BECKHOFF AX2500 User Manual

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Digital Servo Amplifier

AX2500

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 editions

Edition Comments

07/03 First edition

07/05

SSI emulation updated (Multiturn), UL/cUL information updated, typographical changes, chapter 1 new sorted, several corrections

02/06 Chapter feedback updated, label updated, several small corrections

PROFIBUS Topologie, part number scheme, trouble-shooting reduced, "Components of a servo system" extended and moved, disposal acc. to WEEE-2002/96/EG, new document structure,

06/07

Quickstart integrated, EtherCat type new, 24V supply voltage hints, feedback expanded, BISS-Interface, Stop/Emergency-Stop expanded, shock-hazard protection new, DC-Bus link ex panded, accessories removed, timing diagramm motor brake

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 to improve the performance of the equipment may be made without 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 processed, copied or distributed by electronic means without the written permission of BECKHOFF.

BECKHOFF 06/2007 Contents

page

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 / Cleaning ..........................................................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 Digital servo amplifiers in the series AX2500 ..........................................16

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

6.2.1 Rated data ................................................................18

6.2.2 Inputs / Outputs ............................................................19

6.2.3 Recommended tightening torques .............................................19

6.2.4 Fusing ...................................................................19

6.2.5 Ambient conditions, ventilation, mounting position .................................20

6.2.6 Conductor cross-sections ....................................................20

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

6.4 Control for motor holding brake ....................................................21

6.5 Grounding system ..............................................................22

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

6.7 Switch-on/-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

AX2500 Product Manual 3

Contents 06/2007 BECKHOFF

page

7 Mechanical Installation

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

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

7.3 Mounting ......................................................................34

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

7.5 Add-on fan ....................................................................36

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 Shield connection on the front panel............................................40

8.3.3 Requirements to cables......................................................41

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

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

8.6 Connector assignments ..........................................................44

8.7 Connection diagram AX250x and AX251x (overview) ...................................45

8.8 Connection diagram AX252x (overview) .............................................46

8.9 Power supply, master only ........................................................47

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

8.9.2 24V auxiliary voltage (X0) ....................................................47

