Beckhoff AX2070, AX2040 Assembly, Installation, Setup

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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 06/2007

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) Part number scheme new, shock-hazard protection new, servo system graphics / different mains supply

06/07

networks expanded&removed, feedback expanded, enc. emulation, switch-on and switch-off behavior ex panded, AS expanded, accessories removed, DC Bus link expanded, timing diagramm motor brake, dispo sal acc. to WEEE-2002/96/EG, new structure, SynqNet removed, Quickstart integrated, warnings updated

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

06/2007 Contents

1 General

1.1 About this manual ....................................................................... 7

1.2 Hints for the online edition (PDF format) ...................................................... 7

1.3 Symbols used........................................................................... 7

1.4 Abbreviations used....................................................................... 8

2 Safety

2.1 Safety Instructions ....................................................................... 9

2.2 Use as directed ........................................................................ 10

3 Standards

3.1 European directives and standards ......................................................... 11

3.2 American Directives and Standards......................................................... 11

3.3 Asian Directives and Standards ............................................................ 11

3.4 Approvals ............................................................................. 12

3.4.1 CE - conformance ................................................................. 12

3.4.2 UL and cUL- Conformance .......................................................... 12

4 Handling

4.1 Transport ............................................................................. 13

4.2 Packaging ............................................................................ 13

4.3 Storage .............................................................................. 13

4.4 Maintenance........................................................................... 13

4.5 Disposal .............................................................................. 13

5 Package

5.1 Package supplied....................................................................... 14

5.2 Nameplate ............................................................................ 14

5.3 Part number scheme .................................................................... 15

6 Technical description

6.1 The digital servo amplifiers of the series AX2040/2070 .......................................... 16

6.2 Technical data ......................................................................... 18

6.2.1 Recommended torques ............................................................. 19

6.2.2 Fusing .......................................................................... 19

6.2.3 Ambient conditions, ventilation, mounting position......................................... 19

6.2.4 Conductor cross-sections............................................................ 20

6.3 LED display ........................................................................... 20

6.4 Grounding system ...................................................................... 20

6.5 Control for motor holding brake ............................................................ 21

6.6 Regen circuit .......................................................................... 22

6.7 Switch-on and switch-off behavior .......................................................... 23

6.7.1 Behavior in standard operation ....................................................... 24

6.7.2 Behavior in the event of an error (with standard setting) .................................... 25

6.8 Stop/Emergency Stop Function to EN 60204.................................................. 26

6.8.1 Stop: Standards ................................................................... 26

6.8.2 Emergency Stop: Standards ......................................................... 27

6.8.3 Implementation of the Stop Category 0 ................................................. 28

6.8.4 Implementation of the Stop Category 1 ................................................. 29

6.8.5 Implementation of the Stop Category 2 ................................................. 30

6.9 Shock-hazard protection ................................................................. 31

6.9.1 Leakage current ................................................................... 31

6.9.2 Residual-current circuit breakers (FI)................................................... 31

6.9.3 Isolating transformers .............................................................. 32

Page

AX2040/2070 Product Manual 3

Contents

06/2007 BECKHOFF

7 Mechanical Installation

7.1 Important notes ........................................................................ 33

7.2 Guide to mechanical installation............................................................ 33

7.3 Assembly ............................................................................. 34

7.4 Dimensions ........................................................................... 35

8 Electrical Installation

8.1 Important Notes ........................................................................ 37

8.2 Guide to electrical installation.............................................................. 38

8.3 Wiring................................................................................ 39

8.3.1 Important notes ................................................................... 39

8.3.2 Shielding connection to the front panel ................................................. 40

8.3.3 Technical data for cables ............................................................ 41

8.4 Components of a servo system ............................................................ 42

8.5 Block diagram ......................................................................... 43

8.6 Pin assignments........................................................................ 44

8.7 Connection diagram (overview) ............................................................ 45

8.8 Power supply .......................................................................... 46

8.8.1 Connection to various mains supply networks ............................................ 46

8.8.2 Mains supply connection (X0) ........................................................ 47

8.8.3 24V auxiliary supply (X4) ............................................................ 47

8.8.4 DC bus link (X0)................................................................... 47

8.9 Motor connection with brake (X0, X4) ....................................................... 48

8.10 External regen resistor (X0) ............................................................... 48

8.11 Feedback ............................................................................. 49

8.11.1 Resolver (X2) ..................................................................... 50

8.11.2 Sine encoder with BISS (X1) ......................................................... 51

8.11.3 Sine Encoder with EnDat 2.1 or HIPERFACE (X1) ........................................ 52

8.11.4 Sine Encoder without data channel (X1) ................................................ 53

8.11.5 Incremental or sine encoder with hall sensors (X1) ........................................ 54

8.11.6 Incremental Encoder (X5) ........................................................... 55

8.12 Electronic Gearing, Master-slave operation ................................................... 56

8.12.1 Connection to a AX20 master, 5 V signal level (X5)........................................ 57

8.12.2 Connection to incremental encoder master with 24 V signal level (X3) .........................57

8.12.3 Connection to a sine-cosine encoder master (X1) ......................................... 58

8.12.4 Connection to a SSI encoder (X5) ..................................................... 59

8.12.5 Connection to stepper-motor controllers (step and direction)................................. 59

8.12.5.1 Step/Direction with 5 V signal level (X5) ............................................. 60

8.12.5.2 Step/Direction with 24 V signal level (X3) ............................................ 60

8.13 Encoder emulations ..................................................................... 61

8.13.1 Incremental encoder output - A quad B (X5) ............................................. 61

8.13.2 SSI output (X5) ................................................................... 62

8.14 Digital and analog inputs and outputs ....................................................... 63

8.14.1 Analog inputs (X3) ................................................................. 63

8.14.2 Analog outputs (X3) ................................................................ 64

8.14.3 Digital inputs (X3).................................................................. 65

8.14.4 Digital outputs (X3) ................................................................ 66

8.15 RS232 interface, PC connection (X6) ....................................................... 67

8.16 CANopen interface (X6) .................................................................. 68

8.17 Restart lock -AS- ....................................................................... 69

8.17.1 Safety instructions ................................................................. 69

8.17.2 Use as directed ................................................................... 70

8.17.3 Block diagram .................................................................... 70

8.17.4 Functional description .............................................................. 71

8.17.5 Signal diagram (sequence) .......................................................... 71

8.17.6 Functional test .................................................................... 72

8.17.7 Connection diagram (principle) ....................................................... 72

8.17.8 Application example category 1 according to EN 954-1..................................... 73

8.17.8.1 Control circuit ................................................................. 73

8.17.8.2 Mains supply circuit............................................................. 73

8.17.9 Application example category 3 according to EN 954-1..................................... 74

Page

4 AX2040/2070 Product Manual

BECKHOFF

06/2007 Contents

9Setup

9.1 Important notes ........................................................................ 75

9.2 Setup software ......................................................................... 76

9.2.1 General ......................................................................... 76

9.2.1.1 Use as directed ................................................................ 76

9.2.1.2 Software description ............................................................ 76

9.2.1.3 Hardware requirements.......................................................... 77

9.2.1.4 Operating systems ............................................................. 77

9.2.2 Installation under WINDOWS 95 / 98 / 2000 / ME / NT / XP ................................. 77

9.3 Quickstart Guide ....................................................................... 78

9.3.1 Preparation ...................................................................... 78

9.3.1.1 Unpacking, Mounting and Wiring the Servo Amplifier ...................................78

9.3.1.2 Documents ................................................................... 78

9.3.1.3 Minimum Wiring for Drive Test .................................................... 79

9.3.2 Connect ......................................................................... 80

9.3.3 Important Screen Elements .......................................................... 81

9.3.4 Basic Setup ...................................................................... 82

9.3.5 Motor (synchronous) ............................................................... 83

9.3.6 Feedback ........................................................................ 84

9.3.7 Save Parameters and Restart ........................................................ 85

9.3.8 Jogging the Motor (Speed Control) .................................................... 86

9.3.9 Status........................................................................... 87

9.3.10 Monitor.......................................................................... 87

9.3.11 Additional Setup Parameters ......................................................... 87

9.4 Multi-axis system ....................................................................... 88

9.4.1 Node address for CAN-bus .......................................................... 88

9.4.2 Baud rate for CAN-bus.............................................................. 88

9.4.3 Example of connections for a multi-axis system........................................... 89

9.5 Key operation / LED display............................................................... 90

9.5.1 Key operation..................................................................... 90

9.5.2 Status display..................................................................... 90

9.5.3 Standard menu structure ............................................................ 91

9.5.4 Extended menu structure............................................................ 91

9.6 Error messages ........................................................................ 92

9.7 Warning messages ..................................................................... 93

9.8 Removing faults / warnings ............................................................... 94

Page

AX2040/2070 Product Manual 5

Contents

06/2007 BECKHOFF

10 Expansion Cards

10.1 Guide to installation of expansion cards...................................................... 95

10.2 Expansion card -I/O-14/08- ............................................................... 96

10.2.1 Front view ....................................................................... 96

10.2.2 Technical data .................................................................... 96

10.2.3 Light emitting diodes (LEDs) ......................................................... 96

10.2.4 Select motion task number (sample) ................................................... 96

10.2.5 Connector assignments ............................................................. 97

10.2.6 Connection diagram................................................................ 98

10.3 Expansion cards -PROFIBUS-............................................................. 99

10.3.1 Front view ....................................................................... 99

10.3.2 Connection technology.............................................................. 99

10.3.3 Connection diagram................................................................ 99

10.4 Expansion card -SERCOS- .............................................................. 100

10.4.1 Front view ...................................................................... 100

10.4.2 Light emitting diodes (LEDs) ........................................................ 100

10.4.3 Connection technology............................................................. 100

10.4.4 Connection diagram............................................................... 101

10.4.5 Modifying the station address ....................................................... 101

10.4.6 Modifying the baud rate and optical power.............................................. 101

10.5 Expansion card -DEVICENET-............................................................ 102

10.5.1 Front view ...................................................................... 102

10.5.2 Connection technology............................................................. 102

10.5.3 Connection diagram............................................................... 102

10.5.4 Combined module/network status-LED ................................................ 103

10.5.5 Setting the station address (device address) ............................................ 103

10.5.6 Setting the transmission speed ...................................................... 103

10.5.7 Bus cable ....................................................................... 104

10.6 Expansion card -ETHERCAT- ............................................................ 105

10.6.1 Front view ...................................................................... 105

10.6.2 LEDs .......................................................................... 105

10.6.3 Connection diagram............................................................... 105

10.7 Expansion module -2CAN-............................................................... 106

10.7.1 Installation ...................................................................... 106

10.7.2 Front View ...................................................................... 106

10.7.3 Connection technology............................................................. 106

10.7.4 Connector assignments ............................................................ 107

10.7.5 Connection diagram............................................................... 107

11 Appendix

11.1 Glossary............................................................................. 109

11.2 Index ............................................................................... 111

Page

6 AX2040/2070 Product Manual

BECKHOFF

1 General

1.1 About this manual

This manual describes the digital servo amplifiers of the AX2040/2070 series (standard version).

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, Acrobat Reader) 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.

This manual makes the following demands on qualified personnel : Transport : only by personnel with knowledge in handling electrostatically

sensitive components. Unpacking: only by electrically qualified personnel. Installation : only by electrically qualified personnel Setup : only by personnel with extensive knowledge of electrical

engineering / drive technology

06/2007 General

1.2 Hints for the online edition (PDF format)

Bookmark:

Table of contents and index are active bookmarks.

Table of contents and index in the text:

The lines are active cross references. Click on the desired line and the appropriate page is indicated.

Page/chapter numbers in the text:

Page/chapter numbers with cross references are active. Click at the page/chapter number to reach the indicated target.

1.3 Symbols used

ð p.

Danger to personnel from electricity and its effects effects

see page l special emphasis

Danger to maschinery, general warning

Important no tes

AX2040/2070 Product Manual 7

General

1.4 Abbreviations used

The abbreviations used in this manual are explained in the table below.

Abbreviation 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

Bext

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

06/2007 BECKHOFF

8 AX2040/2070 Product Manual

BECKHOFF

2 Safety

2.1 Safety Instructions

Only properly qualified personnel are permitted to perform activities such as trans

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 60364 or DIN VDE 0100 IEC 60664 or DIN VDE 0110 national accident prevention regulations or BGV A3

06/2007 Safety

Read this documentation before carrying out installation and setup. Incorrect hand

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

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 produce a hazard analysis for the machine

and take appropriate measures to ensure that unforeseen movements do not result in personal injury or material damage.

l Do not open or touch the equipment during operation. Keep all covers and cabinet

doors closed during operation. Touching the equipment is allowed during installation and commissioning for properly qualified persons only. Otherwise, there are deadly hazards, with the possibility of death, severe injury or material damage. — During operation, servo amplifiers may have uncovered live

components, depending on their level of enclosure protection.

