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Digital Servo Amplifier AX2500 Assembly, Installation, Setup Keep all product manuals as a product component during the life span of the servo amplifier. Pass all product manuals to future users / owners of the servo amplifier. Edition 06/2007...
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Printed in the Federal Republic of Germany All rights reserved. No part of this work may be reproduced in any form (by printing, photocopying, microfilm or any other method) or processed, copied or distributed by electronic means without the written permission of BECKHOFF.
General About this manual This manual describes the digital servo amplifiers of the AX2500 series. A more detailed description of the field bus interfaces and the digital connection to auto- mation systems can be found on the accompanying CD-ROM in PDF format (system requirements: WINDOWS, Internet browser, Acrobat Reader) in several language ver- sions.
Pulse-width modulation Volatile memory RBext External regen resistor RBint Internal regen resistor Resolver ROD 426 A quad B Encoder SRAM Static RAM Synchronous serial interface Underwriter Laboratory V AC AC voltage V DC DC voltage Verein deutscher Elektrotechniker AX2500 Product Manual...
Capacitors can still have dangerous voltages present up to five minutes after switching off the supply power. To be sure, measure the voltage in the DC Bus link and wait until it has fallen below 40V. AX2500 Product Manual...
If the servo amplifiers are used in residential areas, or in business or commercial premises, then additional filter measures must be implemented by the user. The AX2500 family of servo amplifiers is only intended to drive specific brushless synchronous servomotors with closed-loop control of torque, speed and/or position.
The machine / plant manufacturer must examine whether with its machine / plant still further or other standards or EEC guidelines are to be used. American Directives and Standards Chapter in process Asian Directives and Standards Chapter in process AX2500 Product Manual...
UL 840 UL 840 describes the fulfilment by design of air and insulation creepage spacings for electrical equipment and printed circuit boards. AX2500 Product Manual...
Disposal In accordance to the WEEE-2002/96/EG-Guidelines we take old devices and accessories back for professional disposal, if the transport costs are taken over by the sender. Send the devices to: Beckhoff Automation GmbH Eiserstr. 5 D-33415 Verl AX2500 Product Manual...
BECKHOFF Package 06/2007 Package Package supplied If you order a AX2500 series amplifier from us, you will receive: — AX250x or AX251x (master) — Mating connectors for X0, X1, X3, X6 — Protective cover for the axis-side (required only once per system) —...
Voltage rating Function 230...400V Axis module 115...230V Master module no power supply Comparison (without expansion) device name -> UL part number Device Name UL Part Number AX2503 S4036M-NA AX2506 S4066M-NA AX2513 S403AM-NA AX2516 S406AM-NA AX2523 S403BA-NA AX2526 S406BA-NA AX2500 Product Manual...
BECKHOFF Technical description 06/2007 Technical description Digital servo amplifiers in the series AX2500 Minimum complexity up to 8 axes in a single system only one power supply feed and one auxiliary voltage supply per system shield connection directly on the servo amplifier...
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2 programmable digital outputs freely programmable combinations of all digital signals Options PROFIBUS DP interface instead of CANopen, see page 69 SERCOS interface instead of CANopen, see page 70 EtherCat interface instead of CANopen, see page 71 AX2500 Product Manual...
Residual voltage drop at rated < 5 current Quiescent dissipation, output stage disabled Dissipation at rated current (without regen dissipation) Mechanical Weight Height, without connectors 267* 267* 267* Width Depth, without connectors * with add-on ventilation, see page 36 AX2500 Product Manual...
Internal fusing Function Auxiliary supply 24V 20 AM Regen resistor electronical External fusing Function Fusible cutouts or similar AC supply 16 A slow N1/2/3 24V supply 20 A slow H1/2 Regen resistor F 6 A slow B1/2 AX2500 Product Manual...
Check voltage drop and total current! To reach the max. permitted cable length, observe cable requirements ð p. 41. LED display A 3-digit LED display indicates the amplifier status after switching on the 24V supply (ð p.89). AX2500 Product Manual...
