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Beckhoff AX8000 Operating Instructions Manual
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Beckhoff AX8000 Operating Instructions Manual

Beckhoff AX8000 Operating Instructions Manual

Multi-axis servo system
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Operating instructions | EN
AX8000
Multi-axis servo system
2025-01-07 | Version 2.1.0
Order No.: TDmlAX-8000-0000-0201

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Summary of Contents for Beckhoff AX8000

  • Page 1 Operating instructions | EN AX8000 Multi-axis servo system 2025-01-07 | Version 2.1.0 Order No.: TDmlAX-8000-0000-0201...

  • Page 3: Table Of Contents

    1.1.4 Copyright ..........................Version numbers ..........................Scope of the documentation ......................10 Staff qualification..........................11 Safety and instruction......................... 13 Explanation of symbols ........................13 Beckhoff Services ..........................15 1.7.1 Support services........................15 1.7.2 Training offerings........................15 1.7.3 Service offerings........................15 1.7.4...
  • Page 4 ZK4875-900x | DC link connection cable ................... 77 7.10 Third-party motors..........................77 7.11 TwinSAFE safe drive technology ....................... 78 7.11.1 Beckhoff synchronous servomotors ..................79 7.11.2 Beckhoff linear servomotors....................79 7.11.3 Third-party motors and TwinSAFE ..................81 7.12 Forming the capacitors........................81 8 Mechanical installation ..........................
  • Page 5 AX81xx-0x20 with 1 x D-sub ....................108 9.9.4 AX82xx-0x10 with 2 x D-sub ....................109 9.9.5 AX85xx-0x20 with 1 x D-sub ....................110 9.10 Motor feedback OCT.......................... 111 9.10.1 ZS4800-2013 / Connector axis modules AX81xx / AX8206............ 111 Version: 2.1.0 AX8000 ───...
  • Page 6 14 Guidelines and Standards .......................... 140 14.1 Standards............................140 14.2 Guidelines ............................141 14.2.1 Electrical isolation........................141 14.3 Test centers ............................142 14.4 EU conformity............................. 142 14.5 UL certification ........................... 143 14.5.1 USA and Canada ........................143 Index ................................144 ─── AX8000 Version: 2.1.0...

  • Page 7: Documentation Notes

    Documentation notes 1 Documentation notes 1.1 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 instruc- tions.

  • Page 8: Limitation Of Liability

    • Use of untrained personnel • Use of unauthorized spare parts 1.1.4 Copyright © Beckhoff Automation GmbH & Co. KG, Germany 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 9: Version Numbers

    German original. Product features Only the product properties specified in the current operating in- structions are valid. Further information given on the product pages of the Beckhoff homepage, in emails or in other publications is not authoritative. Version: 2.1.0 AX8000...

  • Page 10: Scope Of The Documentation

    Apart from these operating instructions, the following documents are part of the overall documentation: Documentation Definition AX8000 Functional description Documentation of the various functions of the AX8000 multi- axis servo system AX86x0 Power supply module Operating instructions with short Object description descriptions and attribute tables...

  • Page 11: Staff Qualification

    Trained specialists have received specific technical training and have specific technical knowledge and experience. Trained special- ists can: • apply relevant standards and directives • assess tasks that they have been assigned • recognize possible hazards • prepare and set up workplaces Version: 2.1.0 AX8000 ───...
  • Page 12 They are familiar with relevant standards and directives. Quali- fied electricians can: • independently recognize, avoid and eliminate sources of danger • implement specifications from the accident prevention regula- tions • assess the work environment • independently optimize and carry out their work ─── AX8000 Version: 2.1.0...

  • Page 13: Safety And Instruction

    • damage to the product • damage to the environment Information This symbol indicates information, tips, and notes for handling the product or the software. Examples This symbol shows examples of how to use the product or software. Version: 2.1.0 AX8000 ───...
  • Page 14 Required accessories [+] This symbol shows the accessories required for the following steps. The accessories are not included in the scope of delivery and can be ordered from Beckhoff. Assembly material required This symbol shows the assembly material required for the following steps.

  • Page 15: Beckhoff Services

    +49 5246 963-157 support@beckhoff.com www.beckhoff.com/en-en/support/our-support-services/ 1.7.2 Training offerings Training in Germany takes place at the Beckhoff branches or, after consultation, at the customer's premises. Beckhoff offers both face- to-face and online training courses. +49 5246 963-5000 training@beckhoff.com www.beckhoff.com/en-en/support/training-offerings/ 1.7.3 Service offerings...

  • Page 16: Headquarters Germany

    Hülshorstweg 20 33415 Verl, Germany +49 5246 963-0 info@beckhoff.com www.beckhoff.com/en-en/ A detailed overview of the Beckhoff locations worldwide can be found at: www.beckhoff.com/en-en/company/global-presence/ 1.7.5 Downloadfinder In the Download finder you will find configuration files, technical doc- umentation and application reports to download.

  • Page 17: For Your Safety

    2.1 Safety pictograms You will find safety symbols on Beckhoff products and packaging. The symbols may be glued, printed, or lasered on and may vary de- pending on the product. They serve to protect people and to prevent damage to the products.

  • Page 18: General Safety Instructions

    Observe tightening torques Mount and repeatedly check connections and components, comply- ing with the prescribed tightening torques. Use the original packaging only When shipping, transporting, storing and packing, use the original packaging or non-conductive materials. ─── AX8000 Version: 2.1.0...