— Control and power connections may be live, even though the

motor is not rotating.

— Servo amplifiers may have hot surfaces during operation.

Surface can reach temperatures above 80°C.

Never undo any electrical connections to the servo amplifier while it is live. There is a danger of electrical arcing with damage to contacts and personal injury. Wait at least five minutes after disconnecting the servo amplifier from the main supply power before touching potentially live sections of the equipment (e.g. con tacts) or undoing any connections. Capacitors can still have dangerous voltages pre sent up to five minutes after switching off the supply power. To be sure, measure the voltage in the DC Bus link and wait until it has fallen below 40V.

Safety instructions

AX2040/2070 Product Manual 9

Safety

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 unforeseen movements cannot cause injury or damage to any person or property.

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 earthed(grounded) neutral point, not more than 5000rms symmetrical amperes, 480VAC maximum] when protected by fuses type Fusetron FRS-R-50 for AX20 640 or FRS-R-80 class RK5 for AX20 670, manufactured by Bussman, or equivalent, 480VAC min.

The use of external mains chokes and mains filters is required.

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. 46.

Periodic overvoltages between outer conductor (L1, L2, L3) and housing of the servo ampli

fier 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

06/2007 BECKHOFF

The AX2040/2070 family of servo amplifiers is only intended to drive specific brushless syn-

chronous 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 34. 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.

Consider the specifications on page 70 when you use the personnel safe restart lock -AS-.

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06/2007 Standards

3 Standards

3.1 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 12100 (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.

3.2 American Directives and Standards

Chapter in process

3.3 Asian Directives and Standards

Chapter in process

AX2040/2070 Product Manual 11

Standards

3.4 Approvals

3.4.1 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).

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.

06/2007 BECKHOFF

3.4.2 UL and cUL- Conformance

This servo amplifier is listed under UL file number E195162.

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 Product Manual

BECKHOFF

4 Handling

4.1 Transport

Only by qualified personnel in the manufacturer’s original recyclable packaging

Avoid shocks

Temperature –25 to +70°C (-13...158°F), max. 20K/hr rate of change

Humidity max. 95% relative humidity, no condensation

The servo amplifiers contain electrostatically sensitive components which can be

damaged by incorrect handling. Discharge yourself before touching the servo ampli fier. Avoid contact with highly insulating materials (artificial fabrics, plastic films etc.). Place the servo amplifier on a conductive surface.

If the packaging is damaged, check the unit for visible damage. In this case, inform the ship

per and the manufacturer.

4.2 Packaging

Cardboard box, can be recycled

Dimensions: (HxWxD) 410x470x490 mm

06/2007 Handling

Weight incl. accessories approx. ca. 25 Kg

Labeling : nameplate outside at the box

4.3 Storage

Storage only in the manufacturer’s original recyclable packaging

Max. stacking height 3 cartons

Storage temperature -25 to +55°C, max. rate of change 20°C / hour

Storage humidity 5 ... 95% relative humidity, no condensation

Storage duration Less than 1 year without restriction. More than 1 year: capacitors must be re-formed before setting up and operating the servo amplifier. To do this, remove all electrical connections and apply single-phase 230V AC for about 30 minutes to the terminals L1 / L2.

4.4 Maintenance

The instruments do not require any maintenance, opening the instruments invalidates the warranty.

Cleaning : — if the casing is dirty: clean with Isopropanol or similar

— if there is dirt inside the unit it must be cleaned by the manufacturer — dirty protective grill on fan must be cleaned with a dry brush

do not immerse or spray

4.5 Disposal

In accordance to the WEEE-2002/96/EG-Guidelines we take old devices and accessories back for professional disposal, if the transport costs are taken over by the sender. Send the devices to:

Beckhoff Automation GmbH

Eiserstr. 5

D-33415 Verl

AX2040/2070 Product Manual 13

Package

5 Package

5.1 Package supplied

When you order a AX2040/2070 series amplifier, you will receive:

— AX2040/2070 — mating connectors X3, X4

The mating SubD connectors are not part of the package!

— Online documentation on CD-ROM — Setup software DRIVE.EXE on CD-ROM

06/2007 BECKHOFF

Accessories:

— Mains filter 3EF required — Mains choke 3L required — AC Servomotor (linear or rotary) — motor cable as a cut-off length — brake cable as a cut-off length — feedback cable (pre-assembled) or

both feedback connectors separately, with feedback cable as length

— external regen resistor BAS, usually required — communications cable to the PC (ð p.67) or Y-adapter (ð p.88) for parameter setting of up

to 6 servo amplifiers from one PC

— power cable, control cables, fieldbus cables (as lengths)

5.2 Nameplate

The nameplate depicted below is attached to the side of the servo amplifier. The information described0 below is printed in the individual fields.

Servo amplifier type

Typenbezeichnung

(must be ordered separately)

Eiserstr. 5 D-33415 Verl

Model Number

Expansions, optionsSerial number

Tel.: +49-(0)5246/963-0 Fax: +49-(0)5246/963-149

Ser.Nr

Ser.No.

E195162

Bemerkung

Enclosure Rating

CUS

LISTED

IND. CONT. EQ.

1VD4

Comment

Spannungsversorgung

Umgebungstemp. Ambient temp.

008102106842

max. ambient

temperature

Power Supply

Nennstrom

Electrical supply

Installed load

Nom. Current

Output current

in S1 operation

Schutzart

5.76

Encl.Rating

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5.3 Part number scheme

06/2007 Package

AX20 400 1 - 0000

Family

AX20 AX2000

Current rating

40 40A rms 70 70A rms

Voltage rating

0 230...480V

Expansions

0000 no expansion B110 ETHERCAT B200 Lightbus B310 PROFIBUS B520 DeviceNet B750 SERCOS B900 Ethernet IO01 I/O-Expansion

electr. option

1AS

AX2040/2070 Product Manual 15

Technical description

06/2007 BECKHOFF

6 Technical description

6.1 The digital servo amplifiers of the series AX2040/2070

Standard version

2 current ratings (40 A, 70 A)

wide range of rated voltage (3x208V

shield connection directly at the servo amplifier

integrated CANopen (default 500 kBaud), for integration into CANbus systems and for

–10%

to 3x480V

setting parameters for several amplifiers via the PC-interface of one amplifier

integrated RS232, electrically isolated, integrated pulse-direction interface

-AS- built-in safety relay (personnel-safety starting lock-out), (ð p.69)

Slot for an expansion card

Synchronous servomotors, linear motors and asynchronous motors can be used

Power supply

With external mains filter and mains choke directly off grounded 3~ system,

230V 208V

-10%

... 480V ... 480V

+10%

,50Hz, ,60Hz,

+10%

)

TN-system, TT-system with earthed (grounded) neutral point, not more than 5000 rms symmetrical 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. 46

BB6 rectifier bridge, off 3-phase earthed (grounded) supply, integral inrush circuit

Fusing (e.g. fusible cutout) provided by the user

All shielding connections directly on the amplifier

Output stage: IGBT- module with isolated current measurement

Regen circuit: with dynamic distribution of the regen power between several

amplifiers on the same DC bus link circuit, external regen resistor

DC bus link voltage 260 ... 900 VDC, can be switched in parallel

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

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

Soft-start, overvoltage recognition, short-circuit protection, phase-failure monitoring

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 transfor mer

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06/2007 Technical description

Operation and parameter setting

With our user-friendly software for setup through the serial interface of a PC

Direct operation by means of two keys on the servo amplifier and a 3-character LED display

for status display in case of no PC available

Fully programmable via RS232 interface

Completely digital control

Digital current controller (space vector pulse-width modulation, 62.5 µs)

Freely programmable digital speed controller (62.5 µs or 250 µs)

Integral position controller with adaptation possibilities for customer needs (250 µs)

Pulse direction interface integrated for connection of a servomotor to a stepping motor

control

Evaluation of the resolver signals and sine-cosine signals of a high-resolution encoder

Encoder simulation (incremental or SSI)

Comfort functions

2 analog monitor outputs

4 programmable digital inputs (normally, two are defined as limit-switch inputs)

2 programmable digital outputs

Freely programmable combinations of all digital signals

Expansions

-I/O-14/08- expansion card, ð p. 96

PROFIBUS DP expansion card, ð p. 99

SERCOS expansion card, ð p. 100

DeviceNet expansion card, ð p. 102

EtherCat expansion card, ð p. 105

-2CAN- Expansion module, separated connectors for CAN bus and RS232, ð p. 106

AX2040/2070 Product Manual 17

Technical description

6.2 Technical data

Rated data DIM AX2040 AX2070

Rated-supply voltage (grounded system)

Rated installed load for S1 operation kVA 30 50 Rated DC bus link voltage V= 290...675 Rated output current (rms value, ± 3%)

at 230V Arms 40 85 at 400V Arms 40 80 at 480V Arms 40 70

Peak output current (max. ca. 5s, ± 3%)

at 230V 80 160 at 400V 80 160

at 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 (max. 16) Aux. power supply, electrically isolated V 24 (-0% +15%) with brake (consider voltage loss!) A 5 (max. 16) Min/max. output current, brake A 0.75 / 3

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

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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

V low 0...7 / high 12...36

mA 7

V max. 30

mA 10

V DC max. 30, AC max. 42

mA 500

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6.2.1 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)

6.2.2 Fusing

Internal fusing

Circuit Internal fuse

Auxiliary supply 24V 4 AT Regen resistor electronic

External fusing

Fusible cutouts or similar (Fuse UL time delay)

AC supply F

Type of branch circuit fuses:

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.

N1/2/3

B1/2

06/2007 Technical description

AX2040 AX2070

50 AT (FRx-50) * 80 AT (FRx-80) *

KLM 20 KLM 30

6.2.3 Ambient conditions, ventilation, mounting position

Storage, hints Transport, hints Supply voltage tolerances

Input power (ð p.46)

Aux. power supply

Ambient temperature in operation

Humidity in operation

Site altitude

Pollution level Pollution level 2 to EN60204/EN50178 Vibrations Noise emission Enclosure protection IP 20 Mounting position Ventilation

Make sure that there is sufficient forced ventilation within the switchgear cabinet.

ð p.13 ð p.13

min 3x230V min 3x208V

AC / max 3x 480V

-10%

AC / max 3x 480V

-10%

24 VDC (-0% +15%), check voltage drop 0to+45

C (32 to 113 °F) at rated data

+45 to +55°C (113 to 131 °F) with power derating

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

Class 3111 according to IEC 721-3-3 max. 45 dB(A)

generally vertical. ð p.34 forced convection by built-in fans

+10%

,50Hz

+10%

,60Hz

2.5% / K

AX2040/2070 Product Manual 19

Technical description

6.2.4 Conductor cross-sections

Observe the technical data for connection cables ð p. 41. 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 Regen resistor ð p.41, min. 10 mm² (6 awg), shielded, 1000V,105°C (221°F)

For multi-axis systems, please note the special operating conditions in your installation To reach the max. permitted cable length, observe cable requirements ð p. 41.

25 mm² (2 awg), shielded between filter and amplifier, 600V,105°C (221°F)

ð p.41, 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 max. 2.5 mm² (12 awg), check voltage drop

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6.3 LED display

A 3-character LED display shows the amplifier status after switching on the 24V supply (ð p.91). During operation and parameter setting of the amplifier via the keys on the front panel, the parameter and function numbers (ð p.91) are displayed, as well as the numbers of any errors which occur (ð p.92).

6.4 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. 43).

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06/2007 Technical description

6.5 Control for motor holding brake

A 24 V / max. 3 A 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 100 ms (DECDIS) the speed setpoint of the servo ampli fier is internally driven down a 10 ms ramp to 0. The brake output is switched on when a speed of 5rpm is reached or after 5s (EMRGTO) the latest.

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 48.

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 :

AX2040/2070

AX2040/2070 Product Manual 21

Technical description

6.6 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. ). 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 48.

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. 92). The BTB/RTO contact (terminal X3/2,3) will be opened at the same time (ð p. 66).

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 auto matic 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. 66).

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Regen circuit: technical data

Supply voltage Rated data DIM AX2040 AX2070

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

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06/2007 Technical description

6.7 Switch-on and switch-off behavior

This chapter describes the switch-on and switch-off behavior of the AX2040/2070 and the steps required to achieve operational stopping or emergency stop behavior that complies with standards.

The servo amplifier’s 24 V supply must remain constant. The ASCII commands ACTFAULT (error response) and STOPMODE (ENABLE signal response) dictate how the drive will behave.

