Digital Servo Amplifier
AX2040/2070
Assembly, Installation, Setup
Keep all product manuals as a product component
during the life span of the servo amplifier.
Pass all product manuals to future
users / owners of the servo amplifier.
Edition 02/06
Previous versions :
Edition Remarks
09/05 First edition
02/06
Chapter 1 updated, motor choke added, DeviceNet, SynqNet and EtherCat expansion cards added, chap
ter 6 restructured, feedback section updated, cross section (awg)
-
WINDOWS is a registered trademark of Microsoft Corp.
HIPERFACE is a registered trademark of Max Stegmann GmbH
EnDat is a registered trademark of Dr. Johannes Heidenhain GmbH
Technical changes which improve the performance of the equipment may be made without prior notice !
Printed in the Federal Republic of Germany
All rights reserved. No part of this work may be reproduced in any form (by printing, photocopying, microfilm or
any other method) or stored, processed, copied or distributed by electronic means without the written permission of
Beckhoff.
Beckhoff
02/06 Contents
1 General
1.1 About this manual ...................................................................................7
1.2 Symbols used in this manual ..........................................................................7
1.3 Abbreviations used in this manual ......................................................................8
2 Technical Description
2.1 Safety Instructions ..................................................................................9
2.2 Use as directed ....................................................................................10
2.3 European directives and standards ....................................................................11
2.4 CE - conformance ..................................................................................11
2.5 UL and cUL- Conformance ...........................................................................12
2.6 Nameplate .......................................................................................13
2.7 Instrument description ..............................................................................13
2.7.1 Package supplied ............................................................................13
2.7.2 The digital servo amplifiers of the series AX2040/2070 ...............................................14
2.8 Connection to different mains supply networks ...........................................................16
2.9 Components of a sero system ........................................................................17
2.10 Technical data ....................................................................................18
2.10.1 Fusing .....................................................................................19
2.10.1.1 Internal fusing ...........................................................................19
2.10.1.2 External fusing ...........................................................................19
2.10.2 Allowable ambient conditions, ventilation, mounting position ...........................................19
2.10.3 Conductor cross-sections ......................................................................20
2.10.4 Recommended torques ........................................................................20
2.10.5 LED display .................................................................................20
2.11 Grounding system..................................................................................20
2.12 Control for motor holding brake .......................................................................21
2.13 Regen circuit ......................................................................................22
2.14 Switch-on and switch-off behavior .....................................................................23
2.14.1 Stop function to EN 60204 .....................................................................23
2.14.2 Emergency Stop strategies .....................................................................24
2.15 Restart lock -AS-...................................................................................25
2.15.1 Advantages of the restart lock ...................................................................25
2.15.2 Functional description .........................................................................25
2.15.3 Block diagram ...............................................................................26
2.15.4 Signal diagram (sequence) .....................................................................26
2.15.5 Installation / Setup ............................................................................27
2.15.5.1 Safety instructions ........................................................................27
2.15.5.2 Functional test ...........................................................................27
2.15.5.3 Connection diagram.......................................................................27
2.15.6 Application examples .........................................................................28
2.15.6.1 Moving single axis-groups in setting-up operation................................................28
2.15.6.2 Switching off grouped axes with separate working areas ..........................................28
2.15.6.2.1 Control circuit.......................................................................28
2.15.6.2.2 Mains supply circuit ..................................................................29
3 Installation
3.1 Important notes ....................................................................................31
3.2 Guide to installation and wiring ........................................................................32
3.3 Assembly ........................................................................................33
3.3.1 Dimensions .................................................................................34
3.4 Wiring ...........................................................................................35
3.4.1 Connection diagram ..........................................................................36
3.4.2 Example of connections for a multi-axis system .....................................................37
3.4.3 Pin assignments .............................................................................38
3.4.4 Notes on connection techniques .................................................................39
3.4.4.1 Shielding connection to the front panel ........................................................39
3.4.4.2 Technical data for cables...................................................................40
3.5 Setup software ....................................................................................41
3.5.1 General ....................................................................................41
3.5.1.1 Use as directed ..........................................................................41
3.5.1.2 Software description ......................................................................41
3.5.1.3 Hardware requirements ....................................................................42
3.5.1.4 Operating systems........................................................................42
3.5.2 Installation under WINDOWS 95 / 98 / 2000 / ME / NT / XP ............................................42
Page
AX2040/2070 Installation Manual 3
Contents
02/06 Beckhoff
4 Interfaces
4.1 Block diagram .....................................................................................43
4.2 Power supply .....................................................................................44
4.2.1 Mains supply connection (X0) ...................................................................44
4.2.2 24V auxiliary supply (X4).......................................................................44
4.2.3 DC bus link .................................................................................44
4.3 Motor connection with brake (X0, X4)...................................................................45
4.4 Motor connection with choke (X0) .....................................................................45
4.5 External regen resistor (X0) ..........................................................................45
4.6 Feedback ........................................................................................46
4.6.1 Resolver (X2) ...............................................................................46
4.6.2 ComCoder (X1) ..............................................................................47
4.6.3 Incremental or sine encoder with hall sensors (X1) ..................................................48
4.6.4 Sine Encoder with EnDat or HIPERFACE (X1) ......................................................49
4.6.5 Incremental Encoder (X5) ......................................................................50
4.6.6 Sine Encoder without data channel (X1) ...........................................................51
4.7 Digital and analog inputs and outputs...................................................................52
4.7.1 Analog inputs (X3) ............................................................................52
4.7.2 Analog outputs (X3)...........................................................................53
4.7.3 Digital inputs (X3) ............................................................................54
4.7.4 Digital outputs (X3) ...........................................................................55
4.8 Encoder emulations ................................................................................56
4.8.1 Incremental encoder output - A quad B (X5) ........................................................56
