Indramat Conexoes Eletricas

engineering
mannesmann
Rexroth
Electrical Connections
of Main Spindle Drives
Project Planning Manual
DOK-GENERL-MAIN*EL*CON-PRJ1-EN-P
258653 Indramat
About this documentation
Titel Electrical Connections of Main Spindle Drives
Type of documentation: Project Planning Manual
Documenttype DOK-GENERL-MAIN*EL*CON-PRJ1-EN-E1,44
Internal file reference • 209-0042-4111-00
Reference This electronic document is based on the hardcopy document with document
desig.: 209-0042-4111-00 EN/04.94
This documentation This documentation serves:

is used:
– to introduce and categorize the connections of the main spindle drives,
– as a source for the circuit diagrams for not only the power connections but
also the feedback and CNC connections when developing the machine
circuit 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 and
main spindle motors. This documentation can be referenced via text strings.
Change procedures Designation of documentation Release- Coments

up 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
Copyright © INDRAMAT GmbH, 1994

Copying of this document, and giving it to others and the use or communication
of the contents thereof, are forbidden without express authority. Offenders are
liable to the payment of damages.
All rights are reserved in the event of the grant of a patent or the registration
of a utility model or design. (DIN 34-1)
The electronic documentation (E-doc) may be copied as often as needed if

such are to be used by the consumer for the purpose intended.
Validity All rights reserved with respect to the content of this documentation and the
availability of the products.
Publisher INDRAMAT GmbH • Bgm.-Dr.-Nebel-Straße 2 • D-97816 Lohr

Telefon 0 93 52 / 40-0 • Tx 689421 • Fax 0 93 52 / 40-48 85
Dept ENA (MR, FS)
• DOK-GENERL-MAIN*EL*CON-PRJ1-EN-E1,44 • 07.97 2
Table of Contents
Table of Contents Page
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
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 RAC
controller .........................................................................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. Electrical Connections
1. Electrical
Connections
1.1. Standardization The electrical connections in the entire INDRAMAT main spindle
drive program have been standardized with the goal of reducing the
range of cables available.
There are three categories of electrical connections:

– power connections
– feedback and CNC connections
– controller-specific connections
Power connections The motor connections to the main spindle controller always have the
same terminal assignment, regardless of the controller implemented.
The cable cross sectional area is dependent on the motor power
requirements.
The RAC controller is connected directly to the three-phase mains.

The terminal assignments of the different RAC’s are always the
same. The cable cross sectional area is dependent on the current
type of the respective RAC.
Feedback and Plug assignment is the same regardless of controller and motor type.
CNC connections
Controller-specific connections The KDA/TDA controllers used in modular drive packages have
controller-specific electrical connections. This documentation does
not deal with their connection. It is dealt with in the documentation on
main spindle controllers KDA 3.2, or TDA 1.1, „Project Planning
Notes“. The cables needed are part of the electrical connecting
accessories E...-.DA.
The mains contactor and the respective control circuits are integrated
into the RAC controllers for direct mains connection. The facility
control system must operate this control circuit. The controller-
specific connections are outlined in the mains connection plans in
Section 2.2.
Control
Control input and signal outputs
Additional controller interface

- Incremental encoder output
- Serial interface RS 232 C
Controller"Ready" contact
Supply
- Position set-point
KDA/TDA
unit
Speed set-point
of the controller
Mains
Feedback
and CNC
connections
Controller-
specific Motor
connections (only with KDA) feedback
connection
Mains Motor fan connection
Motor
connections
Power connections
Spindle
feedback
Katelvem
Lead spindle feedback

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

Mains contactor ON
Control
RAC
Mains contactor
Control input and signal outputs

L-
X6
Additional controller interface

- Incremental encoder output
L+
monitoring
DANGER HIGH VOLTAGE
- Serial interface RS 232 C

DISCHARGE TIME
Entladezeit 1Min.
Controller "ready" contact

Q1
- Position set-point
Speed set-point
of the controller
AC-MAINSPINDLE DRIVE RAC 2
Controller-
Internal specific
control X1 connections
circuit and
mains
Mains contactor
AS
SWITCH OFF VOLTAGE BEFORE
CHANGING MODULE AS
Prog. Modul AS nicht unter Spannung wechseln
X13 X4
X2
X5
X3
Feedback
and CNC
connections
Mains connections
Motor
Power feedback
connections connections
Motor fan connections
Motor connections
Spindle
feedback
Katelvek
Figure 1.3: Categories of electrical connections for main spindle drives with RAC
(here RAC 2.2)
Holding brake
Motor fans cannot be connected to the controller in main spindle
drives with RAC3 and RAC4! They are connected directly to the three-
phase mains via appropriate protective motor switches!
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 guarantee

a quick and easy assembly of control cabinet and machine. If only
assembled cables are used, then no addditional cable and plug
accessories 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 guidelines
outlined in Section 5.
Power connections
Assembled Components
To the motor To the motor

No additional plug - Power plug/compression cable
or cable accessories shoe on the motor
needed! - Wire-end ferrule/crimping cable
lug on the controller
To the three-phase mains - Cable
Not available To 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
Exclusively Partially Components

assembled assembled
No additional plug Additional plug Required:

or cable accesso- connectors and - Plug accessory
ries needed! cables for the non- (for the controller)
assembled connec- S1- ••• with KDA/TDA
tions.
S2- ••• with RAC
- Lines
- Individual plug connectors
(for feedback and CNC)
Figure 1.5: Specifications of the feedback and CNC connections with

accessories referenced.
Should only component cables be used with the feedback and CNC
connections, then the plug accessory sets offered guarantee a
complete connection to the controller by means of appropriate plug
connectors.
Controller Connections
Assembled for Components

KDA/TDA for RAC
Connections only Plug connector without

obtainable from cable to contact RAC
INDRAMAT as part of the internal control circuit
modular drive package (part of electrical
(part of the electrical connecting accessories
connecting accessories E1-RAC).
E•• - KDA or
E•• - TDA)
Figure 1.6: Construction of controller-specific connections with electrical
connecting accessories referenced.
The controller-specific connections are always required! The electri-

cal connection accesssories within the KDA/TDA modular drive
package are dependent upon the adjacent controller in the drive
package (see documentation main spindle controller; „Project Plan-
ning Notes“).
1.3. Determination
of Size and Guidelines
Sizing the The conductor cross sections of the assembled INDRAMAT cables
conductor cross sections are sized in accordance with guidelines EN 60 204, Section 1/ 2/86.
The cross sections of the power connections to the main spindle

motor have been selected in acc. with the respective rated current of
the motor (see tables listing assembly specifications beginning with
Fig. 2.19).
The cross sections of the power connections to the three-phase

mains are dimensioned according to the continuous output of the
main spindle motor used in the main spindle controllers for direct
mains connection (see Section 2.2.3).
Load Capacity Table Conversion table for ambient temperatures

greater than 30 degrees C.
Rated conductor Load capacity of the

cross sections conductors in the machines,
normal application
in busway Ambient Conversion
temperature factor
mm2 A o
C
0,75 9 30 1
1 12 35 0,93
1,5 15,5 40 0,87
2,5 21 45 0,79
4 28 50 0,71
6 36 55 0,61
10 50 60 0,50
16 68
25 89
35 111
503) 134
3)
actual cross section equals 47 mm 2
Figure 1.7: Load capacity and conversion factor table for ambient temperatures
greater than 30 degrees C., in acc. with EN 60 204-1/ 2/86.
The permissible operating temperature on the surface of the cable

equals 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 the
example.
See EN 60 204 Section 1 / 2/86 for further details.
Sizing maximum cable lengths Maximum cable length is limited by the electro-magnetic distortions
and the loss of voltage along the cable. Transit time effects in the
motor power cable cause cable-length dependent voltage increases
at the motor terminals. This also limits cable lengths.
The maximum cable lengths given reference the direct connection

between controller and motor, or feedback, in those cases where
assembled 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 maximum

cable length.
– Power connection to motor: 75 m
– Feedback connection: 75 m
2. Power Connections
2. Power Connections INDRAMAT main spindle drives have power connections between
the controller and motor and between the RAC controller and the
three-phase mains.
2.1. Motor-Controller The power connections between motor and controller are broken
Power Connections down 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 and

motor 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.
2.1.1. Breakdown of the There are four types of assembled power connections between
Types of Connections motor and controller.
Types of power connections

motor-controller
direct with intermediate terminal plug with

plugin
to terminal strip design testing points
Figure 2.1: The four types of power connections
Motor-controller This type of connection is characterized by the lowest number of

direct connection imperfections and the lowest drop in voltage in comparison to the
other types of connections.
A terminal point for the strand pair of the holding brake must be
located close to the motor power connection on the controller in the
control cabinet, if main spindle drives with holding brakes are used!
On the motor Cable On the controller
(2AD main spindle motor, (Controller

1MB frameless spindle motor) KDA/TDA or RAC4)
(2AD main spindle motor,

1MB frameless spindle motor) (Controllers RAC2/RAC3)
Symbols:
Power plug Power plug wire end ferrule crimping cable lug Flange
connector (plug) connector (coupling) for line-up terminals for stay bolts connector
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 through
2.27).
Motor-controller connection with With this type of connection it is easy for the CNC control to take
intermediate terminal charge of the electrical holding brake, or to be integrated into the
control circuit.
The intermediate terminal at a terminal strip also makes it possible to

reroute a space-saving, sheathless cable into the cable conduits of
the control cabinet!
On the motor Cable Terminal strip Cable On the controller
(Controllers
(2AD main spindle motor, KDA/TDA or RAC4)
1MB frameless spindle motor)
(Controllers RAC2/RAC3)
1MB frameless spindle motor)
Symbols:
Power plug Power plug wire-end ferrule crimping cable Flange

connector (plug) connector (coupling) for line-up terminals lug for stay bolts connector
st_verb2
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).
Motor-controller connection This type of connection makes it possible to finish the control cabinet
with plug design entirely independent of the machines.
In addition, damaged cables can be very quickly and reliably ex-

changed.
On the motor Cable Plug Cable On the controller

design
(2AD main spindle motor, (Controllers


Symbols:
Power plug Power plug Wire-end ferrule for Crimping cable lug Flange
connector (plug) connector (coupling) line-up terminals for stay bolts connector
ST_VERB3
Figure 2.4: Assembled power cable with plug design (also see Figs. 2.21and
2.22 for 2AD, see Figs. 2.28 through 2.30) for 1MB.
Motor-controller connection This connection type is advantageous for larger facilities because it
with plugin testing points is possible to quickly and reliably exchange the damaged section of
a cable.
The mounting of assembled cables of this type is particularly simple

and quick.
On the motor Cable Plug Cable On the controller

design
(2AD main spindle motor, (Controllers


Symbols:
Power plug Power plug Wire-end ferrule Crimping cable lug Flange
connector (plug) connector (coupling) for line-up terminals for stay bolts connector
ST_VERB4
Figure 2.5: Assembled power cable with plugin testing points (also see figure
2.23, 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 the
plugin testing points.
2.1.2. Connection Plans for Only the connection plans for the direct connection of the motor-
Direct Connections controller power connections are depicted. They also, however,
apply to all other connections types. The respective testing points do
not 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 manufacturer
should be used when wiring the facility!
Technical Data The technical specifications for the motor, the holding brake (op-
tional) and the motor fan are dealt with in the documentation on the
respective main spindle motor - project planning notes. The docu-
mentation also includes a recommendation for the selection of the
protective motor switch for the motor fan.
Motor with Holding Brake If a main spindle motor with holding brake is used, then the control
cabinet must supply it with +24V +/-10%. The facility control system
controls 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 document

entitled „AC Main Spindle Drives with Controlled Asynchronous
Motors or Frameless Spindle Motors; Description of Application“.
2AD 100 motor connection (cooling air flow A => B) and 2AD 101 (motor fan with terminal box)
30 30 140 200 (Assembled power cable IKL•••/IKF•••) approx. 130
ge/gr Tightening
1 length
2
50
3
7
8 Cable
5
Crimping cable lug 6 (numbering of strands Power plug connector
Shield
for stay bolts M6 as per INDRAMAT IN 172/••
Plug terminal standard)
part of elec.
connection
E • • - • DA
operated by
control circuit
2
7 0,75 … 1,5 mm F
+24V
U
KDA / TDA 8 0,75 … 1,5 mm2 G
0V
controller
X8 E
gn/yel cross section motor type D
1 dep. (see table A
A1
2 assembled specifications) B M
A2
A3
3 C 3
3 6 0,75 … 1,5 mm2 H

ϑ
2 5 0,75 … 1,5 mm2 J
1 2AD 100 • - • • • • • • - . . .
X12 2AD 101 • - • • • • • • - . . .
A, B, R or L 2 or 5
Motor fan connection:

capacitor
Mains connection 1
2
5...8 mm 3
motor fan
windings
terminal box
L N PE
N 0,75 … 1,5 mm2 2 M

I>>
3
L 0,75 … 1,5 mm2 1
I>>
Dimension as per tech. specs motor fan

of motor fan (see doc. 2AD•••,
project planning notes) Identifying the rated connection voltage of the
motor fan in the motor type designation
2AD 100 • - • • • • • • - • • • • - • • • •
2AD 101 • - • • • • • • - • • • • - • • • •
Permissible mains voltage:
AC 220 V ±10%, 50...60 Hz : 2 (1 only with 2AD101) APMOT001
AC 115 V ±10%, 50...60 Hz : 5

Figure 2.6: Connection of 2AD 100 motor with air flow from A->B and 2AD 101
with terminal box to motor fan.
2AD 100 motor connection (cooling air flow B => A)
30 30 140 200 (assembled power cable IKL•••/IKF•••) approx. 130

ge/gr Tightening
1 length
2
3
50
7
8 Cable
5
Shield
Plug terminal, standard)
part of elec.
connection
E • • - • DA
operated by
control circuit
7 0,75 … 1,5 mm2 F
+24V
U
KDA / TDA 8 0,75 … 1,5 mm2 G
0V
controller
X8 E
1 dep. (see table A
A1
A2
A3
3 C 3
3 6 0,75 … 1,5 mm2 H

ϑ
2 5 0,75 … 1,5 mm2 J
1 main spindle motor
X12 2AD 100 • - • • • • • • - . . .
1 or 4
approx. 50 untightened
Motor fan connection: 40
Mains connection
26,5
5...8 mm
15,5
L N PE 26,5
Plug connector
N 0,75 … 1,5 mm2 2 M

I>>
L 0,75 … 1,5 mm2 1

I>>

project planning notes) Identifying the rated connection voltage of the motor
fan in the motor type designation
2AD 100 • - • • • • • • - • • • • - • • • •

AC 220 V ±10%, 50...60 Hz : 1 APMOT002
AC 115 V ±10%, 50...60 Hz : 4
Figure 2.7: Connection of 2AD 100 motor with air flow from B->A.
2AD 101 motor connection (motor fan with plug connector)
30 30 140 200 (Assembled power cable IKL•••/IKF•••) approx. 130

ge/gr Tightening
1 length
2
3
50
7
8 Cable
5
Shield
part of elec.
connection acc.
E • • - • DA
operated by
control circuit
2
7 0,75 … 1,5 mm F
+24V
U
KDA / TDA 8 0,75 … 1,5 mm2 G
0V
controller
X8 E
1 dep. (see table A
A1
A2
A3
3 C 3
2 H
3 6 0,75 … 1,5 mm
2 ϑ
2 5 0,75 … 1,5 mm J
X12 2AD 101 • - • • • • • • - . . .
C, D, E or F
Motor fan connection:

9 71 max.
56,5 max.
Mains connection
6...10 mm 28
L N PE Height approx. 21mm

Plug connector
4
3
N 0,75 … 1,5 mm2 2 M
I>>
3
L 0,75 … 1,5 mm2 1
I>>

project planning notes) Identifying rated connection voltage of the motor fan
in the motor type designation
2AD 101 • - • • • • • • - • • • • - • • • •

AC 220 V ±10%, 50...60 Hz : 1 or 2
AC 115 V ±10%, 50...60 Hz : 5 APMOT005
Figure 2.8: Connection of 2AD 101 motor with plug connector to motor fan.
2AD 132 motor connection (power plug connector) to KDA/TDA

ge/gr Tightening
1 length
2
50
3
7
8 Cable
5
Shield
part of elec.
connection acc.
E • • - • DA
operated by
control circuit
7 0,75 … 1,5 mm2 F
+24V
U
KDA / TDA 8 0,75 … 1,5 mm2 G
0V
controller
X8 E
1 dep. (see table A
A1
A2
A3
3 C 3
3 6 0,75 … 1,5 mm2 H

ϑ
2 5 0,75 … 1,5 mm2 J
X12 2AD 132• - ••••••-....
C, E or F
Motor fan connection: 9 71 max.

