Beckhoff AX8000 Operating Instructions Manual
Multi-axis servo system
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Summary of Contents for Beckhoff AX8000
- Page 1 AX8000 | Multi-axis servo system Operating instructions | EN 11/21/2019 | Version 1.0 Order No.: TDmlAX-8000-0000-0201...
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Page 3: Table Of Contents
Version numbers............................... 7 Scope of the documentation .......................... 7 Staff qualification............................... 8 Safety and instruction ............................ 9 Explanation of symbols ............................. 9 Beckhoff Services ............................ 10 For your safety.............................. 11 Safety pictograms ............................ 11 General safety instructions .......................... 12 Product overview............................... 14 Power supply module............................ - Page 4 Accessories................................ 74 Brake resistor.............................. 74 Decommissioning.............................. 75 Disassembly.............................. 75 Disposal ................................ 76 Guidelines and Standards .......................... 77 Standards................................ 77 Guidelines ............................... 78 Test centers .............................. 79 EU conformity .............................. 79 UL certification .............................. 80 Index ................................... 82 ─── AX8000 Version: 1.0...
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Page 5: 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 6 • 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.
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Page 7: 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 8: 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. ─── AX8000... -
Page 9: Safety And Instruction
• Damage to the product • Damage to the environment Information This sign indicates information, tips and notes for dealing with the product or the software. Example This symbol shows examples of how to use the product or soft- ware. Version: 1.0 AX8000 ───... -
Page 10: Beckhoff Services
Beckhoff and its international partner companies offer comprehen- Beckhoff Services sive support and service. The Beckhoff Support offers technical advice on the use of individ- Support ual Beckhoff products and system planning. Staff provide assistance for programming and commissioning complex automation systems and offer a comprehensive training program. -
Page 11: For Your Safety
Work particularly thor- oughly, not under time pressure and responsibly towards other peo- ple. On Beckhoff products you will find attached or lasered safety pic- Safety pictograms tograms, which vary depending on the product. They serve to pro- tect people and to prevent damage to the products. -
Page 12: General Safety Instructions
For your safety This chapter provides you with instructions on security when han- General safety instruc- dling the AX8000 multi-axis servo system. Servo drives cannot be tions used alone and are therefore regarded as incomplete machines. They must be installed in a machine / plant by the machine manu- facturer. - Page 13 30 minutes Do not work on live electrical parts Do not open the AX8000 when it is live. Ensure that the protective conductor is properly connected. Never disconnect electrical con- nections while they are live. Only work on the AX8000 when the voltage has dropped to <...
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Page 14: Product Overview
Fieldbus EtherCAT input X04 Fieldbus EtherCAT output X05 10-pin input terminal X01; DC, 24 V, supply network, PE and external brake resistor Earthing bolt Test contact DC link DC- Test contact DC link DC+ Test contact GND Test contact +24 V ─── AX8000 Version: 1.0... -
Page 15: Power Supply Module
EAC conformity CE approval 3.1.2 Type key AX 8x yz - a b c d - 0000 Explanation Product line Servo drive Series AX8000 Supply 6 In combination with "a" Rated output current 20 = 7 A - single-phase supply 20 = 20 A - three-phase supply 40 = 40 A... -
Page 16: Axis Module
Phone: + 49 52 46 / 9 63 - 0 D-33415 Verl Fax. : + 49 52 46 / 9 63 - 198 Automation GmbH & Co. KG Germany www.beckhoff.com info@beckhoff.com Catalog No. 8206-0000-0000 Serial # : 000000100 Input rated voltage... -
Page 17: Capacitor Module
CE conformity 3.3.2 Type key AX 8 8 yz - a b c d - 0000 Explanation Product line Servo drive Series AX8000 Option module Option modules 10 = capacitor module Supply 0 = 0 to 875 V Reserved 0 = Standard Hardware features 0 = Standard... -
Page 18: Product Characteristics
With the servo drive you can implement fast and highly dynamic po- sitioning tasks through the integrated control technology. EtherCAT enables the ideal connection to the PC-based control technology. With EtherCAT and the AX8000 multi-axis servo system you can achieve minimum cycle times, synchronicity and simultaneity in the drive technology. -
Page 19: Ordering Options
Before putting the axis module with integrated safety technology into operation, read the documentation: • "AX8911 TwinSAFE Drive Option for servo drives from the AX8000 series" The "multi-feedback interface", [Page 63] supports the digital feed- Multi-feedback interface back systems EnDat 2.2 or BiSS-C. -