STOPMODE ACTFAULT

0 (default) 0

1 1 (default)

Behavior during a power failure

The servo amplifiers use an integrated circuit to detect if one or more input phases (power supply feed) fail. The behavior of the servo amplifier is set using the setup software: Under “Response to

Loss of Input Phase” (PMODE) on the Basic Setup screen, select:

Warning if the higher-level control system is to bring the drive to a standstill: Warning n05 is

output if an input phase is missing, and the motor current is limited to 4 A. The servo ampli fier is not disabled. The higher-level control system can now selectively end the current cycle or start bringing the drive to a standstill. Therefore, the error message “MAINS BTB, F16" is output on a digital output of the servo amplifier and evaluated by the control system, for ins tance.

Error message if the servo amplifier is to bring the drive to a standstill: Error message F19

is output if an input phase is missing. The servo amplifier is disabled and the BTB contact opens. Where the factory setting is unchanged (ACTFAULT=1), the motor is braked using the set “EMERGENCY STOP RAMP”.

Behavior when undervoltage threshold is reached

If the undervoltage threshold is undershot in the DC bus link (the threshold value depends on the type of servo amplifier), the error message “UNDERVOLTAGE, F05" is displayed. The drive response depends on the ACTFAULT/STOPMODE setting.

Behavior (see also ASCII reference in the online help of the se tup software) Motor coasts to a standstill in an uncontrolled manner Motor is braked in a controlled manner

Behavior with enabled “holding brake” function

Servo amplifiers with an enabled holding brake function have a special procedure for switching off the output stage ( ð p. 21). Removing the ENABLE signal triggers electrical braking. As with all electronic circuits, the general rule applies that there is a possibility of the internal “holding brake” module failing. Bringing a motor to a standstill using a holding brake in a way that is personnel safe also requires an electromechanical “make” contact for the holding equipment and a suppressor device for the brake.

Behavior of the restart lock -AS-

With the personnel safe restart lock –AS-, the drive can be secured on standstill using its internal electronics so that even when power is being supplied, the drive shaft is protected against uninten tional restart. The chapter “Personnel safe restart lock -AS-” describes how to use the restart lock –AS-. See page 69 onwards.

AX2040/2070 Product Manual 23

Technical description

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6.7.1 Behavior in standard operation

The behavior of the servo amplifier always depends on the current setting of a number of different parameters (e.g., ACTFAULT, VBUSMIN, VELO, STOPMODE, etc.; see online help). The diagram below illustrates the correct functional sequence for switching the servo amplifier on and off.

DC bus link

Motor speed

Power stage Enable (internal)

Devices which are equipped with a selected “Brake” function use a special sequence for switching off the output stage (ð p. 21).

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. 69).

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06/2007 Technical description

6.7.2 Behavior in the event of an error (with standard setting)

The behavior of the servo amplifier always depends on the current setting of a number of different parameters (e.g., ACTFAULT, VBUSMIN, VELO, STOPMODE, etc.; see online help). The diagram shows the startup procedure and the procedure that the internal control system follows in the event of one or more electrical supply phases failing, assuming that the standard parameter settings apply.

(F16/F19 = error messages Mains BTB /input phase, F05 = error message Undervoltage)

Even if there is no intervention from an external control system (in the example, the ENABLE signal remains active), the motor is immediately braked using the emergency stop ramp if an input phase error is detected and assuming that no changes have been made to the factory setting (ACT FAULT=1).

AX2040/2070 Product Manual 25

Technical description

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6.8 Stop/Emergency Stop Function to EN 60204

With the personnel safe restart lock –AS- (see page 69 onwards) the drive can be secured on standstill (torque-free) using its internal electronics so that even when power is being supplied, the drive shaft is protected against unintentional restart.

6.8.1 Stop: Standards

The Stop function is used to shut down the machine in normal operation. The Stop functions are defined by EN 60204 (VDE 0113), paragraphs 9.2.2 and 9.2.5.3.

Category 0: Shut-down by immediate switching-off of the energy supply to the

drive machinery (i.e. an uncontrolled shut-down);

Category 1: A controlled shut-down , whereby the energy supply to the drive

machinery is maintained to perform the shut-down, and the energy supply is only interrupted when the shut-down has been completed;

Category 2: A controlled shut-down, whereby the energy supply to the drive

machinery is maintained.

The parameters “STOPMODE” and “ACTFAULT” must be set to 1 in order to implement the stop categories. If necessary, change the parameters via the terminal screen of the setup software and store the data in the EEPROM.

The Stop Category must be determined by a risk evaluation of the machine. In addition, suitable means must be provided to guarantee a reliable shut-down.

Category 0 and Category 1 Stops must be operable independently of the operating mode, whereby a Category 0 Stop must have priority. Stop functions must be implemented by disconnection of the appropriate circuitry, and have priority over assigned start functions.

If necessary, provision must be made for the connection of protective devices and lock-outs. If applicable, the Stop function must signal its status to the control logic. A reset of the Stop function must not create a hazardous situation.

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06/2007 Technical description

6.8.2 Emergency Stop: Standards

The emergency Stop function is used for the fastest possible shut-down of the machine in a dan gerous situation. The Emergency Stop function can be triggered by the actions of a single person. It must be fully functional and available at all times. The user must not have to work out how to ope rate this mechanism.

The Emergency Stop function is defined by EN 60204 (VDE 0113), paragraph 9.2.5.4.

In addition to the requirements for Stop, the emergency Stop must fulfil the following requirements:

emergency stop must have priority over all other functions and controls in all operating situa

tions;

the energy supply to any drive machinery that could cause dangerous situations must be

switched off as fast as possible, without causing any further hazards (e.g. by using mechani cal latching devices that do not require an external supply of energy, by counter-current bra king in Stop Category 1);

the reset must not initiate a restart.

If necessary, provision must be made for the additional connection of emergency stop devices (see EN 60204, "Requirements for emergency stop devices").

The Emergency Stop must be effective as a stop of either Category 0 or Category 1. The Emergency Stop Category must be determined by a risk evaluation of the machine.

Category 0

Only hard-wired, electromechanical components may be used for the Category 0 Emergency Stop function. It must not be triggered using switching logic (hardware or software), by transferring commands via a communication network, or via a data link. The drive must be shut down using an electromechanical circuit. If the connected servo motor has an integrated brake, this must always be controlled by an electromechanical circuit as well.

Category 1

With the Category 1 Emergency Stop function, there must be absolute certainty in terms of the power supply for the machine drives being switched off (i.e., secured) using electromechanical components. Additional Emergency Stop equipment may be connected. Bringing the motor to a standstill by interrupting the mains supply and using controlled electronic braking. The 24 V supply for the servo amplifier must remain constant. The issue of which circuit should be used is highly dependent on the requirements of the application at hand.

Usually a brake in a servo motor only has the function of a holding brake. To ensure an emergency stop function, the braking torque that is required must be checked. If the holding brake fulfills the dynamic requirements, it must be taken into acount that this application will cause increased wear.

AX2040/2070 Product Manual 27

Technical description

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6.8.3 Implementation of the Stop Category 0

Bringing the motor to a standstill by immediately switching off the amplifier power supply (STOP MODE & ACTFAULT parameters set to 1). The switching sequence is precisely determined by

this circuit in order to avoid undesirable fault messages and servo amplifier failures.

It is not possible to achieve a Category 0 shut-down with the servo amplifier alone, since hard-wired electromechanical components are compulsory for this type of disconnection. A brake that is built into the motor must have an additional electromechanical control circuit, as well as the control through the AX2040/2070, in order to meet Category 0.

Circuit suggestion

(with EMERGENCY STOP Category 0, control function with contactor relays)

AX2040/2070

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06/2007 Technical description

6.8.4 Implementation of the Stop Category 1

Bringing the motor to a standstill by interrupting the mains supply and using controlled electronic braking (STOPMODE & ACTFAULT parameters set to 1). The 24 V supply for the AX2040/2070 must remain constant.

The drive is braked in a controlled manner during the stopping (disabling) procedure. If the speed VEL0 (see sequence diagram in chapter 6.5) is undershot, the holding brake is applied and the output stage is disabled.

As soon as two separate time periods (set at the time relay) have elapsed, the mains supply and the holding brake are electrically isolated.

Should an internal AX2040/2070 fault occur, the motor is forced to a standstill once K20 drops out.

Circuit suggestion

(with EMERGENCY STOP Category 1, control function with contactor relays)

AX2040/2070

AX2040/2070 Product Manual 29

Technical description

06/2007 BECKHOFF

6.8.5 Implementation of the Stop Category 2

The machine receives an operational stop (disable) command and brakes the drive using the set braking ramp (STOPMODE & ACTFAULT parameters set to 1).

If the electrical supply is switched off, not only will the controlled braking procedure be performed, but the mains supply and the holding brake will also be electrically isolated following a time period set at the time relay.

Circuit suggestion

(with EMERGENCY STOP Category 1, control function with contactor relays)

AX2040/2070

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6.9 Shock-hazard protection

6.9.1 Leakage current

Leakage current via the PE conductor results from the combination of equipment and cable leakage currents. The leakage current frequency pattern comprises a number of frequencies, whereby the residual-current circuit breakers definitively evaluate the 50Hz current. For this reason, the leakage current cannot be measured using a conventional multimeter.

As a rule of thumb, the following assumption can be made for leakage current on our low-capacity cables at a mains voltage of 400 V, depending on the clock frequency of the output stage:

Ileak=nx20mA+Lx1mA/m at 8kHz clock frequency at the output stage Ileak=nx20mA+Lx2mA/m at a 16kHz clock frequency at the output stage

(where Ileak=leakage current, n=number of amplifiers, L=length of motor cable)

At other mains voltage ratings, the leakage current varies in proportion to the voltage.

Example: 2 x servo amplifiers + a 25m motor cable at a clock frequency of 8kHz:

2 x 20mA + 25m x 1mA/m = 65mA leakage current.

Since the leakage current to PE is more than 3.5 mA, in compliance with EN50178 the PE connection must either be doubled or a connecting cable with a cross-section >10mm² must be used.

The following measures can be used to minimise leakage currents. — Reduce the length of the engine cable — Use low-capacity cables (see p.41)

06/2007 Technical description

6.9.2 Residual-current circuit breakers (FI)

In conformity with DIN IEC 60364-4-41 – Regulations for installation and EN 60204 – Electrical equipment of machinery, residual-current circuit-breakers (called FI below) can be used provided the requisite regulations are complied with.

The AX2040/2070 is a 3-phase system with a B6 bridge. Therefore, FIs which are sensitive to all currents must be used in order to detect any d.c. fault current. Refer to chapter 6.9.1 for the rule of thumb for determining the leakage current.

Rated residual currents in the FI

10 -30 mA

50 -300 mA

Recommendation: In order to protect against direct contact (with motor cables <5m) we recommend that each servo amplifier be protected individually using a 30mA residual-current circuit-breaker which is sensitive to all currents.

If you use a selective FI circuit-breaker, the more intelligent evaluation process will prevent spurious tripping of the circuit-breakers.

Protection against "indirect contact" (personal fire protection) for stationary and mo bile equipment, as well as for "direct contact". Protection against "indirect contact" (personal fire protection) for stationary equip ment

AX2040/2070 Product Manual 31

Technical description

6.9.3 Isolating transformers

If protection against indirect contact is absolutely essential despite a higher leakage current, or if an alternative form of shock-hazard protection is sought, the AX2040/2070 can also be operated via an isolating transformer.

A ground-leakage monitor can be used to monitor for short circuits.

We would advise you to keep the length of wiring between the transformer and the servo amplifier as short as possible.

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06/2007 Mechanical Installation

7 Mechanical Installation

7.1 Important notes

Protect the servo amplifier from impermissible stresses. In particular, do not let any compo

nents become bent or any insulation distances altered during transport and handling. Avoid contact with electronic components and contacts.

Ensure that there is an adequate flow of cool, filtered air into the bottom of the switchgear

cabinet or use heat exchangers. Observe page 19.

Take care that the servo amplifier and motor are earthed (grounded) properly. Do not use

painted (non-conductive) mounting plates.

Don't mount devices, which produce magnetic fields, directly beside the servo amplifier.

Strong magnetic fields could directly affect internal components. Install devices which pro duce magnetic field with distance to the servo amplifiers and/or shield the magnetic fields.

7.2 Guide to mechanical installation

The following notes should assist you to carry out the mechanical installation in a sensible sequence, without overlooking anything important.

In a closed switchgear cabinet. Observe page 19 .

