Beckhoff AX2500 Series Assembly, Installation, Setup
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- Page 1 Digitaler Servoverstärker 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 02/06...
- Page 2 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.
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Page 3: Table Of Contents
Beckhoff Contents 02/06 page General About this manual ............... 5 Symbols used in this Manual . - Page 4 Beckhoff Contents 02/06 page Interfaces Block diagram ............... . . 37 Power supply, master only .
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Page 5: General
Beckhoff General 02/06 General About this manual This manual describes the digital servo amplifiers of the AX2500 series. In this manual you can find information about: General Chapter 1 Technical description Chapter 2 Assembly / installation Chapter 3 Interfaces Chapter 4... -
Page 6: Abbreviations Used In This Manual
Beckhoff General 02/06 Abbreviations used in this Manual The abbreviations used in this manual are explained in the table below. Abbrev. Meaning AGND Analog ground BTB/RTO Ready to operate Fieldbus (CANopen) Communité Europeenne (=EC) Clock signal Serial interface for a PC-AT... -
Page 7: Technical Description
Beckhoff Technical description 02/06 Technical description Safety Instructions Only properly qualified personnel are permitted to carry out activities such as transport, installation, commissioning and maintenance. Properly qualified per- sons are those who are familiar with the transport, assembly, installation, com- missioning and operation of the product, and who have the appropriate qualifi- cations for their job. -
Page 8: Use As Directed
Beckhoff Technical description 02/06 Use as directed The servo amplifiers are components which are built into electrical equipment or machi- nes, and can only be commissioned as integral components of such equipment. The manufacturer of the machine must produce a hazard analysis for the machine and take appropriate measures to ensure that unforeseen movements do not result in personal injury or material damage. -
Page 9: European Directives And Standards
Beckhoff Technical description 02/06 European Directives and Standards Servo amplifiers are components that are intended to be incorporated into electrical plant and machines for industrial use. When the servoamplifiers are built into machines or plant, the intended operation of the amplifier is forbidden until it has been established that the machine or plant fulfills the requirements of the EC Machinery Directive 98/37/EG and the EC Directive on EMC (89/336/EEC) and the Low Voltage Directive 73/23/EEC. -
Page 10: Ul And Cul- Conformance
Beckhoff Technical description 02/06 UL and cUL- Conformance This servo amplifier is listed under UL file number E217428. UL (cUL)-certified servo amplifiers (Underwriters Laboratories Inc.) fulfil the relevant U.S. and Canadian standard (in this case UL 840 and UL 508C). -
Page 11: Nameplate
Serial Number Firmware Equipment description 2.7.1 Package as 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) —... -
Page 12: Digital Servo Amplifiers In The Series Ax2500
Beckhoff Technical description 02/06 2.7.2 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... - Page 13 Beckhoff Technical description 02/06 Integrated safety safe electrical separation to EN 50178 between the power input / motor connections and the signal electronics, provided by appropriate creepage distances and complete electrical isolation Soft-start, overvoltage detection, short-circuit protection, phase-failure monitoring temperature monitoring of servo amplifier and motor (when using our motors with our...
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Page 14: Components Of A Servo System
Beckhoff Technical description 02/06 Components of a servo system Control / PLC 24V supply AX2500 fuses drive contactor terminals motor AX2500 Installation Manual... -
Page 15: Technical Data
Beckhoff Technical description 02/06 Technical data 2.9.1 Rated data max. 230VAC max. 400VAC AX25 AX25 Rated data 1 x 115V 3 x 230V -10% -10% Rated supply voltage — — 3 x 230V +10% 3 x 400V +10% Max. installed load for S1 operation —... -
Page 16: Connections
Beckhoff Technical description 02/06 2.9.2 Connections Function Connector type Control signals Combicon spring terminal Power supply Power Combicon Motor Combicon Resolver input SubD 9pol. (socket) Incremental encoder input SubD 15pol. (socket) PC interface SubD 9pol. (plug) Encoder emulation, ROD/SSI SubD 9pol. (plug) 2.9.3... -
Page 17: Permissible Ambient Conditions, Ventilation, Mounting Position
Beckhoff Technical description 02/06 2.9.5 Permissible ambient conditions, ventilation, mounting position ð p.73 Storage temp. /humidity/duration ð p.73 Transport temperature/humidity Supply voltage tolerances main power +10% AX250x min 1x115V AC / max 1x230V , 50/60 Hz -10% +10% min 3x115V... -
Page 18: Motor Holding Brake Control