56,5 max.
Mains connection 28
6...10 mm
Height approx. 21mm

L1 L2 L3 PE
Plug connector
2
0,75 … 1,5 mm 3
I>>
M
0,75 … 1,5 mm2 2
I>>
2 3
0,75 … 1,5 mm 1
I>>
motor fan
Dimension as per tech. specs APMOT003
project planning notes)

3x400V ±15%, 50...60Hz
3x460V ±10%, 60Hz
Figure 2.9: Connection of 2AD 132 motor with power plug to KDA/TDA controller.
2AD 132 motor connection (power plug connector) to RAC
250 200 (assembled power cable IKL•••/IKF•••) ca. 130

ge/gr Tightening
1 length
2
50
3
7
Wire-end ferrule 8 Cable
5
in RAC2/RAC3 6 (numbering of strands Power plug connector
Schirm
as per INDRAMAT IN 172/••
part of elec.
connection acc.
E1 - RAC
operated by
control circuit
7 0,75 … 1,5 mm2 F
+24V
U
RAC 8 0,75 … 1,5 mm2 G
0V
controller
X14 E
1 dep. (see table A
A1
A2
A3
3 C 3
1 6 0,75 … 1,5 mm2 H

ϑ
2 5 0,75 … 1,5 mm2 J
3
main spindle motor
X16 2AD 132• - ••••••-....
C, E or F
Motor fan connection: 9 71 max.

56,5 max.
Mains connection
6...10 mm 28
Plug connector Height approx. 21mm

L1 L2 L3 PE
Dimension as per tech. specs
project planning notes)
0,75 … 1,5 mm2 3

I>>
M
0,75 … 1,5 mm2 2
I>>
3
0,75 … 1,5 mm2 1
I>>
motor fan
APMOT004
Permissible mains voltage: X14 RAC2.2 motor power connection

3xAC400V ±15%, 50...60Hz (protective motor circuit breaker is integrated into RAC2.2!)
U2 V2 W2
3xAC460V ±10%, 60Hz
(only with RAC2.2 )
Figure 2.10: Connection of 2AD 132 motor with power plug to RAC controller.
2AD 132 motor connection (terminal box) to KDA/TDA

ge/gr Tightening
1 length
2
3
7
8 Cable
5
Crimping cable lug 6 (numbering of strands
Shield
for stay bolts M6 as per INDRAMAT Crimping cable lug
Plug terminal, standard) for stay bolts, see table on
part of elec. preassembled specifications
connection acc.
E • • - • DA
operated by
control circuit
7 0,75 … 1,5 mm2 1
+24V
U
KDA / TDA 8 0,75 … 1,5 mm2 2
0V
controller
X8
gn/yel cross section motor type
1 dep. (see table U1
A1
2 assembled specifications) V1 M
A2
W1
A3
3 3
3 6 0,75 … 1,5 mm2 3

ϑ
2 5 0,75 … 1,5 mm2 4
X12 2AD 132• - ••••••-....
A, B, R or L
Motor fan connection: terminal

U
Mains connection block
6...10 mm V
L1 L2 L3 PE motor fan W
windings
terminal box
Dimension as per tech. specs of motor fan
(see doc. 2AD•••, project planning notes)
bn
ge
0,75 … 1,5 mm2 U
I>>
win-
0,75 … 1,5 mm2 V
dings ws M
I>>
connec- bl
3
0,75 … 1,5 mm2 W tion
I>>
gn motor fan
sw
APMOT007
Windings connection for:
Permissible 3xAC400V ±15%, 50...60Hz bn ge bn ge 3xAC220V ±10%,
mains voltage is 3xAC460V ±10%, 60Hz 50...60Hz
(Condition at delivery) U U
dependent upon
ws ws
windings V V
bl bl
connection of terminal
motor fan! terminal block
W W
block
sw gn sw gn
Figure 2.11: Connection of 2AD 132 motor with terminal box to KDA/TDA controller.
2AD 132 motor connection (terminal box), 2AD 160, 2AD 180 and 2AD 200 to RAC
250 200 (assembled power cable IKL•••/IKF•••) approx. 150

ge/gr Tightening
1 length
2
3
7
8 Cable
Wire-end ferrule 5
in RAC2/RAC3 6 (numbering of strands
Shield
as per INDRAMAT Crimping cable lug for
Plug terminal, standard) stay bolts, see table for
part of elec. assembled
connection acc. specifications
E1-RAC
operated by
control circuit
7 0,75 … 1,5 mm2 1
+24V
U
RAC 8 0,75 … 1,5 mm2 2
0V
controller
X14
1 dep. (see table U1
A1
2 assembled specifications) V1 M
A2
A3
3 W1 3
3 6 0,75 … 1,5 mm2 3

ϑ
2 5 0,75 … 1,5 mm2 4
1 2AD 160, 2AD 180, 2AD 200
X16 2AD 132 • - • • • • • • - . . .
A, B, R or L
Motor fan connection: terminal

U
Mains connection block
6...10 mm V
L1 L2 L3 PE Motor fan W
windings
Dimension of the motor protective switch as Motor fan windings

per tech. specs on motor fan
(see doc. 2AD•••, project planning notes)
0,75 … 1,5 mm2 U

I>>
0,75 … 1,5 mm2 V M

I>>
3
0,75 … 1,5 mm2 W
I>>
motor fan
APMOT008

3xAC400V ±15%, 50...60Hz
3xAC460V ±10%, 60Hz
X14 RAC2.2 motor fan connection
(protective motor switch is integrated into RAC 2.2!)
U2 V2 W2
(only with RAC2.2)
Figure 2.12: Connection of 2AD 132, 2AD 160, 2AD 180 and 2AD 200 motors
(all have terminal box)
Motor connection 1MB (terminal box) to KDA/TDA

ge/gr Tightening
1 length
2
3
7
8 Cable
5
Crimping cable lug 6 (numbering of cores
Shield
for stay bolts M6 ad per INDRAMAT Crimping cable lugs for
Plug terminal, standard) stay bolts, see table
part of elec. assembled specs
connection acc.
E • • - • DA
(Substitute NTC-resistor,
KDA / TDA function not guaranteed!)
controller
ϑ
X8
1 dep. (see table U
A1 1
A2
2 assembled specifications)
V
M
3 1 3
A3
W
3 6 0,75 … 1,5 mm2 1 0,75...1,5 mm2
5 0,75 … 1,5 mm2

ϑ
2
1 0,75...1,5 mm2
X12 1MB
frameless spindle motor
Terminal box apmot009
Fig. 2.13: Connection via terminal box of 1MB frameless spindle motors to KDA/
TDA controllers
1MB motor connection (power plug connector) to KDA/TDA
30 30 140 200 (assembled power cable IKL•••/IKF•••) ca. 130 25 20

ge/gr Tightening
1 length
2
3
50
7
8 Cable
5
Crimping cable lug 6 (numbering of strands Power plug connector Flange
Shield
for stay bolts M6 as per INDRAMAT IN 172/•• connector
Plug terminal, standard) IN 192/••
part of elec.
connection acc.
E • • - • DA
KDA / TDA (Substitute NTC-resistor,

G function not guaranteed!)
connector
ϑ
X8 E
1 dep. (see table A
A1
A2
A3
3 C 3
3 6 0,75 … 1,5 mm2 H

ϑ
2 5 0,75 … 1,5 mm2 J
1 1MB
X12 frameless spindle motor
APMOT012
Figure 2.14: Connection of 1MB frameless spindle motors to KDA/TDA

controllers via power plug connectors.
1MB motor connection (terminal box) to RAC

200 200 (assembled power cable IKL•••/IKF•••) approx. 150
ge/gr Tightening
1 length
2
3
7
8 Cable
5
Wire-end ferrule 6 (numbering of strands
Shield
in RAC2/RAC3 as per INDRAMAT Crimping cable lug for
Plug terminal, standard) stay bolts, see table for
part of elec. assembled specifications
connection acc.
E 1-RAC
function not guaranteed!)
ϑ
X14
RAC
controller gn/yel cross section motor type
1 dep. (see table U
A1 1
A2
2 assembled specifications)
V
M
3 1 3
A3
W
1 6 0,75 … 1,5 mm2 1 0,75...1,5 mm2
5 0,75 … 1,5 mm2

ϑ
2
3 0,75...1,5 mm2
X16
1MB
frameless spindle motor
terminal box apmot010
Fig. 2.15: Connection via terminal box of 1MB frameless spindle motor to RAC
controller
1MB motor connection (terminal box) to RAC
200 200 (assembled power cable IKL•••/IKF•••) approx. 130 25 20

ge/gr Tightening
1 length
2
50
3
7
8 Cable
5
Wire-end ferrule 6 (numbering of strands Power plug connector Flange
Shield
in RAC2/RAC3 as per INDRAMAT IN 172/•• connector
Plug terminal, standard) IN 192/••
part of elec.
connection acc.
E • • - • DA
G function not guaranteed!)
ϑ
X14 E
RAC
controller
1 dep. (see table A
A1
A2
A3
3 C 3
1 6 0,75 … 1,5 mm2 H

ϑ
2 5 0,75 … 1,5 mm2 J
3 1MB
X16 frameless spindle motor
APMOT011
Fig. 2.16: 1MB frameless spindle motor connection to RAC controller via power
plug connector.
2.1.3. Assembled
Data List
Types of power connections

motor-controller
direct with intermediate terminal plug with

plugin
at terminal strip design testing points
Figure 2.17: Four types of assembled power connections
The four types of power motor-controller connections are motor-type

dependent and have been summarized in a table.
Assembled
Specifications Table
2AD main spindle motor frameless spindle motor 1MB
....plugin testing points ....plugin testing points
....plug design ....plug design
....direct connection + ....direct connection +

intermediate terminal intermediate terminal
ZuordTab
Table listing assembled specifications for... Table listing assembled specifications for...
Figure 2.18: Allocation of main spindle motors in table
The tables list the available flexible and highly flexible assembled
cables and their significant components.
Section 1: 2AD power connections - direct connections and intermediate terminals
Cable Assembled cables Assembled cable components for direct Assembled cables for intermediate
cross for direct connection connection
terminals on terminal strips
section on the Cable on the on the motor on the controller
2 motor
A [mm ] flex./highly flex. flex./highly flex. controller flex./highly flex. flex./highly flex.
For...
2AD100B-B·····-AS·3-···· 4 IKL071/IKF071 IN172/25 IN203/IN403 ...stay bolt M6 IKL074/ *) not available

(KDA /TDA)
2AD100C-B·····-AS·3-···· 4 IKL071/IKF071 IN172/25 IN203/IN403 ...stay bolt M6 IKL074/ *) not available
(KDA /TDA)
2AD100D-B·····-AS·3-···· 6 IKL112/IKF112 IN172/06 IN204/IN404 ...stay bolt M6 IKL115/ *) not available
(KDA /TDA)
2AD101D-B·····-BD·3-···· 10 IKL130/IKF130 IN172/10 IN205/IN405 ...stay bolt M6 IKL134/ *) not available
(KDA /TDA)
2AD132B-B·····-BS·3-····· 10 IKL130/IKF130 IN172/10 IN205/IN405 ...stay bolt M6 IKL134/ *) not available
(KDA /TDA)
2AD132C-B·····-BS·3-····· 16 *) IN172/16 IN206/IN406 ...stay bolt M6 IKL150/IKF150 not available
• DOK-GENERL-MAIN*EL*CON-PRJ1-EN-E1,44 • 07.97
(KDA /TDA)
2AD132D-B·····-BD·3-····· 25 IKL170/IKF170 IN172/25 IN207/IN407 ...stay bolt M6 *) not available
(KDA /TDA)
For...
2AD132B-B·····-DS·3-····· 6 IKL115/ *) IN172/06 IN204/IN404 ...line-up terminals IKL115/ *) not available

(RAC2 /RAC3)
2AD132C-B·····-CS·3-····· 10 IKL134/ *) IN172/10 IN205/IN405 ...line-up terminals IKL134/ *) not available
(RAC2 /RAC3)
2AD132D-B·····-AS·3-····· 16 IKL150/IKF150 IN172/16 IN206/IN406 ...line-up terminals IKL150/IKF150 not available
(RAC2 /RAC3)
alkab01
Symbols:
intermediate terminals on terminal strips for 2AD motors - Section 1.

