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Beckhoff AX8911 Operating Manual

Twinsafe drive option card for servo drive ax8xxx-x2xx
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Operating Manual | EN
AX8911
TwinSAFE drive option card for servo drive AX8xxx-x2xx
2023-07-24 | Version: 2.0.0

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  • Page 1 Operating Manual | EN AX8911 TwinSAFE drive option card for servo drive AX8xxx-x2xx 2023-07-24 | Version: 2.0.0...

  • Page 3: Table Of Contents

    STO + SS1-t........................ 21 5.2.2 SBC.......................... 21 5.2.3 TwinSAFE Safe Motion functions with external encoder .......... 22 Environmental conditions ........................  22 AX8911 project design limits ...................... 23 Error reaction .......................... 24 5.5.1 Global Shutdown...................... 24 5.5.2 Global Fault........................ 24 5.5.3 Module Shutdown ......................
  • Page 4 10.2 Addition of an axis module ...................... 41 10.3 Using the AX8911 with the factory setting project................ 41 10.4 Use of the AX8911 with a safety-related user program .............. 44 10.5 Manual creation of safety functions.................... 46 10.6 Safety parameters ...........................  46 10.6.1...

  • Page 5: Notes On The Documentation

    Notes on the documentation Disclaimer Beckhoff products are subject to continuous further development. We reserve the right to revise the operating instructions at any time and without prior announcement. No claims for the modification of products that have already been supplied may be made on the basis of the data, diagrams and descriptions in these operating instructions.

  • Page 6: Limitation Of Liability

    Modifications and changes to the hardware and/or software configuration that go beyond the documented options are prohibited and nullify the liability of Beckhoff Automation GmbH & Co. KG. The following is excluded from the liability: •...

  • Page 7: Documentation Issue Status

    Product features Only the product properties specified in the current operating instructions are valid. Further information given on the product pages of the Beckhoff homepage, in emails or in other publications is not authoritative. Currentness Please check whether you are using the current and valid version of this document. The current version can be downloaded from the Beckhoff homepage at http://www.beckhoff.de/twinsafe.
  • Page 8 This directive, also known as the Machinery Directive, defines requirements for the placing on the market of machines and machine-like components, such as safety components. 2.0.0 or newer TwinSAFE Safe Motion functions Description of the TwinSAFE Safe Motion functions. Version: 2.0.0 AX8911...

  • Page 9: Document Classification In The Overall Documentation

    (HIPERFACE DSL), ENDAT2.2, ENDAT 3, motor replacement) You can use the firmware of the AX8911 TwinSAFE drive option card in a backward-compatible manner in older AX8xxx firmware versions. Staff qualification These operating instructions are intended exclusively for trained specialists in control technology and automation with the relevant knowledge.
  • Page 10 Notes on the documentation • Evaluate, optimize and execute work independently. Version: 2.0.0 AX8911...

  • Page 11: Safety And Instruction

    Warning of damage to property or environment NOTICE Notes The environment, equipment, or data may be damaged. Information on handling the product This information includes, for example: Recommendations for action, assistance or further information on the product. AX8911 Version: 2.0.0...

  • Page 12: Beckhoff Support And Service

    The employees support you in the programming and commissioning of sophisticated automation systems. Hotline: +49 5246/963-157 E-mail: support@beckhoff.com Web: www.beckhoff.com/support Training Training in Germany takes place in our training center at the Beckhoff headquarters in Verl, at subsidiaries or, by arrangement, at the customer's premises. Hotline: +49 5246/963-5000 E-mail: training@beckhoff.com Web: www.beckhoff.com/training...

  • Page 13: For Your Safety

    Engineering tools allowed are TE9000 and the TE9100. Use only the latest versions of the engineering tools. You will find this on the Beckhoff website. Procedures or engineering tools that deviate from this are not covered by the certificate. This is especially true for externally generated xml files for the TwinSAFE import.

  • Page 14: During Operation

    This test must be performed by the machine manufacturer. The combination of AX8000 and AX8911 may be used in production only when this test has produced a positive result for all safety-relevant functions.

  • Page 15: After Operation

    De-energize and switch off the overall system before working on it Check all safety-relevant equipment for functionality before working on the overall system. Secure the working environment. Secure the machine or plant against being inadvertently started up. AX8911 Version: 2.0.0...

