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Beckhoff XTS Standard Operating Instructions Manual

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eXtended Transport
System | XTS
Operating instructions | EN
05/06/2019 | Version 2.1

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Summary of Contents for Beckhoff XTS Standard

  • Page 1 eXtended Transport System | XTS Operating instructions | EN 05/06/2019 | Version 2.1...

  • Page 2: Table Of Contents

    Ordering options .............................  16 Intended use .............................. 19 Technical data.............................. 20 Definition .................................  20 Data for operation and environment .......................  21 XTS Standard .............................. 22 Dimensional drawings.............................  23 Scope of supply .............................. 40 Packaging ...............................  40 Transport and storage............................ 41 Conditions ...............................
  • Page 3 Table of contents 6-roller 50 mm mover............................ 79 6-roller 70 mm mover............................ 80 12-roller 50 mm mover............................  80 Decommissioning..............................  81 Disassembly.............................. 81 Disposal ................................ 81 Index ...................................  82 Version: 2.1 eXtended Transport System ───...

  • Page 4: Documentation Notes

    Documentation notes D o c u m e n t a t i o n n o t e s The documentation has been prepared with care. Beckhoff products Disclaimer are subject to continuous further development. We reserve the right to revise the documentation at any time and without notice.

  • Page 5: Limitation Of Liability

    • Improper use • Use of untrained personnel • Use of unauthorized spare parts © Beckhoff Automation GmbH & Co. KG, Germany Copyright The copying, distribution and utilization of this document as well as the communication of its contents to others without express autho- rization is prohibited.

  • Page 6: Version Numbers

    Product features The product features specified in the latest version of the original operating instructions are always applicable. Further information given on the product pages of the Beckhoff homepage, in emails or in other publications is not authoritative. Issue Comment...

  • Page 7: Staff Qualification

    The provisions of the accident prevention regulations must be complied with. Customer service Customer service is provided by technicians who have been demonstrably trained and authorized by Beckhoff or the machine manufacturer to work on the respective machine or plant. Version: 2.1 eXtended Transport System...

  • Page 8: Safety And Instruction

    Documentation notes Read the contents, which refer to the activities that you have to Safety and instruction carry out with the product. Always read the chapter "For your safety", [Page 10] in the operating instructions. Observe the warn- ing notes in the chapters so that you can handle and work properly and safely with the product.

  • Page 9: Beckhoff Services

    Verl, at branch offices or, by arrangement, at the customer's premises. Hotline: +49(0)5246/963-5000 Fax: +49(0)5246/963-95000 E-mail: training@beckhoff.com Web: www.beckhoff.de/training The Beckhoff Service Centre supports you in all aspects of after- Service sales service (on-site service, repair service, spare parts service). Hotline: +49(0)5246/963-460 Fax: +49(0)5246/963-479 E-mail: service@beckhoff.com Web: www.beckhoff.de/service...

  • Page 10: For Your Safety

    For your safety F o r y o u r s a f e t y Read this chapter containing general safety information. The chap- ters in these operating instructions also contain warning notices. Al- ways observe the safety instructions for your own safety, the safety of other persons and the safety of the product.
  • Page 11 For your safety Only use original packaging for further processing When shipping, transporting, storing and packing, use the original packaging or conductive materials. Conductive materials are foam or aluminum, for example. Observe the earthing concept During operation Special conditions need to be observed for the earthing of the XTS. Be sure to read the chapter "Earthing of the supply", [Page 68].

  • Page 12: Product Overview

    Product overview P r o d u c t o v e r v i e w Number Explanation Curved rail Straight guide rail with gate Mover Gate Name plate Machine bed Straight guide rail without lock Straight module Curved module ───...

  • Page 13: Name Plate

    XTS Drive 250 mm ECAT Run Link / Act Automation GmbH & Co.KG Huelshorstweg 20 48V | 16A 33415 Verl / Germany www.beckhoff.com 24V | 4A Made in Germany 2000 002082 Number Explanation Link / Act status LED EtherCAT status LED...

  • Page 14: Type Key

    Product overview Type key Module AT 20 xx – xxxx – 000x Explanation Product line      AT = drive technology Product type      2 = module Module variants      00 =   straight      01 =   straight with supply      20 =   22.5° curve      21 =   22.5° curve with supply      25 =  -22.5°...

  • Page 15: Product Characteristics

    Product overview Permanent magnets Product characteristics Permanent magnets made of a hard magnetic material are built into the XTS movers. The permanent magnets develop high forces even in small designs. They enable the precise and highly dynamic posi- tioning of the XTS movers. More modular travel path You have the possibility to choose from a wide variety of module ge- ometries and to assemble them together as you wish.