Site

Ventilation

The site must be free from conductive or corrosive materials. For the mounting position in the cabinet ð p. 34

Check that the ventilation of the servo amplifier is unimpeded and keep within the permitted ambient temperature ð p. 19 . Keep the required space clear above and below the servo amplifier ð p34.

Assembly

Grounding

Shielding

Assemble the servo amplifier and power supply, filter and choke close together on the conductive, grounded mounting plate in the cabinet.

EMC-compliant (EMI) shielding and grounding (ð p. 45) Earth (ground) the mounting plate, motor housing and CNC-GND of the controls. Notes on connection techniques are on page 40

AX2040/2070 Product Manual 33

Mechanical Installation

7.3 Assembly

Ask our customer service for information for pass through mounting Material : 4 hexagon socket screws to DIN 912, M6 Tool required : 5 mm Allen key

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- A.4.038.4/12

AX2040/2070

34 AX2040/2070 Product Manual

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7.4 Dimensions

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AX2040/2070 Product Manual 35

Mechanical Installation

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This page has been deliberately left blank.

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8 Electrical Installation

8.1 Important Notes

Check the combination of servo amplifier and motor. Compare the rated voltage and current

of the units. Carry out the wiring according to the connection diagram on page 39.

Make sure that the maximum permissible rated voltage at the terminals L1, L2, L3 or +DC,

–DC is not exceeded by more than 10% even in the most unfavourable case (see EN 60204-1 Section 4.3.1). An excessive voltage on these terminals can lead to destruction of the regen circuit and the servo amplifier.

The use of external mains chokes and mains filters is required.

The fusing of the AC supply input and the 24V supply is installed by the user (ð p. 19).

Route power and control cables separately. We recommend a separation of at least 200mm.

This improves the interference immunity required by EMC regulations.

Install all shielding with large areas (low impedance), with metallised connector housings or

shield connection clamps where possible. Earth (ground) the shielding at both ends (ðp.45). Notes on connection techniques can be found on page 40.

Feedback lines may not be extended, since thereby the shielding would be interrupted and

the signal processing could be disturbed.

The cable between servo amplifier and regen resistor must be shielded.

Install all heavy-current cables with an adequate cross-section, as per EN 60204 (ð p. 20)

and use the requested cable material (ð p. 41) to reach max. cable length.

Wire the BTB/RTO contact in series into the safety circuit of the installation. The safety cir-

cuit must control the mains relay. Only in this way is the monitoring of the servo amplifier assured.

It is permissible to alter the servo amplifier settings by using the setup software.

Any other alterations will invalidate the warranty.

06/2007 Electrical Installation

Never disconnect the electrical connections to the servo amplifier while it is live. In unfavourable circumstances this could result in destruction of the electronics. Residual charges in the capacitors can have dangerous levels up to 300 seconds after switching off the mains supply voltage. Measure the voltage in the DC bus link (+DC/-DC), and wait until the voltage has fallen below 40V. Control and power connections can still be live, even when the motor is not rotating.

AX2040/2070 Product Manual 37

Electrical Installation

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8.2 Guide to electrical installation

The following notes should assist you to carry out the electrical installation in a sensible sequence, without overlooking anything important.

Cable selec

tion

Grounding

Shielding

Wiring

Select cables according to EN 60204 (ð p. 20)

EMC-compliant (EMI) shielding and grounding (ð p. 45) Earth (ground) the mounting plate, motor housing and CNC-GND of the controls. Notes on connection techniques are on page 40

Route power leads and control cables separately Wire the BTB/RTO contact in series into the safety loop

— Connect the digital control inputs to the servo amplifier — Connect up AGND (also if fieldbuses are used) — Connect the analog setpoint, if required — Connect up the feedback unit (resolver and/or encoder) — Connect the encoder emulation, if required — Connect the expansion card (see corresponding manual on the CD-ROM) — Connect the motor cables, connect shielding to EMI connectors at both ends — Connect motor-holding brake, connect shielding to EMI connectors at

both ends — Connect the external regen resistor (with fusing) — Connect aux. supply (for max. permissible voltage values ð p. 19) — Connect mains choke and mains filter (shielded lines between filter and

servo amplifier) — Connect main power supply (for max. permissible voltage values ð p. 19) — Connect PC (ð p. 67).

Final check

— Final check of the implementation of the wiring,

— according to the wiring diagrams which have been used.

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8.3 Wiring

8.3.1 Important notes

Only professional staff who are qualified in electrical engineering are allowed to install the servo amplifier.The installation procedure is described as an example. A different procedure may

be sensible or necessary, depending on the application of the equipment.

We provide further know-how through training courses (on request).

Caution ! Only install and wire up the equipment when it is not live, i.e. when neither the mains power supply nor the 24 V auxiliary voltage nor the operating voltages of any other connected equipment is switched on. Take care that the cabinet is safely disconnected (with a lock-out, warning signs etc.). The individual voltages will be switched on for the first time during setup.

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The ground symbol that you must take care to provide an electrically conductive connection with the largest possible surface area between the unit indicated and the mounting plate in the switchgear cabinet. This connection is for the effective grounding of HF interference, and must not be confused with the PE- symbol W (a protective measure to EN 60204).

Use the following connection diagrams: Overview : page 45 Mains power : page 47 Motor : page 48 Feedback : page 49ff Electronic Gearing / Master Slave

Master-Slave : page 56 Pulse-Direction : page 59

Encoder Emulation

ROD (A quad B) : page 61

SSI : page 62 Analog/Digital Inputs/Outputs : page 63ff RS232 / PC : page 67 CAN Interface : page 68 Restart lock -AS- : page 72 Multi-axis systems, example : page 89 Expansion cards

I/O-14/08 : page 98

PROFIBUS : page 99

SERCOS : page 101

DeviceNet : page 102

EtherCat : page 105

-2CAN- : page 107

X, which you will find in all the wiring diagrams, indicates

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8.3.2 Shielding connection to the front panel

AX2040/2070

Remove the outer covering of the cable and the shielding braid from the cores for the required length. Secure the cores with a cable tie.

Remove the outer covering of the cable over a length of about 30mm, without damaging the shielding braid.

Pull a cable tie through the slot in the shielding rail (front panel) of the servo amplifier.

Use the cable tie to clamp the shielding braid of the cable firmly to the shielding rail.

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8.3.3 Technical data for cables

Further information on the chemical, mechanical and electrical characteristics of the cables can be obtained from out customer service .

Observe the restrictions in the chapter "Conductor cross-sections" on page 20. To operate the amplifier with the max. permitted cable length, you must use cable material which meets the requirements on the capacity given below.

Insulation material

Sheathing PUR (polyurethane, code 11Y) Core insulation PETP (polyesteraphtalate, code 12Y)

Capacitance

Motor cable £ 4mm² : less than 150 pF /m

>4mm² : less than 250 pF/m

Feedback cable less than 120 pF/m

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8.4 Components of a servo system

AX2040/2070

Control / PLC

restart lock -AS-

24V-power supply

Mains choke

Drive contactor

Fuses

Mains filter

Fuses

Regen resistor

Motor

Terminals

Cables drawn bold are shielded. Electrical ground is drawn with dash-dotted lines.

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8.5 Block diagram

The block diagram below is just an overview.

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8.6 Pin assignments

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8.7 Connection diagram (overview)

Reference Safety Instructions (ð p.9) and Use As Directed (ð p.10) !

AX2040/2070

ð p.51ff

ð p.50

ð p.48

ð p.47

ð p.63

ð p.64

ð p.65

ð p.66

ð p.48

ð p.47

ð p.69

ð p.61 ð p.62 ð p.56

ð p.59

ð p.68

ð p.67

ð p.96

ð p.99 ð p.100

ð p.102

ð p.105

ð p.106

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8.8 Power supply

8.8.1 Connection to various mains supply networks

This page illustrates all the possible connection variations for different electrical supply networks.

An isolating transformer is always required for 400...480V mains networks without earth(ground) and for networks with asymmetrical earth(ground).

AX2040/2070

208V with 60Hz only

230...480V with 50Hz or 60Hz

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8.8.2 Mains supply connection (X0)

— EMI filter and mains choke (required) provided by the user — Fusing (e.g. fusible cut-outs) provided by the user ð p. 19

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8.8.3 24V auxiliary supply (X4)

— Electrically isolated, external 24VDC supply, e.g. with insulating transformer — Required current rating ð p. 18 — Integrated EMI filter for the 24V auxiliary supply

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8.8.4 DC bus link (X0)

Can be connected in parallel, thanks to patented circuit to distribute the regen power among all the amplifiers connected to the same DC bus link circuit. (Connection example ð p. 89).

Only servo amplifiers with mains supply from the same mains (identical mains supply voltage) may be connected by the DC bus link.

The sum of the rated currents for all of the servo amplifiers connected in parallel to an AX2040/2070 must not exceed 300A.

Use unshielded single cores (>=10mm²) with a max. length of 500 mm. Use shielded cables for longer lengths.

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8.9 Motor connection with brake (X0, X4)

Cable cross section see motor documentation.

AX2040/2070

8.10 External regen resistor (X0)

Fusing and regen resistor provided by the user

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8.11 Feedback

Every closed servo system will normally require at least one feedback device for sending actual values from the motor to the servo drive. Depending on the type of feedback device used, informa tion will be fed back to the servo amplifier using digital or analog means.

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AX2040/2070 supports the most common types of feedback device whose functions must be assig ned with the parameters

FBTYPE (screen page FEEDBACK), primary Feedback

EXTPOS (screen page POSITION), secondary Feedback

GEARMODE (screen page GEARING), secondary Feedback

in the setup software. Scaling and other settings must always be made here.

Configuration Location ASCII Parameter

One Feedback

Two Feedbacks

For a detailed description of the ASCII parameters, please refer to the online help of the setup soft ware.

The table below provides an overview of the supported feedback types, their corresponding para meters and a reference to the relevant connection diagram in each case. On each of these, the pin assignment shown on the encoder side relates to the BECKHOFF motors.

Primary feedback type Connector

Resolver X2 SinCos Encoder BISS X1 SinCos Encoder ENDAT X1 SinCos Encoder HIPERFACE X1 SinCos Encoder w/o data channel X1 SinCos Encoder + Hall X1 RS422 5V + Hall X1 RS422 5V X5 Sensorless (w/o feedback) - - 10*

* Can only be set on the terminal screen of the setup software ** RS422 means “incremental encoder AquadB”.

motor FBTYPE motor FBTYPE

externally

EXTPOS GEARMODE

Commu-

tation

XXX XX

Wiring

diagram

ð p.50 ð p.51 ð p.52 ð p.52 ð p.53 ð p.54 ð p.54 ð p.55

Speed

control

FBTYPE

6, 7 (16*)

8*, 9*

0, 3 20* 3, 4 2, 3

11* 12*

Position-

control

electr.

gearing

Hints for combining primary with secondary feedback systems for position control/electr. gearing can be found from page 56.

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8.11.1 Resolver (X2)

Connection of a Resolver (2 to 36-poles) as a feedback system. The thermostat contact in the motor is connected via the resolver cable to the AX20 and evaluated there.

If cable lengths of more than 100 m are planned, please contact our customer service .

FBTYPE 0, 3

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8.11.2 Sine encoder with BISS (X1)

Wiring of a single-turn or multi-turn sine-cosine encoder with BISS interface as a feedback system (firmware revision from 6.68). During start-up of the servo amplifier the parameters stored in the encoder eeprom are uploaded, after that phase only the sine/cosine signals are used.

The thermostat contact in the motor is connected via the encoder cable to X1 and evaluated there. All signals are connected using our pre-assembled encoder connection cable.

If cable lengths of more than 50m are planned, please consult our customer service.

Frequency limit (sin, cos): 250 kHz FBTYPE 20

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8.11.3 Sine Encoder with EnDat 2.1 or HIPERFACE (X1)

Connection of a single-turn or multiturn sine-cosine encoder. Preferred types are ECN1313 and EQN1325.

The thermostat contact in the motor is connected via the resolver cable to the AX20 and evaluated there. All signals are connected using our pre-assembled encoder connection cable.

If cable lengths of more than 50 m are planned, please consult our customer service.

Frequency limit (sin, cos): 250 kHz Encoder with EnDat: FBTYPE 3, 4 Encoder with HIPERFACE: FBTYPE 2, 3

AX2040/2070

SubD15

17pol.round

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8.11.4 Sine Encoder without data channel (X1)

Connection of a sine-cosine encoder without data channel as feedback unit. Every time the 24V auxiliary voltage is switched on, the amplifier needs start-up information for the position controller (parameter value MPHASE). Depending on the feedback type either wake&shake is executed or the value for MPHASE is read out of the amplifier's EEPROM.