  • Page 16: System Description

    System description System description The AX8000 multi-axis servo system allows you to set up multi-channel drive solutions. The AX8911 TwinSAFE drive option card is permanently installed in the servo system and enables you to define the safety functions by application. The servo drive forms the overall system. The of the servo drive determines whether it is a servo drive with STO or Safe Motion.

  • Page 17: Product Overview

    AX8911 – TwinSAFE card for servo drives of the AX8xxx series The AX8911 TwinSAFE drive option card is an optional extension of the Beckhoff AX8xxx servo drive series, in which it is permanently installed. The card enables you to define the safety functions by application. The type key of the servo drive determines whether it is a servo drive with STO or Safe Motion.

  • Page 18: Type Key

    Deceleration • AX8000 in conjunction controlled with integrated encoder (SICK EDS / EDM 35) Ramp monitored in Beckhoff motors: up Safe stop 2 to PL d, Cat 3 / SIL 2 Speed functions • AX8000 in conjunction Safely limited speed with integrated encoder (EnDat2.2) in Beckhoff...

  • Page 19: Intended Use

    This applies in particular to the use cases defined by Beckhoff Automation, which have been fully tested and certified and whose properties and operating conditions can be guaranteed. Use cases beyond this are regarded as inappropriate and require the approval of Beckhoff Automation.

  • Page 20: Technical Data

    Technical data Technical data Product data The current certificates of all TwinSAFE products with the underlying standards and directives can be found at https://www.beckhoff.com/en-en/support/download-finder/certificates-approvals/. Software data Explanation Response times • Internal fault reaction time approx. 1 ms Via hardware inputs or FSoE in the factory setting •...

  • Page 21: Safety Parameters

    Prooftest interval Special proof tests are not required during the entire service life of the TwinSAFE drive option card. 5.6E-9 2.7E-4 MTTF high high, 99.5% >99% According to IEC 61508:2010. Performance Level According to EN ISO 13849-1:2015. According to EN ISO 13849-1:2015. AX8911 Version: 2.0.0...

  • Page 22: Twinsafe Safe Motion Functions With External Encoder

    For further information, please refer to the chapter Service life [} 25]. Environmental conditions Beckhoff products are designed for operation under certain environmental conditions, which vary according to the product. The following specifications must be observed for operation and environment in order to achieve the optimum service life of the products as well as to ensure product safety.

  • Page 23: Ax8911 Project Design Limits

    AX8911 project design limits Project design limits The maximum project design size of the AX8911 is limited by the available memory. This is managed dynamically. The values specified in the following table are therefore only guide values and may differ from the actual values, depending on the safety project.

  • Page 24: Error Reaction

    Module Shutdown If software errors are detected, the affected software module switches to the "Module Shutdown" state. This operating state is a safe state and temporarily shuts down the software module. An Error Acknowledge resets the operating state. Version: 2.0.0 AX8911...

  • Page 25: Service Life

    The internal TwinSAFE drive option card has a unique serial number that you can read out via CoE. The date of manufacture and the serial number of the complete device can be found on the name plate of the axis module. See the chapter Name plate [} 26] and document [2] at References [} 7]. AX8911 Version: 2.0.0...

  • Page 26: Name Plate

    Nominal output current cULus certification Serial number Output frequency range EAC approval Nominal input voltage Date of manufacture CE conformity Max. ambient temperature QR code Serial number sticker Nominal output voltage EtherCAT conformity Attachment of the name plate Version: 2.0.0 AX8911...

  • Page 27: Mechanical Installation

    For information on the mechanical installation of the overall system, refer to document [2] at References [} 7]. Control cabinet / terminal box The TwinSAFE components must be installed for operation in a control cabinet or terminal box with at least protection rating IP54 according to IEC 60529. AX8911 Version: 2.0.0...

  • Page 28: Electrical Installation

    • If both signals are logic 1 (wired with 24 V ), you can move axis B. • If one of the signals is logic 0, STO for axis B is triggered. Axis B is switched torque-free. Fig. 1: AX8911: Connection to X15 and X25 Version: 2.0.0 AX8911...

  • Page 29: Connection Technology

    Wire type Wire cross-section Wire cross-section – stranded wire (with ferrule with plastic collar) 0.25 mm² - 1 mm² For further information on wiring, please refer to the chapter Using the STO inputs with a third-party safety controller [} 63]. AX8911 Version: 2.0.0...