Figure 2.19: Assembled specifications table for direct connection and
Power plug Power plug Wire-end ferrule Crimping cable lug Flange
connector (plug) connector (coupling) PG screw connection
connection
*) Available. For inquiries on type information contact Development Dept., INDRAMAT.
30
Section 2: 2AD power connections - direct connections and intermediate terminals
Cable Assembled cables Cable components Assembled cables for intermediate
cross for direct connection for direct connection terminals on terminal strips
A [mm2] motor flex./highly flex. controller flex./highly flex. flex./highly flex.
Für... For...
2AD132B-B·····-BS·3-····· 10 IKL135/IKF135 ..stay bolt M6 IN205/IN405 ..stay bolt M6 IKL136/IKF136 not

(PG 29) M8 (KDA /TDA) available
2AD132C-B·····-BS·3-····· 16 IKL157/IKF157 ..stay bolt M6 IN206/IN406 ..stay bolt M6 IKL152/IKF152 not

2AD132D-B·····-BD·3-····· 25 IKL174/IKF174 ..stay bolt M8 IN207/IN407 ..stay bolt M6 IKL172/IKF172 not

For... For...
2AD132B-B·····-DS·3-····· 6 IKL110 ..stay bolt M6 IN204/IN404 ...line-up terminals *) not

(PG 29) M8 (RAC2 /RAC3) available
2AD132C-B·····-CS·3-····· 10 IKL136/IKF136 ..stay bolt M6 IN205/IN405 ...line-up terminals IKL136/IKF136 not

2AD132D-B·····-AS·3-···· 16 IKL151/IKF151 ..stay bolt M8 IN206/IN406 ...line-up terminals IKL151/IKF151 not
M8 available
(PG 29) (RAC2 /RAC3)
2AD160B-B·····-BS·3-···· 25 IKL171/IKF171 ..stay bolt M8 IN207/IN407 ...line-up terminals IKL171/IKF171 not
2AD160C-B·····-BS·3-····· 35 IKL182/ *) ..stay bolt M10 IN267 ...line-up terminals IKL182/ *) not
2AD180C-B·····-BS·3-····· 35 IKL182/ *) ..stay bolt M10 IN267 ...line-up terminals IKL182/ *) not
For... For...
2AD180D-B·····-BS·3-····· 50 IKL 191/ *) ..stay bolt M10 IN268/ *) ...Screws *) not

(PG 42 ) M10 M12 (RAC4) available
2AD200C-B·····-AS·3-····· 2 x 25 2 x IKL 175/2 x IKF 175 ..stay bolt M12 2 x IN207/ 2 x IN 407 ...Screws *) not
(PG 48) M12 M12 (RAC4) available
intermediate terminals on terminal strips for 2AD motors - Section 2.

ALKAB02
Symbols:
Figure 2.20: Assembled specifications table for direct connections and

Power plug Power plug *) Available. For inquiries on type information
PG screw connection Wire-end ferrule Crimping cable Flange
connector (plug) connector (coupling) connection
contact Development Dept., INDRAMAT.
lug
31
Section 1: 2AD power connections - plug design
Cable Assembled cables for plug The components of assembled cables with plug
cross connector design
section
on the motor on the controller on the motor Cable Plug design L. on the
A[mm2]
flex. /highly flex. flex. /highly flex. flex./highly flex. controller
see
"Attention" For..
below!
2AD100B-B•••••-AS•3-•••• 4 IKL073/IKF073 *) IN172/25 IN203/IN403 IN217/25 IN218/25 dto. ..stay bolt M6
(KDA/TDA)
2AD100C-B•••••-AS•3-•••• 4 IKL073/IKF073 *) IN172/25 IN203/IN403 IN217/25 IN218/25 dto. ..stay bolt M6
(KDA/TDA)
2AD100D-B•••••-AS•3-•••• 6 IKL111/IKF111 IKL114/IKF114 IN172/06 IN204/IN404 IN217/06 IN218/06 dto. ..stay bolt M6
(KDA/TDA)
2AD101D-B•••••-BD•3-•••• 10 IKL133/IKF133 *) IN172/10 IN205/IN405 IN217/10 IN218/10 dto. ..stay bolt M6
(KDA/TDA)
2AD132B-B•••••-BS•3-•••• 10 IKL133/IKF133 *) IN172/10 IN205/IN405 IN217/10 IN218/10 dto. ..stay bolt M6
(KDA/TDA)
2AD motors - Section 1.

2AD132C-B•••••-BS•3-•••• 16 IKL154/IKF154 *) IN172/10 IN206/IN406 IN217/16 IN218/16 dto. ..stay bolt M6
(KDA/TDA)
2AD132D-B•••••-BD•3-••• 25 *) *) IN172/25 IN207/IN407 IN217/25 IN218/25 dto. ..stay bolt M6
(KDA/TDA)
see
"Attention" For..
below!
2AD132B-B•••••-DS•3-•••• 6 IKL111/IKF111 *) IN172/6 IN204/IN404 IN217/06 IN218/06 dto. ..line-up terminals
(RAC2/RAC3)
2AD132C-B•••••CS•3-•••• 10 IKL133/IKF133 *) IN172/10 IN205/IN405 IN217/10 IN218/10 dto. ..line-up terminals
(RAC2/RAC3)
2AD132D-B•••••-AS•3-•••• 16 IKL154/IKF154 *) IN172/16 IN206/IN406 IN217/16 IN218/16 dto. ..line-up terminals
(RAC2/RAC3)
Symbols:
Power plug Power plug

Attention!
PG screw connection Wire-end Crimping cable Flange Flange connection IN218 must have an insulator
connector (plug) connector (coupling) ferrule connection casing which juts out over the contacts on the
lug
soldered or crimped side by approx. 3 mm!
*) Available. For inquiries on type information contact Development Dept., INDRAMAT. Do not use any other type!
Figure 2.21: Specifications table for assembled cables with plug connectors for
Alkab03
32
Section 2: 2AD power connections - plug design
Cable Assembled cables for plug Assembled cable components with
cross connector plug connector
section on the motor on the controller on the motor Cable plug design L. on the
A[mm]2
flex. /highly flex. flex. /highly flex. flex./highly flex. controller
see
For.. "attention" For..
below!
2AD132B-B•••.•-BS•3-•••• 10 IKL137/IKF137 *) ..stay bolt M6 IN205/IN405 IN217/10 IN218/10 dto. ..stay bolt M6
(PG29) M8 (KDA/TDA)
2AD132C-B•••.•-BS•3-•••• 16 IKL153/IKF153 *) ..stay bolt M8 IN206/IN406 IN217/16 IN218/16 dto. ..stay bolt M6
(PG29) M8 (KDA/TDA)
2AD132D-B•••.•-BD•3-•••• 25 IKL173/IKF173 *) ..stay bolt M8 IN207/IN407 IN217/25 IN218/25 dto. ..stay bolt M6
(PG29) M8 (KDA/TDA)
2.
see
below!
2AD132B-B•••.•-DS•3-•••• 6 *) *) ..stay bolt M6 IN204/IN404 IN217/06 IN218/06 dto. ..line-up terminals

(PG29) M8 (RAC2/RAC3)
2AD132C-B•••.•-CS•3-•••• 10 IKL137/IKF137 *) ..stay bolt M6 IN205/IN405 IN217/10 IN218/10 dto. ..line-up terminals
2AD132D-B•••.•-AS•3-••• 16 *) *) ..stay bolt M8 IN206/IN406 IN217/16 IN218/16 dto. ..line-up terminals
2AD160B-B•••.•-BS•3-•••• 25 *) *) ..stay bolt M8 IN207/IN407 IN217/25 IN218/25 dto. ..line-up terminals
2AD160C-B•••.•-BS•3-•••• 35 not available not available ..stay bolt M10 IN267 not available not available dto. ..line-up terminals
2AD180C-B•••.•-BS•3-•••• 35 not available not available ..stay bolt M10 IN267 not available not available dto. ..line-up terminals
see
below!
2AD180D-B•••.•-BS•3-•••• 50 not available not available ..stay bolt M10 IN268 not available not available dto. ..screws
(PG42) M10 M12(RAC4)
2AD200C-B•••.•AS•3-•••• 2X25 not available not available ..stay bolt M12 2 x IN207/2 x IN 407 not available not available dto. ..screws
(PG48) M12 M12(RAC4)
Symbols:

Attention!
PG screw connection Wire-end Crimping cable Flange Flange connection IN218 must have an insulator
lug
ALKAB04
33
Figure 2.22: Specifications for connection with plug design for 2AD motors-Section
Section 1: 2AD power connections - plugin testing points
Cable Preassembled cables for plugin Components of preassembled cables with plugin
cross testing points testing points
section
on the motor on the controller on the motor Cable plugin testing points L. on the
A[mm2]
flex. /highly flex. flex. /highly flex. flex. /highly flex. controller
For..
2AD100B-B•••••-AS•3-•••• 4 IKL072/IKF072 IKL071/IKF071 IN172/25 IN203/IN403 IN210/25 IN172/25 dto. ..stay bolt M6
(KDA/TDA)
2AD100C-B•••••-AS•3-•••• 4 IKL072/IKF072 IKL071/IKF071 IN172/25 IN203/IN403 IN210/25 IN172/25 dto. ..stay bolt M6
(KDA/TDA)
2AD100D-B•••••-AS•3-•••• 6 IKL113/IKF113 IKL112/IKF112 IN172/06 IN204/IN404 IN210/06 IN172/06 dto. ..stay bolt M6
(KDA/TDA)
2AD101D-B•••••-BD•3-•••• 10 IKL138/IKF138 IKL130/IKF130 IN172/10 IN205/IN405 IN210/10 IN172/10 dto. ..stay bolt M6
(KDA/TDA)
2AD132B-B•••••-BS•3-•••• 10 IKL138/IKF138 IKL130/IKF130 IN172/10 IN205/IN405 IN210/10 IN172/10 dto. ..stay bolt M6
(KDA/TDA)
2AD132C-B•••••-BS•3-•••• 16 IKL158/IKF158 *) IN172/10 IN206/IN406 IN210/16 IN172/16 dto. ..stay bolt M6
(KDA/TDA)
2AD132D-B•••••-BD•3-••• 25 IKL178/IKF178 IKL170/IKF170 IN172/25 IN207/IN407 IN210/25 IN172/25 dto. ..stay bolt M6
(KDA/TDA)
points in 2AD motors - Section 1.

For..
2AD132B-B•••••-DS•3-•••• 6 IKL113/IKF113 *) IN172/6 IN204/IN404 IN210/06 IN172/06 dto. ..line-up terminals

(RAC2/RAC3)
2AD132C-B•••••-CS•3-•••• 10 IKL138/IKF138 IKL134/ *) IN172/10 IN205/IN405 IN210/10 IN172/10 dto. ..line-up terminals
(RAC2/RAC3)
2AD132D-B•••••-AS•3-•••• 16 IKL158/IKF158 *) IN172/16 IN206/IN406 IN210/16 IN172/16 dto. ..line-up terminals
(RAC2/RAC3)
Symbols: ALKAB05
Power plug Power plug Multi-core Flange

connector (plug) connector (coupling) PG screw connection Compression
cable end cable shoe connection
Figure 2.23: Table of assembled specifications for connections with plug testing
34
Section 2: 2AD power connections - plugin testing points
Cable Preassembled cable for plugin Components of preassembled cables with plugin
section
on the motor on the controller on the motor Cable plugin testing points L. on the
A[mm2]
For.. For..
2AD132B-B•••••-BS•3-•••• 10 IKL129/IKF129 IKL130/IKF130 ..stay bolt M6 IN205/IN405 IN210/10 IN172/10 dto. ..stay bolt M6
(PG29) M8 (KDA/TDA)
2AD132C-B•••••-BS•3-•••• 16 IKL149/IKF149 *) ..stay bolt M8 IN206/IN406 IN210/16 IN172/16 dto. ..stay bolt M6
(PG29) M8 (KDA/TDA)
2AD132D-B•••••-BD•3-•••• 25 IKL169/IKF169 IKL170/IKF170 ..stay bolt M8 IN207/IN407 IN210/25 IN172/25 dto. ..stay bolt M6
(PG29) M8 (KDA/TDA)
For.. For..
2AD132B-B•••••-DS•3-•••• 6 *) *) ..stay bolt M6 IN204/IN404 IN217/06 IN172/06 dto. ..line-up terminals

2AD132C-B•••••-CS•3-•••• 10 IKL129/IKF129 IKL134/ *) ..stay bolt M6 IN205/IN405 IN217/10 IN172/10 dto. ..line-up terminals
2AD132D-B•••••-AS•3-••• 16 IKL149/IKF149 *) ..stay bolt M8 IN206/IN406 IN217/16 IN172/16 dto. ..line-up terminals
2AD160B-B•••••-BS•3-•••• 25 IKL169/IKF169 *) ..stay bolt M8 IN207/IN407 IN217/25 IN172/25 dto. ..line-up terminals
2AD160C-B•••••-BS•3-•••• 35 not available not available ..stay bolt M10 IN267 not available not available dto. ..line-up terminals
testing points in 2AD motors - Section 2.

2AD180C-B•••••-BS•3-•••• 35 not available not available ..stay bolt M10 IN267 not available not available dto. ..line-up terminals
For..
For..
2AD180D-B•••••-BS•3-•••• 50 not available not available ..stay bolt M10 IN268 not available not available dto. ..Screws
(PG42) M10 M12(RAC4)
2AD200C-B•••••AS•3-•••• 2X25 not available not available ..stay bolt M12 2 x IN207/2 x IN 407 not available not available dto. ..Screws
(PG48) M12 M12(RAC4)
ALKAB06
Symbols:

connector (plug) connector (coupling) PG screw connection Compression
cable end cable shoes connection
Figure 2.24: Table of assembled specifications for connections with plugin

35
Section 1: 1MB power connections - plugin testing points
Cable Assembled cables Components of assembled cables for direct Assembled cables for intermediate
cross for direct connection connections terminals on terminal strips
For... For...
1MB160E-4B...
(PG )
1MB160B-4A... 10 IKL135/IKF135 ..stay bolt M6 IN205/IN405 ..stay bolt M6 IKL136/IKF136 not
1MB160D-4A... 10 IKL135/IKF135 ..stay bolt M6 IN205/IN405 ..stay bolt M6 IKL136/IKF136 not

1MB160F-4A... 25 IKL174/IKF174 ..stay bolt M8 IN207/IN407 ..stay bolt M6 IKL172/IKF172 not

1MB200D-4E... 25 IKL174/IKF174 ..stay bolt M8 IN207/IN407 ..stay bolt M6 IKL172/IKF172 not
1MB200D-4C...
(PG )
1MB240B-4A... 10 IKL135/IKF135 ..stay bolt M6 IN205/IN405 ..stay bolt M6 IKL136/IKF136 not
1MB240D-4A... 10 IKL135/IKF135 ..stay bolt M6 IN205/IN405 ..stay bolt M6 IKL136/IKF136 not
1MB240F-4A... 25 IKL174/IKF174 ..stay bolt M8 IN207/IN407 ..stay bolt M6 IKL172/IKF172 not

1MB240H-4A... 25 IKL174/IKF174 ..stay bolt M8 IN207/IN407 ..stay bolt M6 IKL172/IKF172 not

1MB241H-6C... 25 IKL174/IKF174 ..stay bolt M8 IN207/IN407 ..stay bolt M6 IKL172/IKF172 not
1MB310B-6A...
(PG )
Symbols: ALKAB07
intermediate terminals on terminals strips in 1MB motors - Section 1.

