

es (

)

1024

or

2048

cycl

es (

)



HG

V 1

HG

V1_

2

45

1

Gro

und

shie

ld o

nly

on o

ne e

nd o

f

set-

poin

t lin

e. If

pos

sibl

e, a

t vol

tage

sour

ce.

**)

Con

nect

the

+5V

sup

ply

only

onc

e

if bo

th in

crem

enta

l enc

oder

out

puts

(X3

and

X4)

are

con

nect

ed!

see *)

see *)



0

SBDSU3

X5



Controller

3

4

8

1

6

rd

bk

pk

gr

0,25 mm2

0,25 mm2

0,25 mm2

0,25 mm2

0

B

B

A

A5

9

12

10

+ 5Vint

0Vint

3

4

8

1

5

6

9

12

10

Spindle feedback incremental encoder(insulated sensor attachment)

gn

br

0,25 mm2

0,25 mm2

wh

br

1 mm2

1 mm2



26

6147

45


1

IKS 327

3.2.4. Spindle Feedback,incremental encoder


Figure 3.11: Connection plan for incremental encoder in the capacity of spindlefeedback (controller with „additional encoder input = P“ option).

IKS327


3.2.5. Lead Spindle Feedback

0

SBDSU2

X5a



Controller

3

4

8

1

6

rd

bk

pk

gr

0,25 mm2

0,25 mm2

0,25 mm2

0,25 mm2

0

B

B

A

A5

9

12

10

+ 5Vint

0Vint

3

4

8

1

5

6

9

12

10

Lead spindle feedbackincremental encoder(insulated sensor attachment)

gn

br

0,25 mm2

0,25 mm2

wh

br

1 mm2

1 mm2



2661

47

45


1

Figure 3.12: Connection plan for incremental encoder in the capacity of leadspindle feedback (controller with „additional encoder input = Y“ option).

Controllers with the „additional encoder input = Y“ areequipped with interfaces X5a and X5. This is necessarybecause spindle synchronization requires, in addition toposition information about the lead spindle, a direct positionmeasuring system (spindle feedback) at the spindle to besynchronized as well!

IKS 331



3.2.6. Control input, signaland analogue outputs,Bb-contact

grwhbnye/blckyelgn/bkrdblrdbkviogr/pkbl/rdwh/gn

(see below!)

wh/yegnye/bnwh/grgr/bnwh/pkpk/bnwh/blbn/blwh/pkbn/rdwh/bkbn/bkgr/gnyel/grgn/rdpk/gnye/pkgn/blyel/bl

0,5 mm20,25 mm2

"""""""""""""

"""""""""""""""""

0,25 mm2

0,5 mm2

0,25 mm20V ext0V intAS (KDA/TDA only)READYN = CMDN < MININ POS90% LOADTEMPWARNLIMITSPEED CHANGE 1SPEED CHANGE 2LOAD LIMITRF SLAVESPINDLE CONT

24V int24V extAnalogue output MAnalogue output N0V int

RFRUNPOS 1POS 2MD-REDOSCILLATEPAR 1PAR 2LIMIT 1LIMIT 2LIMIT 4SPEED 1SPEED 2EXT POS

SBDSUB1

BbBb

X11 KDA/TDAX15 RAC

Bb-contact24V, 1A

X2

2 way plug terminalin KDA/TDA,found in E••-•DA10 way plug terminalin RAC (also see Fig. 3.18),found in E1-RAC



45200

Assembled cable IKS 610/..

123456789101112131415

18

17

19202122232425262728293031323334353637

1

E-STOP (RAC only)

Voltage level input

+36 V

+24 V

+18 V

0 V

+5 V

0 (low) 1 (high)

Voltage level output

+36 V

+24 V

+18 V

0 V

+5 V

0 (low) 1 (high)

Voltage level for 24 Vext

+36 V

+18 V

Voltage supplyfrom the control

U

t

IKS 610


Figure 3.13: Connection plan for control input, signal and analogue outputs, Bb-contact (standard).

IKS610


E1

SBDSUB6

X4

Cable IN 233(color coded asper INDRAMAT standards)


Controller

1

2

5

6

4

9

8

7

bn

wh

yel

gn

0,22 mm2

0,22 mm2

0,22 mm2

0,22 mm2 *)

*)

*) Internal shielding can be dropped if INDRAMAT cables are not used!

E2

E3

E4

+15VM

- 15VM

45

70Assembled cable IKS 045/..

1

(see below!)

+15 V

-15 V

Voltage levelanalogue inputs

The control and signal outputs are DC-decoupled from the controller.The control must supply the outputs with *24V/0 V. Should this notbe possible, then connect terminal 1 with 2 and 18 with 19!

Ground the shield only on one end of the cable. If possible,at voltage source.

3.2.7. Speed set-point,analogue +/- 10V

Figure 3.14: Connection plan for analogue speed set-point(„speed set-point=A“ option)

Inputs E1/E2 and E3/E4 for the analogue set-point are designed asdifferential inputs.

IKS 045

Ground the shield only on one end of the set-point cable. Ifpossible, at voltage source!

Do not directly connect a contactor coil via the relay contactBb, as the high intermittent currents caused by frequentswitching could overload the relay contact and cause it tofail.


IKS045


whbngnyelgrpk

blrdbkviowh/bnwh/gnwh/yelwh/gr

wh/rdwh/bk

bn/gnbn/yel

"""""""""""""

""

0,25 mm2 Bit 1

-15 V int (max. 150 mA)+15 V int (max. 150 mA)

0V ext0V ext

SBDSUB3

X4

Cable 20x0,25(color coded as perINDRAMAT standards)


"

wh/pkwh/bl "

""

Controller

Bit 2Bit 3Bit 4Bit 5Bit 6Bit 7Bit 8Bit 9Bit 10Bit 11Bit 12Bit 13Bit 14Bit 15DATA VALID

45

200Assembled cable IKS 612

12345678910111213141516

1819

2122

25

1

Voltage level

+36 V

+24 V

+18 V

0 V

+5 V

0 (low) 1 (high)

(see below!)

3.2.8. Speed set-point, digital,16 bit parallel

Ground shield only at one end of the cable. If possible, atvoltage source!

Figure 3.15: Connection plan for digital speed set-points(„speed set-point=D“ option)

IKS 612


The inputs for the digital speed set-point (bit 1 ... bit 15, DATA VALID)are DC-decoupled from the controller. Terminal 21 should be con-nected to the OV potential of the control! The inputs are then set withthe +24V potential of the control! If the control does not supply *24V/0, then connect terminal 18 with 21 and set the inputs via terminal 19!Current consumption approx. 15mA per input!