  • Page 30: Address Setting

    Each TwinSAFE address set may only occur once within a network or configuration. Use the set TwinSAFE addresses only once within your configuration. The address 0 is not a valid TwinSAFE address. Failure to observe this may result in malfunctions. DIP switch Address 1023 Version: 2.0.0 AX8911...

  • Page 31: Twinsafe Safe Motion Functionality

    TwinSAFE Safe Motion functionality TwinSAFE Safe Motion functionality Encoder application Encoder type Manufacturer Protocol Resolution Reduced CRC Beckhoff OCT Sick OCT (Hiperface 24-bit 0xD3E0 SingleTurn (EDS35) DSL) Beckhoff OCT Sick OCT (Hiperface 24-bit 0xDF54 MultiTurn (EDM35) DSL) AMO LMKA 3010 EnDat 2.2...

  • Page 32: Factory Setting Project

    AX8000. The ErrAck for errors on the AX8911 is realized via the DS402 control word (bit 7) together with the reset of the axis via TwinCAT 3. If an error occurs on the AX8911, a diag message is generated and the error bit in the DS402 status word (bit 3) is set.

  • Page 33: Factory Setting Sto In The Twinsafe Drive Option Card

    If this does not match your desired functionality, you have the option of replacing the safety-oriented program on the TwinSAFE drive option card with a program suitable for the use case. AX8911 Version: 2.0.0...
  • Page 34 Factory setting project Fig. 2: AX8911 TwinSAFE logic program in factory setting NOTICE Brake control In the delivery state, the brake is only controlled via the servo system according to the parameterization in the TwinCAT 3 Drive Manager 2. The brake output is generally enabled in the firmware of the TwinSAFE drive option card.

  • Page 35: Creating A Project With The Twinsafe Motion Wizard

    2. Select "Start SafeMotion Wizard" via the menu item "Wizards" The "Select Project Targets" window shows the existing components and the virtual axes for single-axis and two-axis modules. 3. Select the desired components and axes 4. Confirm the selection with "Next" AX8911 Version: 2.0.0...
  • Page 36 Factory setting project 5. Configure the feedback in the "Select Motors" window 6. Confirm configuration with "Next" 7. In the "Select Safety Function" window, select the safety functions of the axes 8. Confirm the selection with "Next" Version: 2.0.0 AX8911...
  • Page 37 Either use an existing master project or generate a new one. 12. Confirm with "Next" 13. In the "Safe Address Selection" window, configure safe addresses of all participants Alternatively, you can also configure the safe addresses within the safety project. 14. Confirm the settings with "Finish" AX8911 Version: 2.0.0...
  • Page 38 15. Confirm the window with "OK" You have successfully generated the safety projects. After this procedure you will receive a TC3-Solution with the corresponding safety projects for AX8000 and for example EL6910. The master project contains the connections to the configured axes. Version: 2.0.0 AX8911...
  • Page 39 16. Set parameters according to the present requirements of the safety applications. Shown here using SLS as an example. A detailed explanation of the TwinSAFE Safe Motion functions from the basic project can be found in document [7] at References [} 7]. AX8911 Version: 2.0.0...

  • Page 40: Configuration In Twincat

    Configuration in TwinCAT 10 Configuration in TwinCAT 10.1 Safety Device Info Fig. 3: AX8911 - Safety Device Info Read out the safety device info via CoE of your safety device. Index Name Explanation 0xF9C00:01 Device name May include the following as of FW03 depending on the device: •...

  • Page 41: Addition Of An Axis Module

    For more information about this project, see the chapter Factory setting STO in the TwinSAFE drive option card [} 33]. To use the AX8911 in a safety project, proceed as follows: Fig. 4: Insertion of an alias device 1. Right-click on the Alias Device folder of your safety project 2.
  • Page 42 Configuration in TwinCAT You can use the STO signals as safe outputs in the safety-related user program. Fig. 6: Dialog for linking the variables of the AX8911 The variables are displayed with the corresponding designation in Variable Mapping. Version: 2.0.0 AX8911...
  • Page 43 Configuration in TwinCAT Fig. 7: Projects with outputs to the AX8911 AX8911 Version: 2.0.0...