4.8.2 SSI encoder emulation - position output (X5) .......................................................57
4.9 Master-slave operation, encoder master control ..........................................................58
4.9.1 Connection to a AX20 master, 5B signal level (X5) ..................................................58
4.9.2 Connection to incremental encoder master with 24V signal level (X3) ....................................59
4.9.3 Connection to a sine-cosine encoder master (X1) ...................................................59
4.10 Interface for stepper-motor controllers (pulse-direction) .....................................................60
4.10.1 Connection to a stepper motor controller with 5V signal level (X5) .......................................61
4.10.2 Connection to stepper motor controller with 24V signal level (X3).......................................61
4.11 RS232 interface, PC connection (X6) ...................................................................62
4.12 CANopen interface (X6) .............................................................................63
5Setup
5.1 Important notes ....................................................................................65
5.2 Guide to setup ....................................................................................66
5.3 Parameter setting ..................................................................................67
5.3.1 Multi-axis system .............................................................................67
5.3.1.1 Node address for CAN-bus .................................................................67
5.3.1.2 Baud rate for CAN-bus ....................................................................67
5.3.2 Key operation / LED display ....................................................................68
5.3.2.1 Key operation............................................................................68
5.3.2.2 Status display ...........................................................................68
5.3.2.3 Standard menu structure ...................................................................69
5.3.2.4 Extended menu structure...................................................................69
5.4 Error messages ...................................................................................70
5.5 Warning messages .................................................................................71
Page
4 AX2040/2070 Installation Manual
Beckhoff
02/06 Contents
6 Expansions, accessories
6.1 Expansion Cards ..................................................................................73
6.1.1 Guide to installation of expansion cards ...........................................................73
6.1.2 Expansion card -I/O-14/08- .....................................................................74
6.1.2.1 Front view ..............................................................................74
6.1.2.2 Technical data ...........................................................................74
6.1.2.3 Light emitting diodes (LEDs) ................................................................74
6.1.2.4 Select motion task number (sample) ..........................................................74
6.1.2.5 Connector assignments ....................................................................75
6.1.2.6 Connection diagram.......................................................................76
6.1.3 Expansion cards -PROFIBUS- ..................................................................77
6.1.3.1 Front view ..............................................................................77
6.1.3.2 Connection technology ....................................................................77
6.1.3.3 Connection diagram.......................................................................77
6.1.4 Expansion card -SERCOS- .....................................................................78
6.1.4.1 Front view ..............................................................................78
6.1.4.2 Light emitting diodes (LEDs) ................................................................78
6.1.4.3 Connection technology ....................................................................78
6.1.4.4 Connection diagram.......................................................................79
6.1.4.5 Modifying the station address ...............................................................79
6.1.4.6 Modifying the baud rate and optical power .....................................................79
6.1.5 Expansion card -DEVICENET- ..................................................................80
6.1.5.1 Front view ..............................................................................80
6.1.5.2 Connection technology ....................................................................80
6.1.5.3 Connection diagram.......................................................................80
6.1.5.4 Combined module/network status-LED ........................................................81
6.1.5.5 Setting the station address (device address)....................................................81
6.1.5.6 Setting the transmission speed ..............................................................81
6.1.5.7 Bus cable ...............................................................................82
6.1.6 Expansion card -ETHERCAT- ...................................................................83
6.1.6.1 Front view ..............................................................................83
6.1.6.2 LEDs ..................................................................................83
6.1.6.3 Connection diagram.......................................................................83
6.1.7 Expansion card -SYNQNET- ....................................................................84
6.1.7.1 Front view ..............................................................................84
6.1.7.2 NODE ID Switch .........................................................................84
6.1.7.3 Node LED table .........................................................................84
6.1.7.4 SynqNet Connection, Connector X21B/C (RJ-45)................................................84
6.1.7.5 Digital inputs/outputs, connector X21A (SubD 15-pin, socket) ......................................85
6.1.7.6 Connection diagram digital inputs/outputs, connector X21A ........................................85
6.1.8 Expansion module -2CAN- .....................................................................86
6.1.8.1 Installation ..............................................................................86
6.1.8.2 Front View ..............................................................................86
6.1.8.3 Connection technology ....................................................................86
6.1.8.4 Connector assignments ....................................................................87
6.1.8.5 Connection diagram.......................................................................87
6.2 Accessories ......................................................................................88
6.2.1 External 24VDC / 5A supply ....................................................................88
6.2.2 External 24VDC / 20A supply ...................................................................89
6.2.3 External regen resistor BAS ....................................................................90
6.2.4 Mains filters 3EF .............................................................................91
6.2.5 Mains chokes 3L
6.2.6 Motor chokes 3YLN ...........................................................................93
.............................................................................92
7 Appendix
7.1 Transport, storage, maintenance, disposal...............................................................95
7.2 Removing faults / warnings...........................................................................96
7.3 Glossary .........................................................................................98
7.4 Index ...........................................................................................100
Page
AX2040/2070 Installation Manual 5
02/06 Beckhoff
This page has been deliberately left blank.
6 AX2040/2070 Installation Manual
Beckhoff
1 General
1.1 About this manual
This manual describes the digital servo amplifiers of the AX2040/2070 series (standard version).
You can find information about:
General Chapter 1
l
Technical description Chapter 2
l
Assembly / installation Chapter 3
l
Interfaces Chapter 4
l
Setup Chapter 5
l
Expansikons / Accessories Chapter 6
l
Transport, storage, maintenance, disposal Chapter 7
l
A more detailed description of the expansion cards which are currently available and the digital
connection to automation systems can be found on the accompanying CD-ROM in Acrobat-Reader
format (system requirements: WINDOWS with Internet browser) in several language versions.
You can print this documentation on any standard printer. A printed copy of the documentation is
available from us at extra cost.
02/06 General
This manual makes the following demands on qualified personnel :
Transport : only by personnel with knowledge in handling electrostatically
sensitive components.
Installation : only by electrically qualified personnel
Setup : only by personnel with extensive knowledge of electrical
engineering / drive technology
1.2 Symbols used in this manual
Danger to personnel
from electricity and its
effects effects
ð p.
see page l special emphasis
Danger to maschinery,
general warning
Important
notes
AX2040/2070 Installation Manual 7
General
02/06 Beckhoff
1.3 Abbreviations used in this manual
The abbreviations used in this manual are explained in the table below.