  • Page 16: Ordering Options

    1.6 mm encoder flag for non-Beckhoff movers The use of the 1.6 mm-thick encoder flag is recommended for non- Beckhoff movers. The Mover 1 magnetic plate set with pre-mounted 1.6 mm encoder flag is available under the following article number: • AT9001-1550-1640 ───...
  • Page 17 Product overview In addition to the modules you need a rail system, which consists of Guide rails different guide rails. The guide rails are available in different lengths and angles. Straight guide rails are available in the following lengths, with or Straight guide rails without gate cover: Available lengths...
  • Page 18 Product overview 90° guide rails 90° guide rails are available to you for different applications. You can install these guide rails in case of an arrangement of a straight module with two consecutive 45° modules. 180° guide rails You have the possibility to extend the 90° guide rails to 180° with these additional guide rails.

  • Page 19: Intended Use

    All components of the XTS are intended to be programmed and put into operation only with the help of the Beckhoff TwinCAT automa- tion software. Read the entire drive system documentation This consists of: •...

  • Page 20: Technical Data

    Technical data T e c h n i c a l d a t a Below you will find definitions of terms, environmental conditions, operating details and technical data for the XTS. All details relate to an ambient temperature of 40 °C. The data can Definition have a tolerance of +/- 10%.

  • Page 21: Data For Operation And Environment

    Operate the XTS only under the specified environmental con- ditions Operate the Beckhoff XTS only in accordance with the specifica- tions for operation and the environment listed in this chapter. This ensures a long service life and proper operation.

  • Page 22: Xts Standard

    Technical data XTS Standard Electrical data      Control voltage [V      Power supply [V      Power supply current consumption -      nominal current [A]      Current consumption power supply < 48      short-term peak current [A]      Module control voltage power consumption      [W/m]      Maximum segment length per power supply ≤ 3...

  • Page 23: Dimensional Drawings

    Technical data Dimensional drawings and 3D models online Dimensional drawings You have the possibility to download the dimensional drawings and 3D models of the individual components from the Beckhoff website: www.beckhoff.de/download • Direct link to the download Dimensional drawings -...
  • Page 24 Technical data AT2001-0250 • Motor straight with supply • All figures in millimeters 250 - 0,3 49,9 39,9 A ( 1 : 2 ) ~ 15 39,1 5 F6 (2x) M (3x) 80 0,1 90 0,1 90 0,2 35 0,1 180 0,2 ───...
  • Page 25 Technical data AT2001-0250-0003 • Motor straight with supply and UL • All figures in millimeters 250 - 0,3 51,1 39,6 A ( 1 : 2 ) ~ 15 39,1 5 F6 (2x) M (3x) 80 0,1 90 0,1 90 0,2 35 0,1 180 0,2 Version: 2.1...
  • Page 26 Technical data AT2020-0250 • Motor +22.5° curved • All figures in millimeters (256,2) 22,5° A ( 1 : 2 ) 5 F6 (2x) 120 0,1 39,1 ─── eXtended Transport System Version: 2.1...
  • Page 27 Technical data AT2021-0250 • Motor +22.5° curved with supply • All figures in millimeters (256,2) 22,5° 5 F6 (2x) ( 1 : 2 ) 120 0,1 39,1 Version: 2.1 eXtended Transport System ───...
  • Page 28 Technical data AT2025-0250 • Motor -22.5° curved • All figures in millimeters (278,05) A ( 1 : 2 ) 39,1 ─── eXtended Transport System Version: 2.1...
  • Page 29 Technical data AT2040-0250 • Motor +45° curved • All figures in millimeters (258,93) 45° A ( 1 : 2 ) 5 F6 (2x) 110 0,1 M (3x) 39,1 130 0,2 Version: 2.1 eXtended Transport System ───...
  • Page 30 Technical data AT2041-0250 • Motor +45° curved with supply • All figures in millimeters (258,93) 45° A ( 1 : 2 ) 5 F6 (2x) 110 0,1 M (3x) 39,1 130 0,2 ─── eXtended Transport System Version: 2.1...
  • Page 31 Technical data AT2050-0500 • Motor clothoid 180° curved • All figures in millimeters 194,5 ~ 13,5 20,8 (3x) 96,8 0,2 9,8 (3x) 17,1 0,1 9,7 - 0,1 39,1 Version: 2.1 eXtended Transport System ───...
  • Page 32 Technical data AT2050-0500-0001 • Motor clothoid 180° curved with mounting plate for cooling sys- • All figures in millimeters ~ 13,5 20,8 (3x) 9,8 (3x) 96,8 0,2 17,1 0,1 9,7 - 0,1 50,7 0,2 48,6 0,2 Z ( 1 : 2 ) 39,1 52,1 M4x10 (8x)
  • Page 33 Technical data Dimensional drawings - mover AT9011-0050-0550 • Mover with a length of 50 mm and 6 guide rollers • All figures in millimeters Version: 2.1 eXtended Transport System ───...
  • Page 34 Technical data AT9011-0050-1550 • Mover 1 with a length of 50 mm and 6 guide rollers • All figures in millimeters ─── eXtended Transport System Version: 2.1...
  • Page 35 Technical data AT9011-0070-0550 • Mover with a length of 70 mm and 6 guide rollers • All figures in millimeters Version: 2.1 eXtended Transport System ───...
  • Page 36 Technical data AT9011-0070-1550 • Mover 1 with a length of 70 mm and 6 guide rollers • All figures in millimeters ─── eXtended Transport System Version: 2.1...
  • Page 37 Technical data AT9012-0050-0550 • Mover with a length of 50 mm and 12 guide rollers • All figures in millimeters Version: 2.1 eXtended Transport System ───...
  • Page 38 Technical data AT9012-0050-1550 • Mover 1 with a length of 50 mm and 12 guide rollers • All figures in millimeters ─── eXtended Transport System Version: 2.1...
  • Page 39 Technical data Dimensional drawings magnetic plate sets AT9001-0550 • Standard magnetic plate set • All figures in millimeters AT9001-1550 • Mover 1 magnetic plate set • All figures in millimeters Version: 2.1 eXtended Transport System ───...