IKS612


3.2.9. SERCOS Interface

APSerc

Controller

Electrical output

Location of plug connector strip X4

Receiver diodeFiber optic cable from the control or additional controllers

Electrical input

Driver controlFiber optic cable

to the control or additional controllers

IC 1

IC 2

LED (red)

LED (green)

Transmitter diode

Figure 3.16: SERCOS interface connection plan („speed set-point=L“ option)

For specifications on assembled fiber optic cables, attenuation calcu-lations, for specifications on constructing custom cables see doc. no.209.0090-4101, „LWL Handling; description of application“.

Additional fiber optic cablespecifications



3.2.10. Position set-point,digital, 16 bit parallel

Figure 3.17: Connection plan for digital position set-point(„additional interface=D“ option)

whbngnyegrpk

blrdblckviowh/bnwh/gnwh/yewh/gr

wh/rtwh/sw

bn/gnbn/ye

"""""""""""""

""

0,25 mm2 Bit 1

-15 V int (max. 150 mA)+15 V int (max. 150 mA)

0V ext0V ext

SBDSUB2

X6 KDA/TDAX13 RAC

Cable 20x0,25(color coding as perINDRAMAT standards)


"

wh/rswh/bl "

""

Controller

Bit 2Bit 3Bit 4Bit 5Bit 6Bit 7Bit 8Bit 9Bit 10Bit 11Bit 12Bit 13Bit 14Bit 15DATA VALID

200

Assembled cable IKS 612

200


Cable 20x0,25

4545 In KDA/TDA

In RAC


12345678910111213141516

1819

2122

25

Voltage level

+36 V

+24 V

+18 V

0 V

+5 V

0 (low) 1 (high)

(see below!)

1

Ground shield only at one end of cable. If possible, at voltagesource!

IKS 614


IKS614


Ground shield only at end of cable. If possible, at voltagesource!

Figure 3.18: Connection plans for serial interfaces („additional interface=S“option)

TxD

SBDSUB4

X6 KDA/TDAX13 RAC

Cable IN 234(color coding as perINDRAMAT standards)


Controller

12345

7

RxDRTSCTS

GND

TxD

Programming equipment,PC, or something similar

1234567

20

RxDRTSCTSDSR

DTR


whbngnye

gr

0,25 mm2

0,25 mm2

0,25 mm2

0,25 mm2

0,50 mm2

*)

*)

*) Internal shielding can be dropped if INDRAMAT cables are not used!


45

In RAC


45

In KDA/TDA



Cable IN 234

1

RS 232C

GND

IKS 015IKS 016

3.2.11. Serial interfaceRS 232C


The digital position set-point inputs (bit 1 ... bit 15, DATA VALID) areDC-decoupled from the controller. Terminal 21 should be connectedto the OV potential of the control! The inputs are set with the +24Vpotential of the control! If the control does not supply +24V/0 V, thenconnect terminal 18 with 21 and the inputs via terminal 19! Currentconsumption is approx. 15 mA per input!

IKS015/IKS016


3.2.12. Incremental encoderoutput

Outputs AA, BB and OO are DC-decoupled from the controller. TheCNC control must supply them with +5V/0.

grpkrdblckbngn

wh

bn

""""

0,25 mm2 BB00AA

SBDSUB5

12

X17

X6 KDA/TDAX13 RAC

Plug terminal 3 way,mat. no.: 220 856

Cable IN 209(color coded as per INDRAMAT standards)


813456

910

12

0V

+ 5V

"

1 mm2

70

45 In RAC

In TDA/KDA

45

70Assembled cable IKS 620


Line IN 209


3

Controller

(This is not available as an assembled cable!)

1 mm2

1

(see below!)

Reference switch

Voltage level outputs

+5 V

+1,8 V

0 V

+0,5 V

0 (low) 1 (high)

Voltage levelfor +5V supply

+5 V

+4,75 V

0 V

U+5,25 V

Ground shield only at end of cable. If possible, at voltagesource!

IKS 620IKS 618


Figure 3.19: Connection plan for incremental encoder output and referenceswitch signal („additional interface=l“ option)

IKS618/IKS620


3.2.13. Control of the mainscontactor integrated into theRAC controller

APRACKON

2

Plug terminal, contained in elec. connecting accessories E1-RAC

1

RAC Controller

4

3

6

5

8

7

10

9

X15

ON

OFF

Bb

CS

(Mains contactor K1 opener)

OFFMains contactor

ONMains contactor

Ready

Mains contactor monitoring

(open = set up possible)

+ 24V, 1Afor ext. use

Control

(max. 24V, 1A

intermittent and

continuous)

The controller-internal mains contactor should not be usedto regularly shutdown the drives! It should only be activatedwith standing drive and controller enabler shut off!


Figure 3.20: Connection plan for control of the mains contactor integrated intothe RAC controller.

Do not directly connect a contactor coil via the relay contactBb, as the high intermittent currents caused by frequentswitching could overload the relay contact and cause it tofail.


3.3. Assembled Cable Specifi-cations

Specifications of the assembled cables for the four types of connec-tions is dependent upon the functional options of the main spindlecontroller and are summarized in tables.

Figure 3.21: Four types of assembled feedback and CNC connections

The tables indicate both the assembled cable and its construction.

direct with intermediate terminals with with plugin at the terminal strip plug design testing points

Types of feedback andCNC connections

ZuTAB

....direct connection and intermediate terminal

....plug design


Assembled specifications for...


Figure 3.22: Summary of assembled specifications for feedback and CNCconnections

The tables summarize the available assembled feedback and CNCcables and their significant components.

Table SummarizingAssembled Specifications


Ass

embl

ed c

able

for

dire

ctco

nnec

tion

Ass

embl

ed c

able

for

inte

rmed

iate

term

inal

son

term

inal

str

ip

Cab

leF

eedb

ack

or C

NC

IKS

315

IN 2

90IN

209

IN 4

01

not a

vaila

ble

alka

bf1

Inte

rfac

es o

n th

em

ain

spin

dle

cont

rolle

rC

able

des

ign

for

dire

ct c

onne

ctio

n

On

the

cont

rolle

rO

n th

eco

ntro

ller

Fee

dbac

kor

CN

C

Sta

ndar

d In

terf

aces

Mot

or fe

edba

ck c

onne

ctio

nX

3 X2

IKS

032

IKS

610

Con

trol

inpu

t, si

gnal

and

anal

ogue

out

puts

IN 3

09IN

209

IN 2

90

IN 2

71IN

293

not p

erm

itted

!

not p

erm

itted

!