Abbrev. Meaning
AGND Analog ground
AS Restart Lock, option
BTB/RTO Ready to operate
CAN Fieldbus (CANopen)
CE Communité Européenne (EC)
CLK Clock signal
COM Serial interface for a PC-AT
DGND Digital ground
DIN German Institute for industrial Standards
Disk Magnetic storage (diskette, hard disk)
EEPROM Electrically erasable programmable memory
EMC Electromagnetic compatibility
EMI Electromagnetic interference
EN European standard
ESD Electrostatic discharge
F-SMA Fiber Optic Cable connector according to IEC 60874-2
IEC International Electrotechnical Commission
IGBT Insulated Gate Bipolar Transistor
INC Incremental Interface
ISO International Standardization Organization
LED Light-emitting diode
MB Megabyte
NI Zero pulse
NSTOP Limit-switch input for CCW rotation (left)
PELV Protected low voltage
PGND Ground for the interface
PSTOP Limit-switch input for CW rotation (right)
PWM Pulse-width modulation
RAM Volatile memory
R
regen(RB
R
Bext
R
Bint
RES Resolver
ROD 426 (EEO) A quad B encoder
PLC Programmable logic controller
SRAM Static RAM
SSI Synchronous serial interface
UL Underwriters Laboratory
VAC AC voltage
VDC DC voltage
VDE Verein deutscher Elektrotechniker
XGND Ground for the 24V supply
) Regen resistor
External regen resistor
Internal regen resistor
8 AX2040/2070 Installation Manual
Beckhoff
2 Technical Description
2.1 Safety Instructions
Only properly qualified personnel are permitted to perform activities such as trans
l
port, installation, setup and maintenance. Properly qualified persons are those who
are familiar with the transport, assembly, installation, setup and operation of the pro
duct, and who have the appropriate qualifications for their job. The qualified person
nel must know and observe:
IEC 364 and CENELEC HD 384 or DIN VDE 0100
IEC-Report 664 or DIN VDE 0110
national accident prevention regulations or BGV A3
02/06 Technical Description
-
-
-
Read this documentation before carrying out installation and setup. Incorrect hand
l
ling of the servo amplifier can lead to personal injury or material damage. It is vital
that you keep to the technical data and information on connection requirements (on
the nameplate and in the documentation).
The servo amplifiers contain electrostatically sensitive components which may be
l
damaged by incorrect handling. Ground yourself before touching the servo amplifier
by touching any unpainted metal surface. Avoid contact with highly insulating mater
ials (artificial fabrics, plastic film etc.). Place the servo amplifier on a conductive sur
face.
The manufacturer of the machine must generate a hazard analysis for the machine,
l
and take appropriate measures to ensure that unforeseen movements cannot cause
injury or damage to any person or property.
Do not open the units. Keep all covers and switchgear cabinet doors closed during
l
operation. Otherwise there are deadly hazards, with the possibility of severe danger
to health or material damage.
l
During operation, servo amplifiers, according to their degree of enclosure protection,
may have uncovered live components. Control and power connections may be live,
even if the motor is not rotating.
l
Servo amplifiers may have hot surfaces during operation.
l
Never undo the electrical connections to the servo amplifier while it is live. There is a
danger of electric arcing with damage to contacts and danger to persons.
-
-
-
l
Wait at least five minutes after disconnecting the servo amplifier from the mains
supply voltage before touching live sections of the equipment (e.g. contacts) or
undoing connections. Capacitors can still have dangerous voltages present up to five
minutes after switching off the supply voltages. To be sure, measure the voltage in
the DC bus link circuit and wait until it has fallen below 40V.
Safety instructions
AX2040/2070 Installation Manual 9
Technical Description
2.2 Use as directed
The servo amplifiers are components which are built into electrical equipment or machines, and can
only be used as integral components of such equipment. The manufacturer of the machine must
generate a hazard analysis for the machine, and take appropriate measures to ensure that unfore
seen movements cannot cause injury or damage to any person or property.
02/06 Beckhoff
-
The AX2040/2070 family of servo amplifiers can be connected directly to symmetrically eart
hed(grounded) three-phase industrial mains supply networks [TN-system, TT-system with eart
hed(grounded) neutral point, not more than 5000rms symmetrical amperes, 480VAC maximum]
when protected by fuses type Fusetron FRS-R-50 for AX2040 or FRS-R-80 class RK5 for AX2070,
manufactured by Bussman, or equivalent, 480VAC min.
The servo amplifiers must not be operated directly on power supply networks >230V without an
earth (ground) or with an asymmetrical earth (ground).
Connection to other mains supply networks ð p. 16.
-
-
The use of external mains chokes and mains filters is required.
Periodic overvoltages between outer conductor (L1, L2, L3) and housing of the servo amplifier may
not exceed 1000V (peak value).
Transient overvoltages (< 50µs) between the outer conductors may not exceed 1000V.
Transient overvoltages (< 50µs) between outer conductors and housing may not exceed 2000V.
The regen resistors have to be protected by fuses type Limitron KLM, rated for 500VAC/DC
The AX2040/2070 family of servo amplifiers is only intended to drive specific brushless synchro
nous servomotors with closed-loop control of torque, speed and/or position. The rated voltage of the
motors must be at least as high as the DC bus link voltage of the servo amplifier. The motor must
have integral thermal protection.
The servo amplifiers may only be operated in a closed switchgear cabinet, taking into account the
ambient conditions defined on page 19 and the dimensions shown on page 33. Ventilation or cooling may be necessary to prevent enclosure ambient from exceeding 45°C (113°F).
Use copper wire only. Wire size may be determined from EN 60204 (or table 310-16 of the NEC
60°C or 75°C column for AWG size).
-
We only guarantee the conformance of the servo amplifiers with the standards for industrial areas
(page 11), if the components are delivered by Beckhoff.
Restart lock -AS-
The restart lock -AS- is exclusively intended to provide safety for personnel, by preventing the res
tart of a system. To achieve this personnel safety, the wiring of the safety circuits must meet the
safety requirements of EN60204, EN292 and EN 954-1..
The -AS- restart lock must only be activated,
— when the motor is no longer rotating (setpoint = 0V, speed = 0rpm, enable = 0V).