Beckhoff Technical description 02/06 2.10 Motor holding brake control A motor holding brake (max.1.5A) can be controlled directly by the servo amplifier. Check voltage drop, measure the voltage at brake input and check brake function (brake and no brake). This function does not ensure personnel safety! The brake function must be enabled through the BRAKE parameter (on the screen page for Motor): the setting is WITH. -
Page 19: Regen Circuit
Beckhoff Technical description 02/06 2.11 Regen circuit During braking with the aid of the motor, energy is fed back to the servo amplifier. This energy is converted into heat in the regen resistor. The regen resistor is switched in and out by the regen circuit. -
Page 20: Switch-On/-Off Behaviour
Beckhoff Technical description 02/06 2.13 Switch-on/-off behaviour The diagram below illustrates the correct functional sequence for switching the servo amplifier on and off. 2.13.1 Stop function as per EN 60204 (VDE 0113) If a fault occurs (ð p.66), the output stage of the servo amplifier is switched off and the BTB/RTO contact is opened. -
Page 21: Emergency Stop Methods
Beckhoff Technical description 02/06 2.13.2 Emergency stop methods The Emergency Stop function is defined in EN 60204 (VDE 0113), Para. 9.2.5.4. In addition to the requirements for Stop, the Emergency Stop must fulfill the following requirements: it must have priority over all other functions and controls in all operating situations the energy supply to any drive machinery that could cause dangerous situations must be switched off as fast as possible, without causing any further hazards (e.g. - Page 22 Beckhoff Technical description 02/06 This page has been deliberately left blank. AX2500 Installation Manual...
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Page 23: Installation
Beckhoff Installation 02/06 Installation Important notes Protect the servo amplifier from impermissible stresses. In particular, do not let any components become bent or any insulation distances altered during transport and handling. Avoid contact with electronic components and contacts. Check the combination of servo amplifier and motor. Compare the rated voltage and current of the units. -
Page 24: Guide To Installation / Wiring
Beckhoff Installation 02/06 Guide to installation / wiring The following notes should assist you to carry out the installation in a sensible sequence, without overlooking anything important: In a closed control cabinet. Observe page 17. Site The site must be free from conductive or corrosive materials. -
Page 25: Mounting
Beckhoff Installation 02/06 Mounting Material: 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. -
Page 26: Dimensions
Beckhoff Installation 02/06 3.3.1 Dimensions AX250x and AX251x AX252x AX2500 Installation Manual... -
Page 27: Wiring
Beckhoff Installation 02/06 Wiring Only professional staff who are qualified in electrical engineering are allowed to install the servo amplifier. The installation procedure is described as an example. A different procedure may be appropriate or necessary, depending on the application of the equipment. -
Page 28: Connection Diagram Ax250X And Ax251X
Beckhoff Installation 02/06 3.4.1 Connection diagram AX250x and AX251x Follow the safety instructions (ð p.7) and the use as directed (ð p.8) ! AX250x/AX251x ð p.43 ð p.46 ð p.46 ð p.40 ð p.48 ð p.39 ð p.49 ð p.52 ð... -
Page 29: Connection Diagram Ax252X
Beckhoff Installation 02/06 3.4.2 Connection diagram AX252x Follow the safety instructions (ð p.7) AX252x and the use as directed (ð p.8) ! ð p.43 ð p.46 ð p.46 ð p.40 ð p.48 ð p.39 ð p.52 ð p.57 AX2500 Installation Manual... -
Page 30: Example Of Connections For Multi-Axis System
Beckhoff Installation 02/06 3.4.3 Example of connections for multi-axis system Follow the safety instructions (ð p.7) and the use as directed (ð p.8) ! AX250x/AX251x AX252x AX252x AX2500 Installation Manual... -
Page 31: Connector Assignments
Beckhoff Installation 02/06 3.4.4 Connector assignments AX2500 Installation Manual... -
Page 32: Connection Techniques
Beckhoff Installation 02/06 3.4.5 Connection techniques 3.4.5.1 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. -
Page 33: Requirements To Cables
Beckhoff Installation 02/06 3.4.5.2 Requirements to cables Further information on the chemical, mechanical and electrical characteristics of the cables can be obtained from our customer support. Observe the restrictions in the chapter "Conductor cross-sections" on page 17. To operate the amplifier with the max. permitted cable length, you must use cable material which meets the requirements on the capacity given below. -
Page 34: Setup Software
The operator software is intended to be used for altering and storing the operating para- meters 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 control- led directly by the service functions. -
Page 35: Hardware Requirements
Beckhoff Installation 02/06 3.5.1.3 Hardware requirements The PC interface (X6, RS232) of the master is connected to a serial interface on the PC by a null-modem cable (not a null-modem link cable !) (ð p.56). Connect / disconnect the interface cable only when the supply is switched off for both the PC and the servo amplifier. - Page 36 Beckhoff Installation 02/06 This page has been deliberately left blank. AX2500 Installation Manual...