IKS

610

not p

erm

itted

!

not p

erm

itted

!

Inte

rfac

es fo

r fu

nctio

nal o

ptio

ns

Type

ke

y fie

ld"s

peed

se

t-po

int"

IKS

045

IKS

612

IKO

982

X4

Aan

alog

Ddi

gita

l

LS

erco

s

IN 2

87

IN 2

91

IN 2

09

20 x

0,2

5

IN 4

18IN

414

IN 4

20

not a

vaila

ble

not a

vaila

ble

IKS

613

IKS

612

For

..

..lin

e-up

term

inal

s

For

..

..lin

e-up

term

inal

s

..lin

e-up

term

inal

s

Fee

dbac

k an

d C

NC

con

nect

ions

- d

irect

con

nect

ion

and

link

term

inal

Figure 3.23: Assembled specifications for direct connection and intermediateterminals at terminal strip allocated to the interfaces on the main spindlecontroller.




Typ

e k

ey

field

"a

dd

itio

na

l e

nco

de

r in

pu

t"

X5

IN 2

89

IN 2

89

IN 2

89

IN 2

89

IN 2

89

IN 2

09

IN 2

09

IN 2

09

IN 2

09

IN 2

09

IN 3

01

IN 4

01

IN 3

01

IN 4

01

IN 4

01

IKS

32

7

IKS

31

4

IKS

31

4IN

28

9IN

20

9IN

40

1

no

t p

erm

itte

d!

no

t p

erm

itte

d!

*)

no

t p

erm

itte

d!

no

t p

erm

itte

d!

*)

*)*)

P

..in

cre

me

nta

le

nco

de

r

..hig

h-re

solu

tion

mai

n sp

indl

e po

sitio

n en

code

r

..se

con

d m

oto

r fe

ed

ba

ck

*) *) *)

no

t p

erm

itte

d!

no

t p

erm

itte

d!

no

t p

erm

itte

d!

no

t p

erm

itte

d!

..in

cre

me

nta

le

nco

de

r

..hig

h-re

solu

tion

mai

n sp

indl

e po

sitio

n en

code

r

..se

con

d m

oto

r fe

ed

ba

ck

IKS

33

1IN

20

9IN

40

1

no

t a

vaila

ble

X5

a

X6

/X1

3

(*TA

/RA

C)

*)

IKS

61

4/IK

S 6

12

IN 3

51

IN 2

09

20

x 0

,25

IN 2

95

/IN

29

1

no

t p

erm

itte

d!

no

t p

erm

itte

d!

IKS

61

4/IK

S 6

12

no

t p

erm

itte

d!

no

t p

erm

itte

d!

(

)

Y

IKS

62

0/IK

S 6

18

IKS

01

5/IK

S 0

16

IN 2

09

IN 3

28

/IN

28

9

IN 2

96

/IN

29

2IN

23

4/IN

23

4IN

29

1/IN

29

1

IIn

cre

. o

utp

ut

SR

S2

32

Dd

igit.

Po

s.-s

et-

po

int

IKS

62

0/IK

S 6

18

*) / *)

no

t a

vaila

ble

*)

Le

ge

nd

:

Typ

e k

ey

field

"a

dd

itio

na

l e

nco

de

r in

pu

t"

Con

nect

edto

..

..in

cre

me

nta

le

nco

de

r

..hig

h-re

solu

tion

mai

n sp

indl

e po

sitio

n en

code

r

..se

con

d m

oto

r fe

ed

ba

ck

Con

nect

edto

..

..in

cre

me

nta

le

nco

de

r

..hig

h-re

solu

tion

mai

n sp

indl

e po

sitio

n en

code

r

..se

con

d m

oto

r fe

ed

ba

ck

Co

nn

ect

ed

to..

..in

cre

me

nta

le

nco

de

r

..hig

h-re

solu

tion

mai

n sp

indl

e po

sitio

n en

code

r

..se

con

d m

oto

r fe

ed

ba

ck

Co

nn

ect

ed

to..

Co

nn

ect

ed

to..

..in

cre

me

nta

le

nco

de

r

..hig

h-re

solu

tion

mai

n sp

indl

e po

sitio

n en

code

r

..se

con

d m

oto

r fe

ed

ba

ck

Co

nn

ect

ed

to..

IN 2

90

IN 2

90

D-s

ub

plu

g

con

ne

cto

rP

lug

co

nn

ect

or

(plu

g)

for

fee

db

ack

co

nn

ect

ion

, st

raig

ht ty

pe

Plu

g c

on

ne

cto

r (p

lug

) fo

r fe

ed

ba

ck

con

ne

ctio

n, e

lbo

w typ

eW

ire

-en

d fe

rru

leW

all

bre

akt

hro

ug

hP

lug

co

nn

ect

or

(co

up

ling

)fo

r fe

ed

ba

ck c

on

ne

ctio

n

alk

ab

f2*)

lie

ferb

ar, A

nfr

ag

e d

er

Typ

en

be

zeic

hn

un

g b

ei I

ND

RA

MA

T A

bt. E

NT

Lege

nd:

D-s

ubpl

ug c

onne

ctor

Plu

g co

nnec

tor

(plu

g)fo

r fe

edba

ck c

onne

ctio

n,st

raig

ht ty

pe

Plu

g co

nnec

tor

(plu

g)fo

r fe

edba

ck c

onne

ctio

n,el

bow

type

Mul

ti-co

re c

able

end

Wal

l br

eakt

hrou

ghP

lug

conn

ecto

r (c

oupl

ing)

for

feed

back

con

nect

ion

alka

bf2

Figure 3.23: Assembled specifications for direct connection and intermediateterminals at terminal strip allocated to the interfaces on the main spindlecontroller.


Figure 3.24: Table summarizing assembled specifications for connections using aplugin testing points allocated to the interfaces on the main spindle controller.