Power plug Power plug Wire-end Flange
connector (plug) connector (coupling) PG screw connection Crimping cable
ferrule lug connection
Figure 2.25: Table of assembled specifications for direct connection and for
36
1MB Frameless Spindle Motor
Cable Assembled cables Components of the assembled cable for Assembled cables for intermediate
cross for direct connection direct connection terminals on terminal strips
For... For...
1MB160F-4B...
(PG )
1MB200D-4B... 10 IKL136/IKF136 ..stay bolt M6 IN205/IN405 ...line-up terminals IKL136/IKF136 not
1MB200D-4D...
(PG )
1MB200E-4B...
(PG )
1MB200H-4B...
(PG )
1MB240F-4B...
(PG )
1MB240H-4B... 16 IKL151/IKF151 ..stay bolt M8 IN206/IN406 ...line-up terminals IKL151/IKF151 not
M8 available
(PG 29) (RAC2 /RAC3)
1MB241H-6D... 10 IKL136/IKF136 ..stay bolt M6 IN205/IN405 ...line-up terminals IKL136/IKF136 not
1MB310B-6B... 25 IKL171/IKF171 ..stay bolt M8 IN207/IN407 ...line-up terminals IKL171/IKF171 not

1MB310D-6B... 25 IKL171/IKF171 ..stay bolt M8 IN207/IN407 ...line-up terminals IKL171/IKF171 not

1MB310F-6B... 35 IKL182/ *) ..stay bolt M10 IN267 ...line-up terminals IKL182/ *) not
1MB312B-4A... 25 IKL171/IKF171 ..stay bolt M8 IN207/IN407 ...line-up terminals IKL171/IKF171 not
1MB312C-4A... 35 IKL182/ *) ..stay bolt M10 IN267 ...line-up terminals IKL182/ *) not
ALKAB08
Symbols:
intermediate terminals on terminals strips in 1MB motors - Section 2.

Power plug Power plug Wire-end Crimping cable Flange
connector (plug) connector (coupling) PG screw connection
Figure 2.26: Table of assembled specifications for direct connection and for
37
Section 3: 1MB power connections - direct connections and intermediate terminals
Cable Assembled cables Components of the assembled cables Assembled cable for intermediate
cross for direct connections for direct connections terminals on terminal strips
For... For...
1MB375B-6B... ..Line-up terminals

(PG ) (RAC2/RAC3)
For...
For...
1MB375D-6B... ..Screws
(PG ) M12(RAC4)
ALKAB09
Symbols:

connector (plug) connector (coupling) PG screw connection Crimping cable
and for intermediate terminals on terminal strips in 1MB motors - Section 3.

38
Figure 2.27: Table listing information on assembled cables for direct connections
Section 1: 1MB power connections - plug design
Cable Assembled cables Components of assembled cables
cross for plug design with plug design
section on the motor on the controller on the motor Cable plug L. on the
A[mm2] flex. /highly flex. flex. /highly flex. flex. /highly flex. design controller
see
For.. "Attention" For..
below
1MB160E-4B...
(PG )
10 IKL137/IKF137 *) ..stay bolt M6 IN205/IN405 IN217/10 IN218/10 dto. ..stay bolt M6
1MB160B-4A...
(PG 29) M8 (KDA/TDA)
1MB160D-4A...

1MB160F-4A...

1MB200D-4E...
M8 (KDA/TDA)
(PG 29)
1MB200D-4C...
(PG )
1MB240B-4A... 10 IKL137/IKF137 *) ..stay bolt M6 IN205/IN405 IN217/10 IN218/10 dto. ..stay bolt M6
1MB motors - Section 1.

(KDA/TDA)
(PG 29) M8
1MB240D-4A... 10 IKL137/IKF137 *) ..stay bolt M6 IN205/IN405 IN217/10 IN218/10 dto. ..stay bolt M6
1MB240F-4A...

1MB240H-4A...

1MB241H-6C...
M8 (KDA/TDA)
(PG 29)
1MB310B-6A...
(PG )
Symbols:

Attention!
PG screw connection Wire-end Crimping Flange Flange connection IN218 must have an insulator
cable lug
Figure 2.28: Table of specifications for assembled cables with plug design in
39
ALKAB10
Cable Assembled cable for Components of assembled cable with plug
cross plug design design
section on the motor on the controller on the motor Cable Plug design L. on the
A[mm2] flex. /highly flex. flex. /highly flex. flex. /highly flex. controller
see
below!
1MB160F-4B...
(PG )
1MB200D-4B... 10 IKL137/IKF137 *) ..stay bolts M6 IN205/IN405 IN217/10 IN218/10 dto. ..line-up terminals
(PG 29) M8 (RAC2/RAC3)
1MB200D-4D...
(PG )
1MB200E-4B...
(PG )
1MB200H-4B...
(PG )
1MB240F-4B...
(PG )
motors - Section 2.
1MB240H-4B... 16 IKL153/IKF153 *) ..stay bolts M8 IN206/IN406 IN217/16 IN218/16 dto. ..line-up terminals
1MB241H-6D... 10 IKL137/IKF137 *) ..stay bolts M6 IN205/IN405 IN217/10 IN218/10 dto. ..line-up terminals
1MB310B-6B... 25 IKL173/IKF173 *) ..stay bolts M8 IN207/IN407 IN217/25 IN218/25 dto. ..line-up terminals
1MB310D-6B... IKL173/IKF173 *) ..stay bolts M8 IN207/IN407 IN217/25 IN218/25 dto. ..line-up terminals
25
1MB310F-6B... 35 not available not available ..stay bolts M10 IN267 not available not available dto. ..line-up terminals
M10 (RAC2/RAC3)
(PG 42)
1MB312B-4A... IKL173/IKF173 *) ..stay bolts M8 IN207/IN407 IN217/25 IN218/25 dto. ..line-up terminals
25
1MB312C-4A... not available not available ..stay bolts M10 IN267 not available not available dto. ..line-up terminals
35
(PG 29)
Symbols:

Attention!
cable lug
Figure 2.29: Table of specs on assembled cables with plug design for 1MB
*) Available. For inquiries on type information contact Development Dept., INDRAMAT. Do not use any other types!
ALKAB11
40
Cable Assembled cable for Components of assembled cables with
cross plug design plug design
section on the motor on the controller on the motor Cable Plug design L. on the
A[mm2] flex. /highly flex. flex. /highly flex. flex. /highly flex. controller
see
below!
1MB375B-6B... ..line-up terminals

(PG ) (RAC2/RAC3)
motors - Section 3.
see
For.. For..
"Attention"
below!
1MB375D-6B... ..screws
(PG ) M12(RAC4)
Symbols:

Attention!
cable lug
*) Available. For inquiries on type information contact Development Dept., INDRAMAT. Do not use any other types!
Figure 2.30: Specifications table on assembled cables with plug design for 1MB
ALKAB12
41
Cable Assembled cable for plugin testing Components of preassembled cables with plugin
cross points testing points
section
on the motor on the controller on the motor Cable Plug testing points L. on the
A[mm2]
For.. For..
1MB160E-4B...
(PG )
1MB160B-4A... 10 IKL129/IKF129 IKL130/IKF130 ..stay bolt M6 IN205/IN405 IN210/10 IN172/10 dto. ..stay bolt M6
(PG 29) (KDA/TDA)
M8
1MB160D-4A... 10 IKL129/IKF129 IKL130/IKF130 ..stay bolt M6 IN205/IN405 IN210/10 IN172/10 dto. ..stay bolt M6
(PG 29) (KDA/TDA)
M8
1MB160F-4A... 25 IKL169/IKF169 IKL170/IKF170 ..stay bolt M8 IN207/IN407 IN210/25 IN172/25 dto. ..stay bolt M6
1MB200D-4E... 25 IKL169/IKF169 IKL170/IKF170 ..stay bolt M8 IN207/IN407 IN210/25 IN172/25 dto. ..stay bolt M6
1MB200D-4C...
(PG )
1MB240B-4A... 10 IKL129/IKF129 IKL130/IKF130 ..stay bolt M6 IN205/IN405 IN210/10 IN172/10 dto. ..stay bolt M6
1MB240D-4A... 10 IKL129/IKF129 IKL130/IKF130 ..stay bolt M6 IN205/IN405 IN210/10 IN172/10 dto. ..stay bolt M6
1MB240F-4A... 25 IKL169/IKF169 IKL170/IKF170 ..stay bolt M8 IN207/IN407 IN210/25 IN172/25 dto. ..stay bolt M6
IKL169/IKF169 IKL170/IKF170 ..stay bolt M8 IN207/IN407 IN210/25 IN172/25 dto. ..stay bolt M6
testing points in 1MB motors - Section 1.

1MB240H-4A... 25
1MB241H-6C... 25 IKL169/IKF169 IKL170/IKF170 ..stay bolt M8 IN207/IN407 IN210/25 IN172/25 dto. ..stay bolt M6
1MB310B-6A...
(PG )
ALKAB13
Symbols:

connector (plug) connector (coupling) PG screw connection Crimping
cable end cable lug connection
Figure 2.31: Specifications table on assembled cables for connection with plugin
42
Cable Assembled cable for plugin testing Components of a assembled cables with plugin testing
cross points points
section
on the motor on the controller on the motor Cable Plug testing point L. on the
A[mm2]
For.. For..
1MB160F-4B...
(PG )
1MB200D-4B... 10 IKL129/IKF129 IKL134/ *) ..stay bolt M6 IN205/IN405 IN217/10 IN172/10 dto. ..line-up terminals
1MB200D-4D...
(PG )
1MB200E-4B...
(PG )
1MB200H-4B...
(PG )
1MB240F-4B...
(PG )
1MB240H-4B... IKL149/IKF149 *) ..stay bolt M8 IN206/IN406 IN210/16 IN172/16 dto. ..line-up terminals
16
1MB241H-6D... 10 IKL129/IKF129 IKL134/ *) ..stay bolt M6 IN205/IN405 IN217/10 IN172/10 dto. ..line-up terminals
1MB310B-6B... IKL169/IKF169 *) ..stay bolt M8 IN207/IN407 IN210/25 IN172/25 dto. ..line-up terminals
25
IKL169/IKF169 *) ..stay bolt M8 IN207/IN407 IN210/25 IN172/25 dto. ..line-up terminals

1MB310D-6B... 25
1MB310F-6B... not available not available ..stay bolt M10 IN267 not available not available dto. ..line-up terminals
35
(PG 42) M10 (RAC2/RAC3)
1MB312B-4A... 25 IKL169/IKF169 *) ..stay bolt M8 IN207/IN407 IN210/25 IN172/25 dto. ..line-up terminals
1MB312C-4A... not available not available ..stay bolt M10 IN267 not available not available dto. ..line-up terminals
(PG 29) 35 M10 (RAC2/RAC3)
ALKAB14
Symbols:

ferrule cable lug connection
Figure 2.32: Specifications table on assembled cables for connection with plugin
43
Cable Assembled cable for plugin Components of the assembled cable with plugin
section
on the motor on the controller on the motor Cable Plug testing point L. on the
A[mm2]
flex. /highly flex. flex. /hochflex. flex. /hochflex. controller
For.. For..
1MB375B-6B... ..line-up terminals

(PG ) (RAC2/RAC3)
For..
For..
1MB375D-6B... ..Screws
(PG ) M12(RAC4)

ALKAB15
Symbols:

Figure 2.33: Table of assembled specifications for connections using plug

44
2.1.4. Cable Specifications
Cable Type Cable cross Cable Construction Diameter Bending Radius Weight
Section in mm in mm in kg/m
in 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
2.2. Power connections of the The power connections between the RAC main spindle controller and
RAC three-phase mains the three-phase mains are arranged in ...
Section 2.2.1: Three-phase mains requirements for direct connection

of 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.
Types The power connections of the RAC controller three-phase mains are
generally internal control cabinet cables which are, for the sake of
expediency, constructed with single strands. Motor connection
cables from INDRAMAT can, however, also be used.
2.2.1. Three-Phase Mains

Requirements
Permissible mains voltage Dependent upon the „AC supply voltage“ option, the following mains
voltages are permissible for RAC controllers:
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 Hz

460 460 / 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,N
for control electronics.“
Only in RAC 3.1
220 AC 220V, ±10%, 50..60 Hz, 200VA

Figure 2.35: Permissible mains voltage for RAC controllers.
Periodic voltages Voltage at the RAC should not be permitted to periodically exceed
1000 V (peak value) between the outer wire (terminal L1, L2, L3) and
the housing!
Non-periodic overvoltage Non-periodic overvoltages between the outer wire and housing are
tolerable for RAC controllers, if these are in accordance with VDE
0160 (see Fig. 2.36)!
UN+∆U
UN
3
2,6
2,4
2,3
2,2
∆U
2
∆U
T
2
1,8
1,6
UN
1,4
1,2
1,15
1,1
1
0,1 0,2 0,4 0,6 1 1,3 2 4 6 10 20
T (ms)
Figure 2.36: Non-periodic overvoltages as per VDE 0160.
The peak value of the rated voltage equals UN = 460V* square root
of 2=650V. Maximum tolerable, non-periodic voltage peak equals
1500 V for T<1.3 ms.
Grounded Three-Phase Mains RAC controllers can be directly connected to Wye-point and three-
phase mains grounded on the outer wire. Should the mains voltage
not agree with the RAC rated connection voltage, then an
autotransformer is needed to equalize the voltage (see Figure 2.37)!
Ungrounded Three-Phase Mains Ungrounded three-phase mains run increased danger of unsafe
overvoltages occurring between the outer wire and the housing. RAC
controllers can only be operated on these mains
– if the drive is connected via an isolating transformer, or,
– if surge arresters safeguard the facility.
Connection via an The RAC controller is most protected against damage from overvoltage
Isolating Transformer when it is connected via an isolating transformer. The drive operates
with the greatest possible safety. The use of an isolating transformer
is recommended in that case where an ungrounded three-phase
mains also requires voltage to be matched to the permissible connec-
tion voltage of the unit (see Figure 2.38).
Surge Arresters as Safeguards RAC controllers may only then be operated with ungrounded three-
phase mains if the facility is secured with a surge arrester. An
autotransformer can be used in the event that voltage must be
matched to the permissible rated connection voltage of the unit.
The recommended surge arrester safeguards upto a leakage current

of l2t=750A2s. For thermal reasons, greater leakage currents evoke
a response from the signal contact of the surge arrester.
The signal contact expediently triggers the separation of the machine

from the mains (see Figure 2.39). Should this not be possible, then
the signal contact is switched into the control system of the mains
contactor 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 expense
with larger loads is, however, significantly smaller. The surge arrest-
ers are destroyed after one use and must be exchanged!
2.2.2. Connection Plans