(see motor manual). A description of the interface can be found on page 48. Personnel-safe operation of the holding brake requires an additional “make” contact in the brake circuit and a spark suppressor device (e.g. a varistor) in the recommended brake circuit: AX2500 AX2500 Product Manual...
“holding brake” module failing. Bringing a motor to a standstill using a holding brake in a way that is personnel safe also requires an electromechanical “make” contact for the holding equipment and a suppressor device for the brake. AX2500 Product Manual...
The diagram below illustrates the correct functional sequence for switching the servo amplifier on and off. DC-BUS link Motor speed Power stage Enable (internal) Devices which are equipped with a selected “Brake” function use a special sequence for switching off the output stage (ð p.21). AX2500 Product Manual...
Even if there is no intervention from an external control system (in the example, the ENABLE signal remains active), the motor is immediately braked using the emergency stop ramp if an input phase error is detected and assuming that no changes have been made to the factory setting (ACTFAULT=1). AX2500 Product Manual...
If necessary, provision must be made for the connection of protective devices and lock-outs. If applicable, the Stop function must signal its status to the control logic. A reset of the Stop function must not create a hazardous situation. AX2500 Product Manual...
The parameters “STOPMODE” and “ACTFAULT” must be set to 1 in order to implement the stop categories. If necessary, change the parameters via the terminal screen of the setup software and store the data in the EEPROM. AX2500 Product Manual...
If the hold- ing brake fulfills the dynamic requirements, it must be taken into acount that this applica- tion will cause increased wear. Circuit suggestion (with EMERGENCY STOP Category 0, control function with contactor relays) AX2500 AX2500 Product Manual...
As soon as two separate time periods (set at the time relay) have elapsed, the mains sup- ply and the holding brake are electrically isolated. Should an internal AX2500 fault occur, the motor is forced to a standstill once K20 drops out.
The AX2500 is a 3-phase system with a B6 bridge. Therefore, FIs which are sensitive to all currents must be used in order to detect any D.C. fault current. Refer to chapter 6.9.1 for the rule of thumb for determining the leakage current.
Isolating transformers If protection against indirect contact is absolutely essential despite a higher leakage cur- rent, or if an alternative form of shock-hazard protection is sought, the AX2500 can also be operated via an isolating transformer. A ground-leakage monitor can be used to monitor for short circuits.
(ð p.36) EMC-conform shielding and grounding (ð p.45) Earth the moun- Grounding, ting plate, motor housing and CNC-GND of the controls. Notes Shielding on connection techniques are on page 40 AX2500 Product Manual...
2 mounting rails to EN60715, min. length = system width + 40mm, make sure there is a conductive connection to the mounting plate Mount the protective cover (7mm) on the left side of the system. Tools required: Screwdriver with approx. 5 mm blade width AX2500 AX2500 Product Manual...
Electrical add-on fan for two axes to achieve rated power even under unfavourable ambi- ent conditions, required for AX25x6. To mount the fan, just hook it in the designated slots at the bottom of the AX2500 and screw the fixing bolt into the thread in the housing. The electrical connection takes place automatically when mounting the fan.
Measure the voltage in the DC Bus link (+R /-DC) and wait until the voltage has fallen below 40V. Bext Control and power connections can still be live, even when the motor is not rotating. AX2500 Product Manual...
(maximum permissible voltages ð p.20) — Connect main power supply (maximum permissible voltages ð p.20) — Connect PC (ð p.67). Make a final check of the wiring carried out against the wiring Check diagrams that have been used AX2500 Product Manual...
Electrical Installation 06/2007 8.3.2 Shield connection on the front panel The pre-assembled cables for AX2500 are provided with an over- all metal ferrule at the amplifier end that is electrically connected to the shielding. Thread a cable tie through each slot in the shielding strip (front panel) of the servo amplifier.