Drives with a suspended load must have an additional safe mechanical blocking
(e.g. by a motor-holding brake).
— when the monitoring contacts (KSO1/2 and BTB/RTO) for all servo amplifiers are wired into
the control signal loop (to recognize a cable break).
The -AS- restart lock may only be controlled by a CNC if the control of the internal safety relay is
arranged for redundant monitoring.
The -AS- restart lock must not be used if the drive is to be made inactive for the following reasons :
1. - cleaning, maintenance and repair operations
- long inoperative periods
In such cases, the entire system should be disconnected from the supply by the personnel,
and secured (main switch).
2. - emergency-stop situations
In an emergency-stop situation, the main contactor is switched off (by the emergency-stop
button or the BTB-contact in the safety circuit).
-
10 AX2040/2070 Installation Manual
Beckhoff
02/06 Technical Description
2.3 European directives and standards
Servo amplifiers are components that are intended to be incorporated into electrical plant and
machines for industrial use. When the servo amplifiers are built into machines or plant, the amplifier
must not be used until it has been established that the machine or equipment fulfills the require
ments of the EC Machinery Directive (98/37/EC), the EC EMC Directive (89/336/EEC) and the EC
Low Voltage Directive (73/23/EEC.)
Standards to be applied for conformance with the EC Machinery Directive (98/37/EEC):
EN 60204-1 (Safety and Electrical Equipment in Machines)
EN 292 (Safety of Machines)
The manufacturer of the machine must generate a hazard analysis for the machine,
and take appropriate measures to ensure that unforeseen movements cannot
cause injury or damage to any person or property.
Standards to be applied for conformance with the EC Low Voltage Directive (73/23/EEC):
EN 60204-1 (Safety and Electrical Equipment in Machines)
EN 50178 (Electronic Equipment in Power Installations)
EN 60439-1 (Low Voltage Switchgear Combinations)
Standards to be applied for conformance with the EC EMC Directive (89/336/EEC):
EN 61000-6-1 / EN 61000-6-2 (Interference Immunity in Residential & Industrial Areas)
EN 61000-6-3 / EN 61000-6-4 (Interference Generation in Residential & Industrial Areas)
-
The manufacturer of the machine/plant is responsible for ensuring that it meets the limits required
by the EMC regulations. Advice on the correct installation for EMC (such as shielding, grounding,
treatment of connectors and cable layout) can be found in this documentation.
The machine/plant manufacturer must check whether other standards or EC
Directives must be applied to the machine/plant.
2.4 CE - conformance
Conformance with the EC EMC Directive (89/336/EEC) and the Low Voltage Directive (73/23/EEC)
is mandatory for the supply of servo amplifiers within the European Community. Product standard
EN 61800-3 is applied to ensure conformance with the EMC Directive. The Declaration of Confor
mity form can be found on our website (download area).
Concerning noise immunity the servo amplifier meets the requirements to the 2nd environmental
category (industrial environment). For noise emission the amplifier meets the requirement to a pro
duct of the category C2 (motor cable £ 25m).
Warning! This product can cause high-frequency interferences in non industrial
environments which can require measures for interference suppression.
With a motor cable length from 25m onwards, the servo amplifier meets the requirement to the
category C3.
The servo amplifiers have been tested in a defined configuration, using the system components that
are described in this documentation. Any divergence from the configuration and installation descri
bed in this documentation means that you will be responsible for carrying out new measurements to
ensure conformance with regulatory requirements. The standard EN 50178 is applied to ensure
conformance with the Low Voltage Directive.
-
-
-
AX2040/2070 Installation Manual 11
Technical Description
02/06 Beckhoff
2.5 UL and cUL- Conformance
This servo amplifier is listed under UL file number E217428.
UL (cUL)-certified servo amplifiers (Underwriters Laboratories Inc.) fulfill the relevant U.S. and
Canadian standard (in this case UL 840 and UL 508C).
This standard describes the fulfillment by design of minimum requirements for electrically operated
power conversion equipment, such as frequency converters and servo amplifiers, which is intended
to eliminate the risk of fire, electric shock, or injury to persons, being caused by such equipment.
The technical conformance with the U.S. and Canadian standard is determined by an independent
UL (cUL) inspector through the type testing and regular check-ups.
Apart from the notes on installation and safety in the documentation, the customer does not have to
observe any other points in direct connection with the UL (cUL)-certification of the equipment.
UL 508C
UL 508C describes the fulfillment by design of minimum requirements for electrically operated
power conversion equipment, such as frequency converters and servo amplifiers, which is intended
to eliminate the risk of fire being caused by such equipment.
UL 840
UL 840 describes the fulfillment by design of air and insulation creepage spacings for electrical
equipment and printed circuit boards.
12 AX2040/2070 Installation Manual
Beckhoff
2.6 Nameplate
The nameplate depicted below is attached to the side of the servo amplifier.
The information described0 below is printed in the individual fields.
02/06 Technical Description
Servo amplifier type
Eiserstr. 5
D-33415 Verl
Typenbezeichnung
Spannungsversorgung
Umgebungstemp.
Ambient temp.
Model Number
Power Supply
008102106842
max.
Electrical supply
ambient temperature
2.7 Instrument description
2.7.1 Package supplied
Installed load
Tel.: +49-(0)5246/963-0
Fax: +49-(0)5246/963-149
Ser.Nr
Nennstrom
Nom. Current
Output current
in S1 operation
Ser.No.
E217428
Bemerkung
Schutzart
5.76
CommentsSerial number
U
CUS
L
®
LISTED
IND. CONT. EQ.
1VD4
Comment
Encl.Rating
Enclosure Rating
When you order a AX2040/2070 series amplifier, you will receive:
— AX20xx
— mating connectors X3, X4
The mating SubD connectors are not part of the package!