Page 20: Intended Use
Any use exceeding the permissible values specified in the Technical Improper use data is considered improper and therefore prohibited. The AX8000 multi-axis servo system is not suitable for use in the following areas: • ATEX zones without suitable housing • Areas with aggressive environments, for example aggressive... -
Page 21: Dual Use
Dual Use available frequency converters are categorized as products with a double purpose of use. The Beckhoff AX8000 multi-axis servo sys- tem thus newly belongs to the dual use products. The goods list, Annex 1 of the Dual Use directive 428/2009 has been amended accordingly: •... -
Page 22: Technical Data
The lifetime of the servo drive may be shortened at temperatures above 40 °C and with encapsulated installation. Beckhoff products are designed for operation under certain environ- mental conditions, which vary according to the product. The follow- ing specifications must be observed for operation and environment in order to achieve the optimum service life of the products. -
Page 23: Power Supply Modules
Dependent on the connected resistor Continuous braking power [kW] Maximum braking power [kW] 21.8 21.8 40.1 Minimum brake resistor [Ω] Mechanical data AX8620 AX8640 Width [mm] Height without connectors [mm] Depth without connectors / accessories [mm] Weight [kg] Version: 1.0 AX8000 ───... -
Page 24: Axis Modules
Rated output current as total device current [A] Peak output current I for maximum 5 seconds as total device current [A] Mechanical data AX8108 AX8206 AX8118 Width [mm] Height without connectors [mm] Depth without connectors / accessories [mm] Weight [kg] ─── AX8000 Version: 1.0... -
Page 25: Capacitor Module
Type power at 40 °C [W] 1000 1600 2000 3200 4 % power loss per 10 K temperature increase Resistance [Ω] Mechanical data Weight [kg] 10.3 Dimensions according to the dimensional drawing O [mm] R [mm] H [mm] M [mm] U [mm] Version: 1.0 AX8000 ───... -
Page 26: Dimensional Drawings
All figures in millimeters The following table provides you with information regarding which Narrow modules modules can be assigned to the dimensional drawing: Power supply modules Axis modules Capacitor modules AX8620 AX8108, AX8206 AX8810 R2,75 R2,75 ─── AX8000 Version: 1.0... - Page 27 Technical data The following table provides you with information regarding which Wide modules modules can be assigned to the dimensional drawing: Power supply modules Axis modules AX8640 AX8118 R2,75 R2,75 Version: 1.0 AX8000 ───...
- Page 28 • All data in millimeters according to the table "Technical data", Brake resistor [+] [Page 25] Dimensions according to the dimensional drawing AX2090-BW80-xxxx 1000 1600 2000 3200 O [mm] R [mm] H [mm] M [mm] U [mm] ─── AX8000 Version: 1.0...
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Page 29: Scope Of Supply
Power supply module AX8640 Mains supply DC link 24 V supply External brake resistor [+] Axis modules AX8108 and AX8118 Digital inputs and outputs Axis module AX8206 Digital inputs and outputs Digital inputs and outputs Capacitor module Version: 1.0 AX8000 ───... -
Page 30: Packaging
The packaging must be protected from moisture. The contents are fragile. The following table shows the dimensions of the packages for the in- dividual modules: Dimension AX8108 AX8206 AX8620 AX8118 AX8640 Height [mm] Width [mm] Depth [mm] ─── AX8000 Version: 1.0... -
Page 31: Transport And Storage
• Use of the vendor's original packaging The table shows the maximum stacking height in which you may store and transport the servo drives in their original packaging on a pallet: Servo drive type Stacking height of original packages [qty] AX8000 Version: 1.0 AX8000 ───... -
Page 32: Transport
You have the option to store the servo drive over a short or longer period. For storage we always recommend the original packaging. Observe the conditions specified in chapter: "Transport and stor- age", [Page 31]. Ensure the storage space is vibration-free. ─── AX8000 Version: 1.0... -
Page 33: Technical Description
Therefore, use so-called AC/DC-sensitive residual current circuit breakers type B, in which DC current is also accounted for. Beckhoff recommends residual current circuit breakers with switch-on delay. A power failure can lead to the uncontrolled run-out of the drive Safe system stop axes. -
Page 34: Wide Voltage Range
Due to the wide voltage range of the power supply modules, the Wide voltage range AX8000 multi-axis servo system can be operated worldwide on dif- ferent voltage systems. All networks with a grounded center point are permitted; TT / TN. -
Page 35: Dimensioning
• 10 x AX8206-0000 with 1350 µF • 1 x AX8810-0000 with 1755 µF That makes a total capacitance of 3870 µF. The system is permissible, because a power supply module on the 400 V supply network can charge up a capacitance of 6000 µF. Version: 1.0 AX8000 ───... - Page 36 Technical description In compliance with the EMC category C3, various total motor cable Total motor cable length lengths apply to the AX8000 multi-axis servo system. Without mains choke Motor cable length Total motor cable Number of axes per drive length system Maximum 25 m per motor...