  • Page 19: During Operation

    De-energize and switch off components before working on them Check the functionality of all safety-relevant devices. Secure the working environment. Secure the machine or plant against being in- advertently started up. Observe and comply with the chapter: De- commissioning. Version: 2.1.0 AX8000 ───...

  • Page 20: Product Overview

    PE and external braking re- Input terminal X02 sistor sistor 6-pin; 24 V , PE and exter- nal braking resistor Grounding bolt Test contact DC link DC- Test contact DC link DC+ Test contact GND Test contact +24 V ─── AX8000 Version: 2.1.0...

  • Page 21: Name Plate Ax8600

    50 A DC Ind. Cond. E.q. Made in Germany 41GE Item number Explanation Order number Order number Beckhoff Traceability Number Serial number Nominal input voltage Nominal input current Maximum ambient temperature Nominal output voltage Nominal output current EtherCAT conformity Disposal according to WEEE directive...

  • Page 22: Ax8620, Ax8640 Name Plate

    20 A DC Ind. Cond. E.q. Made in Germany 41GE Item number Explanation Order number Order number Beckhoff Traceability Number Serial number Nominal input voltage Nominal input current Input frequency Maximum ambient temperature Nominal output voltage Nominal output current EtherCAT conformity...

  • Page 23: Type Key Ax86Xx

    Product overview 3.1.3 Type key AX86xx AX 8x yz - a b c d - 0000 Explanation Product area • Servo drive Series • AX8000 Supply • 6 In combination with "a" Nominal output current • 00 = maximum 50 A - DC power supply •...

  • Page 24: Axis Modules Ax81Xx, Ax82Xx

    X23: Motor connector channel B, 8-pin; U, V, W, PE, T+/OCT+, T-/OCT-, B+, B- W, PE, T+/OCT+, T-/OCT-, B+, B- – X13: Motor connector channel A, 8-pin; U, V, W, PE, T+/OCT+, T-/OCT-, B+, B- AX bridge: DC link, FE AX bridge: 24 V ─── AX8000 Version: 2.1.0...

  • Page 25: Name Plate Ax81Xx, Ax82Xx

    848 V DC DC -Link max) 2023 / 01 Item number Explanation Order number Order number Beckhoff traceability number Serial number Nominal input voltage Maximum ambient temperature Nominal output voltage Nominal output current Output frequency range Date of manufacture EtherCAT conformity Safety over EtherCAT conformity •...

  • Page 26: Type Key Ax81Xx, Ax82Xx

    AX 8x yz - a b c d - e f g h Explanation Product area • Servo drives Series • AX8000 Axis module • 1 = 1-channel axis module • 2 = 2-channel axis module Channel nominal current • 06 = 2 x 6 A •...

  • Page 27: Combined Modules Ax85Xx

    Fieldbus EtherCAT output X05 Display X15 digital inputs / TwinSAFE STO connection Optional: X11 encoder feedback connection Quick coupling 24 V ; AX bridge Quick coupling, DC link and protective earth PE; AX bridge Grounding bolt Housing Version: 2.1.0 AX8000 ───...
  • Page 28 Product overview Item number Explanation X01 connection – mains supply and DC link X02 connection – external braking resistor X14 connection – holding brake, motor temperature / OCT X13 plug – motor connection X03 connection 24 V ─── AX8000 Version: 2.1.0...

  • Page 29: Name Plate Ax85Xx

    Nominal input voltage Nominal input current Input frequency Maximum ambient temperature Nominal output voltage Nominal output current Output frequency range Beckhoff traceability number Order number Date of manufacture EtherCAT conformity Safety over EtherCAT conformity Disposal according to WEEE directive cULus approval...

  • Page 30: Type Key Ax85Xx

    AX 85 yz - a b c d -  e f g h Explanation Product area • Servo drive Series • AX8000 Combined power supply and axis module Nominal DC link output current • 25 = up to 50 A • 40 = ≥ 35 A...

  • Page 31: Ax8810 Capacitor Module

    -Link max) Ind. Cond. E.q. Made in Germany 41GE Item number Explanation Order number Order number Beckhoff Traceability Number Serial number Nominal input voltage Maximum ambient temperature DC link capacitance EtherCAT conformity Disposal according to WEEE directive cULus approval UKCA conformity...

  • Page 32: Type Key Ax8810

    Product overview 3.4.2 Type key AX8810 AX 8 8 yz - a b c d - 0000 Explanation Product area • Servo drive Series • AX8000 Option module Option modules • 10 = capacitor module Supply • 0 = 0 to 848 V Version • 0 = Standard Version •...

  • Page 33: Product Characteristics

    The total cable length of an OCT connection is up to 100  m. One motor cable and a maximum of two extension cables can be used. EnDat 3 In addition to OCT, the AX8000 multi-axis servo system also sup- ports the transmission of EnDat® 3 signals directly via the Beckhoff motor cable.
  • Page 34 AX8000 multi-axis servo system enables simple mounting inside the control cabinet. TwinSAFE safe drive technol- The AX8000 multi-axis servo system can be used to implement both basic functions (TwinSAFE STO/SS1) and complex safety functions (TwinSAFE Safe Motion) for safe drive technology. Depending on...