— Assembly and Installation Instructions
— Online documentation on CD-ROM
— Setup software DRIVE.EXE on CD-ROM
Accessories:
— Mains filter 3EF (ð p.91) required
— Mains choke 3L (ð p.92) required
— Motor choke 3YLN (ð p.93) optional to reduce velocity ripple
— AC Servomotor (linear or rotary)
— motor cable as a cut-off length
— brake cable as a cut-off length
— feedback cable (pre-assembled) or
— external regen resistor BAS (ð p.90)
— communications cable to the PC (ð p.62) or Y-adapter (ð p.67) for parameter setting of up
— power cable, control cables, fieldbus cables (as lengths)
(must be ordered separately)
both feedback connectors separately, with feedback cable as length
to 6 servo amplifiers from one PC
- A.4.028.6/10
AX2040/2070 Installation Manual 13
Technical Description
02/06 Beckhoff
2.7.2 The digital servo amplifiers of the series AX2040/2070
Standard version
2 current ratings (40 A, 70 A)
l
wide range of rated voltage (3x208V
l
shield connection directly at the servo amplifier
l
two analog setpoint inputs
l
integrated CANopen (default 500 kBaud), for integration into CANbus systems and for
l
–10%
to 3x480V
setting parameters for several amplifiers via the PC-interface of one amplifier
integrated RS232, electrically isolated, integrated pulse-direction interface
l
-AS- built-in safety relay (personnel-safety starting lock-out), (ð p.25)
l
Slot for an expansion card
l
Power supply
With external mains filter and mains choke directly off grounded 3~ system,
l
230V
208V
-10%
-10%
... 480V
... 480V
+10%
+10%
,50Hz,
,60Hz,
+10%
)
TN-system, TT-system with earthed (grounded) neutral point, not more than 5000 rms sym
metrical amperes, 480VAC maximum; when protected by fuses type Fusetron FRS-R-80
(Class RK5), manufactured by Bussman, or equivalent 480VAC min
Connection to other mains supply networks only with insulating transformer ð p. 16
BB6 rectifier bridge, off 3-phase earthed (grounded) supply, integral inrush circuit
l
Fusing (e.g. fusible cutout) provided by the user
l
l
All shielding connections directly on the amplifier
l
Output stage: IGBT- module with isolated current measurement
l
Regen circuit: with dynamic distribution of the regen power between several
amplifiers on the same DC bus link circuit, external regen resistor
l
DC bus link voltage 260 — 900 VDC, can be switched in parallel
l
Interference suppression filter for the 24V aux. supply (to category C2) is integrated
External interference suppression filter for the supply input (to category C2)
required. External mains choke required.
Integrated safety
l
Safe electrical separation to EN 50178 between the power input / motor connections and the
signal electronics, provided by appropriate insulation/creepage distances and complete elec
trical isolation
l
Soft-start, overvoltage recognition, short-circuit protection, phase-failure monitoring
l
Temperature monitoring of servo amplifier and motor
(when using our motors with our pre-assembled cables)
-
-
Auxiliary supply voltage 24VDC
Electrically isolated, internal fusing, from an external 24VDC psu, e.g. with isolating transformer
14 AX2040/2070 Installation Manual
Beckhoff
02/06 Technical Description
Operation and parameter setting
With our user-friendly software for setup through the serial interface of a PC
l
Direct operation by means of two keys on the servo amplifier and a 3-character LED display
l
for status display in case of no PC available
Fully programmable via RS232 interface
l
Completely digital control
Digital current controller (space vector pulse-width modulation, 62.5 µs)
l
Freely programmable digital speed controller (62.5 µs or 250 µs)
l
Integral position controller with adaptation possibilities for customer needs (250 µs)
l
Pulse direction interface integrated for connection of a servomotor to a stepping motor
l
control
Evaluation of the resolver signals and sine-cosine signals of a high-resolution encoder
l
Encoder simulation (incremental or SSI)
l
Comfort functions
2 analog monitor outputs
l
4 programmable digital inputs (normally, two are defined as limit-switch inputs)
l
2 programmable digital outputs
l
Freely programmable combinations of all digital signals
l
Expansions
-I/O-14/08- expansion card, ð p. 74
l
l
PROFIBUS DP expansion card, ð p. 77
l
SERCOS expansion card, ð p. 78
l
DeviceNet expansion card, ð S. 80
l
EtherCat expansion card, ð S. 83
l
SynqNet expansion card, ð S. 84
l
-2CAN- Expansion module, separated connectors for CAN bus and RS232, ð p. 86
l
Third party expansion cards (ModBus, FireWire, LightBus etc. - contact distributors for furt
her information)
-
AX2040/2070 Installation Manual 15
Technical Description
02/06 Beckhoff
2.8 Connection to different mains supply networks
On this page you'll find all possible connection variations to different mains supply networks.
An isolating transformer is always required for 400...480V mains networks without
earth(ground) and for networks with asymmetrical earth(ground).
- A.4.038.1/12
AX20
208V with 60Hz only
230...480V with 50Hz or 60Hz
AX20
AX20
AX20
AX20
AX20
AX20
AX20
AX20
AX20
AX20
16 AX2040/2070 Installation Manual
Beckhoff
02/06 Technical Description
2.9 Components of a sero system
PC
Control / PLC
AX2040/2070
restart lock -AS-
24V-power
supply
Mains filter
Mains choke
Drive contactor
Fuses
Fuses
Regen resistor
Motor
Terminals
Cables drawn bold are shielded.