- Page 37 6 A must be provided The maximum DC link capacitance is always related to the connec- tion to a common AX86x0 power supply module with 945 µF and is thus ≤ 4226 µF Version: 1.0 AX8000 ───...
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Page 38: Display
Technical description Information about the states of the individual modules is shown on Display the display of the AX8000 multi-axis servo system. There are differ- ent symbols for each module. Display black: The module is switched off. Information about the meaning of the different symbols on the dis-... - Page 39 An error has occurred, but the DC link is being charged/discharged: Fast blinking: DC link voltage > 48 V Slow flashing: DC link voltage ≤ 48 V EtherCAT and power symbol light up green: The power supply module is ready to operate. Version: 1.0 AX8000 ───...
- Page 40 Slow flashing: The axis is disabled and free from errors. Axis symbol lights up red: The module is in EtherCAT INIT state. Axis symbol flashes red: Error. Axis symbol flashes green-red: The error reaction of the axis is active. ─── AX8000 Version: 1.0...
- Page 41 Symbols of EtherCAT, axis module and safety light up green: The safety axis module is in the normal operating state. These symbols are only visible when the two-channel safety axis module has reached its operating state. Version: 1.0 AX8000 ───...
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Page 42: Capacitor Module
• AX8108; 8 A Beckhoff recommends that you place the optional capacitor module 2 directly adjacent to the power supply module 1. Construct the AX8000 multi-axis servo system in decreasing order from the high- est to the lowest rated output current. ───... -
Page 43: Mechanical Installation
The following illustration contains recommended dimensions that you should observe when mounting the servo drive in the control cabinet: Number Explanation Control cabinet door Conductive and galvanized mounting plate Cable duct Cable duct Version: 1.0 AX8000 ───... - Page 44 Mechanical Installation Beckhoff universal drilling pattern Drilling pattern You have the possibility – at any time and without having to drill new holes – to change the configuration of the servo drive mod- ules if you provide the mounting plate with the universal drilling pattern.
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Page 45: Modules
► On all relevant modules, slide the bar for the AX bridge 1 to the right The contacts can then no longer be seen. ► Screw screws once again into the control cabinet mounting plate in accordance with the drilling pattern Version: 1.0 AX8000 ───... - Page 46 2 ► Bay further modules 2 and screw all remaining screws 1 and 3 tight on the module housings ► Observe tightening torques: Components Tightening torque [Nm] Screws M5 x 5 ─── AX8000 Version: 1.0...
- Page 47 ► On all modules that you wish to connect, open the quick connec- tors 1 and place them in the 90° position ► Slide all bars 2 for the AX bridge to the left ► Close all quick connectors again The modules are now connected to one another. Version: 1.0 AX8000 ───...
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Page 48: Electrical Installation
PE rails. Improper grounding or faulty contacting can lead to damage to the AX8000 multi-axis servo system or to EMC interference emis- sions. The minimum cross-sections of separate protective conductors can be found in EN 61439-1. - Page 49 AX8000 and the peripherals are attached. This makes secure grounding possible. If you cannot satisfy the requirements, you must ground the AX8000 multi-axis servo system and corresponding components using a per- missible and adequately dimensioned cable.
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Page 50: Block Diagrams
Measuring and test contacts on the devices Quick coupling of the AX8000 multi-axis servo system; AX bridge Optional brake resistor When using an optional brake resistor on the AX8000 multi-axis servo system, the bridge of the 10-pin supply plug "X01" between R and R... - Page 51 Measuring and test contacts on the devices Quick coupling of the AX8000 multi-axis servo system; AX bridge Optional brake resistor When using an optional brake resistor on the AX8000 multi-axis servo system, the bridge of the 10-pin supply plug "X01" between R and R...
- Page 52 Electrical installation 9.2.3 AX81x8 Number Explanation Quick coupling of the AX8000 multi-axis servo system; AX bridge ZK4800-80xx-xxxx motor cable; including OCT ─── AX8000 Version: 1.0...