To operate the amplifier with the max. permitted cable length, you must use cable material which meets the requirements on the capacity given below. Insulation material Sheathing PUR (polyurethane, code 11Y) Core insulation PETP (polyesteraphthalate, code 12Y) Capacitance Motor cable less than 150 pF/m RES/encoder cable less than 120 pF/m AX2500 Product Manual...
BECKHOFF Electrical Installation 06/2007 Components of a servo system Control / PLC 24V supply fuses drive contactor terminals motor AX2500 Product Manual...
Electrically isolated supply from an external 24 V DC PSU, e.g. with isolating transformer — Required current rating (ð p.19) Observe summarized current and voltage drop! — Integrated EMC filter for the 24 V auxiliary supply AX2500 AX2500 Product Manual...
DC bus link. The sum of the rated currents for all of the servo amplifiers connected in parallel to an AX2500 must not exceed 24 A. Use unshielded single cores (2.5mm²) with a max. length of 200 mm. Use shielded cables for longer lengths.
The table below provides an overview of the supported feedback types, their correspond- ing parameters and a reference to the relevant connection diagram in each case. On each of these, the pin assignment shown on the encoder side relates to the BECKHOFF motors.
Connection of a Resolver (2 to 36-poles) as a feedback system. The thermostat contact in the motor is connected via the resolver cable to the AX2500 and evaluated there. If lead lengths of more than 25 m are planned, please consult our customer support.
The thermostat contact in the motor is connected via the encoder cable to X2 and evaluated there. All signals are connected using our pre-assembled encoder connection cable. If cable lengths of more than 50m are planned, please consult our customer service. Frequency limit (sin, cos): 350 kHz FBTYPE: 20 AX2500 AX2500 Product Manual...
ECN1313 and EQN1325 encoders. The thermostat contact in the motor must be connected via the encoder cable to the AX2500 and evaluated there. All signals are connected using our pre-assembled encoder connection cable. If lead lengths of more than 25 m are planned, please consult our customer support.
Frequency limit (sin, cos): 350 kHz Encoder type FBTYPE Remarks SinCos 5V MPHASE from EEPROM SinCos 5V MPHASE with wake & shake Commutation with resolver, Resolver+SinCos5V Speed&Position with Encoder Don't use this feedback type with vertical load (hanging load). SubD 15 AX2500 AX2500 Product Manual...
Hall encoder. All signals are connected to X2. If cable lengths of more than 25 m are planned, please consult our customer service. Frequency limit (A, B): 350 kHz RS422 with Hall: FBTYPE 12 Encoder with Hall: FBTYPE 11 SubD15 AX2500 AX2500 Product Manual...
Frequency limit (A, B): 1.5 MHz Encoder type FBTYPE Remarks RS422 5V MPHASE from EEPROM RS422 5V MPHASE with wake & shake Don't use this feedback type with vertical load (hanging load). SubD 9 AX2500 AX2500 Product Manual...
Connection to incremental encoder master with 24 V signal level (X3) You can use this interface to set up the AX2500 as a slave following an encoder with a 24V signal level (master-slave operation). This application uses the digital inputs DIGI- TAL-IN 1 and 2 on connector X3.
8.14.3 Connection to a sine-cosine encoder master (X2) You can set up the AX2500 as a slave following a sine/cosine encoder (master-slave operation). This application uses the SubD connector X2. If cable lengths of more than 50m are planned, please consult our customer service.
8.14.4 Connection to a SSI encoder (X4) You can set up the AX2500 as a slave following a synchronous serial absolute-encoder (master-slave operation). This application uses the SubD connector X4. If lead lengths of more than 50 m are planned and for questions concerning the power supply of the encoder, please consult our customer service.
Connection of the servo amplifier to a stepper motor control with a 24 V signal level. The digital inputs DIGITAL-IN 1 and 2 on connector X3 are used for this purpose. Frequency limit: 100 kHz AGND (terminal X3/1) must be connected to the ground of the control system! AX2500 AX2500 Product Manual...