AX2040/2070 Installation Manual 17
Technical Description
2.10 Technical data
Rated data DIM AX2040 AX2070
Rated-supply voltage (grounded system)
Rated installed load for S1 operation kVA 30 50
Max. DC bus link voltage V= 900
Rated output current (rms value, ± 3%)
@ 230V Arms 40 85
@ 400V Arms 40 80
@ 480V Arms 40 70
Peak output current (max. ca. 5s, ± 3%)
@ 230V 80 160
@ 400V 80 160
@ 480V 80 140
Clock frequency of the output stage kHz 8
Technical data of the regen circuit — ð p.22
Overvoltage protection threshold V 450...900
Form factor of the output current
(at rated data and min. load inductance)
Bandwidth of subordinate current controller kHz > 1,2
Residual voltage drop at rated current V 5
Quiescent dissipation, output stage disabled W 40
Dissipation at rated current (incl. power
supply losses, without regen dissipation)
Inputs/Outputs
Setpoint 1/2, resolution 14bit/12bit V
Common-mode voltage max. V
Input resistance to AGND
Digital inputs
Digital outputs, open collector
BTB/RTO output, relay contacts
Aux. power supply, electrically isolated V 24 (-0% +15%)
without brake A 2
Aux. power supply, electrically isolated V 24 (-0% +15%)
with brake (consider voltage loss!) A 4
Max. output current, brake A 2
Connections
Control signals — Combicon 5,08 / 18 pole , 2,5mm²
Power signals — Terminals 10mm² — 50mm²
Resolver input — SubD 9pole (socket)
Sine-cosine encoder input — SubD 15pole (socket)
PC-interface, CAN — SubD 9pole (plug)
Encoder simulation, ROD (EEO) / SSI — SubD 9pole (plug)
Thermal control, Motor — min. 15VDC, 5mA
Mechanical
Weight kg 19,5 21
Height without shield sheet, w/o eyes (w. eyes) mm 345 (375)
Height with shield sheet, w/o eyes (w. eyes) mm 484 (495)
Width mm 250
Depth without connectors mm 300
Depth with connectors mm 325
02/06 Beckhoff
V~ 3 x 230V-10% ... 480V+10%, 50 Hz
V~ 3 x 208V-10% ... 480V+10%, 60 Hz
— 1.01
W 400 700
±10
±10
kW
V low 0...7 / high 12...36
mA 7
V max. 30
mA 10
V DC max. 30, AC max. 42
mA 500
20
18 AX2040/2070 Installation Manual
Beckhoff
2.10.1 Fusing
2.10.1.1 Internal fusing
Circuit Internal fuse
Auxiliary supply 24V 4 AT
Regen resistor electronic
2.10.1.2 External fusing
02/06 Technical Description
Fusible cutouts or similar
(Fuse UL time delay)
AC supply F
N1/2/3
Type of branch circuit fuses:
AX2040 AX2070
50 AT (FRx-50) * 80 AT (FRx-80) *
Class RK5, 480V min
Regen resistor F
* (x=SorS-Rfor480V applications x=NorN-Rfor230V applications ð p. 10)
Note: The AX2040/2070 drives are suitable for use on a circuit capable of delivering not more
than 5000rms symmetrical amperes, 480VAC max.
B1/2
KLM 20 KLM 30
2.10.2 Allowable ambient conditions, ventilation, mounting position
Storage temperature/humidity/duration
Transport temperature / humidity
Supply voltage tolerances
Input power (ð p.16)
Aux. power supply
Ambient temperature in operation
Humidity in operation
Site altitude
Pollution level Pollution level 2 to EN60204/EN50178 Enclosure protection IP 20 Mounting position Ventilation
Make sure that there is sufficient forced ventilation within the switchgear cabinet.
ð p.95
ð p.95
min 3x230V
min 3x208V
AC / max 3x 480V
-10%
AC / max 3x 480V
-10%
+10%
+10%
,50Hz
,60Hz
24 VDC (-0% +15%), check voltage drop
0to+45
o
C (32 to 113 °F) at rated data
+45 to +55°C (113 to 131 °F) with power derating
2.5% / K
rel. humidity 85%, no condensation
up to 1000m a.m.s.l. without restriction
1000...2500m a.m.s.l. with power derating 1.5%/100m
generally vertical. ð p.33
forced convection by built-in fans
AX2040/2070 Installation Manual 19
Technical Description
2.10.3 Conductor cross-sections
Observe the technical data for connection cables ð p. 40.
Following EN 60204 (for AWG: table 310-16 of the NEC 60°C or 75°C column), we recommend for
single-axis systems:
AC connection
DC bus link 25 mm² (2 awg), shielded for lengths > 20 cm, 600V,105°C (221°F)
Motor cables
Resolver, thermostat-motor
Encoder, thermostat-motor
Setpoints, monitors, AGND 0.25 mm² (22awg) twisted pairs, shielded
Control signals, BTB, DGND 0.5 mm² (20 awg)
Holding brake (motor)
+24 V / XGND max. 2.5 mm² (12 awg), check voltage drop
Regen resistor ð p.45, min. 10 mm² (6 awg), shielded, 1000V,105°C (221°F)
For multi-axis systems, please note the special operating conditions in your installation
25 mm² (2 awg), shielded between filter and amplifier, 600V,105°C
(221°F)
ð p.45, cross section see manual of the used motor series,
capacitance <250pF/m, 600V,105°C (221°F)
4x2x0.25 mm² (22awg) twisted pairs, shielded, max.100m,
capacitance <120pF/m
7x2x0,25 mm² (22awg) twisted pairs, shielded, max.50m,
capacitance <120pF/m
min. 1.5 mm² (14 awg), 600V,105°C (221°F), shielded,
check voltage drop
02/06 Beckhoff
2.10.4 Recommended torques
Connector Recommended torque
X3, X4 0.3 Nm(2.25 in lb)
X10 0,3 Nm (2.25 in lb)
X0 6...8 Nm (45... 60 in lb)
2.10.5 LED display
A 3-character LED display shows the amplifier status after switching on the 24V supply
(ð p.69). During operation and parameter setting of the amplifier via the keys on the front panel, the
parameter and function numbers (ð p.69) are displayed, as well as the numbers of any errors
which occur (ð p.70).
2.11 Grounding system
AGND — ground for analog inputs/outputs, internal analog/µC ground
DGND — ground for digital inputs/outputs, optically isolated
XGND — ground for external 24V aux. voltage, optically and inductively isolated
PGND — ground for encoder emulation, RS232, CAN, PROFIBUS, optically isolated
The potential isolation is shown in the block diagram (ð p. 14).
20 AX2040/2070 Installation Manual
Beckhoff
02/06 Technical Description
2.12 Control for motor holding brake
A 24V / max. 2A holding brake in the motor can be controlled directly by the servo amplifier.
Check voltage drop, measure the voltage at brake input and check brake function
(brake and no brake).
This function does not ensure personnel safety!