8.10 DC Bus link (X0) ................................................................48

8.11 Motor connection with brake (X6)...................................................48

8.12 External regen resistor (X0), master only.............................................48

8.13 Feedback .....................................................................49

8.13.1 Resolver (X5) .............................................................50

8.13.2 Sine encoder 5V with BISS (X2) ...............................................51

8.13.3 Sine Encoder with EnDat 2.1 or HIPERFACE (X2) ................................52

8.13.4 Sine Encoder without data channel (X2).........................................53

8.13.5 Incremental or sine encoder with hall sensors (X2) ................................54

8.13.6 Incremental Encoder (X4) ....................................................55

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

8.14.1 Connection to a AX2500 master, 5 V signal level (X4) .............................57

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

8.14.3 Connection to a sine-cosine encoder master (X2).................................58

8.14.4 Connection to a SSI encoder (X4) .............................................59

8.14.5 Connection to stepper motor controllers (pulse and direction) ........................59

8.14.5.1 Step/Direction with 5 V signal level (X4) ......................................60

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

8.15 Encoder emulations .............................................................61

8.15.1 Incremental encoder output - A quad B (X4) .....................................61

8.15.2 SSI output (X4) ............................................................62

8.16 Digital and analog inputs and outputs ...............................................63

8.16.1 Analog input (X3)...........................................................63

8.16.2 Digital inputs (X3) ..........................................................64

8.16.3 Digital outputs (X3) .........................................................65

8.16.4 Digital I/O on the Master (X1) .................................................66

8.17 RS232 interface, PC connection (X8), master only.....................................67

8.18 Fieldbus connection .............................................................68

8.18.1 CANopen interface (X7) .....................................................68

8.18.2 PROFIBUS interface (X7), option ..............................................69

8.18.3 SERCOS interface (X7), option................................................70

8.18.3.1 Light emitting diodes (LEDs) ...............................................70

8.18.3.2 Connection diagram .....................................................70

8.18.4 EtherCat interface (X7), option ................................................71

8.18.4.1 EtherCat connection, connector X7A/B (RJ-45) ................................71

8.18.4.2 Connection diagram .....................................................71

4 AX2500Product Manual

BECKHOFF 06/2007 Contents

page

9Setup

9.1 Important notes.................................................................73

9.2 Setup software .................................................................74

9.2.1 General ..................................................................74

9.2.1.1 Use as directed .........................................................74

9.2.1.2 Software description .....................................................74

9.2.1.3 Hardware requirements...................................................75

9.2.1.4 Operating systems ......................................................75

9.2.2 Installation under WINDOWS 98 / 2000 / ME / NT / XP .............................75

9.3 Quickstart, drive test.............................................................76

9.3.1 Preparation ...............................................................76

9.3.1.1 Unpacking, Mounting and Wiring the Servo Amplifier ...........................76

9.3.1.2 Documents ............................................................76

9.3.1.3 Minimum Wiring for Drive Test .............................................77

9.3.2 Connect ..................................................................78

9.3.3 Important Screen Elements...................................................79

9.3.4 Basic Setup ...............................................................80

9.3.5 Motor (synchronous) ........................................................81

9.3.6 Feedback.................................................................82

9.3.7 Save Parameters and Restart.................................................83

9.3.8 Jogging the Motor (Speed Control) .............................................84

9.3.9 Status ...................................................................85

9.3.10 Monitor...................................................................85

9.3.11 Additional Setup Parameters..................................................85

9.4 Multi-axis systems ..............................................................86

9.4.1 Station Address ............................................................86

9.4.2 Example of connections for multi-axis system ....................................87

9.5 Key pad controls and status displays ................................................88

9.5.1 Operating.................................................................88

9.5.2 Status display on the axis module..............................................88

9.5.3 Status display on the master..................................................89

9.6 Error messages ................................................................90

9.7 Warning messages..............................................................91

9.8 Trouble Shooting ...............................................................92

10 Appendix

10.1 Glossary ......................................................................93

10.2 Index .........................................................................95

AX2500 Product Manual 5

06/2007 BECKHOFF

This page has been deliberately left blank.

6 AX2500 Product Manual

BECKHOFF 06/2007 General

1 General

1.1 About this manual

This manual describes the digital servo amplifiers of the AX2500 series.

A more detailed description of the field bus interfaces and the digital connection to auto mation systems can be found on the accompanying CD-ROM in PDF format (system requirements: WINDOWS, Internet browser, Acrobat Reader) in several language ver sions.

You can print out this documentation on any standard printer. A printed copy of the docu mentation is available from us at extra cost.

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

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

electrical engineering / drive technology.

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

Danger to personnel from electricity and its effects effects

ð p. see page l special emphasis

Danger to maschinery, general warning

Important notes

AX2500 Product Manual 7

General 06/2007 BECKHOFF

1.4 Abbreviations used

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

Abbrev. Meaning

AGND Analog ground BTB/RTO Ready to operate CAN Fieldbus (CANopen) CE Communité Europeenne (=EC) CLK Clock signal COM Serial interface for a PC-AT DGND Digital ground DIN Deutsches Institut für Normung Disk Magnetic storage (diskette, hard disk) EEPROM Electrically erasable memory EMC Electromagnetic compatibility EMI Elektromagnetic 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 ISO International Standardization Organization LED Light-emitting diode MB Megabyte NI Zero pulse NSTOP Limit-switch input, rot. dir. CCW (left) PC Personal Computer PELV Protected low voltage PLC Programmable logic controller PSTOP Limit-switch input, rot. dir. CW (right) PSU Power supply unit PWM Pulse-width modulation RAM Volatile memory RBext External regen resistor RBint Internal regen resistor RES Resolver ROD 426 A quad B Encoder SRAM Static RAM SSI Synchronous serial interface UL Underwriter Laboratory V AC AC voltage V DC DC voltage VDE Verein deutscher Elektrotechniker

8 AX2500 Product Manual

BECKHOFF 06/2007 Safety

2 Safety

2.1 Safety Instructions

Only properly qualified personnel are permitted to carry out activities such as

transport, installation, commissioning and maintenance. Properly qualified per sons are those who are familiar with the transport, assembly, installation, com missioning and operation of the product, and who have the appropriate qualifi cations for their job. The qualified personnel must know and observe the following standards and regulations: — IEC 60364 or DIN VDE 0100 — IEC 60664 or DIN VDE 0110 — national accident prevention regulations or BGV A3

Read this documentation before carrying out the installation and commissio

ning. Incorrect handling 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 (nameplate and documentation).

Discharge your body before touching the servo amplifier. The servo amplifiers

contain electrostatically sensitive components which may be damaged by in correct handling. Avoid contact with highly insulating materials (artificial fab rics, plastic film etc.). Place the servo amplifier on a conductive surface.

The manufacturer of the machine must produce a hazard analysis for the ma-

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

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 in jury. 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. contacts) or undoing any connections. Capacitors can still have dangerous voltages present 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.

AX2500 Product Manual 9

Safety 06/2007 BECKHOFF

2.2 Use as directed

The servo amplifiers are components which are built into electrical equipment or ma

chines, and can only be commissioned as integral components of such equipment.

The manufacturer of the machine must produce a hazard analysis for the ma

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

The servo amplifier should only be used with power supplies with a maximum

symmetrical rated current of 5000A and a voltage of 115/230V AC (AX250x) or 400V AC (AX251x).

Mains voltage Servo amplifier

1 x 115V AC only AX250x, unearthed operation is permissible 3 x 115V AC only AX250x, unearthed operation is permissible 1 x 230V AC only AX250x, unearthed operation is permissible 3 x 230V AC all types, unearthed operation is permissible 3 x 400V AC only AX251x, TN-system or TT-system with earthed neutral point

If the servo amplifiers are used in residential areas, or in business or commercial

premises, then additional filter measures must be implemented by the user.