Ass

embl

ed c

able

sfo

r pl

ug d

esig

n

cabl

efe

edba

ck s

ide

IKS

332

IKS

321

IN 2

90IN

209

Mai

n sp

indl

eco

ntro

ller

inte

rfac

esC

able

str

uctu

re fo

r pl

ug d

esig

n

on th

eco

ntro

ller

Plu

g ty

peF

eedb

ack

side

Sta

ndar

d in

terf

aces

Mot

or fe

edba

ck c

onne

ctio

nX

3

*)

on th

eco

ntro

ller

IN 3

04

cabl

e

IN 3

42IN

209

IN 4

01

IN 3

42IN

209

IN 3

09

IN 3

14IN

314

*) *)

*)IN

209

IN 4

01

*)IN

209

IN 3

09

X2

Con

trol

inpu

t, si

gnal

and

anal

ogue

out

puts

- no

t ava

ilabl

e -

- no

t ava

ilabl

e -

Fun

ctio

nal o

ptio

ns in

terf

aces X

6/X

13

(*TA

/RA

C)

*)

/

*)

IN 2

90/IN

292

Type

key

fie

ld

"add

ition

al

inte

rfac

es"

SD, I

- no

t ava

ilabl

e -

- no

t ava

ilabl

e -

*)

/

*)

IN 2

34IN

324

IN 2

34*)

IN 2

91IN

314

*)

/

*)

IN 3

14

IN 2

34*)

IN 2

91

ALK

AB

F5

Type

key

field

"spe

ed s

et-p

oint

"A

,D,L

X4

- no

t ava

ilabl

e -

- no

t ava

ilabl

e -

Fee

dbac

k an

d C

NC

Con

nect

ions

- p

lug

type



Typ

e c

od

e

fie

ld

"ad

ditio

na

l e

nco

de

r in

pu

t"

X5

IKS

30

5

IKS

32

1

IN 2

89

IN 2

89

IN 2

09

IN 2

09

IKS

33

0

IKS

33

0

IKS

33

0IK

S 3

21

IN 2

89

IN 2

09

Pin

cre

me

nta

l e

nco

de

r

hig

h-r

eso

lutio

ne

nco

de

r

se

co

nd

mo

tor

fee

db

ack

*)IK

S 3

05

IN 2

90

IN 2

09

X5

a

Co

nn

ect

ed

to..

Co

nn

ect

ed

to..

IN 2

89

IN 2

89

IN 2

89

IN 2

09

IN 2

09

IN 2

09

IN 3

03

IN 3

04

IN 3

04

IN 3

03

IN 2

09

IN 2

09

IN 2

09

IN 3

05

IN 3

42

IN 3

42

IN 3

01

IN 4

01

IN 4

01

IN 2

09

IN 2

09

IN 2

09

IN 3

51

IN 3

09

IN 3

09

IN 2

09

IN 3

05

IN 3

01

IN 2

09

IN 3

05

IN 3

51

IN 3

13

IN 3

14

IN 3

14

IKS

33

0

IKS

33

0

IKS

33

0

incre

me

nta

l e

nco

de

r

hig

h-r

eso

lutio

ne

nco

de

r

se

co

nd

mo

tor

fee

db

ack

IN 3

13

IN 3

14

IN 3

14

IKS

30

8

*) *)

IN 3

13

IN 3

14

IN 3

14

IN 3

03

IN 3

04

IN 3

04

IN 3

13

IN 3

14

IN 3

14

IN 3

05

IN 3

42

IN 3

42

IN 2

89

IN 2

89

IN 2

09

IN 2

09

IKS

33

0

IKS

33

0

IKS

33

0IN

28

9IN

20

9

incre

me

nta

l e

nco

de

r

hig

h-r

eso

lutio

ne

nco

de

r

se

co

nd

mo

tor

fee

db

ack

Co

nn

ect

ed

to..

Co

nn

ect

ed

to..

IN 2

89

IN 2

89

IN 2

89

IN 2

09

IN 2

09

IN 2

09

IN 3

03

IN 3

04

IN 3

04

IN 2

09

IN 2

09

IN 2

09

IN 3

01

IN 4

01

IN 4

01

IN 2

09

IN 2

09

IN 2

09

IN 3

51

IN 3

09

IN 3

09

IN 3

13

IN 3

14

IN 3

14

IKS

33

0

IKS

33

0

IKS

33

0

incre

me

nta

l e

nco

de

r

hig

h-r

eso

lutio

ne

nco

de

r

se

co

nd

mo

tor

fee

db

ack

IN 3

13

IN 3

14

IN 3

14

*) *)

IN 3

13

IN 3

14

IN 3

14

IN 3

03

IN 3

04

IN 3

04

IN 3

13

IN 3

14

IN 3

14

IN 3

23

*) *)

*)*) *) *)

IN 3

23

*) *)

IN 3

13

IKS

30

8

*) *)

IN 3

13

IN 3

13

IN 2

09

IN 3

23

IN 3

01

IN 2

09

IN 3

23

IN 3

51 AL

KA

BF

6

Lege

nd:

D-s

ubpl

ug c

onne

ctor

Plu

g co

nnec

tor

(plu

g)fo

r fe

edba

ck c

onne

ctio

n,st

raig

ht ty

pe

Plu

g co

nnec

tor

(plu

g)fo

r fe

edba

ck c

onne

ctio

n,el

bow

type

Mul

ti-co

re c

able

end

Wal

l br

eakt

hrou

ghP

lug

conn

ecto

r (c

oupl

ing)

for

feed

back

con

nect

ion

alka

bf2


Figure 3.24: Table summarizing assembled specifications for connections using aplugin testing points allocated to the interfaces on the main spindle controller.


Figure 3.25: Table of assembled specifications for plug connections allocated tothe interfaces on the main spindle controller.

Ass

embl

ed c

able

for

plug

in te

stin

g po

ints

cabl

eF

eedb

ack

or C

NC

IKS

315

IKS

322

IN 2

90IN

209

Mai

n sp

indl

e co

ntro

ller

inte

rfac

esC

able

con

stru

ctio

n w

ith p

lugi

n te

stin

g po

ints

On

the

cont

rolle

rP

lugi

n te

stin

g po

ints

Fee

dbac

k si

de

Sta

ndar

d in

terf

aces

Mot

or fe

edba

ck c

onne

ctio

nX

3 X2

IKS

315

Con

trol

inpu

t, si

gnal

and

anal

ogue

out

puts

IKS

360

On

the

cont

rolle

r - no

t ava

ilabl

e -

- no

t ava

ilabl

e -

IN 4

01

IN 2

90IN

209

IN 4

01

cabl

e

IN 3

09IN

209

IN 4

01

IN 3

06IN

209

IN 3

09

ALK

AB

F3

Fee

dbac

k an

d C

NC

Con

nect

ions

- p

lugi

n te

stin

g po

ints



Type

key

fie

ld

"add

ition

al

enco

der

inpu

t"

X5

IKS

303

IKS

322

IN 2

89

IN 2

89

IN 2

09

IN 2

09

IKS

327

IKS

314

IKS

314

IKS

322

IN 2

89IN

209

Pin

crem

enta

l en

code

r

high

-res

olut

ion

enco

der

seco

nd m

otor

fe

edba

ck

IKS

331

IKS

303

IN 2

90IN

209

X5a

X6/

X13

(*

TA/R

AC

)

IKS

331

IN 2

09IN

290

(

)

*)

/

*)

IN 2

96/IN

292

Type

key

fie

ld

"add

ition

al

inte

rfac

e"R

S 2

32

D, I

Fun

ctio

nal o

ptio

n in

terf

aces

Type

key

fiel

d "s

peed

set

-poi

nt"

A,D

,LX

4-

not a

vaila

ble

--

not a

vaila

ble

-

Con

nect

edto

..