  • Page 35: Ordering Options

    (SCA), Safely Limited Increment (SLI) Safety standard EN ISO 13849-1:2015 (Cat 4, PL e), EN 61508:2010 (SIL 3) and EN 62061:2005 + A1:2013/A2:2015 (SIL CL3) Further information on this can be found in the chapter "TwinSAFE safe drive technology", [Page 78]. Version: 2.1.0 AX8000 ───...

  • Page 36: Multi-Feedback Interface

    Product overview 3.6.2 Multi-feedback interface All axis modules of the AX8000 multi-axis servo system support OCT or EnDat 3. Linear servomotors AL8000 and third-party motors can also be operated with the digital encoder systems (En- Dat  2.2/22, BiSS  C) and analog encoder systems (TTL (DIFF RS422), SinCos 1 Vpp) via the optional multi-feedback inter-...
  • Page 37 Product overview AX82xx | Dual-axis modules Digital encoder systems The following protocols are supported: • EnDat® 2.2/22 • BiSS® C The following modules of the AX8000 multi-axis servo system with multi-feedback interface support digital encoder systems: Ordering informa- Description tion AX8206-0110-0000 Dual-axis module, 2 x 6 A...

  • Page 38: Intended Use

    Product overview 3.7 Intended use The modules of the AX8000 multi-axis servo system may be oper- ated only for the intended activities defined in this documentation, taking into account the prescribed environmental conditions. The components are to be installed only in closed control cabinets in electrical plants or machines and put into operation only as inte- grated components of the plant or machine.

  • Page 39: Dual Use

    The type key of the AX8000 multi-axis servo system determines whether export control in accordance with a dual-use listing is re- quired. If the type key for the axis modules of the Beckhoff AX8000 multi-axis servo system contains a "g", export control in accordance with the dual-use listing is required.
  • Page 40 Product overview AX8xxx–xxxx–xx8x Under certain conditions, the modules of the AX8000 multi-axis servo system are suitable for operating high-frequency spindles with a maximum speed of up to 96,000 rpm. In this version, the rotary field frequency is ≥ 600 Hz and the device is subject to export con- trol.

  • Page 41: 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 42 Installation position Vertical Vibration resistance 1 g, 150 Hz according to EN 61800-5-1 Shock resistance 5 g, 30 ms according to EN 60068-2-27 EMC requirements conforms to EN 61800-3:2004 + A1:2012 Approvals cULus UKCA See chapter: "Guidelines and Standards", [Page 140] ─── AX8000 Version: 2.1.0...

  • Page 43: Power Supply Module Ax86Xx

    External braking resistor Dependent on the connected resistor Continuous braking power [kW] Maximum braking power [kW] 21.8 Minimum braking resistor [Ω] Mechanical data AX8600-0000 Width [mm] Height without connectors [mm] Depth without connectors / accessories [mm] Weight [kg] Version: 2.1.0 AX8000 ───...

  • Page 44: Power Supply Module Ax8620 (20 A)

    Dependent on the connected resistor Continuous braking power [kW] Maximum braking power [kW] 21.8 Minimum braking resistor [Ω] Mechanical data Single-phase AX8620 Width [mm] Height without connectors [mm] Depth without connectors / accessories [mm] Weight [kg] ─── AX8000 Version: 2.1.0...
  • Page 45 Dependent on the connected resistor Continuous braking power [kW] Maximum braking power [kW] 21.8 Minimum braking resistor [Ω] Mechanical data Three-phase AX8620-0000 Width [mm] Height without connectors [mm] Depth without connectors / accessories [mm] Weight [kg] Version: 2.1.0 AX8000 ───...

  • Page 46: Power Supply Module Ax8640 (40 A)

    Dependent on the connected resistor Continuous braking power [kW] Maximum braking power [kW] 40.1 Minimum braking resistor [Ω] Mechanical data Three-phase AX8640-0000 Width [mm] Height without connectors [mm] Depth without connectors / accessories [mm] Weight [kg] ─── AX8000 Version: 2.1.0...

  • Page 47: Axis Modules Ax81X8, Ax8206

    Height without connectors [mm] Depth without connectors / accessories [mm] Weight [kg] AX8108 (18 A) Electrical data Single-axis module 18 A AX8118-0000 Nominal output current [A]; 8/16 kHz 18 / 9 Minimum nominal output current with full current reso- lution [A] Version: 2.1.0 AX8000 ───...
  • Page 48 24 V current consumption without holding brake [mA] Maximum current brake output [A] Basic power loss and power-dependent power loss Basic power loss [W] Power-dependent power loss at 230 V [W/A] Power-dependent power loss at 400 V [W/A] ─── AX8000 Version: 2.1.0...
  • Page 49 Output frequency of the limited standard version [Hz] 0…599 Output frequency of the dual-use version [Hz] 0…1600 Mechanical data Single-axis module 28 A AX8128-0000 Width [mm] Height without connectors [mm] Depth without connectors / accessories [mm] Weight [kg] Version: 2.1.0 AX8000 ───...

  • Page 50: 2-Channel Axis Module Ax8206

    18 / 9 5 seconds for channel A; Up to FW 1.02: 14 / - 8/16 kHz Peak output current [A] I for maximum 18 / 9 5 seconds for channel B; 8/16 kHz ─── AX8000 Version: 2.1.0...
  • Page 51 [Hz] 0…599 Output frequency of the dual-use version 0…1600 Mechanical data Dual-axis module 6 A AX8206-0000 Width [mm] Height without connectors [mm] Depth without connectors / accessories [mm] Weight [kg] Version: 2.1.0 AX8000 ───...