  • Page 40: Scope Of Supply

    Scope of supply S c o p e o f s u p p l y Check missing or damaged parts Check your delivery for completeness. If any parts are missing or became damaged during transport, contact the carrier, manufac- turer or our service department immediately.

  • Page 41: Transport And Storage

    Transport and storage T r a n s p o r t a n d s t o r a g e Avoid damage to the components and loss of guarantee Observe the conditions specified in the following chapters for Transport and Storage.

  • Page 42: Mechanical Installation

    The following illustration provides you with an initial overview of the Preparation components that you need for the mechanical installation of the XTS assembly example. Please note that the design of individual compo- nents can vary depending on the application. BECKHOFF ─── eXtended Transport System Version: 2.1...
  • Page 43 Rail on support Mover 50 mm depending on the application Mover 70 mm depending on the application M5 x 20 screws and washers for modules with a Beckhoff machine bed Short locating pins for modules Long locating pins for modules Rubber seal...
  • Page 44 XTS system and you can minimize the downtime and maintenance work. With locating pins BECKHOFF With the standard assembly, all guide rails are connected with the locating pins 1 and all individual modules with locating pins 2. The...
  • Page 45 Mechanical installation Module segment BECKHOFF Without the locating pins this module segment 1 then consists of a guide rail 2 and a module without supply 3 with a power supply mod- ule 4. You can lift the module segment vertically out of the XTS sys- tem.

  • Page 46: Modules

    Mechanical installation 7.2.1 Modules Straight modules ► Insert short locating pins 1 and 2 on the top of the module ► Insert long locating pins 3 and 4 at the sides ► Insert short locating pins 5 and 6 underneath the module ►...
  • Page 47 The marking 2 then lines up with the outer edge of the module. The lettering 3 is for orientation. BECKHOFF ► Insert the seal 1 ► Insert connector card 1 at the position of the seal 2 ►...
  • Page 48 [+] The alignment gauge is not included in the standard scope of de- livery. Beckhoff recommends the use of the alignment gauge for the assembly of the straight modules. If you don't use an alignment gauge you can use, for example, a vernier caliper instead.
  • Page 49 Assembly with vernier caliper Assembly without alignment gauge [+] If you don't use an alignment gauge [+], Beckhoff recommends that you use a vernier caliper for the assembly of the straight mod- ules. Without an alignment gauge [+] you can align the modules to the prescribed distance of 250 mm between the locating pins with a...
  • Page 50 Mechanical installation ► Connect further modules 1 in line and fix them hand tight in the center to the machine bed with screw and washer 2 ► Using the vernier caliper, check that the distance between the lo- cating pins is 250 mm ►...
  • Page 51 Mechanical installation ► Connect further modules in line and fix them hand tight in the center to the machine bed with screws and washers 1 and 2 ► Make sure that the modules are slightly movable in the slots Version: 2.1 eXtended Transport System ───...
  • Page 52 Mechanical installation Assemble curved modules after straight modules Curved modules Make sure that you assemble the curved modules only after hav- ing assembled the upper and lower straight modules. You cannot mechanically close the system if you have not fully as- sembled the straight modules.
  • Page 53 Mechanical installation ► Make sure that you insert the screw 4 behind the cables 5 ► Tighten the screw and washer 4 immediately by hand No connector card exists on the supply modules! No connector card is inserted on the cable side of supply modules. At this point there is only sealing compound 1.
  • Page 54 • Check the power supply units and fuses for voltage • Check whether the connector card has been inserted • Contact the Support/Applications Department TwinCAT Beckhoff also recommends checking the modules using the Twin- CAT software. ► Start a TwinCAT project ► Scan the modules ►...