Con

nect

edto

..

IKS

327

IKS

314

IKS

314

incr

emen

tal

enco

der

high

-res

olut

ion

enco

der

seco

nd m

otor

fe

edba

ck

- no

t ava

ilabl

e -

- no

t ava

ilabl

e -

*)

/

*)

IN 2

89

IN 2

89

IN 2

89

IN 2

09

IN 2

09

IN 2

09

IN 2

34

IN 3

01

IN 4

01

IN 4

01

IN 3

01

IN 4

01

IN 4

01

IN 3

01 *)

IN 3

01

IN 2

09

IN 2

09

IN 2

09

IN 3

18

IN 3

06

IN 3

06

IN 3

01

IN 4

01

IN 4

01

IN 2

09

IN 2

09

IN 2

09

IN 3

18

IN 3

06

IN 3

06

IN 3

51

IN 3

09

IN 3

09

IN 2

09IN

318

IN 3

01

IN 2

09IN

318

IN 3

51

IN 2

34IN

307

IN 2

91

ALK

AB

F4

Lege

nd:

D-s

ubpl

ug c

onne

ctor

Plu

g co

nnec

tor

(plu

g)fo

r fe

edba

ck c

onne

ctio

n,st

raig

ht ty

pe

Plu

g co

nnec

tor

(plu

g)fo

r fe

edba

ck c

onne

ctio

n,el

bow

type

Mul

ti-co

re c

able

end

Wal

l br

eakt

hrou

ghP

lug

conn

ecto

r (c

oupl

ing)

for

feed

back

con

nect

ion

alka

bf2


Figure 3.25: Table of assembled specifications for plug connections allocated tothe interfaces on the main spindle controller.


Cable typ Cable Construction Diameter Bending radius in mm Weight inin mm kg/m

Fixed Flexiblerouting routing

IN 209 (2x1,0+4x2x0,25)C 8,8 ±0,3 40 90 0,102

IN 233 (2x2x0,25)C 8,3 ±0,3 80 125 0,102

IN 234 2x(2x0,22)C+2x0,5 7,0 ±0,3 45 70 0,070

IN 271 34x0,25+2x0,5 11,0 ±1,0 60 125 0,195

20 x 0,25 (20x0,25)C 9,1 ±0,4 137 182 0,153

3.4. Cable Specifications List The cable specifications used in the assembled cables are summa-rized below in table form. All necessary specifications and measure-ments are listed.

Figure 3.26: Table of cable specifications for feedback and CNC connections.



4. Installation Guide-lines

4. Installation Guidelines

Metal cable conduit

Kab_Kan

2 - 4 mm>=100 mm

Synthetic cable conduit

There must be a clearance of at least 100 mm between the powerconnections and the feedback or CNC connections if the cables arerouted parallel. Otherwise, it is necessary to separate the cableconduit with metal (see Fig. 4.1)

Figure 4.1: Routing the cables together in the cable conduit.

The guidelines outlined in the connection plans on power, feedbackand CNC connections with reference to the twisting of conductors andthe shielding of bunched conductors must be followed in order toachieve interference-free operation!

The shielding should be connected as outlined in the connectionplans. This avoids mass potential loops!

Feedback units which the main spindle controller evaluates must bemounted and electrically insulated at the machine or motor.

Do not route the feedback cables in the vicinity of high-frequencyequipment, the magnetic fields of transformers, chokes, motors andother magnetic consumers, as well as high-voltage cables , asotherwise interference could be coupled in!

Cable routing guidelines

Wiring

Feedback units


Figure 4.2: Degree of contamination in acc. with DIN VDE 0160.

IN172 IN217 IN172 IN217IN172 IN210IN316

V1 V1 V1V2 V2 V2

IN218

V2 V3

Machine housing Control cabinet wall

2AD...V2

IN192

Spindle housing

V1

V3

Degree of contamination Immediate environmental conditions

V1 Conductive contamination cannot occur during operation of thedrive because IP 65 type of protection is a given.

V2 Conductive contamination cannot occur during operation of thedrive (IP65). Non-conductive contamination, or light condensationof short duration can occur during installation or exchange ofdrive components.

V3 Conductive contamination can occur because contact parts areexposed and can be wetted by condensation.

Power plug connectors The dimensioning of the contact distances and leakage paths of thepower plug connectors is based on the degree of contamination asoutlined in DIN VDE 0160.

If wetting from coolants or lubricants is to be expected wheninstalling a drive or exchanging drive components, then sealthe open plug side of power connections with protectivecaps.

Only join power plug connectors if plug side is dry!


Detach and join power plug connectors only when no poweris present!

If a power plug connector is used to connect 1MB framelessmotors, then do not spill coolant onto the backside of theflanged socket on either the spindle or machine housing!


The plug connectors of the power cable and the feedback connec-tions must be firmly screwed into place when the drive is operating!

Category IP65 protects assembled INRAMAT cables when they arefirmly screwed in and attached. This does not, however, apply to theopen side of control cabinet and housing breakthroughs as well as d-sub plug connectors!

– Do not detach the AS programming module when unit is still underpower. The knurling screw must be firmly affixed during operation!

– The d-sub plug connectors must be firmly screwed into place!

– Twist the motor power cable strands!

– The transparent panes on the safety guards on the front side of theunit must be firmly affixed during operation!

– Ground the motor on the controller and ground the controller directlyon the supply module!

– Plug the control voltage bus end plug (supply module accessories)into the last controller on the drive configuration!

– Adhere to maximum tightening torque of the stay bolts, otherwisethere is the risk of tearing!

– Plug in heatsink fan cable, if present.

– The power connection safety guards on the front of the RAC4 mustbe closed when the unit is switched on and during operation!

– Ground the motor on the controller and ground the controllerhousing to the main incoming earth terminal!