The brake function must be enabled through the BRAKE parameter (setting: WITH BRAKE). In the
diagram below you can see the time and functional relationships between the ENABLE signal,
speed setpoint, speed and braking force.
During the internal ENABLE delay time of 100ms the speed setpoint of the servo amplifier is
internally driven down a 10ms ramp to 0V. The brake output is switched on when 3% of the final
speed is reached.
The rise (tbrH) and fall (tbrL) times of the holding brake which is built into the motors are different
for the various types of motor (see motor manual). A description of the interface can be found on
page 45.
A safe (for personnel) operation of the holding brake requires an additional “make” (n.o.) contact in
the brake circuit and a suppressor device (varistor) for the brake.
Recommended brake circuit diagram :
- A.4.031.3/01, A.4.038.1/10
AX2040/2070
AX2040/2070 Installation Manual 21
Technical Description
2.13 Regen circuit
During braking with the aid of the motor, energy is fed back to the servo amplifier. This energy is
converted into heat in the regen resistor (ð p. 90). The regen resistor is switched into circuit by the
regen circuit. The regen circuit (thresholds) are adjusted to the supply voltage with the help of the
setup software.
Our customer service can help you with the calculation of the regen power which is required. A des
cription of the interface can be found on page 45.
Functional description:
1.- Individual amplifiers, not coupled through the DC bus link (DC+, DC-)
The circuit starts to respond at a DC bus link voltage of 400V, 720V or 840V (depending on the
supply voltage). If the energy which is fed back from the motor, as an average over time or
as a peak value, is higher than the preset regen power, then the servo amplifier will output
the status “regen power exceeded” and the regen circuit will be switched off. At the next
internal check of the DC bus link voltage (after a few ms) an overvoltage will be detected and
the servo amplifier will be switched off with the error message “Overvoltage F02” (ð p. 70).
The BTB/RTO contact (terminal X3/2,3) will be opened at the same time (ð p. 55).
2.- Several servo amplifiers coupled through the DC bus link circuit (DC+, DC-)
Thanks to the built-in regen circuit with its patented power distribution, several amplifiers
(even with different current ratings) can be operated off a common DC bus link. This is achieved
by an automatic adjustment of the regen thresholds (which vary, because of tolerances).
The regen energy is distributed equally among all the amplifiers. The combined power of
all the amplifiers is always available, as continuous or peak power. The switch-off takes
place as described under 1. (above) for the servo amplifier with the lowest switch-off
threshold (resulting from tolerances).
The RTO (BTB) contact of this amplifier (terminals X3/2,3) will be opened at the same time
(ð p. 55).
02/06 Beckhoff
-
Regen circuit: technical data AX
Supply voltage Rated data DIM 2040 2070
External regen resistor Ohm 15 10
Upper switch-on level of regen circuit V 400 - 430
3 x 230 V
Switch-off level of regen circuit V 380 - 410
Overvoltage F02 V 450
Continuous power of regen circuit (R
Pulse power, external (R
max. 1s) kW 10 16
Bext
) max. kW 6
Bext
External regen resistor Ohm 15 10
Upper switch-on level of regen circuit V 720 - 750
3 x 400 V
Switch-off level of regen circuit V 680 - 710
Overvoltage F02 V 800
Continuous power of regen circuit (R
Pulse power, external (R
max. 1s) kW 35 50
Bext
) max. kW 6
Bext
External regen resistor Ohm 15 10
Upper switch-on level of regen circuit V 840 - 870
3 x 480 V
Switch-off level of regen circuit V 800 - 830
Overvoltage F02 V 900
Continuous power of regen circuit (R
Pulse power, external (R
max. 1s) kW 45 70
Bext
) max. kW 6
Bext
22 AX2040/2070 Installation Manual
Beckhoff
02/06 Technical Description
2.14 Switch-on and switch-off behavior
The diagram below illustrates the correct functional sequence for switching the servo amplifier on
and off.
DC bus link
2.14.1 Stop function to EN 60204
If a fault occurs (ð p. 70) the output stage of the servo amplifier is switched off and the BTB/RTO
contact is opened. In addition, a global error signal can be given out at one of the digital outputs
(terminals X3/16 and X3/17) (see online help for the setup software). These signals can be used by
the higher-level control to finish the current PLC cycle or to shut down the drive (with additional
brake or similar.).
The built-in restart lock -AS- can be used to switch off the drive via a positive-action (approved by
Trade Liability Association) safety relay, so that personnel safety is ensured at the drive shaft
(ð p. 25).
Instruments which are equipped with a selected “Brake” function use a special sequence for swit
ching off the output stage (ð p. 21).
The Stop functions are defined in EN 60204 (VDE 0113), Para. 9.2.2, 9.2.5.3.
There are three categories of Stop functions:
Category 0: Shut down by immediately switching off the supply of energy to the
drive machinery (i.e an uncontrolled shut-down);
Category 1: A controlled shut-down, during which the supply of energy to the drive
machinery is maintained to perform the shut-down, and where the energy
supply is only interrupted when the shut-down has been completed;
Category 2: A controlled shut-down, where the supply of energy to the drive machinery
is maintained.
Every machine must be equipped with a Stop function to Category 0. Stop functions to Categories 1
and/or 2 must be provided if the safety or functional requirements of the machine make this neces
sary.
-
-
You can find additional information and implementation examples in our application note “Stop and
Emergency Stop functions".
- A.4.038.3/01
AX2040/2070 Installation Manual 23
Technical Description
02/06 Beckhoff
2.14.2 Emergency Stop strategies
The Emergency Stop function is defined in EN 60204 (VDE 0113), Para. 9.2.5.4.
Implementation of the Emergency Stop function :
You can find wiring recommendations in our application note
“Stop and Emergency Stop functions”
Category 0:
The controller is switched to “disable”, the electrical supply (208...480VAC) is disconnected.
The drive must be held by an electromagnetic holding device (brake).
In multiaxis systems with connected DC bus link bus (intermediate circuit) the motor cable
has to be disconnected by a changeover switch (contactor, e.g. Siemens 3RT1516-1BB40)
and short-circuited by resistors connected in a star configuration.