  • Page 52: Combined Power Supply Modules And Axis Modules Ax8525, Ax8540

    Peak output current I 50 / 19 80 / 30.5 for maximum 5 seconds; 8 / 16 kHz Output frequency Output frequency of the limited standard version [Hz] 0…599 Output frequency of the dual-use version [Hz] 0…1600 ─── AX8000 Version: 2.1.0...
  • Page 53 Continuous braking power [kW] Maximum braking power [kW] Mechanical data Combined power supply Combined power supply modules and axis mod- modules and axis mod- ules 25 A ules 40 A AX8525-0xx0 AX8540-0xx0 Width [mm] Height [mm] Depth [mm] Weight [kg] Version: 2.1.0 AX8000 ───...

  • Page 54: Ax8810 Capacitor Module

    Technical data 4.5 AX8810 capacitor module Electrical data AX8810-0000 DC link Maximum voltage [V Capacitance [µF] 1755 Mechanical data AX8810-0000 Width [mm] Height without connectors [mm] Depth without connectors / accessories [mm] Weight [kg] ─── AX8000 Version: 2.1.0...

  • Page 55: Dimensional Drawings

    Technical data 4.6 Dimensional drawings • Dimensions without connectors and cables • All figures in millimeters 4.6.1 Narrow modules (AX8108, AX8206, AX8600, AX8620, AX8810) AX8600, AX8620 Ø5,2 Version: 2.1.0 AX8000 ───...
  • Page 56 Technical data AX8108, AX8206, AX8810 R2,75 R2,75 Illustration: Axis modules AX8108, AX8206 and capacitor module AX8810 ─── AX8000 Version: 2.1.0...

  • Page 57: Wide Modules (Ax8118, Ax8128, Ax8640)

    Technical data 4.6.2 Wide modules (AX8118, AX8128, AX8640) R2,75 R2,75 Illustration: Power supply modules AX8640 and Axis modules AX8118 Version: 2.1.0 AX8000 ───...

  • Page 58: Combined Modules (Ax8525, Ax8540)

    Technical data 4.6.3 Combined modules (AX8525, AX8540) Illustration: Combined power supply modules and axis modules AX8525, AX8540 ─── AX8000 Version: 2.1.0...

  • Page 59: Scope Of Supply

    • Digital inputs and outputs • Digital inputs and outputs Combined AX85xx power supply ZS4500-2047 modules and axis modules • External braking resistor [+] ZS4800-2003 • 24 V supply ZS4800-2015 • Digital inputs and outputs AX8810 capacitor module Version: 2.1.0 AX8000 ───...

  • Page 60: Packaging

    This is the correct position for the packaging. The packaging must be protected from moisture. The contents are fragile. The table below shows the dimensions of the packages: Dimension AX8108 AX8206 AX8600 AX8620 AX8118 AX8128 AX8640 AX8525 AX8540 Height [mm] Width [mm] Depth [mm] ─── AX8000 Version: 2.1.0...

  • Page 61: 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: AX8000 multi-axis servo sys- Stacking height [pieces] Power supply modules, axis modules, capacitor modules Combined modules Version: 2.1.0...

  • Page 62: Transport

    You have the option to store the servo drive over a short or longer period. ► Store the product in its original packaging. ► Adhere to the conditions specified in the chapter: "Transport and storage", [Page 61]. ► Ensure the storage space is vibration-free. ─── AX8000 Version: 2.1.0...

  • Page 63: Technical Description

    This fault current may cause malfunctions of standard residual current circuit breakers. 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. 7.3 Safe system stop A power failure can lead to the uncontrolled run-out of the drive axes.

  • Page 64: Wide Voltage Range

    7.4 Wide voltage range Due to the wide voltage range of the power supply modules, the 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 65: Dimensioning

    •   1 x AX8810-0000 with 1755 µF That makes a total capacitance of 3730 µF. The system is permissible, because a power supply module on the 400 V supply network can charge up a capacitance of 13500 µF. Version: 2.1.0 AX8000 ───...
  • Page 66 After about 5 Tau the charging time is completed. Examples AX8620 at 400 V with maximum number of axis modules: • Tau = 33 ohm x 8500 µF = 280 ms Charging time = 5 x 280 ms = 1.4 s AX8540 at 400 V with maximum number of axis modules: • Tau = 10 ohm x 23000 µF = 230 ms Charging time = 5 x 230 ms = 1.15 s ─── AX8000 Version: 2.1.0...

  • Page 67: Total Motor Cable Length

    Technical description 7.5.2 Total motor cable length In compliance with the EMC category C3, various total motor cable lengths apply to the AX8000 multi-axis servo system. Without mains choke Motor cable length Total motor cable Number of axes per length drive system Maximum 25 m* per...
  • Page 68 AX2090-NF80-0040 and mains choke AX2090-ND80-0040 AX8525 and AX8540 with mains filter AX2090-NF80-0080 and mains choke AX2090-ND80-0080 Further information on mains filters can be found in the chapter Ac- cessories under "Mains filters", [Page 137]. ─── AX8000 Version: 2.1.0...