- Page 53 Electrical installation 9.2.4 AX8206 Number Explanation Quick coupling of the AX8000 multi-axis servo system; AX bridge ZK4800-80xx-xxxx motor cable; including OCT Version: 1.0 AX8000 ───...
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Page 54: Grounding
The shields have to be applied with a sufficiently large contact area on both sides. The shield of the AX8000 multi-axis servo system is connected via the grounding hangers and hexagonal nuts, similar to DIN 6923 with flange and serrations class 8 with the galvanized surface. These components are included in the scope of supply of the AX8206 or AX81x8 axis module. - Page 55 ► Screw the nut 3 onto the earthing bolt 2 on top of the grounding hanger 1 ► Do not use a spring washer 4 ► Swivel the grounding hanger 1 onto the earthing bolt 5 of the left- hand module + DC - DC Version: 1.0 AX8000 ───...
- Page 56 1 ► Do not use a spring washer 7 ► Tighten both nuts firmly ► Observe tightening torques: Components Tightening torque [Nm] Hexagonal nut with serration ► Mount further protective conductors 8 + DC - DC ─── AX8000 Version: 1.0...
- Page 57 Tightening torque [Nm] Hexagonal nut with serration ► Attach the assembled cable properly to the control cabinet mounting plate. Clean the contact surfaces prior to the assembly and ensure that the mounting plate is not painted. Version: 1.0 AX8000 ───...
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Page 58: Power Supply
Observe the order of connection The rated current of the device should decrease from the power supply module onwards. Beckhoff recommends the following order of connection of the modules: • AX8640 – AX8118 – AX8206 – AX8108 Supply connections for the 24 V... -
Page 59: Voltage Input
R and R is not removed. Alternatively, an ex- Bint+ ternal brake resistor can be connected. Without this measure the AX8000 multi-axis servo system will be shut down with an error message. ZS4800-2001 AX8620 • X01 slot on AX8620 power supply modules... -
Page 60: Brake Chopper
X02 slot on AX8640 power supply modules Terminal point Connection Wire cross-section Mounting Brake resistor - Maximum 16 mm² Screws with tighten- AWG 6 ing torque 1.2 Nm to Brake resistor + 1.5 Nm / 10.6 lbf in to 13.3 lbf in ─── AX8000 Version: 1.0... -
Page 61: Dc Link
Electrical installation No external DC link group possible DC link In order to avoid damaging the AX8000 multi-axis servo system, an external DC link group with a servo drive from the AX5000 se- ries is not permissible. ZS4800-2001 AX8620 •... -
Page 62: Fieldbus System
Electrical installation The EtherCAT real-time Ethernet fieldbus is available in the AX8000 Fieldbus system multi-axis servo system. 9.8.1 EtherCAT • X04 slot and X05 slot on power supply modules AX8620, AX8640 and AX85xx Terminal Connection point X04 IN Incoming EtherCAT line... -
Page 63: Multi-Feedback
The connectors are angled upwards. If the connectors are con- nected correctly, the cables can only be guided upwards. ► Guide cable 1 upwards Cables The following cable is available for the feedback system EnDat 2.2 / 22 with M12 connection: • ZK4810-0020-zzzz Version: 1.0 AX8000 ───... - Page 64 ± 10% Data; DX+ Data+ / SLO+ Us 11 V n.c. n.c. Clock; CLK+ CLK+ / MA+ n.c. n.c. n.c. n.c. n.c. n.c. n.c. n.c. Data; DX- Data- / SLO- n.c. n.c. Clock; CLK- CLK- / MA- ─── AX8000 Version: 1.0...
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Page 65: Motor Feedback
For the axis modules AX81xx and AX8206 you need a combined Motor feedback motor connector and feedback connector. The connector is part of the preassembled Beckhoff motor cable. ZS4800-2013 Maximum output current for the motor brake B- and B+: AX8108 and AX8206 = 1 A AX8118 = 2 A... -
Page 66: Digital Inputs
Connection Wire cross-section Mounting point Input 1; 20 µs With ferrule accord- push in ing to DIN 46 228/1 Input 2; 20 µs maximum 1.5 mm² Input 3; 8 µs AWG 16 Input 4; 8 µs ─── AX8000 Version: 1.0... -
Page 67: Supply Networks
The system will be damaged or destroyed if you do not use an iso- lating transformer under these circumstances. EMC law in Europe In Europe, the AX8000 multi-axis servo system may be operated on an IT network only with an isolating transformer on account of the electromagnetic emission. -
Page 68: Fuse Protection
IEC60269 or automatic circuit-breakers with the characteristic "C". External fuse protection Fuse protection AX8620 AX8640 Maximum AC supply 25 A 50 A Maximum 24 V supply 20 A Internal fuse protection Fuse protection Fuse 24 V – system voltage / peripherals electronic Internal brake resistor electronic ─── AX8000 Version: 1.0... - Page 69 UL standard "UL 508A, chapter SB4.2.3, exception no. 1". External fuse protection Fuse protection AX8620 AX8640 Maximum AC supply 25 A 50 A Maximum 24 V supply 20 A Internal fuse protection Fuse protection Fuse 24 V – system voltage / peripherals electronic Internal brake resistor electronic Version: 1.0 AX8000 ───...