Category 1:
If hazardous conditions can result from an emergency stop switch-off with an unbraked
run-down, then the drive can be switched off by a controlled shut-down.
Stop Category 1 permits electromotive braking with a switch-off when zero speed has
been reached. Safe shut-down can be achieved, when the loss of the mains supply is not
rated as a fault and the control takes over the disabling of the servoamplifier.
In the normal situation, only the supply power is switched off in a safe manner.
The 24V auxiliary supply remains switched on.
24 AX2040/2070 Installation Manual
Beckhoff
02/06 Technical Description
2.15 Restart lock -AS-
2.15.1 Advantages of the restart lock
A frequently required application task is the protection of personnel against the restarting of drives.
This can not be achieved by an electronic inhibit, but must be implemented with mechanical ele
ments (positively driven relay contacts).
To get round this problem, up to now either the main contactor in the mains supply line was swit
ched off, or another contactor was used to disconnect the motor from the servo amplifier.
The disadvantages of this method are :
— the DC bus link has to be charged up again at restart
— wear on the contacts of the contactors, caused by switching under load
— extensive wiring required, with additional switching components
The restart lock -AS- avoids these disadvantages. A safety relay in the servo amplifier is activated
either by the PLC or manually. Positively driven contacts provide a safe disconnection of the ampli
fier, the setpoint input of the servo amplifier is inhibited, and a signal is sent to the safety circuit.
The suggested circuits (ð p. 28) fulfills safety category 1 (EN 954-1). You can fulfill safety
category 3, if you use a mains contactor with suited supervision.
Advantages of the restart lock -AS- :
— the DC bus link remains charged up, since the mains supply line remains active
— only low voltages are switched, so there is no contact wear
— very little wiring is required
— the functionality and the personnel safety when using the circuit recommendations in
this documentation have been approved by the Trade Liability Association.
-
-
-
2.15.2 Functional description
The connector (X10) is mounted on the front panel of the AX2040/2070.The coil connections and a
make (n.o.) contact of a safety relay are made available through 4 terminals on this connector.
The 24VDC safety relay in the servo amplifier (approved) is controlled externally. All the relay contacts have positive action.
Two contacts switch off the driver supply of the output stage in the servo amplifier, and short the
internal setpoint signal to AGND (0 V).
The make (n.o.) contact used for monitoring is looped into the control circuit.
If the safety relay is not energized, then the monitoring contact is open and the servo amplifier is
ready for operation.
If the drive is electronically braked, the servo amplifier is disabled and the motor-holding brake is
on, then the safety relay is energized (manually or by the controls).
The supply voltage for the driver circuit of the output stage is switched off in a safe manner, the
internal setpoint is shorted to 0V, and the monitoring contact bridges the safety logic in the control
circuit of the system (monitoring of protective doors etc.)
Even if the output stage or driver is destroyed, it is impossible to start the motor.
If the safety relay itself is faulty, then the monitoring contact cannot bridge the safety logic of the
system. Opening the protective devices will then switch off the system.
AX2040/2070 Installation Manual 25
Technical Description
2.15.3 Block diagram
02/06 Beckhoff
2.15.4 Signal diagram (sequence)
- A.4.031.1/32,30
26 AX2040/2070 Installation Manual
Beckhoff
2.15.5 Installation / Setup
2.15.5.1 Safety instructions
Observe the prescribed use of the restart lock -AS- (ð p. 10)
l
The monitoring contacts (KSO1/2) for each amplifier must be looped into the control
l
circuit. This is vital, so that a malfunction of the internal safety relay or a cable break
can be recognized.
If the restart lock -AS- is automatically activated by a control system (KSI1/2), then
l
make sure that the output of the control is monitored for possible malfunction. This
can be used to prevent a faulty output from activating the restart lock -AS- while the
motor is running.
Keep to the following functional sequence when the restart lock -AS- is used :
l
1. Brake the drive in a controlled manner (speed setpoint = 0V)
2. When speed = 0 rpm, disable the servo amplifier (enable = 0V)
3. If there is a suspended load, block the drive mechanically
4. Activate the restart lock -AS-
2.15.5.2 Functional test
02/06 Technical Description
The functioning of the restart lock must be tested during setup, after every alteration in the wiring of
the system, or after exchanging one or more components of the system.
1. Stop all drives, with setpoint 0V, disable drives,
mechanically block any suspended loads
2. Activate the restart lock -AS-.
3. Open protective screens (but do not enter hazardous area)
4. Pull off the X10 connector from an amplifier: the mains contactor must drop out
5. Reconnect X10. Switch on mains contactor again.
6. Repeat steps 4 and 5 for each individual servo amplifier.
2.15.5.3 Connection diagram
AX2040/2070
- A.4.031.1/30
AX2040/2070 Installation Manual 27
Technical Description
02/06 Beckhoff
2.15.6 Application examples
2.15.6.1 Moving single axis-groups in setting-up operation
In setting-up operation, people will frequently be within the danger zone of the machinery. Axes will
normally be moved under the control of permission switches. An additional switch-off of the unused
axes, by means of the restart lock, increases the safety margin and avoids the repeated switching
of main contactors or motor contactors.
2.15.6.2 Switching off grouped axes with separate working areas
Even when several AX2040/2070 are operating off a common mains supply and DC bus link, it is
possible to set up groups for separate working areas. These groups can then be switched off sepa
rately for personnel safety. For this purpose, we have provided you with a suggested circuit (mains
supply circuit and control circuit for 2 separate working groups which have interconnected DC bus
links and a common mains supply voltage).
2.15.6.2.1 Control circuit
The suggested circuit fulfills safety category 1 (EN 954-1). You can fulfill safety category 3, if you
use a mains contactor with suited supervision.
- A.4.031.1/31
-
28 AX2040/2070 Installation Manual
Beckhoff
2.15.6.2.2 Mains supply circuit
02/06 Technical Description
- A.4.031.3/05
AX20
AX20 AX20 AX20 AX20
AX2040/2070 Installation Manual 29
Technical Description
02/06 Beckhoff
This page has been deliberately left blank.
30 AX2040/2070 Installation Manual
Loading...