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Page 37: Interfaces
Beckhoff Interfaces 02/06 Interfaces This chapter presents all the important interfaces, divided between master and axis module. The precise location of the connectors and terminals can be seen on page 31. Block diagram AX2500 Installation Manual... -
Page 38: Power Supply, Master Only
Beckhoff Interfaces 02/06 Power supply, master only 4.2.1 Mains supply connection (X0) 4.2.1.1 Three-phase supplies Directly to earthed supply, filter is integrated, fusing (e.g. fusible cut-outs) to be provided by the user (ð p.16). AX2500 for AX250x for AX251x 4.2.1.2 Single-phase supplies Directly to supply, filter is integrated, fusing (e.g. -
Page 39: Dc Bus Link/Dc-Bus (X0)
Beckhoff Interfaces 02/06 DC Bus link/DC-bus (X0) Can be connected in parallel with further, identical masters (via terminals -DC and RB Only servo amplifiers with mains supply from the same mains (identical mains supply voltage) may be connected by the DC bus link. -
Page 40: Feedback
Beckhoff Interfaces 02/06 Feedback Feedback system Conn. Remarks Resolver p.40 2 to 36 poles ComCoder p.41 A, B, Zero, Hall Incremental with Hall or A, B, Zero, Hall or p.42 sine Encoder with Hall Sine, Cosine, Zero, Hall Sine Encoder with EnDat / HIPERFACE p.43 Sine, Cosine, Clock, Data... -
Page 41: Comcoder (X2)
Beckhoff Interfaces 02/06 4.6.2 ComCoder (X2) As an option our motors can be equipped with a ComCoder as feedback unit. For the commutation hall sensors are used and for the resolution an incremental encoder. The thermostat contact in the motor is connected via the ComCoder cable to X2 and evaluated there. -
Page 42: Incremental Or Sine Encoder With Hall Sensors (X2)
Beckhoff Interfaces 02/06 4.6.3 Incremental or sine encoder with hall sensors (X2) Feedback devices (incremental or sine-cosine), which don't deliver an absolute informa- tion for commutation, can be used as complete feedback system combined with an addi- tional Hall encoder. All signals are connected to X2. -
Page 43: Sine Encoder With Endat Or Hiperface (X2)
Beckhoff Interfaces 02/06 4.6.4 Sine Encoder with EnDat or HIPERFACE (X2) As an option, the motors can be fitted with a single-turn or multiturn sine-cosine encoder. Preferred types are the ECN1313 and EQN1325 encoders. The encoder is used by the AX2500 as a feedback device for drive tasks that require highly precise positioning or extremely smooth running. -
Page 44: Sine Encoder Without Data Channel (X2)
Beckhoff Interfaces 02/06 4.6.5 Sine Encoder without data channel (X2) A sine-cosine encoder without data channel can be used as standard motor feedback. Select feedback type 7 "SinCos 5V with W&S". Drive executes wake&shake to calculate the necessary start-up information for the position controller every time the 24V auxiliary voltage is switched on. -
Page 45: Incremental Encoder (X4)
Beckhoff Interfaces 02/06 4.6.6 Incremental Encoder (X4) An incremental encoder can be used as standard motor feedback. Select feedback type 19 "ROD 5V mit W&S". Drive executes wake&shake to calculate the necessary start-up information for the position controller every time the 24V auxiliary vol- tage is switched on. -
Page 46: Digital And Analog Inputs And Outputs
Beckhoff Interfaces 02/06 Digital and analog inputs and outputs 4.7.1 Analog input (X3) The servo amplifier has a programmable input for analog setpoints. AGND (X3/1) must always be joined to the CNC-GND of the controls to provide a ground reference. -
Page 47: Digital Inputs (X3)
Beckhoff Interfaces 02/06 4.7.2 Digital inputs (X3) All digital inputs are electrically isolated through optocouplers. Technical data — Reference ground is digital-GND (DGND, terminal X1/4,5 on the master) — The logic is dimensioned for +24V / 7mA (PLC-compatible) — H-level from +12...36V / 7mA, L-level from 0...7V / 0 mA —... -