  • Page 69: Control Voltage

    AM8051 = 5.88 A Result The maximum single cable length for the AM8051-0G21 is 25 m and is thus ≤ 25 m The total cable length of all servomotors is 131  m and is thus ≤ 300 m • No AX2090-ND80-xxxx mains choke required Version: 2.1.0 AX8000 ───...

  • Page 70: Display

    AX8620 power supply module with 945 µF and is thus ≤ 6000 µF 7.6 Display Information about the states of the individual modules is shown on the display of the AX8000 multi-axis servo system. There are differ- ent symbols for each module. Display black: The module is switched off.
  • Page 71 The power supply module is ready to operate. 7.6.1.3 Debug firmware D = Debug firmware Debug firmware symbol flashes green: a preliminary test version, debug firmware, is installed. Replace the version as soon as possible by a released firmware. Version: 2.1.0 AX8000 ───...

  • Page 72: Axis Module

    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: 2.1.0...

  • Page 73: Combined Module

    The display of the combined module contains the information from the display of the "power supply module", [Page  70] and the "axis module", [Page 72]: • EtherCAT • Mains voltage • Axis module • Safety • Debug firmware Version: 2.1.0 AX8000 ───...

  • Page 74: 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 75: Ax8600 Power Supply Module Dc

    AX8600 DC power supply module. The plug of the DC link connection cable  [1] is connected to the AX-Bridge of the last AX8000 axis module [2] and the plug [3] in the next row is con- nected to the AX8600 [4].
  • Page 76 Technical description ─── AX8000 Version: 2.1.0...

  • Page 77: Zk4875-900X | Dc Link Connection Cable

    The maximum cable length is 5 meters and the connection may only be made in the same control cabinet. 7.10 Third-party motors The AX8000 axis modules also support the connection of third-party motors. This includes, for example, asynchronous motors, synchro- nous motors, linear motors and torque motors.

  • Page 78: Twinsafe Safe Drive Technology

    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 ap- plication.

  • Page 79: Beckhoff Synchronous Servomotors

    AX8xxx-x2xx), only for AM802x to AM807x 7.11.2 Beckhoff linear servomotors The axis modules of the AX8000 servo system also support safe drive technology with AL8000 linear servomotors. A suitable exter- nal encoder system must be selected. Please observe the following...
  • Page 80 Non-observance may endanger product safety If an external encoder is used, the machine builder is responsible • the right choice of components • correct installation in accordance with the encoder operating instructions • the FMEA (Failure Mode and Effects Analysis) ─── AX8000 Version: 2.1.0...

  • Page 81: Third-Party Motors And Twinsafe

    Technical description 7.11.3 Third-party motors and TwinSAFE The axis modules of the AX8000 servo system can be used to im- plement safe drive technology with third-party motors. Please ob- serve the following notes: NOTICE TwinSAFE STO/SS1 The basic TwinSAFE STO/SS1 functions can be used with third- party motors.

  • Page 82: Mechanical Installation

    Note that when dimensioning the control cabinet you may have to mount input filters, mains chokes and braking resistors for your ap- plication. Allow sufficient space in the control cabinet for these com- ponents so that cooling air circulation is ensured. ─── AX8000 Version: 2.1.0...
  • Page 83 Number Explanation Control cabinet door Conductive and galvanized mounting plate Control cabinet roof, cable channel or anything that disturbs the convection Control cabinet floor, cable channel or anything that disturbs the convection Version: 2.1.0 AX8000 ───...

  • Page 84: Drilling Pattern

    Mechanical installation 8.1.1 Drilling pattern Beckhoff universal drilling pattern You have the possibility – at any time and without having to drill new holes – to change the configuration of the servo drive modules if you provide the mounting plate with the universal drilling pattern.

  • Page 85: Axis Modules And Capacitor Modules

    ► Place the axis module [1] at the right side of the power supply module [2] onto the screw [3] and carefully press against the mounting plate [4] ► Once again, guide the screws [1] through the rectangular cut- outs in the module housing [2] Version: 2.1.0 AX8000 ───...
  • Page 86 ► 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. ─── AX8000 Version: 2.1.0...

  • Page 87: Electrical Installation

    The project planning is the detailed planning of your drivetrain. Tak- ing into account various views, you can design your drive system with the help of the following information. Please note that this sup- port is only an example. Version: 2.1.0 AX8000 ───...

  • Page 88: Energy Management

    The Beckhoff software "TE5910 | TwinCAT 3 Motion Designer" is available for energy management purposes.

  • Page 89: Block Diagrams

    Connection socket for incoming EtherCAT cable Connection socket for outgoing EtherCAT cable Measuring and test contacts on the devices Quick coupling of the AX8000 multi-axis servo system; AX bridge Optional braking resistor Schematic contacts on the 7-pin supply plug "X01"...

  • Page 90: Ax8620 Power Supply Module 20 A

    Measuring and test contacts on the devices Quick coupling of the AX8000 multi-axis servo system; AX bridge Optional braking resistor When using an optional braking resistor on the AX8000 multi-axis servo system, the bridge of the 10-pin supply plug X01 between R and R...

  • Page 91: Ax8640 Power Supply Module 40 A

    Measuring and test contacts on the devices Quick coupling of the AX8000 multi-axis servo system; AX bridge Optional braking resistor When using an optional braking resistor with the AX8000 multi-axis servo system, the bridge of the 6-pin supply plug X02 between R and R...