  • Page 44: Use Of The Ax8911 With A Safety-Related User Program

    Target System For the use of the user-specific functions in the AX8911, a safety project is created in TwinCAT 3 and the AX8911 or the axis module is selected as the target system. Proceed as follows: 1.
  • Page 45 The "Add New Item" window opens. Here you can select your desired AX8xxx variant. The name and the ModuleIdent in the alias device description tell you which AX8911 variant it is. Which ModuleIdent belongs to which firmware version and which AX8000 firmware is supported can be found in the chapter Version history [} 9].

  • Page 46: Manual Creation Of Safety Functions

    NOTICE Switch back to the factory setting project By deleting the entire project (Safe Logic, parameters and mapping) on the AX8911 TwinSAFE drive option card, the factory setting project is active again after a power cycle of the complete device.
  • Page 47 True: Test pulses active TestPulse active False: Test pulses inactive FSIN settings 0xC121:01 Ch A FSIN Channel UINT16 Input filter time of the input X15.1 [in µs] 1.InputFilterTime (in 125 µs) Factory setting: 28 Minimum: 1 Maximum: 500 AX8911 Version: 2.0.0...
  • Page 48 Ch A SAFEDRIVEFEEDBACK BIT6 Detection limit for position detection Encoder Position Shift Ch A Secondary Feedback 0xC141:01 Ch A SAFEDRIVEFEEDBACK BIT4 Average acceleration calculation Average Calculation Acceleration 0xC141:05 Ch A SAFEDRIVEFEEDBACK BIT4 Average velocity calculation Average Calculation Velocity Version: 2.0.0 AX8911...
  • Page 49 Minimum Singleturn Referenced SafePosition 0xC142:17 Ch A SAFEDRIVEFEEDBACK INT32 Minimum safe multi-turn reference position Minimum Multiturn Referenced SafePosition 0xC142:18 Ch A SAFEDRIVEFEEDBACK UINT32 Permissible deviation when initializing the Deviation Startup Position reference position Ch A Secondary Feedback AX8911 Version: 2.0.0...
  • Page 50 Minimum safe single-turn reference position Minimum Singleturn Referenced SafePosition 0xC3C2:17 Ch B SAFEDRIVEFEEDBACK INT32 Minimum safe multi-turn reference position Minimum Multiturn Referenced SafePosition 0xC3C2:18 Ch B SAFEDRIVEFEEDBACK UINT32 Permissible deviation when initializing the Deviation Startup Position reference position Version: 2.0.0 AX8911...
  • Page 51 Minimum safe single-turn reference position Minimum Singleturn Referenced SafePosition 0xC3C3:17 Ch B SAFEDRIVEFEEDBACK INT32 Minimum safe multi-turn reference position Minimum Multiturn Referenced SafePosition 0xC3C3:18 Ch B SAFEDRIVEFEEDBACK UINT32 Permissible deviation when initializing the Deviation Startup Position reference position AX8911 Version: 2.0.0...

  • Page 52: Local Process Image

    Local process image 11 Local process image The process image of the AX8911 is composed of the input process image and the output process image. The following local process image is available for your customer-specific safety application. WARNING Use non-safe signals only functionally For each signal in the process image, the column "Group"...
  • Page 53 BOOL Standard Run signal for axis 2 of the AX8xxx control word 42.1 ChB_DriveReq_ErrAck BOOL Standard Error acknowledge signal for axis 2 of the AX8xxx control word (link to output signal 0.4, 1.5, 2.2, 4.0, 14.0, 18.0) AX8911 Version: 2.0.0...
  • Page 54 ChA_SecFb_RefRequired BOOL Safety True: Reference position of secondary feedback module of axis 1 required False: No error 98.6 ChA_SecFb_RefPosition_V BOOL Safety True: Reference position of the secondary alid feedback module of axis 1 valid False: No error Version: 2.0.0 AX8911...
  • Page 55 (axis 2, port X23.T+ and T-) (unit: increments/ms²) 166.0 ChB_PriFb_Velocity_Maxim INT32 Safety Analog value of the maximum velocity in the last logic cycle (axis 2, port X23.T+ and T-) (unit: increments/ms) AX8911 Version: 2.0.0...