  • Page 55: Guide Rails

    Mechanical installation 7.3.1 Guide rails Straight guide rails ► Always use guide rail 1 with lock 2 on top of the assembled sys- tem 3 Pre-mounted gate A gate is available for the mounting of the movers on the guide rails.
  • Page 56 XTS. Subsequent movement Beckhoff recommends initially fixing all guide rails hand tight with a screw in the center. This allows you to compensate unequal dis- tances later on.
  • Page 57 Mechanical installation ► Observe the alignment of the guide rails 1 and 2 to each other ► The guide rails on the lower side of the XTS are now mounted horizontally and vertically mirrored ► Fix the opposite guide rail 1 with screw 2 and threadlocker hand tight again ►...
  • Page 58 ► Insert locating pins 1 and 2 into the curved rail 3 Facilitated assembly Beckhoff recommends greasing the connecting surfaces and the inner running surfaces of the curved rails before assembly. Straight guide rails and curved rails will be easier to fit together as a result.
  • Page 59 Mechanical installation The hole 3 in the center of the curved rail is not used for fixing. You have the option to use hole 3 for dismantling. Completion of the assembly ► Tighten the screws 1 in the curved rails ►...
  • Page 60 Mechanical installation Small washer with power supply modules Beckhoff recommends using a smaller washer at the cut-outs for the cables in the machine bed. That way you can avoid damage to the cables. ► Insert all screws with washers 1 and 2 into the remaining straight modules on the machine bed and screw tight ►...

  • Page 61: Mover

    Mechanical installation Better running characteristics Mover Beckhoff recommends greasing the running surface on the guide rails in the entire system prior to mounting the movers and the commissioning of the XTS. A suitable substance for greasing is, for example: • Vaseline ►...
  • Page 62 Mechanical installation 50 mm mover Damage due to strong magnetic attraction When mounting the movers on the rails, always hold them tight with both hands. The magnetic plate set of the mover and the modules strongly attract one another magnetically. If you don't hold the movers tight with both hands, the magnetic forces can attract the mover to the XTS in an uncontrolled man- ner, so that components hit against one another and are dam-...
  • Page 63 Mechanical installation ► Carefully push the mover 1 by hand along the guide rail 2 and out of the rail on support The mover is now mounted on the guide rail. ► Mount the remaining movers of the XTS When all remaining movers have been mounted: ►...
  • Page 64 Mechanical installation 70 mm mover Damage due to strong magnetic attraction When mounting the movers on the rails, always hold them tight with both hands. The magnetic plate set of the mover and the modules strongly attract one another magnetically. If you don't hold the movers tight with both hands, the magnetic forces can attract the mover to the XTS in an uncontrolled man- ner, so that components hit against one another and are dam-...
  • Page 65 Mechanical installation ► Carefully push the mover 1 by hand along the guide rail 2 and out of the rail on support The mover is now mounted on the guide rail. ► Mount the remaining movers of the XTS When all remaining movers have been mounted: ►...

  • Page 66: Electrical Installation

    The cable end of the power supply is pre-assembled with ferrules and the EtherCAT cable comes with an RJ45 plug (TSB568A configuration). Beckhoff cables have been tested with regard to the materials, Cables shielding and connection method used. They ensure proper func- tioning and compliance with statutory regulations such as EMC and UL.

  • Page 67: Pin Assignment Of The Power Cable

    Electrical installation Here is an overview of the cable configuration for the establishment Pin assignment of the of the power supply: power cable 11 31 1 R1 R3 1 R1 R3 12 32 2 R2 R4 2 R2 R4 4 1 2 3 4 1 2 EtherCAT wire...

  • Page 68: Earthing Of The Supply

    U 48 V I 48V 2,5 mm  2,5 mm Load current circuit Beckhoff recommends that you don't earth the 48 V power supply unit The 24 V return line (0.75 mm ) could be overloaded. If the 48 V power supply unit is earthed, the currents will be distrib- uted to the 48 V...