Grounded Three-Phase Mains
TT-Mains
Permissible voltages see Sec. 2.2.1, "Three-Phase Mains Requirements"
L1
L2
L3
PE
F1 F1 200VA
Does not apply if 220V ±10%
voltage matching not 50...60Hz
needed!
Does not
For information on connection
0,75...2,5mm2
0,75...2,5mm2
apply to
cross sections, rated fuse AC 220 V!
currents and transformers (if
needed), see Sec. 2.2.3, "List of
Connecting Components
Specifications".
X14 X14
L1 L2 L3 L1 L2 L3 L N
RAC2, RAC4 RAC3

APRAC001
Figure 2.37: Connecting RAC2, RAC3 and RAC4 to a grounded three-phase mains.
Ungrounded Three-Phase Mains

IT-Mains
Permissible voltages see Sec. 2.2.1, "Three-Phase Mains Requirements"
L1
L2
L3
F1 F1
200VA
220V ±10%
Ungrounded 50...60Hz
Three-Phase
Mains
Does not
apply to
0,75...2,5mm2
0,75...2,5mm2
For information on connection AC 220 V!

cross sections, rated fuse
currents and transformers (if
needed), see Sec. 2.2.3, "List of
Connecting Components
Specifications".
X14 X14
L1 L2 L3 L1 L2 L3 L N
RAC2, RAC4 RAC3

APRAC002
Figure 2.38: Connecting RAC2, RAC3 and RAC4 to an ungrounded three-phase

mains using an isolating transformer.
An earth leakage circuit breaker (FI) should not be built into

the RAC controllers!
Machine Does not apply if

master switch voltage matching not
IT-Mains needed!
Permissible voltage see Sec. 2.2.1, "Three-Phase Mains Requirements"
L1
L2
L3
Remote control
F1 F1 200VA
220V ±10%
50...60Hz
F3
Does not
0,75...2,5mm2
apply to
0,75...2,5mm2
AC 220 V!
F2
F2
cross sections, rated fuse currents
and transformers (if needed), see
Sec. 2.2.3, "List of Connecting
Components Specifications".
Control cabinet - L1 L2 L3 L1 L2 L3 L N
earth potential. X14 X14
RAC2, RAC4 RAC3
APRAC003
Figure 2.39: Connecting RAC2, RAC3 and RAC4 to ungrounded three-phase

mains, actuation of surge arrester triggers mains separation.
Does not apply if

voltage matching not
IT-Mains needed!
Permissible voltage, see Sec. 2.2.1, "Three-Phase Mains Requirements".
L1
L2
L3

cross sections, rated fuse currents
and transformers (if needed), see
Sec. 2.2.3, "List of Connecting F1 F1
200VA
Components Specifications".
220V ±10%
50...60Hz
F3 Does not
apply to
AC 220 V!
0,75...2,5mm2
0,75...2,5mm2
F2 F2
L1 L2 L3 L1 L2 L3 L N
Control cabinet - X14 X14

earth potential X15 X15
OFF
OFF
3 4 3 4
RAC3
RAC2, RAC4
APRAC004
Response from F2
triggers break.
Control Control
Relay Relay Relay Relay
Figure 2.40: Connecting RAC2, RAC3 and RAC4 to ungrounded three-phase

mains, actuation of surge arrester triggers release of mains contactor in the
RAC.
For thermal reasons, the surge arresters disconnect at l2t=750A2s
(30s at 5A) once they are actuated (leakage current). They are then
no longer functional and must be exchanged!
An earth leakage circuit breaker (Fl) must not be built into the
RAC controller!
2.2.3. Connecting Compo-

nents Data List
Connection cross section, The dimensions of the mains fuse and the mains connection cable
type of fuse are dependent upon the rated output of the main spindle motor
operated on the RAC controller.
If the rated output of the main spindle motor is fully utilized during a
processing cycle, then the following values are achieved:
Main spindle PRated IMains RAC Fuse Cable cross

motor in kW in A F1, Type section in mm2
2AD132B-...-DS 10 19
1MB200E-4B-... 11 21 3xNH25gl 4
1MB240F-4B-... 11 26
2AD132C-..-CS 15 29
1MB240H-4B-... 15 29
1MB241H-6D-... 16 30 3xNH35gl 6
1MB200D-4D-... 19 36
1MB310B-6B-... 19 36
1MB200H-4B-... 19,5 37
1MB312B-4A-... 20 38
2AD132D-...-AS 22 42 3xNH50gl 10
1MB310D-6B-... 25 48
1MB312C-4A-... 25 48
2AD160B-...-BS 30 57 3xNH63gl 16
1MB310F-6B-... 35 66
2AD160C-...-BS 37 70 3xNM80gl 25
1MB375B-6B-... 40 76
2AD180C-...-BS 52 99 3xNH100gl 35
1MB375B-6B-... 55 105
2AD180D-...-BS 63 120 3xNH125gl 50
2AD200C-...-AS 79 150 3xNH160gl 2x25
2AD225C-...-AS 93 176 3xNH200gl 2x35
Figure 2.41: Mains connection specifications with rated service of main spindle
motors, 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!
Should the rated power of the main spindle motor not be completely
utilized during the duty cycle, including acceleration and braking, then
the RAC mains connection can be engineered lower. The minimum
values 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 Cross

F1, 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
IMainsRAC=1,9*PCont.Motor*A/kW
PCont.Motor= continuous output (kw) actually

required of the motor
(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 cross
section and its corresponding fuse must not fall short of the minimum
values listed in Figure 2.42!
Sizing the Autotransformer The output, Smains, of a possibly needed autotransformer, corre-
sponds to the rated output, or the actually required continuous output
of the main spindle motor. The inductive components of the relative
short-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)
uKX = UKX1/URated1*100%
UKX1 = Prim. short-circuit voltage in V, inductive component

URated1= Rated voltage of the transformer in V, primary
Sizing the Isolating Transformer The output, Smains, of an isolating transformer, if needed, also de-
pends upon the rated output, or the actual continuous output required
of the main spindle motor.
The stray inductance of an isolating transformer is significantly higher

than that of an autotransformer. Depending upon the type of RAC, the
minimum transformer output of the isolating transformer must, as a
result, achieve the minimum value! The inductive component of the
relative short-circuit voltage, Ukx, must be smaller than 4%!
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
Figure 2.43: Minimum transformer output if the RAC controller is connected via i
an isolating transformer.
The already stated formulae are used to calculate the mains current,
ImainsRAC, and the mains connection output, Smains, of the main spindle
motor:
ImainsRAC=1,9*Pcont.Motor*A/kW
Pcont.Motor= continuous output (kw) actually
demanded of motor
(Formula valid for 3 x AC 380 V ... 3 x AC 460 V.)
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)
Overvoltage Protectors
Controller Type Fuse F3 Surge arrester
Type 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
Figure 2.44: Specifications for surge arresters in an ungrounded three-phase

mains.
Controller Lay-Out
on the mains cable on the controller
Multi-core cable end for

line-up terminals (RAC2/RAC3)
Compression cable shoes for

screws M12 (RAC4)
Netzan1
Figure 2.45: Mains connection cable for RAC controllers.
3. Feedback and CNC Connections
3. Feedback and Signal exchange with the CNC control takes place via the CNC
connections; feedback of position or speed of the motor shaft and the
CNC Connections spindle 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 optional
interfaces
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
3.1. Types of feedback and There are four types of assembled feedback and CNC connections.
CNC connections
Types of Feedback and CNC

Connection
direct with intermediate terminal with plug with plugin

on terminal strip design testing points
Figure 3.1: Four types of assembled feedback and CNC connections
Direct connection This type of connection is characterized by the lowest number of

imperfections in comparison to other connection types.
on the controller Cable feedback side
CNC side
Symbols:
Plug connector Plug connector

(plug) (plug) D-sub- Multi-core Wall
for feedback connection, for feedback connection, plug connector cable end breakthrough
straight type elbow type
XXkab01
Figure 3.2: Assembled cables for direct connections (also see figure 3.22).
Connection with This type of connection permits an easy diagnosis of the signal
Intermediate Terminals exchange to the CNC control at the intermediate terminal points.
Intermediate terminals in feedback connections with incremental

encoder are not to be recommended because of increased sensitivity
to interference! Intermediate terminals are not permitted with high-
resolution motor and spindle feedback!
on the controller cable terminal strip cable feedback side
CNC side
Symbols:

for feedback connection, for feedback connection, plug connector cable ends breakthrough
XXkab02
Figure 3.3: Assembled cables for intermediate terminals on the terminal strip
(also see Figure 3.22).
Connection with plug design The control cabinet can be finished entirely independent of the
machine with this type of connection. The melding of machine and
control cabinet is quick and simple.
In addition, damaged cables on the outside of the control cabinet can

be quickly and safely exchanged.
on the controller cable Plug design cable feedback side
CNC side
Symbols:

for feedback connection, for feedback connection, plug connector cable ends breakthrough
XXkab03
Figure 3.4: Assembled cables for plug design (also see Figure 3.23).
Connection with This type of connection is advantageous with larger facilities as it is

plugin testing point possible to quickly and safely exchange a damaged section.
The mounting of assembled cables of this type of connection is

particularly simple and quick.
on the controller cable Plugin testing point cable feedback side
CNC side
Symbols:
Plug connector Plug connector Plug connector

(plug) (plug) D-sub- (coupling)
Multi-core for feedback
for feedback connection, for feedback connection, plug connector cable end
straight type elbow type connection
XXkab04
Figure 3.5: Assembled cable with plugin testing points (also see Figure 3.24)
3.2. Connecting plans for Only the connection plans for the direct connection of feedback and
direct connections CNC connections are depicted. They do, however, apply to all other
types of connections. The respective testing points do not alter the
allocation of the connections for feedback or CNC control and main
spindle controller.
The connection plans are to be used to develop the plant connection

diagrams. The plant connection diagrams of the machine manufac-
turer are to be used when wiring the plant!
Standard interfaces Main spindle controllers are always equipped with motor feedback
and optional interfaces connection (X3, standard) and control input, signal and analogue
outputs (X2, standard). The controllers can optionally be equipped
with additional feedback and CNC interfaces.
The optional interfaces are listed in the type designations of the

controller to be mounted. The type key is listed in the documentation
about main spindle controllers - „Project Planning Notes“.
3.2.1. Motor feedback,

high-resolution
61
assembled cable IKS 032
47
IKS 315
plug connector (9 way)
IN 309
52
assembled cable IKS 315/..
26
45
cable IN 209
plug connector (9 way)
(Color coded as per
IN 401
INDRAMAT standards)
D-Sub-plug connector (15 way)
IN 290
X3
1 pk 0,25 mm2 2 0
2 gr 0,25 mm2 11 0ref
3 gn 0,25 mm2 13 B
4 br 0,25 mm2 14 Bref
5 bl 0,25 mm2 7 A
6 vio 0,25 mm2 15 Aref
9 9
7 br 1 mm2 12 + 5Vint
8 wh 1 mm2 10 0Vint
Motor feedback
high-resolution Controller
(insulated sensor attachment)
SBDSUB7
IKS315
Figure 3.6: Connection plan for high-resolution motor feedback (standard)
The high-resolution motor feedback cable must not be fed

over a terminal strip due to sensitivity to interference!
52
Assembled cable IKS 315/.. Assembled cable IKS 617/..
26
45
45
45
cable IN 209 cable IN 209
Plug connector (9 way) (color coded as per
(color coded as per
IN 401 INDRAMAT standards)
INDRAMAT standards)
D-sub-plug connector (15 poles) Plug connector (15 way) D-sub-plug connector (15 way)
IN 290 IN 289 IN 290
X1 X2 X3
1 pk 0,25 mm2 2 0 0 2 pk 0,25 mm2 2 0
2 gr 0,25 mm2 11 0ref 0ref 11 gr 0,25 mm2 11 0ref
3 gn 0,25 mm2 13 B B 13 gn 0,25 mm2 13 B
4 br 0,25 mm2 14 Bref Bref 14 br 0,25 mm2 14 Bref
5 bl 0,25 mm2 7 A A 7 bl 0,25 mm2 7 A

HGV 1
6 vio 0,25 mm2 15 Aref Aref 15 vio 0,25 mm2 15 Aref
9 9 9 9
7 br 1 mm2 12 + 5Vint + 5Vint 12 br 1 mm2 12 + 5Vint

(The outputs A A, B B, and 0 0 of X3 and X4
8 wh 1 mm2 10 0Vint have been DC-decoupled from the controller!) 0Vint 10 wh 1 mm2 10 0Vint
feedback cable.
Motor feedback
high-resolution (insulated
sensor attachment) Controller
B
B
0
0
A
A
0V
+ 5V
B
B
0
0
A
A
0V
+ 5V
(motor type key field
"motor feedback = 3") X3 X4
8
1
3
4
5
6
8
1
3
4
5
6
9
9
10
10
12
12
D-sub-plug connector (15 way)

IN 289
45
*)
Ground shield only on one end of
see *)
see *)
"
"
"
"
"
"
"
"
"
"
set-point line. If possible, at voltage
0,25 mm2
0,25 mm2
source.
1 mm2
1 mm2
gr
pk
rd
bk
bn
gn
wh 1 mm2
bn
gr
pk
rd
bk
bn
gn
wh 1 mm2
bn
cable IN 209 **) Connect the +5V supply only once

(color coding as per
INDRAMAT if both incremental encoder outputs
Preassembled cable IKS 618

standards) (X3 and X4) are connected!
70
Figure 3.7: HGV1 connection plan switched into the high-resolution motor
HGV1_1
512 cycles ( ) 1024 cycles ( )

Voltage supply
for A A, B B, 0 0
see **)
Voltage supply
for A A, B B, 0 0
see **)
62
3.2.2. Motor feedback, incre-

mental encoder
52
Assembled cable IKS 331/..
26
45
Cable IN 209
Plug connector (12 way)
(color coded as per
IN 301
INDRAMAT standards) 1

IN 290
X3
3 rd 0,25 mm2 3 0
4 bk 0,25 mm2 4 0
8 gr 0,25 mm2 8 B
1 pk 0,25 mm2 1 B
5 br 0,25 mm2 5 A
6 gn 0,25 mm2 6 A
9 9
12 br 1 mm2 12 + 5Vint
10 wh 1 mm2 10 0Vint
Motor feedback
incremental encoder Controller
(insulated attachment)
SBDSU1
Figure 3.8: Connection plan for incremental encoder motor feedback (motor type
key field „motor feedback = 1“).
IKS 331
IKS 317
3.2.3. Spindle Feedback,

high-resolution
61
47
Plug connector (12 way) IKS 314

IN 351
52
26
45
Cable IN 209
(color coded as per
IN 301
D-sub plug connector (15 way)

IN 289
X5
3 rd 0,25 mm2 3 0
4 bk 0,25 mm2 4 0
8 gr 0,25 mm2 8 B
1 pk 0,25 mm2 1 B
5 br 0,25 mm2 5 A
6 gn 0,25 mm2 6 A
9 9
12 br 1 mm2 12 + 5Vint
Spindle feedback
SBDSU3
Figure 3.9: Connection plan for high-resolution main spindle position encoder as
spindle feedback (controller with „additional encoder input = P“ option).
The cable to the high-resolution spindle feedback must not

be fed over a terminal strip because of sensitivity to
interference!
IKS314
52
Assembled cable IKS 314/.. Assembled cable IKS 049/..
26
45
45
45
Cable IN 209 Cable IN 209
(color coded as per (color coded as per
IN 401 1 1 1
INDRAMAT standards) INDRAMAT standards)
D-sub-plug connector (15 way) D-sub-plug connector (15 way)
IN 290
IN 289 IN 289
X2 X1 X2
1 pk 0,25 mm2 2 0 0 2 pk 0,25 mm2 2 0
2 gr 0,25 mm2 11 0ref 0ref 11 gr 0,25 mm2 11 0ref
3 gn 0,25 mm2 13 B B 13 gn 0,25 mm2 13 B
4 br 0,25 mm2 14 Bref Bref 14 br 0,25 mm2 14 Bref
5 bl 0,25 mm2 7 A A 7 bl 0,25 mm2 7 A

HGV 1
6 vio 0,25 mm2 15 Aref Aref 15 vio 0,25 mm2 15 Aref
9 9 9 9
(The outputs A A, B B, and 0 0 of X3 and X4 are
7 br 1 mm2 12 + 5Vint
CD-decoupled from the controller) + 5Vint 12 br 1 mm2 12 + 5Vint
8 wh 1 mm2 10 0Vint 0Vint 10 wh 1 mm2 10 0Vint
Spindle feedback
high-resolution
B
B
0
0
A
A
B
B
0
0
A
A
(insulated X3 X4
8
1
3
4
5
6
8
1
3
4
5
6
9
9
sensor attachment)
10 0V
10 0V
12 + 5V
12 + 5V
spindle position encoder cable.