  • Page 92: Ax85Xx Combined Power Supply Modules And Axis Modules 25 A, 40 A

    Connection socket for outgoing EtherCAT cable Optional mains filter Optional mains choke Optional braking resistor When using an optional braking resistor on the AX8000 multi-axis servo system, the bridge of the 4-pin connector plug external braking resistor X02 between R must be removed. Bint+ ZK4800-85xx motor cable;...

  • Page 93: Ax81X8 Single-Axis Module 8 A, 18 A, 28 A

    Electrical installation 9.2.5 AX81x8 single-axis module 8 A, 18 A, 28 A Number Explanation Quick coupling of the AX8000 multi-axis servo system; AX bridge ZK4800-80xx-xxxx motor cable; including OCT Version: 2.1.0 AX8000 ───...

  • Page 94: Ax8206 Dual-Axis Module 6 A

    Electrical installation 9.2.6 AX8206 Dual-axis module 6 A Number Explanation Quick coupling of the AX8000 multi-axis servo system; AX bridge ZK4800-80xx-xxxx motor cable; including OCT ─── AX8000 Version: 2.1.0...

  • Page 95: Grounding

    The shields have to be applied with a suffi- ciently large contact area on both sides. The earth connection of the AX8000 multi-axis servo system is con- nected via the grounding hangers and hexagonal nuts, similar to DIN 6923 with class 8 flange and serrations with a galvanized sur- face.
  • Page 96 ► Do not use a spring washer [7] ► Tighten both nuts firmly ► Observe tightening torques: Components Tightening torque [Nm] Serrated hexagonal nut M5, strength class A2-50 ► Mount [8] further grounding hangers + DC - DC ─── AX8000 Version: 2.1.0...

  • Page 97: Protective Earth

    Serrated hexagonal nut M5, strength class A2-50 ► 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: 2.1.0 AX8000 ───...

  • Page 98: Connector Power Supply 24 V

    AX85xx combined modules for the 24 V power sup- ply. Connect the components of the AX8000 multi-axis servo system ac- cording to standard EN 60204-1:2006 Protective Extra Low Voltage; PELV: • The PE and 0 V conductors of the voltage source must be on the same potential and connected in the control cabinet.

  • Page 99: Zs4800-2003 | Connector Combined Modules Ax85Xx

    Terminal point Connection 24 V 24 V +6/-10 % system voltage and peripheral voltage Wire cross-section Maximum 16 mm² AWG 6 Mounting Screws with tightening torque 1.2 Nm – 1.5 Nm / 10.6 lbf in – 13.3 lbf in Version: 2.1.0 AX8000 ───...

  • Page 100: Connector Voltage Input

    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. 9.5.1 ZS4800-2001 | Connector power supply module AX8620 • X01 slot on AX8620 power supply modules...

  • Page 101: Zs4800-2041 | Connector Power Supply Module Ax8640

    Wire cross-section Maximum 35 mm² AWG 2 Mounting Screws with tightening torque 1.2 Nm – 1.5 Nm / 10.6 lbf in – 5.3 lbf in <= 25 mm² = 2.5 Nm, 35 mm² = 4.5 Nm Version: 2.1.0 AX8000 ───...

  • Page 102: Connector External Brake Resistor

    • X01 slot on AX8600 combined modules Terminal point Connection Braking resistor - Braking resistor + Wire cross-section Maximum 16 mm² AWG 6 Mounting Screws with tightening torque 1.2 Nm to 1.5 Nm / 10.6 lbf in to 13.3 lbf in ─── AX8000 Version: 2.1.0...

  • Page 103: Zs4800-2042 | Connector Power Supply Module Ax8640

    • X02 slot on AX85xx combined modules Terminal point Connection External braking resistor GND External braking resistor + Wire cross-section Maximum 16 mm² AWG 6 Mounting Screws with tightening torque 1.2 Nm to 1.5 Nm / 10.6 lbf in to 13.3 lbf in Version: 2.1.0 AX8000 ───...

  • Page 104: Dc Link

    Electrical installation 9.7 DC link No external DC link group possible In order to avoid damaging the AX8000 multi-axis servo system, an external DC link group with a servo drive from the AX5000 series is not permissible. 9.7.1 Terminal strip •...

  • Page 105: Multi-Feedback Interface

    Cables and connection of the cable The following cable is available for the EnDat 2.2/22 feedback sys- tem with M12 connection: • ZK4810-0020-zzzz encoder cable, EnDat 2.2 Connection of the feedback line ► Remove cover [1] Version: 2.1.0 AX8000 ───...
  • Page 106 Electrical installation The D-sub connectors [2] and [3] are exposed. ► Connect feedback The connectors are angled upwards. If the connectors are con- nected correctly, the cables can only be guided upwards. ► Guide cables [4] upwards ─── AX8000 Version: 2.1.0...

  • Page 107: Ax81Xx-0X10 With 2 X D-Sub

    GND sense GND sense n.c. n.c. 5V sense 5V sense Data; DX- Data- / SLO- n.c. n.c. Clock; CLK- CLK- / MA- Only one protocol can be set per module. Maximum output current per D-sub connector: 250 mA Version: 2.1.0 AX8000 ───...