  • Page 69: Earthing Of The Machine Beds

    Beckhoff recommends the use of wide connections with large contact surfaces. Wide earth straps are suit- able for this. The table below illustrates typical suitable connectors:...
  • Page 70 Electrical installation 8.4.1 Painted surfaces ► Earth painted surface as shown in the illustration with spring washer 1, washer 2, contact washer 3, nut 4 and bolt 5 8.4.2 Unpainted surfaces ► Earth unpainted surface as shown in the illustration with spring washer 1, washer 2, nut 3 and bolt 4 ───...

  • Page 71: Parallel Connection Of The Modules

    Electrical installation Single-channel contactor switch-off Parallel connection of The figure below shows a wiring example of a single-channel con- the modules tactor switch-off for a maximum of two modules: 11 31 1 R1 R3 1 R1 R3 1 R1 R3 1 R1 R3 12 32 2 R2 R4...
  • Page 72 Electrical installation Single-channel contactor switch-off Control The figure below shows a wiring example of a single-channel con- tactor switch-off: 11 31 1 R1 R3 1 R1 R3 12 32 2 R2 R4 2 R2 R4 1. XTS 24 V power supply unit 48 V power supply unit Puls power supply unit...

  • Page 73: Parallel Connection Of The Power Supply

    Electrical installation Single-channel contactor switch-off parallel connection of The figure below shows a wiring example of a single-channel con- the power supply tactor switch-off: 11 31 1 R1 R3 1 R1 R3 1 R1 R3 1 R1 R3 1 R1 R3 1 R1 R3 12 32 2 R2 R4...
  • Page 74 Electrical installation Two-channel contactor switch-off Control The figure below shows a wiring example of a two-channel contactor switch-off: 11 31 1 R1 R3 1 R1 R3 12 32 2 R2 R4 2 R2 R4 1 R1 R3 1 R1 R3 2 R2 R4 2 R2 R4 24 V...

  • Page 75: Commissioning

    • Check protective measures against moving and live parts Configuration Beckhoff recommends the use of the latest TwinCAT XAE and TF5850 for the configuration of new projects • Create a new TwinCAT project and select the target system • Add modules to the I/O devices via the Scan function •...

  • Page 76: Prerequisites During Operation

    Commissioning • Pay attention to atypical noise development Prerequisites during op- • Pay attention to smoke development eration • Always check drive surfaces and cables for dirt, leaks, moisture or dust • Check temperature development • Observe recommended maintenance intervals •...

  • Page 77: Maintenance And Cleaning

    M a i n t e n a n c e a n d c l e a n i n g Beckhoff recommends service intervals in order to avoid permanent damage to the system. Contamination, dust or chips can have a negative effect on the function of the components.

  • Page 78: Intervals

    Maintenance and cleaning Operation beyond the permissible environmental conditions and op- Intervals erating states will shorten the intervals. The service life of consum- ables may be shortened depending on the mechanical dynamics due to mounted devices and movements. We have provided you with a list of maintenance work and intervals for the associated com- ponents below.

  • Page 79: Accessories

    The alignment gauge is a device with which you can align straight XTS standard modules. 11.2 Rail on support The XTS standard movers are mounted on the guide rails via the rail on support. 11.3 6-roller 50 mm mover The roller set is available for the replacement of worn or damaged guide rollers in the 50 mm-long movers with 6 guide rollers:...

  • Page 80: 6-Roller 70 Mm Mover

    Accessories 11.4 6-roller 70 mm mover The roller set is available for the replacement of worn or damaged guide rollers in the 70 mm-long movers with 6 guide rollers: • AT9011-0070-0550 • AT9011-0070-1550 Scope: • 4 cylindrical guide rollers of the same design •...

  • Page 81: Decommissioning

    Impermissible dismantle of XTS components Only Beckhoff Automation GmbH & Co. KG is permitted to dis- mantle the modules. Contact Beckhoff Service for further information. Removal of the XTS from the machine •...

  • Page 82: Index

    Index I n d e x Modules Control  72 Accessories Generate supply segments  44 12 roller set 50 mm Mover  80 Mount  46 6 roller set 50 mm Mover  79 Switch  71 6 roller set 70 mm Mover  80 Movers Alignment gauge  79 Mount...
  • Page 83 Index Disassemble  81 Install electrically  66 Install mechanically  42 Put into operation  75 Store  41 Transport  41 Version: 2.1 eXtended Transport System ───...
  • Page 84 Beckhoff Automation GmbH & Co. KG Hülshorstweg 20 D-33415 Verl Tel +49 (0) 5246 963-0 Fax +49 (0) 5246 963-198 www.beckhoff.de info@beckhoff.de More information: www.beckhoff.com/xts...

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