The thermostat contact in the motor is connected via the encoder cable to X1 and evaluated there.

If lead lengths of more than 50 m are planned, please consult our customer service.

Frequency limit (sin, cos): 250 kHz

Encoder type FBTYPE Remarks

SinCos 5V 6 MPHASE from EEPROM SinCos 5V 7 MPHASE with wake & shake Resolver+SinCos5V 16 Commutation with Resolver, speed&position with Encoder

Don't use this feedback type with vertical load (hanging load).

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8.11.5 Incremental or sine encoder with hall sensors (X1)

Feedback devices (incremental or sine-cosine), which don't deliver an absolute information for com mutation, can be used as complete feedback system combined with an additional Hall encoder. All signals are connected to X1.

If cable lengths of more than 25 m are planned, please consult our customer service.

Frequency limit (A, B): 250 kHz RS422 with Hall: FBTYPE 12 Encoder with Hall: FBTYPE 11

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SubD15

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8.11.6 Incremental Encoder (X5)

An incremental encoder can be used as standard motor feedback.

Every time the 24V auxiliary voltage is switched on, the amplifier needs start-up information for the position controller (parameter value MPHASE). Depending on the feedback type either wake&shake is executed or the value for MPHASE is read out of the amplifier's EEPROM.

The thermostat contact in the motor is connected to X1 (see p.52) or X2 (see p.50).

If lead lengths of more than 50 m are planned and for questions concerning the power supply of the encoder, please consult our customer service.

AGND and DGND (connector X3) must be joined together !

Frequency limit: 1.5 MHz

Encoder type FBTYPE Remarks

RS422 5V 9 MPHASE from EEPROM RS422 5V 8 MPHASE with wake & shake

Don't use this feedback type with vertical load (hanging load).

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8.12 Electronic Gearing, Master-slave operation

In the case of the “electronic gearing” functionality (see setup software and description of GEAR MODE parameter), the servo amplifier is controlled by a secondary feedback device as a slave. It is possible to set up master/slave systems, use an external encoder as a setpoint encoder or con nect the amplifier to a stepper motor control. The amplifier is parameterized using the setup software (electronic gearing).

Primary Feedback: adjust on screen page "Feedback" (FBTYPE)

Secondary Feedback: adjust on screen pages "Position" and "Gearing" (EXTPOS, GEARMODE)

Master-/Slave adjustment Master: adjust encoder emulation on screen page "ROD/SSI/Encoder" (ENCMODE) Slave: adjust on screen pages "Position" and "Gearing" (EXTPOS, GEARMODE)

The following types of external encoder can be used:

Secondary Feedback type Connector

Incremental Encoder 5V X5 Incremental Encoder 24V X3 Sine/Cosine Encoder X1 SSI Encoder X5 Pulse and Direction 5V X5 Pulse and Direction 24V X3

* adjustable via terminal screen of the setup software

The follwing table shows the allowed feedback combinations:

diagram

Wiring

ð p.57 ð p.57 ð p.58 ð p.59 ð p.60 ð p.60

GEARMODE

3, 5*, 13*, 15* 0, 2*, 10*, 12*

6, 8*, 9*, 16*

7*, 17*

4, 14* 1, 11*

Secondary Feedback for Position control/Following

Primary Feedback

Resolver (X2)

FBTYPE = 0

Sine Encoder (X1)

FBTYPE = 2,4,6,7,20

Encoder & Hall (X1)

FBTYPE = 11,12

RS422 Encoder (X5)

FBTYPE = 8,9

Sensorless

FBTYPE = 10 -

Sine Encoder (X1)

EXTPOS = 1,2,3 GEARMODE = 6,8,9,16 FPGA = 0 ENCMODE = 0

Increment. Encoder5V/24V (X5/X3)

EXTPOS = 1,2,3 GEARMODE = 0,2,3,5,10,12,13,15 FPGA = 0 ENCMODE = 0 EXTPOS = 1,2,3 GEARMODE =

--- -

0,2,3,5,10,12,13,15 FPGA = 1 ENCMODE = 0 EXTPOS = 1,2,3 GEARMODE = 0,2,3,5,10,12,13,15 FPGA = 1 ENCMODE = 0

EXTPOS = 1,2,3 GEARMODE = 0,2,3,5,10,12,13,15 FPGA = 0 ENCMODE = 0

Pulse&Direct. 5V/24V (X5/X3)

EXTPOS = 1,2,3 GEARMODE = 1,4,11,14 FPGA = 0 ENCMODE = 0 EXTPOS = 1,2,3 GEARMODE = 1,4,11,14 FPGA = 1 ENCMODE = 0 EXTPOS = 1,2,3 GEARMODE = 1,4,11,14 FPGA = 1 ENCMODE = 0

EXTPOS = 1,2,3 GEARMODE = 1,4,11,14 FPGA = 0 ENCMODE = 0

SSI Encoder (X5)

EXTPOS = 1,2,3 GEARMODE = 7,17 FPGA = 1 ENCMODE = 2 EXTPOS = 1,2,3 GEARMODE = 7,17 FPGA = 1 ENCMODE = 2

EXTPOS = 1,2,3 GEARMODE = 7,17 FPGA = 1 ENCMODE = 2

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8.12.1 Connection to a AX20 master, 5 V signal level (X5)

You can link several AX20 amplifiers together in master-slave operation. Up to 16 slave amplifiers can be controlled by the master via the encoder output. The connector X5 must be used.

Frequency limit: 1.5 MHz, slew rate tv £ 0,1 µs

AX2040/2070

AX20

AGND and DGND (connector X3) must be joined together !

8.12.2 Connection to incremental encoder master with 24 V signal level (X3)

This interface can be used to operate the AX2040/2070 as a slave, mastered by an encoder with 24 V signal level (master-slave operation). The digital inputs DIGITAL-IN 1 and 2 at connector X3 must be used.

Frequency limit: 250 kHz, slew rate tv £ 0.1 µs

AX2040/2070

AGND and DGND (connector X3) must be joined together !

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8.12.3 Connection to a sine-cosine encoder master (X1)

You can operate the AX2040/2070 as a slave, mastered by a sine-cosine encoder (master-slave operation). The connector X1 must be used.

If cable lengths of more than 25 m are planned, please consult our customer service.

Frequency limit: 250 kHz

AX2040/2070

AGND and DGND (connector X3) must be joined together!

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8.12.4 Connection to a SSI encoder (X5)

You can set up the AX2040/2070 as a slave following a synchronous serial absolute-encoder (master-slave operation). This application uses the SubD connector X5. If lead lengths of more than 50 m are planned and for questions concerning the power supply of the encoder, please consult our customer service.

Frequency limit: 1.5MHz

AX2040/2070

AGND and DGND (connector X3) must be joined together!

8.12.5 Connection to stepper-motor controllers (step and direction)

This interface can be used to connect the servo amplifier to a third-party stepper-motor controller. The parameters for the servo amplifier are set up with the aid of the setup software (electrical gearing). The number of steps can be adjusted, so that the servo amplifier can be adjusted to the pulse-direction signals of any stepper-motor controller. Various monitoring signals can be output.

Observe the frequency limit! Using an A quad B encoder provides better EMC noise immunity.

Speed profile and signal diagram

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8.12.5.1 Step/Direction with 5 V signal level (X5)

This interface can be used to connect the servo amplifier to a stepper-motor controller with 5 V signal level. The connector X5 must be used. Frequency limit: 1.5 MHz

AGND and DGND (connector X3) must be joined together !

AX2040/2070

8.12.5.2 Step/Direction with 24 V signal level (X3)

This interface can be used to connect the servo amplifier to a stepper-motor controller with 24 V signal level. The digital inputs DIGITAL-IN 1 and 2 at connector X3 must be used. Frequency limit: 250 kHz

AGND and DGND (connector X3) must be joined together!

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8.13 Encoder emulations

8.13.1 Incremental encoder output - A quad B (X5)

The incremental-encoder interface is part of the package supplied. Select the encoder function ROD (screen page “Encoder”). In the servo amplifier, the position of the motor shaft is calculated from the cyclic-absolute signals of the resolver or encoder. Incremental-encoder compatible pulses are generated from this information. Pulses are output on the SubD-connector X5 as two signals, A and B, with 90° phase difference and a zero pulse. The resolution (lines before quadrature) can be changed with the RESOLUTION parameter:

Encoder function (ENCMODE)

ROD (1)

ROD interpolation (3) Encoder

You can also adjust and store the position of the zero pulse within one mechanical turn (parameter NI-OFFSET).

Feedback system Resolution Zero position

Resolver 256...4096

Encoder

256...524288

... 219)

...2

TTL lines per sine line

one per revolution (only if A=B=1) one per revolution (only if A=B=1) analog pass through from X1 to X5

The drivers are supplied from an internal supply voltage. PGND must always be connected to the controls. The max. admissible cable length is 10 m.

Connections and signal description for incremental-encoder interface : The count direction is upwards when the motor shaft is rotating clockwise (looking at the shaft end).

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8.13.2 SSI output (X5)

The SSI interface (synchronous serial absolute-encoder simulation) is part of the delivered package. Select the encoder function SSI (screen page “Encoder”). In the servo amplifier, the posi tion of the motor shaft is calculated from the cyclically absolute signals from the resolver or encoder. This information is used to create a position output in a format that is compatible with the standard SSI-absolute-encoder format. 24 bits are transmitted. SINGLE TURN selected: The upper 12 bits are fixed to ZERO, the lower 12 bits contain the posi tion information. For 2-pole resolvers, the position value refers to the position within one turn of the motor, for 4-pole resolvers it is within half a turn, and for 6-pole resolvers it is within a third of a turn. Exception: bits are set to 1 (data invalid!) until a homing run is performed.

If an encoder with a commutation track is used as the feedback unit, then the upper 12

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MULTI TURN selected: The upper 12 bits contain the number of motor turns, the lower 12 bits con tain the position information.

The signal sequence can be output in Gray code (standard) or in binary code (parameter SSI-CODE). The servo amplifier can be adjusted to the clock frequency of your SSI-evaluation with the SSI-CLOCK parameter (cycle time 200 kHz or 1.5 MHz and inverted).

The drivers are supplied from internal supply voltage. PGND must always be connected.

Connection and signal description for SSI interface :

The count direction is upwards when the motor shaft is rotating clockwise (looking at the shaft end).

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8.14 Digital and analog inputs and outputs

8.14.1 Analog inputs (X3)

The servo amplifier is equipped with two differential inputs for analog setpoints which are programmable. AGND (X3/1) must always be joined to the CNC-GND of the controls as a ground reference.

Technical characteristics

— Differential-input voltage max. ± 10 V — Resolution 1.25 mV — Ground reference : AGND, terminal X3/1 — Input resistance 20 kW — Common-mode voltage range for both inputs ± 10 V — Update rate 62.5 µs

AX2040/2070

Input Analog-In1 (terminals X3/4-5)

Differential input voltage max. ± 10 V, resolution 14-bit, scalable Standard setting : speed setpoint

Input Analog-In2 (terminals X3/6-7)

Differential input voltage max. ± 10 V, resolution 12-bit, scalable Standard setting : torque setpoint

Application examples for setpoint input Analog-In2: — adjustable external current limit — reduced-sensitivity input for setting-up/jog operation — pre-control / override

Fixing the direction of rotation

Standard setting : clockwise rotation of the motor shaft (looking at the shaft end) — Positive voltage between terminal X3/4 (+ ) and terminal X3/5(-)or — Positive voltage between terminal X3/6 (+ ) and terminal X3/7(-)

To reverse the direction of rotation, swap the connections to terminals X3/4-5 and. X3/6-7 or change the ROT. DIRECTION parameter in the “Speed controller” screen.

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8.14.2 Analog outputs (X3)

Technical characteristics

— Reference ground is analog-GND (AGND, terminal X3/1 and X3/10) — Output resistance : 2.2 kW — Output voltage ±10 V — Resolution : 10 bit. — Update rate 62.5 µs

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AX2040/2070

Programmable analog outputs Analog-Out 1 / Analog-Out 2

The terminals X3/8 (Analog-Out 1) or X3/9 (Analog-Out 2) can have the following analog signals assigned to them:

Standard setting :

Analog-Out 1 : Tachometer voltage n The output delivers ±10 V at the preset limit speed.

Analog-Out 2 : Current actual value I The output delivers ± 10 V at the preset peak current (effective r.m.s. value).

You can use the terminals X3/8 (Analog-Out 1) or X3/9 (Analog-Out 2) to output converted analog values for digital measurements which are contained in the servo amplifier.