- Page 70 0.7. Example: handling system with three axes: Servomotor AM8042-0JH0 AM8031-0DH0 AM8021-0BH1 Current 6.90 A 1.95 A 0.85 A Total sum current: 9.70 A x simultaneity factor 0.7 = 6.8 A Selected power supply module: AX8620-0000 Selected fusing: 10 A ─── AX8000 Version: 1.0...
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Page 71: Commissioning
Check protective measures against moving and live parts Configuration Beckhoff recommends the use of the latest TwinCAT version and the TwinCAT Drive Manager 2 for the configuration of new projects. • Create a new TwinCAT project and select the target system •... -
Page 72: Prerequisites During Operation
Ensure safe condition of the machine / system Make sure that all moving parts on the machine come completely to a standstill. After switching off the power supply, the components of the AX8000 multi-axis servo system may perform uncontrolled move- ments and cause serious injuries. ─── AX8000... -
Page 73: Maintenance And Cleaning
Cleaning by immersion will destroy the servo drive. Impermissible solutions will damage the servo drives and surfaces. The components of the AX8000 multi-axis servo system are mainte- nance-free. However, dirt, dust or swarf can negatively affect the function of the components. In the worst case, contamination can lead to failure. -
Page 74: Accessories
A c c e s s o r i e s Use accessories with UL approval Accessories with UL approval are also required for the operation of the AX8000 in the USA or Canada. 12.1 Brake resistor Regenerative energy is converted into heat via the brake resistors of the AX2090-BW80 series when braking a servo motor. -
Page 75: Decommissioning
Serious or even fatal injuries may result if this is ignored. Impermissible removal of servo drive components Only Beckhoff Automation GmbH & Co. KG is permitted to dis- mantle the servo drives. Contact Beckhoff Service for further information. -
Page 76: Disposal
Send the devices with the note “For disposal” to: Beckhoff Automation GmbH & Co. KG Huelshorstweg 20 D-33415 Verl Alternatively, you can contact a certified specialist disposal company for waste electrical and electronic equipment in your area. -
Page 77: Guidelines And Standards
G u i d e l i n e s a n d S t a n d a r d s Test procedures and certifications vary by product. Beckhoff prod- ucts are certified and tested according to the following directives and standards. -
Page 78: Guidelines
This guarantees secure shock pro- tection on all terminals in the control unit, even without further mea- sures. The air gaps and creepage distances conform to EN 50178 / VDE 0160. ─── AX8000 Version: 1.0... -
Page 79: Test Centers
Guidelines and Standards 14.3 The AX8000 multi-axis servo system does not fall within the area of applicability of the Machinery Directive. Test centers However, Beckhoff products are designed and evaluated in full compliance with all relevant regulations for personal safety and use in a machine or system. -
Page 80: Ul Certification
English version. The German version of this chapter is purely informative. A UL certificate is necessary for the operation of the AX8000 multi- axis servo system in the economic area of the USA or Canada. The... - Page 81 Use tested fuses of the class "J" Please note that the tested system group of the AX8000 multi-axis servo system has been "protected", [Page 69] with a current-limit- ing circuit breaker of class "J" with 50 A.
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Page 82: Index
Grounding 54 Technical data 22 Transport 31 Installation position 33 Instruction 9 80 Intended use 20 Label, see Safety pictograms 11 Maintenance 73 Intervals 73 Motor feedback 65 Multi-feedback 63 Operating Conditions 22 Ordering options 19 ─── AX8000 Version: 1.0... - Page 83 Beckhoff Automation GmbH & Co. KG Hülshorstweg 20 D-33415 Verl www.beckhoff.com info@beckhoff.com More Information: www.beckhoff.com/ax8000...