  • Page 56: Output

    The local process image of the output signals consists of a maximum of 32 bytes of data. Offset Name Data Group Description type ChA_STO_1 BOOL Safety True: Enable switch-off path A (STO axis 1, port X13) False: Disable switch-off path A (STO axis 1, port X13) Version: 2.0.0 AX8911...
  • Page 57 ChA_DriveCmd_GroupError BOOL Standard Status to AX8xxx: Group error at axis 1 ChB_EncoderVoltage_ErrAc BOOL Standard Acknowledgement of an error of the encoder voltage monitoring of axis 2 10.0 ChB_DriveCmd_GroupError BOOL Standard Status to AX8xxx: Group error at axis 2 AX8911 Version: 2.0.0...
  • Page 58 On falling edge, Diag message 0xD300 is entered in the Diag history. 28.1 ChA_DiagMessage_2 BOOL Safety On falling edge, Diag message 0xD301 is entered in the Diag history. 28.2 ChA_DiagMessage_3 BOOL Safety On falling edge, Diag message 0xD302 is entered in the Diag history. Version: 2.0.0 AX8911...
  • Page 59 On falling edge, Diag message 0xD31A is entered in the Diag history. 31.3 ChB_DiagMessage_12 BOOL Safety On falling edge, Diag message 0xD31B is entered in the Diag history. 31.4 ChB_DiagMessage_13 BOOL Safety On falling edge, Diag message 0xD31C is entered in the Diag history. AX8911 Version: 2.0.0...
  • Page 60 On falling edge, Diag message 0xD31D is entered in the Diag history. 31.6 ChB_DiagMessage_15 BOOL Safety On falling edge, Diag message 0xD31E is entered in the Diag history. 31.7 ChB_DiagMessage_16 BOOL Safety On falling edge, Diag message 0xD31F is entered in the Diag history. Version: 2.0.0 AX8911...

  • Page 61: Motor Replacement

    • the module is activated for one encoder only and the read encoder parameters of the encoder do not match the stored encoder parameters. The encoder ID is not evaluated. The module sends a diagnostic message in the Diag history once when the motor is replaced. AX8911 Version: 2.0.0...

  • Page 62: Application Examples

    Create the realizable safety functions with the TwinSAFE Motion Wizard in the TwinCAT 3 Safety Editor. Procedures and application examples can be found in the TwinSAFE Motion Wizard tutorials. The tutorials can be found at https://www.beckhoff.com/de-de/support/webinare/index.html. Further application examples can be found in document [5] at References [} 7].

  • Page 63: Using The Sto Inputs With A Third-Party Safety Controller

    If the safety controller does not implement test pulses on the outputs, but only supplies static 24 V signals, carry out the wiring in such a way that fault exclusion is permissible for the wiring. Further information about fault exclusions can be found in EN ISO 13849-2. AX8911 Version: 2.0.0...

  • Page 64: Using The Sto Function Via Fsoe

    Here the signals of the connection to the TwinSAFE logic, for example EL6910, are used in the logic of the servo system. This allows the STO channels and the brake control of the servo system to be switched off. Version: 2.0.0 AX8911...

  • Page 65: Appendix

    Appendix 14 Appendix 14.1 Certificate Fig. 13: AX servo drive EC Declaration of Conformity, page 1 AX8911 Version: 2.0.0...
  • Page 66 Appendix Fig. 14: AX servo drive EC Declaration of Conformity, page 2 Version: 2.0.0 AX8911...

  • Page 67: Volatility

    If there is customer specific data saved on the product, it cannot be ensured that this data might not be restored through for example forensic measures, even after the data is deleted through the provided tool chain. If this data is confidential, the scrapping of the product after usage is recommended to protect this data. AX8911 Version: 2.0.0...

  • Page 68: Focus Of Certificates

    The current certificates of all TwinSAFE components with the underlying standards and directives can be found at https://www.beckhoff.com/en-en/support/download-finder/certificates-approvals/. If the document refers only to the first four figures of a product (ELxxxx), the certificate is valid for all available variants of the component (ELxxxx-abcd).
  • Page 70 More Information: www.beckhoff.com/twinsafe Beckhoff Automation GmbH & Co. KG Hülshorstweg 20 33415 Verl Germany Phone: +49 5246 9630 info@beckhoff.com www.beckhoff.com...

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