IN 289
45
1
"
"
"
"
"
"
"
"
"
"
1 mm2
Ground shield only on one end of

1 mm2
see *)
see *)
0,25 mm2
0,25 mm2
1 mm2
set-point line. If possible, at voltage
source.
wh
bn
gr
pk
rd
bk
bn
gn
wh 1 mm2
bn
gr
pk
rd
bk
bn
gn
Preassembled cable IKS 618

Line IN 209
(color coded acc. **) Connect the +5V supply only once
to INDRAMAT
standards) if both incremental encoder outputs
70
(X3 and X4) are connected!
512 or 1024 1024 or 2048
Voltage supply
for A A, B B, 0 0
see **)
Voltage supply
for A A, B B, 0 0
see **)
cycles ( ) cycles ( )
HGV1_2
Figure 3.10: HGV1 connection plan switched into the high-resolution main
65
3.2.4. Spindle Feedback,

incremental encoder
61
47

IN 351 IKS 327
52
26
45
Cable IN 209
(color coded as per
IN 301

IN 289
X5
3 rd 0,25 mm2 3 0
4 bk 0,25 mm2 4 0
8 gr 0,25 mm2 8 B
1 pk 0,25 mm2 1 B
5 br 0,25 mm2 5 A
6 gn 0,25 mm2 6 A
9 9
12 br 1 mm2 12 + 5Vint
Spindle feedback
SBDSU3
Figure 3.11: Connection plan for incremental encoder in the capacity of spindle
feedback (controller with „additional encoder input = P“ option).
IKS327
3.2.5. Lead Spindle Feedback
47 61
Plug connector (12 way) IKS 331

IN 351
52
26
45
Cable IN 209
(color coded as per
IN 301

IN 290
X5a
3 rd 0,25 mm2 3 0
4 bk 0,25 mm2 4 0
8 gr 0,25 mm2 8 B
1 pk 0,25 mm2 1 B
5 br 0,25 mm2 5 A
6 gn 0,25 mm2 6 A
9 9
12 br 1 mm2 12 + 5Vint

SBDSU2
Figure 3.12: Connection plan for incremental encoder in the capacity of lead
spindle feedback (controller with „additional encoder input = Y“ option).
Controllers with the „additional encoder input = Y“ are

equipped with interfaces X5a and X5. This is necessary
because spindle synchronization requires, in addition to
position information about the lead spindle, a direct position
measuring system (spindle feedback) at the spindle to be
synchronized as well!
3.2.6. Control input, signal

and analogue outputs, IKS610
Bb-contact
200
Cable IN 271
45
(color coded as per
INDRAMAT standards)
IKS 610 1
IN 293
X2
gr 0,5 mm2 1 0V ext
Voltage level input wh 0,25 mm2 2 0V int
bn " 3 AS (KDA/TDA only)
+36 V
ye/blck " 4 READY
yel " 5 N = CMD
+24 V
gn/bk " 6 N < MIN
+18 V rd 7 IN POS
"
bl " 8 90% LOAD
+5 V
rd " 9 TEMPWARN
0V bk " 10 LIMIT
0 (low) 1 (high)
vio " 11 SPEED CHANGE 1
gr/pk " 12 SPEED CHANGE 2
bl/rd " 13 LOAD LIMIT
wh/gn " 14 RF SLAVE
" 15 SPINDLE CONT
Voltage level output
+36 V (see below!) 17

wh/ye 0,25 mm2 18 24V int
gn 0,5 mm2 19 24V ext
+24 V
ye/bn 0,25 mm2 20 Analogue output M
+18 V
wh/gr " 21 Analogue output N
gr/bn " 22 0V int
+5 V
wh/pk " 23 E-STOP (RAC only)
0V
0 (low) 1 (high) pk/bn " 24 RF
wh/bl " 25 RUN
bn/bl " 26 POS 1
wh/pk " 27 POS 2
Voltage level for 24 Vext bn/rd " 28 MD-RED
U 29 OSCILLATE
wh/bk "
+36 V bn/bk " 30 PAR 1
gr/gn " 31 PAR 2
yel/gr " 32 LIMIT 1
+18 V gn/rd " 33 LIMIT 2
pk/gn " 34 LIMIT 4
ye/pk " 35 SPEED 1
gn/bl " 36 SPEED 2
t
yel/bl " 37 EXT POS
Voltage supply
from the control X11 KDA/TDA
X15 RAC
Bb
Bb-contact
Bb 24V, 1A
2 way plug terminal
in KDA/TDA,
SBDSUB1
found in E••-•DA
10 way plug terminal
in RAC (also see Fig. 3.18),
found in E1-RAC
Figure 3.13: Connection plan for control input, signal and analogue outputs, Bb-
contact (standard).
The control and signal outputs are DC-decoupled from the controller.
The control must supply the outputs with *24V/0 V. Should this not
be 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.
Do not directly connect a contactor coil via the relay contact

Bb, as the high intermittent currents caused by frequent
switching could overload the relay contact and cause it to
fail.
3.2.7. Speed set-point,

analogue +/- 10V
70
Cable IN 233
45
(color coded as
per INDRAMAT standards)

IN 287
X4
IKS 045
wh 0,22 mm2 1 E1
*)
bn 0,22 mm2 2 E2
gn 0,22 mm2 *) 5 E3
yel 0,22 mm2 6 E4
(see below!) 4
Voltage level
analogue inputs
9 +15VM
+15 V
8 - 15VM
-15 V Controller
SBDSUB6
*) Internal shielding can be dropped if INDRAMAT cables are not used!
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 as
IKS045
differential inputs.
Ground the shield only on one end of the set-point cable. If

possible, at voltage source!
3.2.8. Speed set-point, digital,

16 bit parallel IKS612
200
Assembled cable IKS 612
Cable 20x0,25
(color coded as per
45
INDRAMAT standards)
IKS 612
1

IN 291
X4
wh 0,25 mm2 1 Bit 1
bn " 2 Bit 2
gn " 3 Bit 3
yel " 4 Bit 4
gr " 5 Bit 5
Voltage level pk " 6 Bit 6
+36 V bl " 7 Bit 7
rd " 8 Bit 8
+24 V bk " 9 Bit 9
vio " 10 Bit 10
+18 V
wh/bn " 11 Bit 11
wh/gn " 12 Bit 12
+5 V
wh/yel " 13 Bit 13
0V
0 (low) 1 (high) wh/gr " 14 Bit 14
wh/pk " 15 Bit 15
wh/bl " 16 DATA VALID
wh/rd " 18 -15 V int (max. 150 mA)

wh/bk " 19 +15 V int (max. 150 mA)
bn/gn " 21 0V ext

bn/yel " 22 0V ext
(see below!) 25
Controller
SBDSUB3
Figure 3.15: Connection plan for digital speed set-points

(„speed set-point=D“ option)
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 with
the +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!
Ground shield only at one end of the cable. If possible, at

voltage source!
3.2.9. SERCOS Interface
Location of plug connector strip X4
Receiver diode
Fiber optic cable
from the control or
additional controllers
Electrical output
IC 1
Transmitter Driver
Fiber optic cable
diode control
to the control
or additional
controllers
Electrical input
IC 2
LED (red)
LED (green)
Controller
APSerc
Figure 3.16: SERCOS interface connection plan („speed set-point=L“ option)
Additional fiber optic cable For specifications on assembled fiber optic cables, attenuation calcu-
specifications lations, for specifications on constructing custom cables see doc. no.
209.0090-4101, „LWL Handling; description of application“.
3.2.10. Position set-point,

IKS614
digital, 16 bit parallel
200
45
In KDA/TDA
Cable 20x0,25
IKS 614
200 IN 295
Cable 20x0,25
(color coding as per
45
INDRAMAT standards) In RAC
1
IN 291
X6 KDA/TDA
X13 RAC
wh 0,25 mm2 1 Bit 1
bn " 2 Bit 2
gn " 3 Bit 3
ye " 4 Bit 4
Voltage level gr " 5 Bit 5
+36 V pk " 6 Bit 6
bl " 7 Bit 7
+24 V
rd " 8 Bit 8
blck " 9 Bit 9
+18 V
vio " 10 Bit 10
wh/bn " 11 Bit 11
+5 V
wh/gn " 12 Bit 12
0V
0 (low) 1 (high) wh/ye " 13 Bit 13
wh/gr " 14 Bit 14
wh/rs " 15 Bit 15
wh/bl " 16 DATA VALID
wh/rt " 18 -15 V int (max. 150 mA)

wh/sw " 19 +15 V int (max. 150 mA)
bn/gn " 21 0V ext

bn/ye " 22 0V ext
(see below!) 25
Controller
SBDSUB2
Figure 3.17: Connection plan for digital position set-point

(„additional interface=D“ option)
Ground shield only at one end of cable. If possible, at voltage

source!
The digital position set-point inputs (bit 1 ... bit 15, DATA VALID) are
DC-decoupled from the controller. Terminal 21 should be connected
to the OV potential of the control! The inputs are set with the +24V
IKS015/IKS016
potential of the control! If the control does not supply +24V/0 V, then
connect terminal 18 with 21 and the inputs via terminal 19! Current
consumption is approx. 15 mA per input!
Ground shield only at end of cable. If possible, at voltage

source!
3.2.11. Serial interface

RS 232C
45
Cable IN 234
In KDA/TDA
IKS 015
IKS 016
D-sub-plug connector (25 way) IN 296
IN 291 Assembled cable IKS 016
Cable IN 234
45
(color coding
as per In RAC
INDRAMAT standards)
1
D-sub-plug connector (25 way) D-sub-plug connector (25 way)

IN 291 IN 292
X6 KDA/TDA
X13 RAC
1 1
TxD 2 wh 0,25 mm2 *) 2 TxD
RxD 3 bn 0,25 mm2 3 RxD
RTS 4 gn 0,25 mm2 4 RTS
*)
CTS 5 ye 0,25 mm2 5 CTS
DSR 6
GND 7 gr 0,50 mm2 7 GND
RS 232C
20
DTR
Programming equipment,
PC, or something similar Controller
SBDSUB4
*) Internal shielding can be dropped if INDRAMAT cables are not used!
Figure 3.18: Connection plans for serial interfaces („additional interface=S“

option)
3.2.12. Incremental encoder

output
70
45
In TDA/KDA
IKS 620 Line IN 209
IKS 618
IN 328
70
Cable IN 209
45
In RAC
(color coded
as per
Voltage level outputs INDRAMAT standards) 1
+5 V D-sub plug connector (15 way)

IN 289
X6 KDA/TDA
X13 RAC
+1,8 V
gr 0,25 mm2 8 B
+0,5 V pk 1 B
"
0V rd " 3 0
0 (low) 1 (high)
blck " 4 0
bn " 5 A
Voltage level gn " 6 A
for +5V supply
U
+5,25 V (see below!) 9
wh 1 mm2 10 0V
+5 V
+4,75 V
bn 1 mm2 12 + 5V
X17
0V (This is not available as an 1
assembled cable!) 2 Reference switch
3
Plug terminal 3 way, Controller
mat. no.: 220 856
SBDSUB5
Figure 3.19: Connection plan for incremental encoder output and reference
switch signal („additional interface=l“ option)
IKS618/IKS620 Outputs AA, BB and OO are DC-decoupled from the controller. The
CNC control must supply them with +5V/0.
Ground shield only at end of cable. If possible, at voltage

source!
3.2.13. Control of the mains

contactor integrated into the
RAC controller
Control X15 RAC Controller

10
+ 24V, 1A
9 for ext. use
Mains contactor monitoring 8

CS
(open = set up possible) 7
(Mains contactor K1 opener)
6
(max. 24V, 1A
Ready Bb intermittent and
5 continuous)
Mains contactor OFF

4
OFF
3
Mains contactor ON
2
ON
1
APRACKON
Plug terminal, contained in elec.

connecting accessories E1-RAC
Figure 3.20: Connection plan for control of the mains contactor integrated into
the RAC controller.
The controller-internal mains contactor should not be used

to regularly shutdown the drives! It should only be activated
with standing drive and controller enabler shut off!
Do not directly connect a contactor coil via the relay contact

Bb, as the high intermittent currents caused by frequent
switching could overload the relay contact and cause it to
fail.
3.3. Assembled Cable Specifi- Specifications of the assembled cables for the four types of connec-
cations tions is dependent upon the functional options of the main spindle
controller and are summarized in tables.
Types of feedback and

CNC connections
direct with intermediate terminals with with plugin

at the terminal strip plug design testing points
Figure 3.21: Four types of assembled feedback and CNC connections
The tables indicate both the assembled cable and its construction.
Table Summarizing
Assembled Specifications
....plugin testing points
....plug design
....direct connection and

intermediate terminal
ZuTAB
Assembled specifications for...
Figure 3.22: Summary of assembled specifications for feedback and CNC

connections
The tables summarize the available assembled feedback and CNC

cables and their significant components.
Feedback and CNC connections - direct connection and link terminal
Interfaces on the Assembled cable Cable design for direct connection Assembled cable for intermediate terminals
main spindle controller for direct on terminal strip
controller.
connection
On the Cable Feedback On the Feedback
controller or CNC controller or CNC
Standard Interfaces
IKS 315 IN 290 IN 209 IN 401 not permitted! not permitted!
Motor feedback connection X3