PGND must always be connected to the control ground. The max. admissible cable length is 10 m. Connections and signal description for the incremental-encoder interface : The count direction is UP when the motor shaft is rotating clockwise (looking at the end of the motor shaft). AX2500 AX2500 Product Manual...
PGND must always be connected to the control ground. Connection and signals for the SSI interface : The count direction is UP when the motor shaft is rotating clockwise (looking at the end of the motor shaft). AX2500 AX2500 Product Manual...
(looking at shaft end) with positive voltage on terminal X3/3 (+ ) against X3/2 ( - ) To reverse the direction of rotation you can swap the connections to terminals X3/2-3 or change the DIRECTION parameter in the SPEED screen. AX2500 Product Manual...
(fail-safe for cable break). A low signal (open) inhibits the corresponding direction of rotation. DIGITAL-IN 1 / DIGITAL-IN 2 You can link the digital inputs at terminals X3/4 (DIGITAL-IN 1) and X3/5 (DIGITAL-IN2) with a pre-programmed function. AX2500 Product Manual...
If an input is freshly assigned to a pre-programmed function, then the data set must be stored in the EEPROM of the servo amplifier, and the 24 V auxiliary supply of the servo amplifier must be switched off and on again (to reset the amplifier software). AX2500 Product Manual...
All faults cause the BTB/RTO contact to open and the switch-off of the output stage (if the BTB contact is open, the output stage is disabled -> no power). A list of the error messages can be found on page 90. AX2500 Product Manual...
Further notes can be found on page 74 . AX2500 Interface cable between the PC and servo amplifiers of the AX2500 series: (View: front view of the built-in SubD connectors, this corresponds to looking at the solder side of the SubD connector on the cable.)
(Characteristic impedance 150 ± 5 W Þ terminating resistance 150 ± 5 W). For EMC reasons, the SubD connector housing must fulfill the following conditions: — metal or metallized housing — provision for connecting the cable shielding within the housing, large-area connections AX2500 Product Manual...
06/2007 8.18.2 PROFIBUS interface (X7), option This section describes the PROFIBUS interface for AX2500. Information on the range of functions and the software protocol can be found in the man- ual “Communication profile PROFIBUS-DP”. The selection of cables, cable routing, shielding, bus connectors, bus termination and propagation times are described in the “Setup guidelines for PROFIBUS-DP/FMS”...
06/2007 8.18.3 SERCOS interface (X7), option This section describes the SERCOS interface of the AX2500. Information on the range of functions and the software protocol can be found in the manual “IDN Reference Guide SERCOS”. For the fiber optic cable connection, only use SERCOS components to the SERCOS Standard IEC 61491.
Electrical Installation 06/2007 8.18.4 EtherCat interface (X7), option This section describes the EtherCat interface of the AX2500. Information on the range of functions and the software protocol can be found in the EtherCat documentation (actually in process). 8.18.4.1 EtherCat connection, connector X7A/B (RJ-45) Connection to the EtherCat network with RJ-45 connectors (IN and OUT interfaces).
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BECKHOFF Electrical Installation 06/2007 This page has been deliberately left blank. AX2500 Product Manual...
The adaptation of parameters and their effects on the control loop behaviour are described in the online help of the setup software. The commissioning of the fieldbus interface is described in the corresponding manual. We can provide further know-how through training courses (on request). AX2500 Product Manual...
The operator software is intended to be used for altering and storing the operating param- eters for the AX2500 series of servo amplifiers. The attached servo amplifier is commis- sioned with the assistance of the software - during this process the drive can be con- trolled directly by the service functions.
CD drive). Click on OK and then on the link to the Setup Software and follow the instructions. Connection to the serial interface of the PC Connect the interface cable to a serial interface on your PC and the PC interfaces (X8) of the AX2500 (ð p.67). AX2500 Product Manual...