If contacts or semi-conductors are used in connection with electronicequipment and components to switch such inductive loads as chokes,contactors and relays, then these must be appropriately cleared ofinterference. If direct current is used, then this is achieved by thearrangement of freewheeling diodes, and if alternating current isused, then this is achieved with the arrangement of commercial safetyRC suppressor components situated directly at the inductivity. Do notuse varistors as protective circuits!

Only that suppression component situated directly at the inductivityserves the purpose. Otherwise an interference level is radiated whichis too high. This influences both the function of the drive and theelectronics. Other interference sources, such as high-frequencyequipment (anodized components, and similar) must be placed andwired outside of the control cabinet.

Installing Cables

Category of Protectionfor the Cable


General ControllerInstallation Guidelines

Modular Drive System Installa-tion Guidelines

RAC Installation Guidelines

Measures Against Sources ofInterference from Inside theControl Cabinet


Controller type KDA/TDA 1RAC 2

Type key field for the controller:

Speed set-point:analog +/- 10V Adigital (16 Bit parallel) DSERCOS interface L

Additional encoder input:Without add. encoder input OWith add. encoder input for spindle feedb. or 2nd motor feedb. PWith add. encoder input and synchronous input(AS •5 and speed set-point = A) Y

Additional encoder input:Without add. encoder input OPosition set-point, digital (16 bit parallel) DSerial interface (RS 232C) SIncremental encoder output I

5. Delivery, Identifica-tion,Storage

Assembled Cables Assembled cables are rolled up and loosely packed in with thedelivery. They do have a label (cable marker), which bears the orderdesignation and the length of the assembled cable.

Figure 5.1: Label (cable marker) on INDRAMAT assembled cables.

The plug accessory sets contain the plug connector (D-sub) for theoptional interfaces of the controller. They are packed in plastic bagsand bear a packaging slip (see Figure 5.3).

The plug accessory sets are delivered in a sealed carton togetherwith single plug connectors and the controller-specific connections.

Note: The plug accessory sets are not necessarily needed (see Fig.1.2)!

INDRAMAT - Cable

No.Length: m

TSKabel

Designation: S • - • • •

Plug accessories

5. Delivery, Identification, Storage

Figure 5.2: Designations of the plug accessory sets


Page 1 Page 2

Page 3 Page 4

S2 - APINo. Designation Mat. No.

Acc. pack. slip S2-APIZ.No.:109-0743-4248-00

Date: 24.05.93File: S2-APIMat. No. BPZ: 253227

1 220623

10 221657

3 221661

D-SUB-plug 15 way, pins

screw

Housing, 15 way

1 221652

No. Designation Mat. No.

D-SUB-plug 37 way, bushing

housing 37 way1 221659

1 222154Housing, 9 way


1 222740D-SUB-plugr 9 way, bushing


X2

X2

X3, X5, X13

X3

X4

X4

2 223008D-SUB-plug 15 way, bushing

X5, X13

1 2 3

1 220856

X17

Plug terminal 3 way

Additional plug accessoriesRAC •.• - • • • - • • • - API - • •

239 164

Packaging slip


Figure 5.3: An example of the plug accessories set packaging slip.


Individual cables are rolled up and loosely packed in with the delivery.The sequential order number is always printed on them.

Single plug connectors are packed into plastic bags. The bags havea label which indicate order number, appearance and dimensions ofthe mounted plug connector.

Single plug connectors are packed into a sealed carton along withplug accessories sets and the controller-specific connections.

The controller-specific connections are also packed in plastic bagsand labelled with the respective order number. E••-• for KDA/TDAcontrollers (depending upon the arrangement within the drive pack-age), E1-RAC for RAC controllers.

Further information about the controller-specific connections can befound in the document on the respective controller - „Project PlanningNotes“.

Note: The controller-specific connections are always required!

Assembled cables, plug accessory sets, the controller-specific con-nections, individual plug connectors and cables should be stored dryand dust-free. Permissible storage temperature range equals -30 to+85 degrees C.

Individual plug connectorsand cables

INVERP

Figure 5.4: Packing single plug connectors (example)

Leistungsstecker


Controller-specific connections

Storage

Plug connector: IN 401

INDRAMAT Part No.: 230 647

bushing

View "X"

Power plug: IN 217/06

INDRAMAT Part No.: 228 351

Pin

Pin

View "X"


6. Customizing Specifications

Selbstkonfektionierung eines Leistungskabels

Test guidelines

Workingguidelines

Construction diagrams

with parts list1

Request construction documentation

from INDRAMAT

2Order the

individual partsand tools needed

3 Constructing the cableSoldering

(tools)Crimping

(tools)

Attaching pins, or

bushings into the insulator casing (tools)

4 Testing the cable High-voltage test

Run-through test

Insulationtest

A functioning cable without INDRAMAT guarantee

Figure 6.1: Customizing a power cable

FertigungsunterlagenWerkzeugeLötenCrimpenIsolierkörperHochspannungstestDurchgangsprüfungIsolationsprüfung

6. Customizing Specifi-cations

crimpingrun-through testhigh-voltage testinsulation testinsulator casingsoldering(tools)

Cable construction


Customizing amotor power cable

Allocation of motor type to the PG thread of the respective terminalbox is listed in the table outlining assembled specifications in Section2.1.3.

Figure 6.2: Screw and reduction specifications for motor power connections viaterminal boxes.

Crim

ping

cabl

e lu

gC

able

PG

RE

DK

LK

IN20

4 (f

lex.

)

Pow

er p

lug

conn

ecto

r (p

lug)

Sym

bols

:

Wire

-end

ferr

ule

Crim

ping

cabl

e lu

gF

lang

e co

nnec

tion

Pow

er p

lug

conn

ecto

r (c

oupl

ing)

PG

scr

ew c

onne

ctio

n

*) A

vaila

ble.

For

inqu

iries

on

type

info

rmat

ion

cont

act D

evel

opm

ent D

ept.,

IND

RA

MA

T.

Cro

ss s

ectio

nin

mm

2R

educ

tion

Scr

ews

IN40

4 (h

ighl

y fle

x.)

IN20

5 (f

lex.

)

IN40

5 (h

ighl

y fle

x.)

IN20

6 (f

lex.

)

IN40

6 (h

ighl

y fle

x.)

IN20

7 (f

lex.

)

IN40

7 (h

ighl

y fle

x.)

IN26

7 (f

lex.

)

IN26

8 (f

lex.

)

IN20

7 (f

lex.

)

IN40

7 (h

ighl

y fle

x.)