Page 48: Digital Outputs (X3)
Beckhoff Interfaces 02/06 4.7.3 Digital outputs (X3) Technical characteristics — Ground reference is Digital-GND (DGND, terminal X1/4,5 on the master) — Alle digital outputs are floating — DIGITAL-OUT1 and 2 : Open-collector, max. 30V DC, 10mA — Update rate: 250 µs... -
Page 49: Digital I/O On The Master (X1)
Beckhoff Interfaces 02/06 4.7.4 Digital I/O on the Master (X1) Technical characteristics — Ground reference is Digital-GND (DGND, terminal X1/4,5) — The logic is dimensioned for +24V / 7mA (PLC-compatible) — H-level from +12...36V / 7mA, L-level from 0...7V / 0 mA BTB/RTO: Relay output, max. -
Page 50: Encoder Emulations
Beckhoff Interfaces 02/06 Encoder emulations 4.8.1 Incremental encoder output - A quad B (X4) The incremental-encoder interface is part of the package supplied. Select the encoder function ROD (screen page “Encoder”, funktion ENCMODE). In the servo amplifier, the position of the motor shaft is calculated from the cyclic-absolute signals of the resolver or encoder. -
Page 51: Ssi Output (X4)
Beckhoff Interfaces 02/06 4.8.2 SSI output (X4) The SSI interface (synchronous serial absolute-encoder emulation) is part of the package supplied. Select encoder function ROD (“Encoder” screen page). The servo amplifier calculates the motor shaft position from the cyclic-absolute signals of the resolver or encoder. -
Page 52: Master-Slave Operation, Encoder Master Control
Beckhoff Interfaces 02/06 Master-slave operation, encoder master control This interface can be used to link several AX2500 amplifiers in master-slave operation. The parameters for the slave amplifier are set up with the aid of the setup software (elec- trical gearing). The resolution (no. of pulses/turn) can be adjusted. The analog setpoint input is inactive. -
Page 53: Connection To Incremental Encoder Master With 24V Signal Level (X3)
Beckhoff Interfaces 02/06 4.9.2 Connection to incremental encoder master with 24V 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. -
Page 54: Interface For Stepper Motor Controllers (Pulse/Direction)
Beckhoff Interfaces 02/06 4.10 Interface for stepper motor controllers (pulse/direction) This interface can be used to connect the servo amplifier to a third-party stepper-motor controller. The parameters for the servo amplifier are set up with the aid of the setup soft- ware (electrical gearing). -
Page 55: Connection To A Stepper Motor Controller With 5V Signal Level (X4)
Beckhoff Interfaces 02/06 4.10.1 Connection to a stepper motor controller with 5V signal level (X4) You can use this interface to connect the servo amplifier to a stepper motor control with a 5V signal level. The SubD connector X4 is used for this purpose. -
Page 56: Rs232 Interface, Pc Connection (X8), Master Only
Further notes can be found on page 34 . 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.) -
Page 57: Fieldbus Connection
Beckhoff Interfaces 02/06 4.12 Fieldbus connection 4.12.1 CANopen interface (X7) The interface for connection to the CAN bus (default: 500 kbps). The master is fitted with a CAN input. All axis modules in the system are connected to this through the internal bus. -
Page 58: Profibus Interface (X7), Option
Beckhoff Interfaces 02/06 4.12.2 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 manual “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”... -
Page 59: Sercos Interface (X7), Option
Beckhoff Interfaces 02/06 4.12.3 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. - Page 60 Beckhoff Interfaces 02/06 This page has been deliberately left blank. AX2500 Installation Manual...