For..
Control input, signal X2
and analogue outputs
IKS 610 IN 293 IN 271 ..line-up terminals IKS 610 not available
Interfaces for functional options

For..
A
analog IKS 045 IN 287 IN 209 ..line-up terminals IKS 613 not available
Type
key field
"speed D IKS 612 IN 291 20 x 0,25 ..line-up terminals IKS 612 not available
digital X4
set-point"
terminals at terminal strip allocated to the interfaces on the main spindle

L
Figure 3.23: Assembled specifications for direct connection and intermediate

Sercos
IKO 982 IN 418 IN 414 IN 420
alkabf1
78
Connected Connected Connected
P to.. to.. to..
IKS 327 ..incremental IN 289 IN 209 IN 301 ..incremental *) *) ..incremental

encoder encoder encoder
..high-resolution main ..high-resolution main ..high-resolution main
IKS 314 spindle position encoder IN 289 IN 209 IN 401 not permitted! not permitted! spindle position encoder
spindle position encoder
..second motor ..second motor ..second motor
IKS 314 feedback IN 289 IN 209 IN 401 feedback not permitted! not permitted! feedback
X5
Connected Connected Connected
to.. to.. to..
..incremental IN 289 IN 209 IN 301 ..incremental *) *) ..incremental

*) encoder encoder encoder
..high-resolution main ..high-resolution main not permitted! not permitted! ..high-resolution main
*) spindle position encoder IN 289 IN 209 IN 401 spindle position encoder spindle position encoder
Type key ..second motor ..second motor ..second motor
field *) IN 289 IN 209 IN 401 not permitted! not permitted!
feedback feedback feedback
"additional
encoder
input"

Y X5a
controller.
( ) *) IN 290 IN 209 IN 351 not permitted! not permitted!
D
digit. IKS 614/IKS 612 IN 295/IN 291 20 x 0,25 IKS 614/IKS 612 not available
Type key Pos.-set-point X6/X13
field (*TA/RAC)
"additional I IN 328/IN 289 IN 209 IKS 620/IKS 618 not available
Incre. output IKS 620/IKS 618
encoder
input"
S
RS232
IKS 015/IKS 016 IN 296/IN 292 IN 234/IN 234 IN 291/IN 291 *) / *) *)
Legend:
D-sub plug Plug connector (plug) for Plug connector (plug)

connector Plug connector (coupling) Wall
feedback connection, for feedback Wire-end ferrule for feedback connection breakthrough
straight type connection, elbow type
alkabf2
*) lieferbar, Anfrage der Typenbezeichnung bei INDRAMAT Abt. ENT
Legend:
D-sub Plug connector (plug) Plug connector (plug) Plug connector (coupling) Wall
plug connector for feedback connection, for feedback connection, Multi-core cable end
for feedback connection breakthrough
alkabf2
terminals at terminal strip allocated to the interfaces on the main spindle

Figure 3.23: Assembled specifications for direct connection and intermediate
79
Feedback and CNC Connections - plug type
Main spindle Assembled cables Cable structure for plug design
controller interfaces for plug design
on the feedback side on the cable Plug type cable Feedback side
controller controller
Standard interfaces
IKS 332 IN 314 IKS 321 IN 290 IN 209 IN 304 IN 314 IN 342 IN 209 IN 401
*) IN 342 IN 209 IN 309
*) *) IN 209 IN 401
*) *) IN 209 IN 309
Control input, signal

and analogue outputs X2 - not available - - not available -
Functional options interfaces
Type
key field A,D,L X4 - not available - - not available -
"speed set-point"
D, I - not available - - not available -
Type key X6/X13

field S (*TA/RAC)
"additional
interfaces" *) / *) IN 314 *) / *) IN 290/IN 292 IN 234 IN 324 IN 314 *) IN 234 IN 291
*) / *) *) IN 234 IN 291
plugin testing points allocated to the interfaces on the main spindle controller.
80
Figure 3.24: Table summarizing assembled specifications for connections using a
ALKABF5
Connected
to..
P IKS 330 incremental IN 313 IKS 305 IN 289 IN 209 IN 303 IN 313 IN 305 IN 209 IN 301
encoder
high-resolution
IKS 330 encoder IN 314 IKS 321 IN 289 IN 209 IN 304 IN 314 IN 342 IN 209 IN 401
second motor
IKS 330 feedback IN 314 IKS 321 IN 289 IN 209 IN 304 IN 314 IN 342 IN 209 IN 401
Connected
to..
Type code IKS 330 incremental IN 313 IKS 308 IN 289

encoder IN 209 IN 303 IN 313 IN 305 IN 209 IN 351
field
"additional high-resolution IN 314
encoder input" IKS 330 *) IN 289 IN 209 IN 304 IN 314 IN 342 IN 209 IN 309
encoder
X5 IKS 330
second motor IN 314 *) IN 289 IN 209 IN 304 IN 314 IN 342 IN 209 IN 309
feedback
Connected
to..
IKS 330 incremental IN 313 *) IN 289 IN 209 IN 303 IN 313 IN 323 IN 209 IN 301
encoder
high-resolution *) *)
IKS 330 encoder IN 314 IN 289 IN 209 IN 304 IN 314 IN 209 IN 401
second motor *)
IKS 330 feedback IN 314 *) IN 289 IN 209 IN 304 IN 314 IN 209 IN 401
Connected
to..
IKS 330 incremental IN 313 *) IN 289 IN 209 IN 303 IN 313 IN 323 IN 209 IN 351
encoder
high-resolution IN 314 *)
IKS 330 encoder IN 289 IN 209 IN 304 IN 314 *) IN 209 IN 309
IKS 330
second motor IN 314 *) IN 289 IN 209 IN 304 IN 314 *) IN 209 IN 309
feedback
X5a
*) IN 313 IKS 305 IN 290 IN 209 IN 303 IN 313 IN 305 IN 209 IN 301
IKS 308 IN 305 IN 209 IN 351
*) IN 323 IN 209 IN 301
*) IN 323 IN 209 IN 351

ALKABF6
Legend:
plugin testing points allocated to the interfaces on the main spindle controller.
alkabf2
Figure 3.24: Table summarizing assembled specifications for connections using a
81
Feedback and CNC Connections - plugin testing points
Main spindle Assembled cable for Cable construction with plugin testing points
controller interfaces plugin testing points

On the Feedback On the cable Plugin testing points cable Feedback side
the interfaces on the main spindle controller.

controller or CNC controller
Standard interfaces
IKS 315 IKS 322 IN 290 IN 209 IN 401 IN 309 IN 209 IN 401
Control input, signal

and analogue outputs X2 - not available - - not available -
Figure 3.25: Table of assembled specifications for plug connections allocated to

ALKABF3
82
Functional option interfaces
Type key field A,D,L X4

"speed set-point" - not available - - not available -
Connected
to..
P IKS 327 incremental IKS 303 IN 289 IN 209 IN 301 IN 318 IN 209 IN 301
encoder
high-resolution
IKS 314 encoder IKS 322 IN 289 IN 209 IN 401 IN 306 IN 209 IN 401
second motor
IKS 314 feedback IKS 322 IN 289 IN 209 IN 401 IN 306 IN 209 IN 401
X5
Connected
to..
Type key IKS 327 incremental IN 301

encoder IN 289 IN 209 IN 318 IN 209 IN 351
field
"additional high-resolution
encoder IKS 314 encoder IN 289 IN 209 IN 401 IN 306 IN 209 IN 309
input"
second motor
IKS 314 feedback IN 289 IN 209 IN 401 IN 306 IN 209 IN 309
X5a
( ) IKS 331 IN 290 IN 209 IN 301 IN 318 IN 209 IN 351
D, I - not available - - not available -

Type key
field X6/X13
(*TA/RAC)
the interfaces on the main spindle controller.

"additional
interface"
RS 232 *) / *) *) / *) IN 296/IN292 IN 234 *) IN 307 IN 234 IN 291
ALKABF4
Legend:
alkabf2
Figure 3.25: Table of assembled specifications for plug connections allocated to
83
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.
Cable typ Cable Construction Diameter Bending radius in mm Weight in

in mm kg/m
Fixed Flexible
routing 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

Figure 3.26: Table of cable specifications for feedback and CNC connections.
4. Installation Guidelines
4. Installation Guide-
lines
Cable routing guidelines There must be a clearance of at least 100 mm between the power
connections and the feedback or CNC connections if the cables are
routed parallel. Otherwise, it is necessary to separate the cable
conduit with metal (see Fig. 4.1)
Synthetic cable conduit Metal cable conduit
>=100 mm 2 - 4 mm
Kab_Kan
Figure 4.1: Routing the cables together in the cable conduit.
Wiring The guidelines outlined in the connection plans on power, feedback

and CNC connections with reference to the twisting of conductors and
the shielding of bunched conductors must be followed in order to
achieve interference-free operation!
The shielding should be connected as outlined in the connection

plans. This avoids mass potential loops!
Feedback units Feedback units which the main spindle controller evaluates must be
mounted and electrically insulated at the machine or motor.
Do not route the feedback cables in the vicinity of high-frequency

equipment, the magnetic fields of transformers, chokes, motors and
other magnetic consumers, as well as high-voltage cables , as
otherwise interference could be coupled in!
Power plug connectors The dimensioning of the contact distances and leakage paths of the
power plug connectors is based on the degree of contamination as
outlined in DIN VDE 0160.
Spindle housing
IN316
IN172 IN217 IN172 IN210 IN172 IN217 IN218
V3
IN192
V1 V1 V1 V1
V2 V2 V2 V2 V2 V3
2AD...
Machine housing Control cabinet wall
Degree of contamination Immediate environmental conditions
V1 Conductive contamination cannot occur during operation of the

drive because IP 65 type of protection is a given.
V2 Conductive contamination cannot occur during operation of the

drive (IP65). Non-conductive contamination, or light condensation
of short duration can occur during installation or exchange of
drive components.
V3 Conductive contamination can occur because contact parts are

exposed and can be wetted by condensation.
Figure 4.2: Degree of contamination in acc. with DIN VDE 0160.
If wetting from coolants or lubricants is to be expected when

installing a drive or exchanging drive components, then seal
the open plug side of power connections with protective
caps.
Only join power plug connectors if plug side is dry!
Detach and join power plug connectors only when no power

is present!
If a power plug connector is used to connect 1MB frameless

motors, then do not spill coolant onto the backside of the
flanged socket on either the spindle or machine housing!
Installing Cables The plug connectors of the power cable and the feedback connec-
tions must be firmly screwed into place when the drive is operating!
Category of Protection Category IP65 protects assembled INRAMAT cables when they are
for the Cable firmly screwed in and attached. This does not, however, apply to the
open side of control cabinet and housing breakthroughs as well as d-
sub plug connectors!
General Controller – Do not detach the AS programming module when unit is still under
Installation Guidelines power. 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!
Modular Drive System Installa- – The transparent panes on the safety guards on the front side of the
tion Guidelines unit must be firmly affixed during operation!
– Ground the motor on the controller and ground the controller directly
on 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, otherwise
there is the risk of tearing!
– Plug in heatsink fan cable, if present.
RAC Installation Guidelines – The power connection safety guards on the front of the RAC4 must
be closed when the unit is switched on and during operation!
– Ground the motor on the controller and ground the controller
housing to the main incoming earth terminal!
Measures Against Sources of If contacts or semi-conductors are used in connection with electronic
Interference from Inside the equipment and components to switch such inductive loads as chokes,
Control Cabinet contactors and relays, then these must be appropriately cleared of
interference. If direct current is used, then this is achieved by the
arrangement of freewheeling diodes, and if alternating current is
used, then this is achieved with the arrangement of commercial safety
RC suppressor components situated directly at the inductivity. Do not
use varistors as protective circuits!
Only that suppression component situated directly at the inductivity

serves the purpose. Otherwise an interference level is radiated which
is too high. This influences both the function of the drive and the
electronics. Other interference sources, such as high-frequency
equipment (anodized components, and similar) must be placed and
wired outside of the control cabinet.
5. Delivery, Identification, Storage
5. Delivery, Identifica-
tion,
Storage
Assembled Cables Assembled cables are rolled up and loosely packed in with the
delivery. They do have a label (cable marker), which bears the order
designation and the length of the assembled cable.
INDRAMAT - Cable
No.
Length: m
TSKabel
Figure 5.1: Label (cable marker) on INDRAMAT assembled cables.
Plug accessories The plug accessory sets contain the plug connector (D-sub) for the
optional interfaces of the controller. They are packed in plastic bags
and bear a packaging slip (see Figure 5.3).
The plug accessory sets are delivered in a sealed carton together

with single plug connectors and the controller-specific connections.
Note: The plug accessory sets are not necessarily needed (see Fig.
1.2)!
Designation: S•-•••
Controller type KDA/TDA 1

RAC 2
Type key field for the controller:
Speed set-point:
analog +/- 10V A
digital (16 Bit parallel) D
SERCOS interface L
Additional encoder input:

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

Without add. encoder input O
Position set-point, digital (16 bit parallel) D
Serial interface (RS 232C) S
Incremental encoder output I
Figure 5.2: Designations of the plug accessory sets
Packaging slip
Page 1 Page 2
No. Designation Mat. No.
S2 - API 1 D-SUB-plug 15 way, pins 220623
X3
3 Housing, 15 way 221661
239 164
Additional plug accessories X3, X5, X13
RAC •.• - • • • - • • • - API - • •
No. Designation Mat. No.
1 D-SUB-plug 37 way, bushing 221652 2 D-SUB-plug 15 way, bushing 223008
X2 X5, X13
1 housing 37 way 221659
X2
Page 3 Page 4
No. Designation Mat. No. No. Designation Mat. No.
1 D-SUB-plugr 9 way, bushing 222740
X4
1 Housing, 9 way 222154
X4
1 Plug terminal 3 way 220856
1 2 3
X17
10 screw 221657
Date: 24.05.93
Acc. pack. slip S2-API
File: S2-API
Z.No.:109-0743-4248-00
Mat. No. BPZ: 253227
Figure 5.3: An example of the plug accessories set packaging slip.
Individual plug connectors Individual cables are rolled up and loosely packed in with the delivery.
and cables The sequential order number is always printed on them.
Single plug connectors are packed into plastic bags. The bags have
a label which indicate order number, appearance and dimensions of
the mounted plug connector.
Plug connector: IN 401 Power plug: IN 217/06

INDRAMAT Part No.: 228 351
INDRAMAT Part No.: 230 647
bushing
Pin
Pin
View "X"
View "X"
INVERP
Figure 5.4: Packing single plug connectors (example)