6 6 10 10 16 16 25 25 35 50 25 25

PG

29

PG

42

PG

48

... o

n th

eco

ntro

ller

Fra

me

less

sp

ind

le m

oto

r 1

MB

Mot

or

Term

inal

bo

x bo

lts

(dro

pped

)

(dro

pped

)

(dro

pped

)

(dro

pped

)

(dro

pped

)

(dro

pped

)

PG

29/P

G36

Mat

. no.

226

349

PG

42/P

G36

Mat

. no.

226

350

PG

48/P

G36

Mat

. no.

248

674

PG

36/P

G29

Mat

. no.

220

474

(dro

pped

)

(dro

pped

)

PG

48/P

G36

Mat

. no.

248

674

and

PG

29M

at. n

o. 2

20 8

74

PG

29M

at. n

o. 2

20 8

74

PG

29M

at. n

o. 2

20 7

42

PG

29M

at. n

o. 2

20 5

54

PG

29M

at. n

o. 2

20 4

72

PG

36M

at. n

o. 2

20 4

73

PG

29M

at. n

o. 2

20 4

72

PG

36M

at. n

o. 2

43 5

52

PG

42M

at. n

o. 2

53 4

79

PG

36M

at. n

o. 2

20 4

73

PG

29M

at. n

o. 2

20 4

72

PG

29M

at. n

o. 2

20 4

72

Ma

in s

pin

dle

mo

tor

2A

D

ReduzierungVerschraubung



It is only possible to solder the power plug connectors – independentof cable core cross sections – in types IN172/25, IN 210/25 andIN217/25!

Pow

erpl

ugco

nnec

tor

Cab

le

PG

RE

D17

2

IN20

4 (f

lex.

)

Pow

er p

lug

conn

ecto

r (p

lug)

Sym

bols

:

Wire

-end

ferr

ule

Crim

ping

cabl

e lu

gF

lang

eco

nnec

tion

Pow

er p

lug

conn

ecto

r (c

oupl

ing)

PG

scr

ew c

onne

ctio

n

*) A

vaila

ble.

For

inqu

iries

on

type

info

rmat

ion

cont

act D

evel

opm

ent D

ept.,

IND

RA

MA

T.

Cro

ss s

ectio

nin

mm

2R

educ

tion

Bol

ts

IN40

4 (h

ighl

y fle

x.)

IN20

5 (f

lex.

)

IN40

5 (h

ighl

y fle

x.)

IN20

6 (f

lex.

)

IN40

6 (h

ighl

y fle

x.)

IN20

7 (f

lex.

)

IN40

7 (h

ighl

y fle

x.)

6 6 10 10 16 16 25 25

... o

n th

eco

ntro

ller

Mot

or

IN20

3 (f

lex.

)

IN40

3 (h

ighl

y fle

x.)

4 4

IN17

2/••

(Spe

cs a

lso

appl

y to

IN

210/

..,

IN21

7/..)

Fra

mel

ess

spin

dle

mot

or 1

MB

Red

uctio

n

PG

36/P

G29

Mat

. no.

220

474

PG

36/P

G29

Mat

. no.

220

474

PG

36/P

G29

Mat

. no.

220

474

PG

36/P

G29

Mat

. no.

220

474

PG

36/P

G29

Mat

. no.

220

474

PG

36/P

G29

Mat

. no.

220

474

PG

36/P

G29

Mat

. no.

220

474

PG

36/P

G29

Mat

. no.

220

474

PG

36/P

G29

Mat

. no.

220

474

PG

36/P

G29

Mat

. no.

220

474

PG

29M

at. n

o. 2

20 8

74

PG

29M

at. n

o. 2

20 8

74

PG

29M

at. n

o. 2

20 8

74

PG

29M

at. n

o. 2

20 8

74

PG

29M

at. n

o. 2

20 4

72

PG

29M

at. n

o. 2

21 5

54

PG

29M

at. n

o. 2

20 4

72

PG

29M

at. n

o. 2

20 4

72

PG

36M

at. n

o. 2

20 4

73

PG

29M

at. n

o. 2

20 4

72

Mai

n sp

indl

e m

otor

2A

D


Figure 6.3: Specifications for bolts and reduction for motor power connectionsvia power plug connectors.


7. Index

7. Index

Symbole1MB connected to RAC 281MB to KDA/TDA 272AD 100 with KDA/TDA 212AD 100 and 2AD 101 connections 202AD 132 CONNECTED TO KDA/TDA 232AD 132 connected to KDA/TDA 252AD to KDA/TDA 272S 100 WITH KDA/TDA 22

AAmbient temperatures 13Analogue outputs 68AS programming module 87Autotransformer 48

BBending radius 45

CCable conduit 85Cable construction 91Category of Protection for the Cable 87CNC Connections 56Conductive contamination 86Conductor cross sections, sized 13Connecting an RAC to a three-phase mains 49Connecting components 53Connecting RAC with overvoltage surge arresters 50Connection 2AD 132 with KDA/TDA 21Connection 2AD 180 26Connection of 1MB to KDA/TDA 27Connection of 2AD 100 to KDA/TDA 20Connection plans for feedback and CNC 60Connection plans, motor-controller 19Connection with intermediate terminals, feedback/C 58Connection with plug design 58Connection with plugin testing point 59Contamination, degree of 86Control circuits RAC 75Control input 68Control voltage bus end plug 87Controller-specific connections 12Crimping 91Customizing specification 91

DDiameter 45Direct connections, feedback and CNC 57Drive configuration 87Drive shutdown 75


EEarth leakage circuit breaker 49Environmental conditions 86Equalizing the voltage 48

FFeedback and CNC Connections 11, 56Feedback and CNC connections 76Feedback connections 56Flanged socket 86Freewheeling diodes 87Fuse type 52

GGrounded Three-Phase Mains 48

HHeatsink fan cable 87High-resolution motor feedback 61High-voltage test 91Holding Brake 19Holding brake 9

IIKS015/IKS016 73IKS045 69IKS314 64, 66IKS610 68IKS612 70IKS614 72IKS618/IKS620 74IN 203 45IN 204 45IN 205 45IN 206 45IN 207 45IN 209 84IN 233 84IN 234 84IN 267 45IN 271 84IN 403 45IN 404 45IN 405 45IN 406 45IN 407 45Incremental encoder output 74Individual plug connectors 11, 90Installation guidelines 85Insulation test 91Insulator casing 91Interference sources inside the control cabinet 87Interference-free operation 85Isolating transformer 48

7. Index


KKDA/TDA elec. conn. 8

LLead Spindle Feedback 67Line 10Line construction 45Line lengths 14Line routing 85Line specifications for feedback and CNC connectio 45Load capacity table 13