  • Page 108: Ax81Xx-0X20 With 1 X D-Sub

    Data- / SLO- B- n.c. n.c. n.c. Clock; CLK- CLK- / MA- n.c. Only one protocol can be set per module. Maximum output current per D-sub connector: 250 mA Cut-off frequency SinCos 1 Vpp: 270 kHz Cut-off frequency TTL (DIFF RS422): 10 MHz ─── AX8000 Version: 2.1.0...

  • Page 109: Ax82Xx-0X10 With 2 X D-Sub

    GND sense n.c. n.c. 5 V sense 5 V sense Data; DX- Data- / SLO- n.c. n.c. Clock; CLK- CLK- / MA- Only one protocol can be set per module. Maximum output current per D-sub connector: 250 mA Version: 2.1.0 AX8000 ───...

  • Page 110: Ax85Xx-0X20 With 1 X D-Sub

    Data- / SLO- B- n.c. n.c. n.c. Clock; CLK- CLK- / MA- n.c. Only one protocol can be set per module. Maximum output current per D-sub connector: 250 mA Cut-off frequency SinCos 1 Vpp: 270 kHz Cut-off frequency TTL (DIFF RS422): 10 MHz ─── AX8000 Version: 2.1.0...

  • Page 111: Motor Feedback Oct

    A temperature sensor with double insulation or reinforced insula- tion is required for the operation of a third-party motor with a tem- perature sensor on the AX8000. The AX8000 multi-axis servo system and further components can be damaged if this is ignored. Version: 2.1.0 AX8000 ───...

  • Page 112: Motor Connector Ax85Xx

    Electrical installation 9.11 Motor connector AX85xx A motor connector is required for the AX85xx combined modules. The connector is part of the preassembled Beckhoff motor cable. 9.11.1 ZS4800-2043 / Connector combined modules AX85xx • X13 connection on AX85xx combined modules...

  • Page 113: Holding Brake / Oct / Temperature Sensor

    A temperature sensor with double isolation or reinforced isolation is required for the operation of a third-party motor with a tempera- ture sensor on the AX8000. The AX8000 multi-axis servo system and further components can be damaged if this is ignored. Version: 2.1.0 AX8000 ───...

  • Page 114: Digital Inputs

    3 and 4. 9.13.1 ZS4800-2015 I/O connector plug The I/O connector plug ZS4800-2015 is required to connect signals to slot X15 and slot X25. The I/O connector plug is included in the scope of delivery. ─── AX8000 Version: 2.1.0...

  • Page 115: Modules Without Twinsafe

    : 60 µs typ. 300 µs typ. digital input 15 µs typ. digital output : 60 µs typ. 300 µs typ. Cable Configuration Ferrule with collar according to DIN 46 228/4 Wire cross- 1 mm² max., AWG 17 section Mounting Push in Version: 2.1.0 AX8000 ───...

  • Page 116: Modules With Twinsafe

    Direct link to the original operating instructions of the Twin- SAFE drive option card for servo drive AX8xxx-x1xx Original operating instructions | AX8911 for AX8xxx-x2xx Direct link to the original operating instructions of the Twin- SAFE drive option card for servo drive AX8xxx-x2xx ─── AX8000 Version: 2.1.0...

  • Page 117: Leakage Currents

    The leakage current values given in the table are based on the fol- lowing: - original Beckhoff motor cables are used - shielding and grounding concepts are adhered to Composition of the maximum total leakage current The maximum total leakage current is composed of: - device-dependent fixed part with 50 ...

  • Page 118: Supply Networks

    Electrical installation 9.15 Supply networks The AX8000 multi-axis servo system is suitable for operation on grounded single-phase or three-phase networks. The respective network configurations differ by the type of ground connection. For a better understanding, the table below contains examples with the...

  • Page 119: Three-Phase Connection

    NOTICE Connection only with upstream isolating transformer The use of an isolating transformer is generally required for the following grid forms. Non-compliance may damage the AX8000 multi-axis servo sys- tem and the components. 9.15.1.3 Asymmetrically grounded network with star point Version: 2.1.0...
  • Page 120 Electrical installation 9.15.1.4 Asymmetrically grounded delta network 100 – 240 V AC 400 – 480 V AC 9.15.1.5 IT delta network ─── AX8000 Version: 2.1.0...

  • Page 121: Single-Phase Connection

    Electrical installation 9.15.2 Single-phase connection 9.15.2.1 TN network 9.15.2.2 TT network 9.15.2.3 TN-C network Version: 2.1.0 AX8000 ───...
  • Page 122 Electrical installation 9.15.2.4 TN-S network 9.15.2.5 Split-phase with grounded center tap 120 V L3/N ─── AX8000 Version: 2.1.0...
  • Page 123 L3/N NOTICE Connection only with upstream isolating transformer Use an upstream isolating transformer with the following net- works. The AX8000 multi-axis servo system and the components can be damaged if this is ignored. 9.15.2.7 IT network with star point 9.15.2.8 IT delta network Version: 2.1.0...
  • Page 124 Electrical installation 9.15.2.9 Asymmetrically grounded network with star point 9.15.2.10 Asymmetrically grounded delta network 9.15.2.11 Split-phase ungrounded networks 9.15.2.12 DC power supply AX8600 ─── AX8000 Version: 2.1.0...
  • Page 125 Electrical installation 9.15.2.13 DC power supply AX8620 Important: Observe derating! Version: 2.1.0 AX8000 ───...