Leistungsstecker
Single plug connectors are packed into a sealed carton along with
plug accessories sets and the controller-specific connections.
Controller-specific connections The controller-specific connections are also packed in plastic bags
and labelled with the respective order number. E••-• for KDA/TDA
controllers (depending upon the arrangement within the drive pack-
age), E1-RAC for RAC controllers.
Further information about the controller-specific connections can be

found in the document on the respective controller - „Project Planning
Notes“.
Note: The controller-specific connections are always required!
Storage Assembled cables, plug accessory sets, the controller-specific con-

nections, individual plug connectors and cables should be stored dry
and dust-free. Permissible storage temperature range equals -30 to
+85 degrees C.
6. Customizing Specifications
6. Customizing Specifi-
cations
Selbstkonfektionierung eines Leistungskabels

Test guidelines
Working
guidelines
Construction
diagrams
Request construction with
1 documentation parts list
from INDRAMAT
Order the
2 individual parts
and tools needed
Soldering Crimping
3 Constructing the cable (tools) (tools)
Cable construction
Attaching
pins, or Fertigungsunterlagen
bushings into Werkzeuge
the insulator
casing (tools) Löten
Crimpen
Isolierkörper
Hochspannungstest
High-voltage Durchgangsprüfung
4 Testing the cable test Isolationsprüfung
Run-through
crimping test
run-through test
high-voltage test
insulation test
insulator casing Insulation
soldering test
(tools)
A functioning cable without INDRAMAT guarantee
Figure 6.1: Customizing a power cable
Motor Crimping Reduction Screws Cable Cross section ... on the
cable lug in mm2 controller
Customizing a
Terminal
box bolts
motor power cable
Reduzierung
(dropped) PG29 IN204 (flex.) 6
Verschraubung
Mat. no. 220 874
(dropped) PG29 IN404 (highly flex.) 6

Mat. no. 220 874

Mat. no. 220 742
Main spindle motor 2AD
Mat. no. 220 554
PG 29
2.1.3.
Mat. no. 220 472

Mat. no. 220 472
terminal boxes.
Frameless spindle motor 1MB PG29/PG36 PG36 IN207 (flex.) 25
Mat. no. 226 349 Mat. no. 220 473
(dropped) PG29 IN407 (highly flex.)
25
Mat. no. 220 472
PG42/PG36 PG36 IN267 (flex.) 35

Mat. no. 226 350 Mat. no. 243 552

PG 42
Mat. no. 253 479
PG48/PG36 PG36 IN207 (flex.) 25

Mat. no. 248 674 Mat. no. 220 473
PG 48
PG48/PG36 PG29 IN407 (highly flex.) 25
Mat. no. 248 674 Mat. no. 220 472
and
PG36/PG29
Mat. no. 220 474
Symbols: PGREDKLK

Figure 6.2: Screw and reduction specifications for motor power connections via
Allocation of motor type to the PG thread of the respective terminal
92
box is listed in the table outlining assembled specifications in Section
Motor Power Reduction Bolts Cable Cross section ... on the
plug in mm2 controller
connector
PG36/PG29 PG29 IN203 (flex.) 4

Mat. no. 220 474 Mat. no. 220 874
Main spindle motor 2AD PG36/PG29 PG29 IN403 (highly flex.) 4

Mat. no. 220 474 Mat. no. 220 874
PG36/PG29 PG29 IN204 (flex.) 6

Mat. no. 220 474 Mat. no. 220 874

Mat. no. 220 474 Mat. no. 220 874
IN217/25!
IN172/••
(Specs also PG36/PG29 PG29 IN205 (flex.) 10

apply to Mat. no. 220 474 Mat. no. 220 472
Frameless spindle motor 1MB
IN210/..,
IN217/..) PG36/PG29 PG29 IN405 (highly flex.) 10
Mat. no. 220 474 Mat. no. 221 554
via power plug connectors.
PG36/PG29 PG29 IN206 (flex.) 16
Mat. no. 220 474 Mat. no. 220 472

Mat. no. 220 474 Mat. no. 220 472
PG36/PG29 PG36 IN207 (flex.) 25

Mat. no. 220 474 Mat. no. 220 473

Mat. no. 220 474 Mat. no. 220 472
Symbols:
Power plug Power plug Wire-end Flange Reduction

PGRED172
Figure 6.3: Specifications for bolts and reduction for motor power connections
It is only possible to solder the power plug connectors – independent

of cable core cross sections – in types IN172/25, IN 210/25 and
93
7. Index
7. Index Symbole
1MB connected to RAC 28
1MB to KDA/TDA 27
2AD 100 with KDA/TDA 21
2AD 100 and 2AD 101 connections 20
2AD 132 CONNECTED TO KDA/TDA 23
2AD 132 connected to KDA/TDA 25
2AD to KDA/TDA 27
2S 100 WITH KDA/TDA 22
A
Ambient temperatures 13
Analogue outputs 68
AS programming module 87
Autotransformer 48
B
Bending radius 45
C
Cable conduit 85
Cable construction 91
Category of Protection for the Cable 87
CNC Connections 56
Conductive contamination 86
Conductor cross sections, sized 13
Connecting an RAC to a three-phase mains 49
Connecting components 53
Connecting RAC with overvoltage surge arresters 50
Connection 2AD 132 with KDA/TDA 21
Connection 2AD 180 26
Connection of 1MB to KDA/TDA 27
Connection of 2AD 100 to KDA/TDA 20
Connection plans for feedback and CNC 60
Connection plans, motor-controller 19
Connection with intermediate terminals, feedback/C 58
Connection with plug design 58
Connection with plugin testing point 59
Contamination, degree of 86
Control circuits RAC 75
Control input 68
Control voltage bus end plug 87
Controller-specific connections 12
Crimping 91
Customizing specification 91
D
Diameter 45
Direct connections, feedback and CNC 57
Drive configuration 87
Drive shutdown 75
7. Index
E
Earth leakage circuit breaker 49
Environmental conditions 86
Equalizing the voltage 48
F
Feedback and CNC Connections 11, 56
Feedback and CNC connections 76
Feedback connections 56
Flanged socket 86
Freewheeling diodes 87
Fuse type 52
G
Grounded Three-Phase Mains 48
H
Heatsink fan cable 87
High-resolution motor feedback 61
High-voltage test 91
Holding Brake 19
Holding brake 9
I
IKS015/IKS016 73
IKS045 69
IKS314 64, 66
IKS610 68
IKS612 70
IKS614 72
IKS618/IKS620 74
IN 203 45
IN 204 45
IN 205 45
IN 206 45
IN 207 45
IN 209 84
IN 233 84
IN 234 84
IN 267 45
IN 271 84
IN 403 45
IN 404 45
IN 405 45
IN 406 45
IN 407 45
Incremental encoder output 74
Individual plug connectors 11, 90
Installation guidelines 85
Insulation test 91
Insulator casing 91
Interference sources inside the control cabinet 87
Interference-free operation 85
Isolating transformer 48
7. Index
K
KDA/TDA elec. conn. 8
L
Lead Spindle Feedback 67
Line 10
Line construction 45
Line lengths 14
Line routing 85
Line specifications for feedback and CNC connectio 45
Load capacity table 13
M
Mains connection line for RACs 55
Mains connection specifications 52
Mains voltage 47
Mass potential loops 85
Motor fan 19
Motor feedback, incremental encoder 63
Motor with blocking brake 19
Motor-controller connection with plug design 17
Motor-controller connection with plugin testing po 18
Motor-controller direct connection 16
Motor-controller power connections 15
N
Non-conductive contamination 86
O
Operating temperature, cable 13
Outer wire 47
Overvoltages 47
P
Packaging slip 89
PG thread 92
Plug accessory sets 88
Plug connector 90
Position set-point, digital 72
Power cable with intermediate terminal at terminal 17
Power cable with plug design 17
Power cable with plugin testing points 18
Power cables for direct connections 16
Power connections of the RAC three-phase mains 46
Power motor-controller connections 29
Power plug 90
Power plug connectors 86
Processing cycle 53
Protective caps 86
Protective circuits 87
Protective motor switch 19
R
RAC elec. conn. 9
Rated connection voltag 47
7. Index
Rated connection voltage for control electronics 47

RC suppressor components 87
Reduction 92, 93
Relative short-circuit voltage 53
Run-through test 91
S
Screws 92
SERCOS Interface 71
Serial interface 73
Shielding of bunched conductors 85
Sizing the Autotransformer 53
Sizing the Isolating Transformer 54
Soldering 91
Soldering of power plug connectors 93
Specifications of the power connection 10
Speed set-point, analog 69
Speed set-point, digital 70
spindle feedback 66
Storage 90
Storage temperature 90
Supply module 87
Surge arresters 48, 55
T
Table of power connections to the motor 29
Tables, feedback and CNC conn. 76
Terminal box 92
Three-Phase Mains 47
Tools 91
U
Ungrounded Three-Phase Mains 48
V
Varistors 87
Viewing panes 87
W
Weight 45
Wetting from coolants or lubricants 86
Wiring 85
Wye-point and outer wire grounded three-phase main 48
8. Supplementary Documentation
Summary of supplementary documentation
AC Main spindle drive

with controlled 2AD main spindle mo-
tor
(details, order)
8. Weiterführende Selection specifications

Selection
AC Main spindle
drive with controlled – Summary of the AC main drive system
Dokumentation 2AD main
spindle motor – 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
You have this document

(construction, mounting, installing the machine)
Asynchronous motor
Asynchronous motor 225
RAC4 Asynchronous motor 200
RAC3 Asynchronous motor 180
RAC2 Elektrische Asynchronous motor 160
Asynchronous motor
TDA1 132
Verbindungen Asynchronous motor 101
Controller KDA3 für Haupt- 2AD100
spindelan-
triebe
Planning and Design
Main spindle controller Electrical connections Main spindle motor

of the main spindle drive
Planning and Design Planning and Design
– Control cabinet plans Planning and Design – Machine construction plans
– AS programming module – General guidelines on the – Delivery, storage and transport
– Delivery, storage and transport electrical connections – Mounting and installation guidelines
– Mounting and installation guidelines – Circuit diagrams for feed-
back and CNC
connections 2AD 100, Doc. No. 9.567.009.4
KDA 3.2, Doc. No. 209-0042-4110 – Circuit diagramss for the 2AD 101, Doc. No. 9.567.018.4
TDA 1.1, Doc. No. 209-0042-4112 power connections of all 2AD 132, Doc. No. 9.567.010.4
RAC 2, Doc. No. 209-0042-4115 main spindle drives 2AD 160, Doc. No. 9.567.011.4
RAC 3, Doc. No. 209-0042-4116 2AD 180, Doc. No. 9.567.012.4
Doc. No. 209-0042-4111
RAC 4, Doc. No. 209-0042-4113 2AD 200 - in preparation
2AD 225 - in preparation
(Commissioning, Operating, Diagnosing)
Application of the main spindle drive
AC main spindle drives with controlled asynchronous

AC main spindle drives
with controlled
motors or frameless spindle motors
asynchronous motors 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
Figure 8.1: Summary of supplementary documentation
8. Supplementary Documentation
AC main spindle drives with controlled

AC Main spindle drive
asynchronous motor 2AD and
with controlled frameless spindle motor 1MB
changeover planetary gearboxes 2K
Selection specifications
AC Main spindle drive – Summary of the AC main drive system
(details, order)
with controlled frame- AC main spindle
less spindle motor 1MB – Power range drive with Selection specifications
Selection
changeover
1MB – Applications of the technical functions gearboxess 2K – Summary of the
of the AC main spiindle drive AC main drive system
– Selection protocol and items order list – Power range
– Delivery program – Order guidelines
Doc. No. 9.567.012.4 Doc. No. 9.567.022.4
(construction, mounting, installing the machine)

Frameless
spindle motor
Frameless
Absolute
1MB 375
spindle motor
Frameless value
1MB 310
spindle motor
Frameless 1MB encoder
spindle1MB 240
Frameless
motor
1MB - Stator HGV 2AD
spindle1MB
motor 200
1MB 160 - Rotor IGS

High-resolution
main spindle
position encoder
Planning and Design

Frameless spindle motor
Planning and Design Mounting guidelines Supplementary documentation
– Machine construction plans – Delivery, handling, transport
– Integrating into the cooling system – Mounting - high-resolution main spindle encoder
– Electrical and coolant connections – Cooling guidelines • application description
– Delivery Doc. No. 9.552.247.4
Stator, Doc. No. 9.600.063.4
1MB 160, Doc. No. 9.576.014.4 Rotor, Doc. No. 9.600.062.4 • mounting guidelines
1MB 200, Doc. No. 9.576.016.4 Doc. No. 9.600.060.4
1MB 240/241, Doc. No. 9.576.015.4 - incremental encoder output IGS
1MB 310/312, Doc. No. 9.576.008.4 Doc. No. 9.568.015.4
1MB 375, Doc. No. 9.576.007.4 - 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 (Commissioning, Operating, Diagnosing)
Application of the main spindle drive
Indramat

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engineering

Project Planning Manual

Titel Electrical Connections of Main Spindle Drives

Type of documentation: Project Planning Manual

Internal file reference • 209-0042-4111-00

This documentation This documentation serves:

Change procedures Designation of documentation Release- Coments

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

Copyright © INDRAMAT GmbH, 1994

The electronic documentation (E-doc) may be copied as often as needed if

Publisher INDRAMAT GmbH • Bgm.-Dr.-Nebel-Straße 2 • D-97816 Lohr

Dept ENA (MR, FS)

Table of Contents Page

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

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

3. Feedback and CNC Connections 56

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

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

5. Delivery, Identification, Storage 88

There are three categories of electrical connections:

The RAC controller is connected directly to the three-phase mains.

Control input and signal outputs

Additional controller interface

Lead spindle feedback

Mains contactor OFF

Control input and signal outputs

Additional controller interface

- Serial interface RS 232 C

Controller "ready" contact

Lead spindle feedback

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

Assembled cables are supplied in the lengths ordered and guarantee

Component electrical connections are made up of individual, assem-

To the motor To the motor

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

Feedback and CNC Connections

Exclusively Partially Components

No additional plug Additional plug Required:

Figure 1.5: Specifications of the feedback and CNC connections with

Assembled for Components

Connections only Plug connector without

The controller-specific connections are always required! The electri-

The cross sections of the power connections to the main spindle

The cross sections of the power connections to the three-phase

Load Capacity Table Conversion table for ambient temperatures

Rated conductor Load capacity of the

The permissible operating temperature on the surface of the cable

Load capacity must be converted in accordance with EN 60 204-1/ 2/

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

The maximum cable lengths given reference the direct connection

Terminal points and intermediate couplings can reduce maximum

Section 2.1.1: Division of the types of connections

Section 2.1.2: Connection plans for direct connection of motor and

Section 2.1.3: Table of assembled cable specifications for

Section 2.1.4: Table of cable specifications such as

Types of power connections

direct with intermediate terminal plug with

Figure 2.1: The four types of power connections

Motor-controller This type of connection is characterized by the lowest number of