You can find a list of pre-programmed functions on the "analog I/O" screen of our setup software.

act

(speed)

(torque)

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8.14.3 Digital inputs (X3)

All digital inputs are electrically isolated through optocouplers.

Technical characteristics

— Reference ground is Digital-GND (DGND, terminal X3/18) — Inputs at X3 meet PLC standards (IEC 61131-2 Typ 1) — High: 11...30 V / 2...11 mA, Low -3...+5V/<1mA — Update rate: 250 µs

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ENABLE input

The output stage of the servo amplifier is activated by the enable signal (terminal X3/15, input 24 V, active-high). In the inhibited state (low signal) the motor which is attached does not have any torque.

Programmable digital inputs :

You can use the digital inputs PSTOP / NSTOP / DIGITAL-IN1 and DIGITAL-IN2 to initiate preprogrammed functions that are stored in the servo amplifier. You can find a list of pre-programmed functions on the "digital I/O" screen of our setup software. If an input is freshly assigned to a pre-programmed function, then the data set must be stored in the EEPROM of the servo amplifier, and the 24 V auxiliary supply of the servo amplifier must be swit ched off and on again (to reset the amplifier software).

Limit-switches PSTOP / NSTOP

Terminals X3/13 and X3/14 are normally programmed for the connection of limit switches. If these inputs are not needed for the connection of limit switches, then they are programmable for other input functions.

Limit-switch positive/negative (PSTOP / NSTOP, terminals X3/13 and X3/14), high level in normal operation (fail-safe for a cable break).

A low signal (open) inhibits the corresponding direction of rotation, the ramp function remains

effective.

DIGITAL-IN 1 / DIGITAL-IN 2

The digital inputs on terminals X3/11 (DIGITAL-IN 1) or terminal X3/12 (DIGITAL-IN 2) can be logi cally combined in a pre-programmable function.

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8.14.4 Digital outputs (X3)

Technical characteristics

— Reference ground is digital-GND (DGND, terminal X3/18) — All digital outputs are floating — DIGITAL-OUT1 and 2: Open-collector, max. 30 VDC, 10 mA

BTB/RTO: Relay output, max. 30 VDC or 42 VAC, 0.5 A

— Update rate: 250 µs

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Ready-to-operate contact BTB/RTO

Operational readiness (terminals X3/2 and X3/3 ) is signalled by a floating relay contact. The contact is closed when the servo amplifier is ready for operation, the signal is not influenced by the enable signal, the I²t- limit, or the regen threshold.

All faults cause the BTB/RTO contact to open and the switch-off of the output stage (if the BTB contact is open, the output stage is disabled -> no power). A list of the error messages can be found on page 92.

Programmable digital outputs DIGITAL-OUT1/2:

You can use the digital outputs DIGITAL-OUT1 (terminal X3/16) and DIGITAL-OUT2 (terminal X3/17) to outputs messages from pre-programmed functions that are stored in the servo amplifier. You can find a list of pre-programmed functions on the "digital I/O" screen of our setup software.

If an input is freshly assigned to a pre-programmed function, then the data set must be stored in the EEPROM of the servo amplifier, and the 24 V auxiliary supply of the servo amplifier must be swit ched off and on again (to reset the amplifier software).

Evaluate the outputs via inverting interface relays (see connection diagram), for example Phönix DEK-REL-24/I/1 (turn-on delay 6 ms, turn-off delay 16ms).

The described logic in the online help of the setup software refers to the output of the inverting interface relays. Consider the delay of the applied relay !

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8.15 RS232 interface, PC connection (X6)

The setting of the operating, position control, and motion-block parameters, can be carried out on an ordinary commercial PC.

Connect the PC interface (X6) of the servo amplifier while the supply to the equipment is swit

ched off via a normal commercial 3-core null-modem cable to a serial interface on the PC.

Do not use a null-modem link cable!

The interface is electrically isolated through an optocoupler, and is at the same potential as the CANopen interface.

The interface is selected and set up in the setup software. Further notes can be found on page 76.

With the optional expansion card -2CAN- the two interfaces for RS232 and CAN, which otherwise use the same connector X6, are separated onto two connectors (ð p. 106).

AX2040/2070

Interface cable between the PC and servo amplifiers of the

(View : looking at the face of the built-in SubD connectors, this corresponds to the solder side of the SubD sockets on the cable)

AX2040/2070 series:

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8.16 CANopen interface (X6)

The interface for connection to the CAN bus (default 500 kBaud). The integrated profile is based on the communication profile CANopen DS301 and the drive profile DSP402. The following functions are available in connection with the integrated position controller: Jogging with variable speed, reference traverse (zeroing), start motion task, start direct task, digital setpoint provision, data transmission functions and many others. Detailed information can be found in the CANopen manual. The interface is electrically isolated by optocouplers, and is at the same potential as the RS232 interface. The analog setpoint inputs can still be used. With the optional expansion card -2CAN- the two interfaces for RS232 and CAN, which otherwise use the same connector X6, are separated onto two connectors (ð p. 106).

AGND and DGND (connector X3) must be joined together !

AX2040/2070

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CAN bus cable

To meet ISO 11898 you should use a bus cable with a characteristic impedance of 120 W. The maximum usable cable length for reliable communication decreases with increasing transmission speed. As a guide, you can use the following values which we have measured, but they are not to be taken as assured limits: Cable data: Characteristic impedance 100-120 W

Cable capacity max. 60 nF/km Lead resistance (loop) 159.8 W/km

Cable length, depending on the transmission rate

Transmission rate / kbaud max. cable length / m

1000 20

500 70 250 115

Lower cable capacity (max. 30 nF/km) and lower lead resistance (loop, 115 W/km) make it possible to achieve greater distances. (Characteristic impedance 150 ± 5 WÞterminating resistor 150 ± 5 W). For EMC reasons, the SubD connector housing must fulfil the following conditions:

— metal or metallized housing — provision for cable shielding connection in housing, large-area connection

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8.17 Restart lock -AS-

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. 73) fulfills safety category 1 (EN 954-1) or category 3 with additional safety relay (e.g. PNOZ of PILZ company).

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.

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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.

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 separately for personnel safety.

8.17.1 Safety instructions

Observe the chapter "use as directed" for the restart lock -AS- (ð p. 70)

The monitoring contacts (KSO1/2) for each amplifier must be looped into the control

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

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 :

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-

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8.17.2 Use as directed

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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, EN12100 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) for all servo amplifiers are wired into

the control signal loop.

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).

8.17.3 Block diagram

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8.17.4 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.

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The 24VDC safety relay in the servo amplifier (approved) is controlled externally. All the relay con tacts 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.

8.17.5 Signal diagram (sequence)

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8.17.6 Functional test

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.

8.17.7 Connection diagram (principle)

AX2040/2070

Application examples for category 1 see chapters 8.17.8.

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8.17.8 Application example category 1 according to EN 954-1

8.17.8.1 Control circuit

8.17.8.2 Mains supply circuit

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8.17.9 Application example category 3 according to EN 954-1

Please contact our customer service.

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9 Setup

9.1 Important notes

Only professional personnel with extensive knowledge in the fields of electrical/ drive technology are allowed to setup the servo amplifier.

The setup procedure is described as an example. Depending on the application, a different procedure may be sensible or necessary. In multi-axis systems, setup each servo amplifier individually.

Check that all live connecting elements are protected from accidental contact. Deadly voltages can be present, up to 900V. Never disconnect any of the electrical connections to the servo amplifier while it is live. Capacitors can still have residual charges with dangerous levels up to 300 seconds after switching off the supply power. Heat sinks of the amplifier can reach a temperature of up to 80°C (176°F) in operation. Check (measure) the heat sink temperature. Wait until the heat sink has cooled down below 40°C (104°F) before touching it.

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If the servo amplifier has been stored for longer than 1 year, then the DC bus link capacitors will have to be re-formed. To do this, disconnect all the electrical connections. Supply the servo amplifier for about 30 min. from single-phase 230VAC to the terminals L1 / L2. This will re-form the capacitors.

Further setup information: The adaptation of parameters and the effects on the control loop behavior are described in the online help. The setup of the expansion card (if present) is described in the corresponding manual on the CD-ROM. We can provide further know-how through training courses (on request).

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9.2 Setup software

9.2.1 General

This chapter describes the installation of the setup software for the AX2040/2070 digital servo amplifiers.

We offer training and familiarisation courses on request.

9.2.1.1 Use as directed

The setup software is intended to be used for setting up and storing the operating parameters for the AX2040/2070 series of servo amplifiers. The attached servo amplifier can be setup with the assistance of the software - during this process the drive can be controlled directly by the service functions.

Only professional personnel who have the relevant expertise described on page 7 are permitted to carry out online parameter setting for a drive which is running. Sets of data which are stored on data media are not safe against unintended alteration by other persons. After loading a set of data you must therefore check all parameters thoroughly before enabling the servo amplifier.

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9.2.1.2 Software description

The servo amplifiers must be adapted to the requirements of your installation. Usually you will not have to carry out this parameter setting yourself on the amplifier, but on a PC, with the assistance of the setup software. The PC is connected to the servo amplifier by a null-modem cable (ð p. 67). The setup software provides the communication between AX2040/2070 and the PC.

You will find the setup software on the accompanying CD-ROM and at our web site in the download area.

With very little effort you can alter parameters and instantly observe the effect on the drive, since there is a continuous (online) connection to the amplifier. Simultaneously, important actual values are read out from the amplifier and displayed on the PC monitor (oscilloscope function).

Any interface modules (expansion cards) which may be built into the amplifier are automatically recognized, and the additional parameters which are required for position control or motion-block definition are made available.

Sets of data can be stored on data media (archived) and loaded again. Sets of data which are stored on data media can be printed.

We supply you with motor-specific default sets of data for the most common combinations of servo amplifier and motor. In most applications you will be able to use these default values to get your drive running without any problems.

An extensive online help with integrated description of all variables and functions supports you in each situation.

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9.2.1.3 Hardware requirements

The PC interface (X6, RS232) of the servo amplifier is connected to the serial interface of the PC by a null-modem cable (not a null-modem link cable !)(ð p. 67).

Connect / disconnect the interface cable only when the supply is switched off for both the PC and the servo amplifier.

The interface in the servo amplifier is electrically isolated by an optocoupler, and is at the same potential as the CANopen interface.

Minimum requirements for the PC:

Processor : Pentium I or higher Operating system : WINDOWS 95(c) / 98 / 2000 / ME / NT4.0 / XP Graphics adapter : Windows compatible, color Drives : hard disk with at least 10 MB free space

Main memory : at least 8MB Interface : one free serial interface (COM1...COM10)

9.2.1.4 Operating systems

WINDOWS 95(c) / 98 / 2000 / ME / NT / XP

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CD-ROM drive

DRIVE.EXE is executable under WINDOWS 95(c) / 98 / 2000 / ME / NT 4.0 / XP. The HTML help system is not available under WINDOWS 95a and 95b.

WINDOWS FOR WORKGROUPS 3.xx, DOS, OS2

DRIVE.EXE is not executable under WINDOWS 3.xx, DOS and OS2. In emergency, operation is possible through an ASCII terminal emulation (without user-interface). Interface settings : 9600 bps, no parity, no handshake

Unix, Linux

The software function has not been tested running within Unix or Linux.

9.2.2 Installation under WINDOWS 95 / 98 / 2000 / ME / NT / XP

The CD-ROM includes an installation program for the setup software.

Installation

Autostart function activated: Insert the CD-ROM into a free drive. A window with the start screen opens. There you find a link to the setup software DRIVE.EXE. Click it and follow the instructions.

Autostart function deactivated: Insert the CD-ROM into a free drive. Click on START (task bar), then on Run. Enter the program call: x:\index.htm (x = correct CD drive letter). Click OK and proceed as described above.

Connection to the serial interface of the PC

Connect the interface cable to a serial interface on your PC and the PC interface (X6) of the AX2040/2070 (ð p. 67).

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9.3 Quickstart Guide

9.3.1 Preparation

9.3.1.1 Unpacking, Mounting and Wiring the Servo Amplifier

1. Unpack servo amplifier and accessories

2. Observe safety instructions in the manuals

3. Mount the servo amplifier as described in chapter 7.3

4. Wire the servo amplifier as described in chapter 8.3 or apply the minimum wiring for drive testing

as described in chapter 9.3.1.3

5. Install the software as described in chapter 9.2

9.3.1.2 Documents

You need access to these documents (located on the product CD-ROM, you can download the latest editions from our website):

Product Manual (this manual)

CANopen Communication Profile Manual

Depending on the installed expansion card you need one of these documents:

PROFIBUS DP Communication Profile Manual

DeviceNet Communication Profile Manual

SERCOS Communication Profile Manual

EtherCat Communication Profile Manual (in process)

You need Acrobat Reader to read the PDFs, an installation link is on every screen of the product CD-ROM.