CANopen Communication Profile Manual PROFIBUS DP Communication Profile Manual SERCOS Communication Profile Manual EtherCat Communication Profile Manual (in process) You need Acrobat Reader to read the PDFs, an installation link is on every screen of the product CD-ROM. AX2500 Product Manual...
Minimum Wiring for Drive Test This wiring does not fulfill any requirements to safety or functionality of your application, it just shows the required wiring for drive testing without load. Enable 24V ON 24V DC Power ON Motor Motor Power AX2500 Product Manual...
- interface is used by another software - 24 V auxiliary voltage for the servo amplifier not working - interface cable broken or wrong wiring Click OK to remove the error message. Detect and remove the error source. Restart the software. AX2500 Product Manual...
Save to EEPROM, required if you changed parameters. Reset (coldstart), required if you changed important configuration parameters. Operation Mode, use Digital Velocity mode for drive testing. Disable and Enable of the amplifier's output stage via soft- ware. Status Bar AX2500 Product Manual...
Select usable units for your application referring to the moved load. Address: Adjust for master amplifier only (= highest address of the drive system, see p.86) Leave all other fields unchanged. Click OK. On the start screen click "Motor" button. AX2500 Product Manual...
If you click "Yes", the parameters are sa- ved in the EEPROM and the amplifier makes a coldstart (reset). This takes some seconds. On the start screen, click "Feedback" button. AX2500 Product Manual...
If everything was ok, the same procedure (parameter upload) that has been described for the motor selection starts. If you click "Yes", the parameters are saved in the EEPROM and the amplifier makes a coldstart (reset). This takes some seconds. AX2500 Product Manual...
Save the parameters to the EEPROM of the servo amplifier manually by clicking the sym- in the tool bar. A coldstart of the amplifier is not necessary. Reset the amplifier You can reset the amplifier manually (e.g. in case of an error). Click the iconl AX2500 Product Manual...
The symbol's color changes to green as long as the function is active. The function is active until you click the "Stop" button or press F9. The output stage can be disabled by pressing function key F12. AX2500 Product Manual...
Click the icon "Monitor" The Monitor screen shows all important electrical and mechanical actual values. 9.3.11 Additional Setup Parameters Detailed information on all setup functions can be found in the Online Help systemand and the integrated command reference. AX2500 Product Manual...
The highest permitted master address is 128. When choosing the master address, please consider that at least address 1 will be assigned to the last (leftmost) axis module. In CAN and PROFIBUS field bus systems the automatically assigned addresses must not match the address of other nodes. AX2500 Product Manual...
BECKHOFF Setup 06/2007 9.4.2 Example of connections for multi-axis system Follow the safety instructions (ð p.9) and the use as directed (ð p.10) ! AX250x / AX251x AX252x AX252x AX2500 Product Manual...
RESET function is used, only the CLRFAULT command will be executed. More information to the messages can be found in the ASCII Object Reference (Online Help), see parameter ERRCODE. Hints for removal can be found in the Online help chapter "Trouble-Shooting". AX2500 Product Manual...
* = these warning messages result in a controller shut-down of the drive (braking by emergency stop ramp) More information to the messages can be found in the ASCII Object Reference (Online Help), see parameter STATCODE. Hints for removal can be found in the Online help chapter "Trouble-Shooting". AX2500 Product Manual...
— increase T-Tacho — offset not correctly adjusted for — adjust setpoint-offset (analog axis drifts at analog setpoint provision I/O) — AGND not joined to the — join AGND and CNC-GND setpoint = 0V CNC-GND of the controls AX2500 Product Manual...
Set of all the position control parameters which are required for a motion task multi-axis system Machine with several driven axes natural convection Free movement of air for cooling optocoupler Optical connection between two electrically independent systems AX2500 Product Manual...
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Voltage proportional to the actual speed thermostat Temperature-sensitive switch built into the motor winding Tn, I-integration time Integral section of a control loop zero pulse Output once per turn from incremental encoders, used to zero the machine AX2500 Product Manual...