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Page 61: Setup
Beckhoff Setup 02/06 Setup Important notes Only professional personnel with extensive knowledge in the fields of electrical engineering and drive technology are allowed to setup the servo amplifier. The procedure for commissioning is described as an example. Depending on the applica- tion, a different procedure may be appropriate or necessary. -
Page 62: Guide To Setup
Beckhoff Setup 02/06 Guide to setup The following instructions should help you to carry out the commissioning in a sensible order, without any hazards to people or machinery: See Chapter 3. Disconnect the servo amplifier from Check installation the supply. -
Page 63: Parameterization
Beckhoff Setup 02/06 Parameterization A default parameter set is loaded into your servo amplifier at the factory. This contains valid and safe parameters for the current and speed controllers. A database for motor parameters is stored in the servo amplifier. During commissioning you must select the data set for the motor that is connected and store it in the servo amplifier. -
Page 64: Key Pad Controls And Status Displays
Beckhoff Setup 02/06 5.3.2 Key pad controls and status displays Two keys are fitted in the operating panel of the master. Here you can enter the basic address for the system and call up status information on all the axes that are connected. -
Page 65: Status Display On The Master
Beckhoff Setup 02/06 5.3.2.3 Status display on the master AX2500 Installation Manual... -
Page 66: Error Messages
Beckhoff Setup 02/06 Error messages Any errors that occur are shown in coded form by an error number in the LED display on the front panel. All error messages result in the BTB/RTO contact being opened, and the output stage of the amplifier being switched off (motor loses all torque). The motor-hol- ding brake is activated. -
Page 67: Warning Messages
Beckhoff Setup 02/06 Warning messages Faults which occur, but which do not cause a switch-off of the amplifier output stage (BTB/RTO contact remains closed), are indicated in the LED display on the front panel by a coded warning number. Number Designation... - Page 68 Beckhoff Setup 02/06 This page has been deliberately left blank. AX2500 Installation Manual...
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Page 69: Accessories
Beckhoff Accessories 02/06 Accessories External PSU 24V DC / 5A Technical data Input voltage 120 / 230V Input current 0.9 / 0.6A Frequency 50/60Hz Primary fusing 3.15AT Output voltage 24V ± 1% Max. output current 5A Residual ripple <150mVss Switching peaks <240mVss... -
Page 70: External Psu 24V Dc / 20A
Beckhoff Accessories 02/06 External PSU 24V DC / 20A Mounting plate Mounting plate Technical data Input voltage 3 x 400V AC ± 10% Input current approx. 1.1A Frequency 50/60Hz Primary fusing none Output voltage 24V ± 1% Max. output current 20A Residual ripple <0.1%... -
Page 71: External Regen Resistor Bar(U)
Beckhoff Accessories 02/06 External regen resistor BAR(U) Caution: Surface temperature may exceed 200°C. Observe the requested free space. Do not mount to combustible surface. AX2500 Installation Manual... -
Page 72: Add-On Fan
Beckhoff Accessories 02/06 Add-on fan Electrical add-on fan for two axes to achieve rated power even under unfavourable ambient conditions, required for AX25x6. To mount the fan, just hook it in the designated slots at the bottom of the AX25 and screw the fixing bolt into the thread in the housing. -
Page 73: Appendix
Beckhoff Appendix 02/06 Appendix Transport, storage, maintenace, disposal Transport: — only by qualified personnel — only in the manufacturer’s original recyclable packaging — avoid shocks — temperature -25 to +70°C, max. rate of change 20°C/hour — humidity max. 95% relative humidity, no condensation —... -
Page 74: Fault-Finding
Beckhoff Appendix 02/06 Fault-finding The table below should be regarded as a “First-aid” box. Depending on the conditions in your installation, there may be a wide variety of reasons for the fault. In multi-axis sys- tems there may be further hidden causes of a fault. Our customer support can give you further assistance with problems. - Page 75 Beckhoff Appendix 02/06 Fault possible causes Measures to remove the fault — motor cable: short-circuit/ — replace cable ground short — motor has short-circuit / ground — replace motor F14 message: short output stage — output module is overheated — improve ventilation fault —...
- Page 76 Beckhoff Appendix 02/06 Fault possible causes Measures to remove the fault — offset not correctly adjusted for — adjust setpoint-offset (analog axis drifts at analog setpoint provision I/O) — AGND not joined to the setpoint = 0V — join AGND and CNC-GND CNC-GND of the controls —...
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Page 77: Glossary
Beckhoff Appendix 02/06 Glossary clock Clock signal common-mode voltage The maximum amplitude of a disturbance (on both inputs) which a differential input can eliminate continuous power of regen circuit Mean power which can be dissipated in the regen circuit counts... - Page 78 Beckhoff Appendix 02/06 P-controller Control loop with purely proportional behaviour phase shift Compensation for the lag between the electro- magnetic and magnetic fields in the motor PID-controller Control loop with proportional, integral and differential behaviour PID-T2 Filter time constant for the speed controller output...
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Page 79: Index
Beckhoff Appendix 02/06 Index key operation....64 24V aux. supply, interface ..38 LED display ....64 abbreviations . - Page 80 Beckhoff Appendix 02/06 safety instructions ... . . 7 SERCOS interface ... . 59 setpoint input ....46 setup software .
- Page 81 Beckhoff Appendix 02/06 This page has been deliberately left blank. AX2500 Installation Manual...
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