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9.3.1.3 Minimum Wiring for Drive Test

This wiring does not fulfill any requirements to safety or functionality of your application, it just shows the required wiring for drive testing without load.

RES

CAN

Motor-Feedback

ENC

Power ON

24V DC

Enable

24V ON

Power

Choke Filter

Motor-Power

Motor

Brake Res.

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Setup

9.3.2 Connect

Connect the interface cable to a serial interface on your PC and to the serial interface X6 of

the servo amplifier. USB to serial converter can be used optionally.

Switch on the 24 V power supply for the servo amplifier.

Wait about 30 seconds, until the front display of the servo amplifier displays the current

classe (e.g. for 40 amps). If the power supply voltage is switched on, too, a leading P is displayed (e.g. for Power, 40 amps).

If a fault code ( ) or a warning ( ) or a status message (./_ / E/S) appears in the display, you will find the description on page 92ff. If there is fault, fix the problem.

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Double-Click the DRIVE.EXE icon on your Windows desktop to start the software.

You can work offline or online with . Work ONLINE now. Select the interface where the servo am plifier is connected to.

The software tries to communicate with the drive and to upload the parameters. If it's not successful, you receive this error mes sage.

- wrong interface chosen

- wrong connector chosen at the servo amplifier

Frequent causes:

Click OK to remove the error message. Detect and remove the error source. Restart the software.

- interface is used by another software

- 24 V auxiliary voltage for the servo amplifier not working

- interface cable broken or wrong wiring

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If communication works, parameters are transmitted from the servoamplifier to the computer. Then you see the start screen.

9.3.3 Important Screen Elements

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Make sure, that the amplifier is disabled (Input HW-Enable con nector X3 pin 15 must be 0 V or open)!

Help Function

The Online-Help gives detailed information to all parameters the servo amplifier can work with.

Key F1 Menu Bar ? or Online HTML Help

Tool Bar

Save to EEPROM, required if you changed parameters.

Reset (coldstart), required if you changed important configuration parameters.

Starts Online Help for the actual screen page.

Starts Online Help with table of contents.

Operation Mode, use Digital Velocity mode for drive testing.

Disable and Enable of the amplifier's output stage via software.

Status Bar

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Setup

9.3.4 Basic Setup

On the start screen click "Basic Setup" button.

Regen Resistor: Select "external" regen resistor

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max.Regen Power: Fill in the power of the connected regen resistor.

max. Mains Voltage: Select the nominal mains AC voltage

Mains Phase Missing: You can select either warning "n05" or error "F19" in case of phase loss.

The setting "F19" disables the output stage, "n05" is just a message.

Units: Acceleration, Velocity, Position

Select usable units for your application referring to the moved load.

Leave all other fields unchanged.

Click OK. On the start screen click "Motor" button.

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9.3.5 Motor (synchronous)

Press function key F12 (SW disable) before changing motor parameters.

Motor Type: Select Synchronous Motor. If you use a linear motor or an induction motor, please

contact our support department.

Number-Name: Click the list to start uploading the motor parameter table, which is stored in the servo amplifier. Search and select the connected motor. If your motor is not listed, please contact our support department.

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Leave all other fields unchanged.

Click OK.

If your motor has a built-in brake, click Yes, otherwise "No".

If Software Enable is active, a warning appe ars. You can proceed, but after the amplifier is restarted, you must check whether the holding brake configuration is correct. Click OK.

Parameters are uploaded to the amplifier's RAM now (takes some seconds). When this is done, you have to accept the changed confi guration with "Yes" or to discard the changes in the appearing screen. If you click "Yes", the parameters are saved in the EEPROM and the amplifier makes a cold start (reset). This takes some seconds.

On the start screen, click "Feedback" button.

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9.3.6 Feedback

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Press function key F12 (disable) before chan ging feedback parameters.

Feedback Type:

Select the feedback type used.

Leave all other fields unchanged.

If Software Enable is active, a warning appears. The configuration change cannot be performed.

Click OK on the warnings, press F12 (SW disab le) and start the Feedback procedure again.

If everything was ok, the same procedure (para meter upload) that has been described for the motor selection starts. If you click "Yes", the parameters are saved in the EEPROM and the amplifier makes a coldstart (reset). This takes some seconds.

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9.3.7 Save Parameters and Restart

You are going to finish setup and you have changed several basic parameters. Depending on the parameters you changed, two possible reactions can occur:

Configuration parameters changed

A warning appears, that you have to restart the amplifier. This is called "coldstart". Click "YES". The parameters are saved to the amplifier's EEPROM automatically and a reset command restarts the amplifier (takes a few seconds). For example, this happens after motor or feedback selection.

Other parameters changed

No warning appears. Parameters are saved in the volatile RAM only. Save the parameters to the

EEPROM of the servo amplifier manually by clicking the symbol in the tool bar. A coldstart of the amplifier is not necessary.

Reset the amplifier

You can reset the amplifier manually (e.g. in case of an error). Click the icon .

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9.3.8 Jogging the Motor (Speed Control)

Be aware that the actual position of the load permits the subsequent moving operations. The axis could move to the hardware limit-switch or the mechanical stop. Make sure that a jerk or a fast acceleration of the load cannot cause any damage.

Switch on the power supply for the drive.

Hardware-Enable: +24 VDC to Enable [connector X3 pin 15].

Software-Enable: Click the "Enable" button on the start screen or use key

combination Shift+F12. Now, the front display shows an E and the current rating (e.g.

for Enable, 40 amps)

Click the icon "Oscilloscope"

Select Service-Mode "Speed F6", then click "Parameter" button

Enter a safe speed. The sign defines the direction of movement.

Observe the "safe reduced speed" requirements for your application!

Click OK.

Start the service function ("Start" button or press F6).

Click OK on the warning notice. Opmode is switched to "0" and the output stage is enabled automatically. The symbol's color changes to green as long as the function is active.

The function is active until you click the "Stop" button or press F9.

The output stage can be disabled by pressing function key F12.

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9.3.9 Status

Actual warnings and errors are listed on the Status screen, which can be accessed on the start screen by clicking the "Status" button. This button monitors the current status of the amplifier and can appear with different text.

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The Reset button can be used to clear some actual error messages. A description of errors/warnings can be found on page 92.

Now you have setup and tested the basic functions of the drive successfully.

9.3.10 Monitor

9.3.11 Additional Setup Parameters

Detailed information on all setup functions can be found in the Online Help systemand and the inte grated command reference.

Click the icon "Monitor"

The Monitor screen shows all important electrical and me chanical actual values

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Setup

9.4 Multi-axis system

Using a special multilink cable, you can connect up to six servo amplifiers together and to your PC : Cable type -SR6Y- (for 4 amplifiers) or -SR6Y6- (for 6 amplifiers).

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X6 PC/CAN

COMx RS232

Baud rates are the same for all amplifiers, see table below

With the PC connected to just one servo amplifier you can now use the setup software to select all amplifiers through the preset station addresses and set up the parameters.

Add.:01

Cable -SR6Y-

9.4.1 Node address for CAN-bus

During setup it makes sense to preset the station addresses for the individual amplifiers and the baud rate for communication by means of the keypad on the front panel (ð p. 91).

Add.:02

Add.:03

Add.:04

9.4.2 Baud rate for CAN-bus

After changing the station address and baud rate you must turn the 24V auxiliary supply of the servo amplifier off and on again.

Coding of the baud rate in the LED display :

Coding Baud rate in kbit/s Coding Baud rate in kbit/s

0 10 5 250 1 20 6 333 2 50 7 500 3 100 8 666 4 125 9 800

10 1000

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9.4.3 Example of connections for a multi-axis system

Reference Safety Instructions (ð p.9) and Use As Directed (ð p.10) !

AX2040/2070

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9.5 Key operation / LED display

In this chapter the two possible operation menus and the use of the keys in the front panel are shown. Normally, the AX2040/2070 only places the standard menu at your disposal. If you want to attend the amplifier via the detailed menu, you must keep the right key pressed while switching on the 24V-supply.

9.5.1 Key operation

The two keys can be used to perform the following functions:

Key symbol Functions

press once : go up one menu item, increase number by one press twice in rapid succession : increase number by ten press once : go down one menu item, decrease number by one press twice in rapid succession : decrease number by ten press and hold right key, then press left key as well :

enters a number, return function

9.5.2 Status display

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9.5.3 Standard menu structure

9.5.4 Extended menu structure

Keep the right key pressed while switching on the 24V-supply.

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see p.88 the entry will be stored automatically, when you exit the input field.

see p.88

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9.6 Error messages

Errors which occur are shown in coded form by an error number in the LED display on the front panel. All error messages result in the BTB/RTO contact being opened, and the output stage of the amplifier being switched off (motor loses all torque). If a motor-holding brake is installed, it will be activated.

Number Designation Explanation E/S/A/P ...

F01*

F02*

F03* F04

F05*

F06

F07 F08* F09 F10 F11 F12 F13* F14 F15 F16*

F17

F18

F19*

F20 F21 F22 F23 F24 F25 F26

F27

F28

F29 F30 F31 F32

* = These error messages can be cancelled by the ASCII command CLRFAULT, without executing a reset. If only these errors are present, and the RESET button or the I/O-function RESET is used, the CLRFAULT com mand is also all that is carried out.

Status Messages Status messages, no error, see p. 90 Status Message Updating the startup configuration Status Message Programming mode

Heat sink temperature

Overvoltage

Following error Message from the position controller Feedback Cable break, short-circuit, short to ground

Undervoltage

Motor temperature

Internal voltage supply Internal amplifier supply voltages are out of tolerance Overspeed Motor runs away, speed is too high EEPROM Checksum error Flash-EPROM Checksum error Brake Cable break, short-circuit, short to ground Motor phase Motor phase missing (cable break or similar) Internal temperature Internal temperature too high Output stage Fault in the power output stage I²t max. I²t maximum value exceeded Supply BTB/RTO 2 or 3 phases missing in the mains supply feed

A/D converter

Regen Regen circuit faulty or incorrect setting

Supply phase

Slot fault Slot error (hardware fault on expansion card) Handling error Software error on the expansion card Earth short circuit Short-circuit between motor phase and ground CAN-bus off Severe CAN bus communication error Warning Warning is displayed as fault Commutation error Commutation error Limit switch Homing error (machine has driven onto hardware limit switch)

External Trajectory

Slot Fault depends on expansion card, see online help Emergency timeout Timeout emergency stop Macro Macro program error System Error system software not responding correctly

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Heat sink temperature too high limit is set by manufacturer to 80° Overvoltage in DC bus link limit depends on the electrical supply voltage

Undervoltage in DC bus link limit is set by manufacturer to 100V Motor temperature too high or temp. sensor defect limit is set by manufacturer to 145°C

Error in the analog-digital conversion, normally caused by extreme electromagnetic interferences.

A phase is missing in the mains supply power feed (can be switched off for 2-phase operation)

Operational error with -AS- , input for AS-Enable and ENAB LE have been set at the same time External position profile generator created a step, that excee ded the maximum value

More information to the messages can be found in the ASCII Object Reference (Online Help), see parameter ERRCODE. Hints for removal can be found in section "Trouble-Shooting" of the online help.

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9.7 Warning messages

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Faults which occur, but which do not cause a switch-off of the amplifier output stage (BTB/RTO con tact remains closed), are indicated in the LED display on the front panel by a coded warning number.

Number Designation Explanation E/S/A/P ...

n01 n02 n03* n04* n05 n06* n07* n08 n09 n10* n11*

n12

n13*

n14

n15 n16

n17

n18

n19 n20 n21

n22

n23...n31 n32

* = These warning messages lead to a controlled shut-down of the drive (braking with the emergency ramp)

Status Messages Status messages, no error, see p. 90 Status Message Updating the startup configuration Status Message Programming mode I²t I²t threshold exceeded Regen power Reached preset regen power limit S_fault Exceeded preset following error limit Response monitoring Response monitoring (fieldbus) has been activated Supply phase Mains supply phase missing SW limit switch 1 Underrun software limit switch 1 SW limit switch 2 Overrun software limit switch 2 Motion task error A faulty motion task was started No reference point No reference point (Home) set at start of motion task PSTOP PSTOP limit-switch activated NSTOP NSTOP limit-switch activated

Motor default values loaded

Slot warning 24V supply of the I/O expansion board is missing

SinCos feedback

Table error Fault according to speed/current table INXMODE 35 Summarized warning Summarized warning for n17 to n31

Fielbus Synchronization

Multiturn overrun

Motion task ramps are limited Range overflow on motion task data Wrong GMT data Wrong "Graphical Motion Task" data PLC program error For details see plc code max. motor temperatur rea ched reserved reserved firmware beta version Firmware is an unreleased beta version

Only for ENDAT or HIPERFACE discrepancy between motor number saved in the en coder and the amplifier, motor default values loaded

SinCos commutation (wake & shake) not completed, will be canceled when amplifier is enabled and wake&shake carried out

The mode synchronization SYNCSRC is selected but the drive isn’t in synchronies cycle Using Multiturn encoder feedback, an overrun over the maximum number of resolutions was detected

The user can shut down the process before the tem perature eror will interrupt the process immediately

More information to the messages can be found in the ASCII Object Reference (Online Help), see parameter STATCODE. Hints for removal can be found in section "Trouble-Shooting" of the online help.