MMains connection line for RACs 55Mains connection specifications 52Mains voltage 47Mass potential loops 85Motor fan 19Motor feedback, incremental encoder 63Motor with blocking brake 19Motor-controller connection with plug design 17Motor-controller connection with plugin testing po 18Motor-controller direct connection 16Motor-controller power connections 15

NNon-conductive contamination 86

OOperating temperature, cable 13Outer wire 47Overvoltages 47

PPackaging slip 89PG thread 92Plug accessory sets 88Plug connector 90Position set-point, digital 72Power cable with intermediate terminal at terminal 17Power cable with plug design 17Power cable with plugin testing points 18Power cables for direct connections 16Power connections of the RAC three-phase mains 46Power motor-controller connections 29Power plug 90Power plug connectors 86Processing cycle 53Protective caps 86Protective circuits 87Protective motor switch 19

RRAC elec. conn. 9Rated connection voltag 47

7. Index


Rated connection voltage for control electronics 47RC suppressor components 87Reduction 92, 93Relative short-circuit voltage 53Run-through test 91

SScrews 92SERCOS Interface 71Serial interface 73Shielding of bunched conductors 85Sizing the Autotransformer 53Sizing the Isolating Transformer 54Soldering 91Soldering of power plug connectors 93Specifications of the power connection 10Speed set-point, analog 69Speed set-point, digital 70spindle feedback 66Storage 90Storage temperature 90Supply module 87Surge arresters 48, 55

TTable of power connections to the motor 29Tables, feedback and CNC conn. 76Terminal box 92Three-Phase Mains 47Tools 91

UUngrounded Three-Phase Mains 48

VVaristors 87Viewing panes 87

WWeight 45Wetting from coolants or lubricants 86Wiring 85Wye-point and outer wire grounded three-phase main 48

7. Index


Summary of supplementary documentation

Figure 8.1: Summary of supplementary documentation

RAC4RAC3

RAC2TDA1

Controller KDA3

ElektrischeVerbindungen

für Haupt-spindelan-

triebe

Asynchronous motor

225

8. WeiterführendeDokumentation

Selection specifications– Summary of the AC main drive system– Power range– Applications of the technical functions

of the AC main spindle drive– Selection protocol and item order list– Delivery program

Doc. No.: 9.567.013.4

AC Main spindle drivewith controlled 2AD main spindle mo-tor

Main spindle motor

Planning and Design– Machine construction plans– Delivery, storage and transport– Mounting and installation guidelines

Main spindle controller

Planning and Design– Control cabinet plans– AS programming module– Delivery, storage and transport– Mounting and installation guidelines

KDA 3.2, Doc. No. 209-0042-4110TDA 1.1, Doc. No. 209-0042-4112RAC 2, Doc. No. 209-0042-4115RAC 3, Doc. No. 209-0042-4116RAC 4, Doc. No. 209-0042-4113

2AD 100, Doc. No. 9.567.009.42AD 101, Doc. No. 9.567.018.42AD 132, Doc. No. 9.567.010.42AD 160, Doc. No. 9.567.011.42AD 180, Doc. No. 9.567.012.42AD 200 - in preparation2AD 225 - in preparation

Electrical connectionsof the main spindle drive

Planning and Design– General guidelines on the

electrical connections– Circuit diagrams for feed-back and CNCconnections– Circuit diagramss for the

power connections of allmain spindle drives

AC main spindle driveswith controlled

asynchronous motors orframeless spindle motors

AC main spindle drives with controlled asynchronousmotors or frameless spindle motors

Description of Application– Commissioning the AC main spindle drives– Operating the controller– Controller function– Diagnostics and fault elimination– Summary of parameters and interfaces

Doc. No. 209-0041-4109

Doc. No. 209-0042-4111

8. Supplementary Documentation

Pla

nnin

g an

d D

esig

n(c

onst

ruct

ion,

mou

ntin

g, in

stal

ling

the

mac

hine

)S

elec

tion

(det

ails

, ord

er)

App

licat

ion

of th

e m

ain

spin

dle

driv

e(C

omm

issi

onin

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pera

ting,

Dia

gnos

ing)

AC Main spindledrive with controlled

2AD mainspindle motor

You have this documentAsynchronous motor

200Asynchronous motor





2AD100


1MB- Stator1MB

- Rotor

Supplementary documentation

- high-resolution main spindle encoder • application description Doc. No. 9.552.247.4 • mounting guidelines Doc. No. 9.600.060.4- incremental encoder output IGS Doc. No. 9.568.015.4- high-resolution encoder junction HGV Doc. No. 9.568.010.4- absolute value encoder attachment for 2AD 132, 2AD 160, 2AD 180 Doc. No. 9.568.020.4

Absolutevalue

encoder2ADHGV

IGSHigh-resolutionmain spindle

position encoder

Selection specifications– Summary of the AC main drive system– Power range– Applications of the technical functions

of the AC main spiindle drive– Selection protocol and items order list– Delivery program

AC Main spindle drivewith controlled frame-

less spindle motor 1MB

1MB

Doc. No. 9.567.012.4

AC Main spindle drivewith controlled frameless spindle motor 1MB

AC main spindledrive with

changeovergearboxess 2K

AC main spindle drives with controlledasynchronous motor 2AD andchangeover planetary gearboxes 2K

Selection specifications– Summary of the

AC main drive system– Power range– Order guidelines

Frameless spindle motor

Mounting guidelines– Delivery, handling, transport– Mounting– Cooling guidelines

Planning and Design– Machine construction plans– Integrating into the cooling system– Electrical and coolant connections– Delivery

1MB 160, Doc. No. 9.576.014.41MB 200, Doc. No. 9.576.016.41MB 240/241, Doc. No. 9.576.015.41MB 310/312, Doc. No. 9.576.008.41MB 375, Doc. No. 9.576.007.4

Stator, Doc. No. 9.600.063.4Rotor, Doc. No. 9.600.062.4

Doc. No. 9.567.022.4

8. Supplementary Documentation

Pla

nnin

g an

d D

esig

n(c

onst

ruct

ion,

mou

ntin

g, in

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ling

the

mac

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atio

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the

mai

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ive

(Com

mis

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ing,

Ope

ratin

g, D

iagn

osin

g)S

elec

tion

(det

ails

, ord

er)

Framelessspindle motor

1MB 375Frameless

spindle motor

1MB 310Frameless

spindle motor

1MB 240Frameless

spindle motor

1MB 200Frameless

spindle motor

1MB 160

Indramat

electrical connections of main spindle drives connections of main spindle drives...

Documents