  • Page 126: Isolating Transformers

    9.15.3 Isolating transformers Special network configurations require an upstream isolating trans- former. Like the power supply modules of the AX8000, this supplies a short-term peak current of 100%. Full input power is not required for many applications. If this is the case, isolating transformers with a lower power rating can also be used.

  • Page 127: Fuse Protection

    Device Fuse protec- Semiconductor max. SCCR tion fuse AX8620 gG(A) or Bussmann 65 kA Automat “C” FWC-32A10F, max. 25 A 10x38 mm, type aR, 32 A AX8640 gG(A) or Bussmann 65 kA Automat “C” FWP-63A22F, max. 50 A 22x58 mm, type aR, 63 A Version: 2.1.0 AX8000 ───...
  • Page 128 20 A 9.16.1.5 Internal fuse protection Fuse protection Fuse 24 V system voltage / electronic periphery Internal braking resistor electronic External braking resistor electronic Requirements: • Active thermal model for selected braking resistor • Correct braking resistor line ─── AX8000 Version: 2.1.0...

  • Page 129: Ul-Compliant

    External protection | Fuse type class J + semiconductor fuse Semiconductor fuses only serve as short-circuit protection. A Class J fuse must always be connected in series for line protection. When using semiconductor fuses, be sure to use the exact type specified for the device: Version: 2.1.0 AX8000 ───...
  • Page 130 UL approved. Device Max. fuse protection Max. SCCR AX8525 125 A 65 kA AX8540 125 A 65 kA 9.16.2.4 External fuse protection 24 V DC Device Fuse protection AX8620 20 A AX8640 20 A AX8525 20 A AX8540 20 A ─── AX8000 Version: 2.1.0...

  • Page 131: Device Fusing

    1.95 A 0.85 A Total sum current: 9.70 A x simultaneity factor 0.7 = 6.8 A Selected power supply AX8620-0000 module: Selected fuse protec- 10 A tion: Example of the design of the current-limiting fuses in the sys- tem group Version: 2.1.0 AX8000 ───...
  • Page 132 Total nominal output current = 26 A The system group must be fused with at least 26 A. Select the next higher standard level for this according to UL 508A, Tab. SB4.2. This corresponds to class "J" with 40 A. ─── AX8000 Version: 2.1.0...

  • Page 133: Commissioning

    10.1.1 Voltage testing and insulation resistance measurement Factory testing All AX8000 series devices are voltage tested in the end of line test in accordance with the requirements for routine testing of product standard 61800-5-1 to prove that air gaps in the basic isolation and reinforced isolation have not been reduced during manufacture.

  • Page 134: During 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 135: 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 136: Accessories

    12 Accessories 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 servomotor.

  • Page 137: Mains Filter

    • Category C3 – Drive systems for operation in the second environment. The power supply modules of the AX8000 servo system are de- signed with integrated mains filters for compliance with category C3. Optional mains filters are available for use in the first environment.

  • Page 138: Decommissioning

    Serious or even fatal injuries may result if this is ignored. Do not remove components from the products Only Beckhoff Automation GmbH & Co. KG is permitted to remove components. Contact Beckhoff Service for further information. Removal of the servo drive from the machine •...

  • Page 139: Disposal

    Products marked with a crossed-out waste bin must not be disposed of with general waste. Electronic components and device are con- sidered as waste electrical and electronic equipment for disposal. Observe the national regulations for the disposal of old electrical and electronic equipment. Version: 2.1.0 AX8000 ───...

  • Page 140: Guidelines And Standards

    "Adjustable speed electrical power drive systems" Part 5-1: Safety requirements - Electrical, thermal and energy IEC 61800-5-3 "Adjustable speed electrical power drive systems” Part  5-3: Safety requirements - Functional, electrical and environ- mental requirements for encoders ─── AX8000 Version: 2.1.0...

  • Page 141: 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. Version: 2.1.0 AX8000 ───...

  • Page 142: Test Centers

    The cURus logo can be found on the name plate. 14.4 EU conformity Provision Beckhoff Automation GmbH & Co KG will be pleased to provide you with EU declarations of conformity and manufacturer's declarations for all products on request. Send your request to: info@beckhoff.com...

  • Page 143: 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 144: Index

     11 Instruction  13 Technical data  41 Intended use  38 Total motor cable length  67 Transport  61 Label, see Safety pictograms  17  143 Mains choke [+] Documentation  136 Maintenance  135 Intervals  135 Motor feedback  111 Multi-feedback  105 ─── AX8000 Version: 2.1.0...
  • Page 145 Trademark statements Beckhoff®, TwinCAT®, TwinCAT/BSD®, TC/BSD®, EtherCAT®, EtherCAT G®, EtherCAT G10®, EtherCAT P®, Safety over EtherCAT®, TwinSAFE®, XFC®, XTS® and XPlanar® are registered trademarks of and licensed by Beckhoff Automation GmbH. Third-party trademark statements BiSS is a trademark of IC Haus GmbH.
  • Page 146 More Information: www.beckhoff.com/ax8000 Beckhoff Automation GmbH & Co. KG Hülshorstweg 20 33415 Verl Germany Phone: +49 5246 9630 info@beckhoff.com www.beckhoff.com...

This manual is also suitable for:

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