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9.8 Removing faults / warnings

Depending on the conditions in your installation, there may be a wide variety of reasons for the fault. In multi-axis systems there may be further hidden causes of a fault.

Detailled hints for removal of faults can be found in the Online help chapter "Trouble-Shooting".

Our customer service can give you further assistance with problems.

Fault possible causes

HMI message: communicati on fault

— wrong cable used — cable plugged into wrong position

in servo amplifier or PC — wrong PC interface selected — servo amplifier not enabled — break in setpoint cable

motor does not rotate

— motor phases swapped — brake not released — drive is mechanically blocked — no. of motor poles set incorrectly — feedback set up incorrectly

motor oscillates

drive reports following error

motor overheating

— gain too high (speed controller) — shielding in feedback cable broken — AGND not wired up

or I

—I

rms

is set to low

peak

— setpoint ramp is too long

—I

rms/Ipeak

set too high — reduce I

— Kp (speed controller) too low — Tn (speed controller) too high

drive too soft

— PID-T2 too high — T-Tacho too high — Kp (speed controller) too high

drive runs roughly

— Tn (speed controller) too low

— PID-T2 too low — T-Tacho too low — offset not correctly adjusted for analog

axis drifts at setpoint = 0V

setpoint provision — AGND not joined to the CNC-GND of

the controls

Measures to remove the cause of the fault

— use null-modem cable — plug cable into the correct sockets

on the servo amplifier and PC — select correct interface — apply enable signal — check setpoint cable — correct motor phase sequence — check brake control — check mechanism — set no. of motor poles — set up feedback correctly — reduce Kp (speed controller) — replace feedback cable — join AGND to CNC-GND — increase I

rms

or I

peak

(keep within motor data !) — shorten setpoint ramp +/-

rms/Ipeak

— increase Kp (speed controller) — use motor default value for

Tn (speed controller) — reduce PID-T2 — reduce T-Tacho — reduce Kp (speed controller) — use motor default value for

Tn (speed controller) — increase PID-T2 — increase T-Tacho — adjust setpoint-offset (analog I/O)

— join AGND and CNC-GND

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10 Expansion Cards

10.1 Guide to installation of expansion cards

Use a suitable screwdriver to unscrew the cover of the option slot.

Take care that no small items (such as screws) fall into the open option slot.

Press the expansion card firmly into the slot, until the front cover touches the fixing lugs. This ensures that the connectors make good contact.

Screw the screws on the front cover into the threads in the fixing lugs.

Push the expansion card carefully

into the provided guide rails of the main slot, without twisting it.

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10.2 Expansion card -I/O-14/08-

This chapter describes the I/O-expansion card -I/O-14/08-. It only describes the additional features that the expansion card makes available for the AX2040/2070.

If you ordered the expansion card together with the servo amplifier, then it will be delivered already inserted into the expansion slot of the servo amplifier and screwed fast.

The -I/O-14/08- provides you with 14 additional digital inputs and 8 digital outputs. The functions of the inputs and outputs are fixed. They are used to initiate the motion tasks that are stored in the servo amplifier and to evaluate signals from the integrated position control in the higher-level control.

The functions of the inputs and signal outputs correspond exactly to the functions that can be assig ned to the digital-I/O on connector X3 of the AX2040/2070.

All inputs and outputs are electrically isolated from the servo amplifier by optocoupler.

10.2.1 Front view

10.2.2 Technical data

Control inputs Signal outputs

Supply inputs, to IEC 1131

Fusing (external) Connectors

Cables

Waiting time between 2 motion tasks Addressing time (min.) Starting delay (max.) Response time of digital outputs

24V / 7mA, PLC-compatible 24V / max. 500mA, PLC-compatible 24V (18 ... 36V) / 100mA plus total current of the outputs (depends on the input wiring of the controls)

The 24VDC voltage has to be supplied by an electrically isolated power supply, e.g. with insulating transformer.

4AT MiniCombicon, 12-pole, coded on PIN1 and 12 respectively Data – up to 50m long : 22 x 0.5mm², unshielded, Supply – 2 x 1mm², check voltage drop

depends on the response time of the control system

4ms 2ms max. 10ms

10.2.3 Light emitting diodes (LEDs)

Two LEDs are mounted next to the terminals on the expansion card. The green LED signals that the 24V auxiliary supply is available for the expansion card. The red LED signals faults in the out puts from the expansion card (overload, short-circuit).

10.2.4 Select motion task number (sample)

Motion task no. A7 A6 A5 A4 A3 A2 A1 A0

binary 1010 1110 10101110 decimal 174 128 - 32 - 8 4 2 -

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10.2.5 Connector assignments

Connector X11A

Terminal Dir Function Description

1 In A0 Motion task no., LSB 2 In A1 Motion task no., 2 3 In A2 Motion task no., 2 4 In A3 Motion task no., 2 5 In A4 Motion task no., 2 6 In A5 Motion task no., 2 7 In A6 Motion task no., 2 8 In A7 Motion task no., MSB

9 In Reference

10 In FError_clear

11 In Start_MT Next

12 In Start_Jog v=x

06/2007 Expansion Cards

Polls the reference switch. If a digital input on the basic unit is used as a reference input, then the input on the I/O expan

sion card will not be evaluated. Clear the warning of a following error or the response moni

toring. The following task, that is defined in the motion task by “Start with I/O” is started. The target position of the present motion task must be reached before the following task can be start ed. The next motion block can also be started by an appro

priately configured digital input on the basic unit. Start of the setup mode "Jog Mode" with a defined speed. Af ter selecting the function, you can enter the speed in the au

xiliary variable “x”. The sign of the auxiliary variable defines the direction. A rising edge starts the motion, a falling edge cancels the motion.

Connector X11B

Continues the motion task that was previously interrupted.

1 In MT_Restart

The motion task can also be continued by an appropriately configured digital input on the basic unit. Start of the motion task that has the number that is presented, bit-coded, at the digital inputs (A0 to A7).

2 In Start_MT I/O

The digital function with the same name, in the basic unit, starts the motion task with the address from the digital inputs on the basic unit. When the target position for a motion task has been reached

3 Out InPos

(the InPosition window), this is signalled by the output of a HIGH-signal.

A cable break will not be detected

The start of each motion task in an automatically executed sequence of motion tasks is signalled by an inversion of the output signal. The output produces a Low signal at the start of the first motion task of the motion task sequence.

4 Out

Next-InPos

The form of the message can be varied by using ASCII com mands.

PosReg0 Can only be adjusted by ASCII commands.

5 Out FError

Following-error (low-active).

6 Out PosReg1 7 Out PosReg2 8 Out PosReg3

The preset function of the corresponding position register is indicated by a HIGH-signal.

9 Out PosReg4 10 Out PosReg5 Can only be adjusted by ASCII commands. 11 Supply 24VDC auxiliary supply voltage 12 Supply I/O-GND Digital-GND for the controls

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10.2.6 Connection diagram

AX2040/2070

-I/O-14/08

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AGND and DGND (connector X3) must be joined together !

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10.3 Expansion cards -PROFIBUS-

This chapter describes the PROFIBUS expansion card for the AX2040/2070. Information on the range of functions and the software protocol can be found in the manual "Communication profile PROFIBUS DP". The PROFIBUS expansion card has two 9-pin Sub-D sockets wired in parallel. The supply voltage for the expansion card is provided by the servo ampli fier.

10.3.1 Front view

10.3.2 Connection technology

Cable selection, cable routing, shielding, bus connector, bus termination and transmission times are described in the “Installation guidelines for PROFIBUS-DP/FMS” from PNO, the PROFIBUS User Organization.

10.3.3 Connection diagram

AX2040/2070

AGND and DGND (connector X3) must be joined together !

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10.4 Expansion card -SERCOS-

This chapter describes the SERCOS expansion card for AX2040/2070. Information on the range of functions and the software protocol can be found in the manual "IDN Reference Guide SERCOS".

10.4.1 Front view

10.4.2 Light emitting diodes (LEDs)

indicates whether SERCOS telegrams are being correctly received. In the final Communi

cation Phase 4 this LED should flicker, since cyclical telegrams are being received. indicates that SERCOS telegrams are being transmitted. In the final Communication Phase 4 this LED should flicker, since cyclical telegrams are being transmitted. Check the stations addresses for the controls and the servo amplifier if:

- the LED never lights up in SERCOS Phase 1 or

- the axis cannot be operated, although the RT LED is lighting up cyclically. indicates that SERCOS communication is faulty or suffering from interference. If this LED is very bright, then communication is suffering strong interference, or is non-existent. Check the SERCOS transmission speed for the controls and the servo amplifier (BAUDRATE) and the fibre-optic connection. If this LED flickers, this indicates a low level of interference for SERCOS communication,

ERR

or the optical transmitting power is not correctly adjusted to suit the length of cable. Check the transmitting power of the (physically) previous SERCOS station. The transmitting power of the servo amplifier can be adjusted in the setup software DRIVE.EXE on the SERCOS screen page, by altering the parameter for the cable length.

10.4.3 Connection technology

For the fiber optic cable connection, only use SERCOS components to the SERCOS Standard IEC 61491.

Receive data

The fiber optic cable carrying receive data for the drive in the ring structure is connected to X13 with an F-SMA connector.

Transmit data

Connect the fiber optic cable for the data output to X14 with an F-SMA connector.

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Beckhoff AX2070, AX2040 Assembly, Installation, Setup

Specifications and Main Features

Frequently Asked Questions

User Manual

06/2007 Contents

1 General

1.1 About this manual

1.2 Hints for the online edition (PDF format)

1.3 Symbols used

1.4 Abbreviations used

2 Safety

2.1 Safety Instructions

Safety instructions

2.2 Use as directed

06/2007 Standards

3 Standards

3.1 European directives and standards

3.2 American Directives and Standards

3.3 Asian Directives and Standards

3.4 Approvals

3.4.1 CE - conformance

3.4.2 UL and cUL- Conformance

4 Handling

4.1 Transport

4.2 Packaging

4.3 Storage

4.4 Maintenance

4.5 Disposal

5 Package

5.1 Package supplied

5.2 Nameplate

5.3 Part number scheme

6 Technical description

6.1 The digital servo amplifiers of the series AX2040/2070

6.2 Technical data

6.2.1 Recommended torques

6.2.2 Fusing

External fusing

6.2.3 Ambient conditions, ventilation, mounting position

Site altitude

Pollution level Pollution level 2 to EN60204/EN50178 Vibrations Noise emission Enclosure protection IP 20 Mounting position Ventilation

6.2.4 Conductor cross-sections

6.3 LED display

6.4 Grounding system

6.5 Control for motor holding brake

6.6 Regen circuit

6.7 Switch-on and switch-off behavior

6.7.1 Behavior in standard operation

6.7.2 Behavior in the event of an error (with standard setting)

6.8 Stop/Emergency Stop Function to EN 60204

6.8.1 Stop: Standards

6.8.2 Emergency Stop: Standards

6.8.3 Implementation of the Stop Category 0

6.8.4 Implementation of the Stop Category 1

6.8.5 Implementation of the Stop Category 2

6.9 Shock-hazard protection

6.9.1 Leakage current

6.9.2 Residual-current circuit breakers (FI)

6.9.3 Isolating transformers

7 Mechanical Installation

7.1 Important notes

7.2 Guide to mechanical installation

Site

7.3 Assembly

7.4 Dimensions

8 Electrical Installation

8.1 Important Notes

8.2 Guide to electrical installation

8.3 Wiring

8.3.1 Important notes

8.3.2 Shielding connection to the front panel

8.3.3 Technical data for cables

8.4 Components of a servo system

8.5 Block diagram

8.6 Pin assignments

8.7 Connection diagram (overview)

8.8 Power supply

8.8.1 Connection to various mains supply networks

8.8.2 Mains supply connection (X0)

8.8.3 24V auxiliary supply (X4)