The AX2500 family of servo amplifiers is only intended to drive specific brushless

synchronous 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 servo amplifiers may only be operated in a closed control cabinet, taking into

account the ambient conditions defined on page 20. Ventilation or cooling measures may be required to keep the temperature below 45°C.

Use only copper-cored cables for wiring. The conductor cross-sections can be taken from the European standard EN 60204 (or Table 310-16 of NEC for 60°C or 75°C in the column for AWG cross-sections).

We can only guarantee that the system will conform to the standards cited on page 11 if the components used are exclusively those supplied by us (servo amplifier, mo tor, cables etc.).

Not more than 7 axis modules can be connected to a master module.

10 AX2500 Product Manual

BECKHOFF 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 servoamplifiers are built into machines or plant, the intended operation of the amplifier is forbidden until it has been established that the machine or plant fulfills the requirements of the EC Machinery Directive 98/37/EG and the EC Directive on EMC (89/336/EEC) and the Low Voltage Directive 73/23/EEC.

To fulfill the EC Machinery directive 98/37/EG, the following standards have to be applied: EN 60204-1 (Safety and electrical equipment of machines) EN 12100 (Safety of machines)

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.

To fulfill the Low Voltage Directive 73/23/EEC, the following standards have to be applied: EN 60204-1 (Safety and electrical equipment of machines) EN 50178 (Equipment of high voltage plant with electronic devices) EN 60439-1 (Low-voltage switchgear and controlgear assemblies)

To fulfill the EC EMC regulations 89/336/EEC, the following standards have to be applied: EN 61000-6-1 or EN 61000-6-2 (noise immunity in the domestic range/industrial range) EN 61000-6-3 or EN 61000-6-4 (noise emission in the domestic range/industrial range)

The manufacturer of the machine or plant is responsible for ensuring that they meet the limits required by the EMC regulations. Advice on the correct installation for EMC – such as shielding, grounding, arrangement of connectors and cable routing – can be found in this documentation.

The machine / plant manufacturer must examine whether with its machine / plant still further or other standards or EEC guidelines are to be used.

3.2 American Directives and Standards

Chapter in process

3.3 Asian Directives and Standards

Chapter in process

AX2500 Product Manual 11

Standards 06/2007 BECKHOFF

3.4 Approvals

3.4.1 CE conformance

Conformity with the EC Directive on EMC 89/336/EEC and the Low Voltage Directive 73/23/EEC is mandatory for servoamplifiers supplied within the European Union. To fulfill the EMC directive, the standard EN 61800-3 is applied. The Declaration of Con formity form can be found on our website (download area).

In the reference to noise immunity the servoamplifier fulfills the requirement to the cate gory second environment (industrial environment). For noise emission the amplifier meets

the requirement to a product of the category C2 (motor cable £ 25m).

Warning! This product can cause high-frequency interferences in non industrial environments which can require measures for interference suppression.

The servo amplifiers have been tested by an authorized testing laboratory in a defined configuration with the system components which are described in this documentation. Any divergence from the configuration and installation described in this documentation means that you will be responsible for carrying out new measurements to ensure that the regulatory requirements are fulfilled.

To fulfill the Low Voltage Directive, the standard EN 50178 has to be applied.

3.4.2 UL and cUL- Conformance

This servo amplifier is listed under UL file number E217428.

UL (cUL)-certified servo amplifiers (Underwriters Laboratories Inc.) fulfil the relevant U.S. and Canadian standard (in this case UL 840 and UL 508C).

This standard describes the fulfilment 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.

UL(cUL) regulations also specify the minimum technical requirements of electrical devices, in order to take the necessary measures against the risk of fire, which can be triggered by electrically operated devices. The technical conformance with the U.S. and Canadian standard is determined by an independent UL (cUL) inspector through the type testing and regular checkups.

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 fulfilment by design of minimum requirements for electrically oper ated 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 fulfilment by design of air and insulation creepage spacings for electrical equipment and printed circuit boards.

12 AX2500 Product Manual

BECKHOFF 06/2007 Handling

4 Handling

4.1 Transport

Transport only by qualified personnel in the manufacturer’s original packaging

Avoid shocks

Transport temperature -25 to +70°C, max. rate of change 20°C/hour

Transport 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 ser vo amplifier. 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 such a case, in

form the shipper and the manufacturer.

4.2 Packaging

Recyclable cardboard with inserts

Dimensions AX252x (HxWxD) 100x300x270 mm

AX250x/AX251x (HxWxD) 150x300x270 mm

Labelling instrument label on outside of box

4.3 Storage

l Storage only in the manufacturer’s original recyclable packaging

Max. stacking height: 8 cartons

Storage temp. –25 to +55°C, max. rate of change 20°C/hr

Humidity relative humidity max. 5...95%, no condensation

Storage duration < 1 year without restriction > 1 year: capacitors must be re-formed before the servo amplifier is commissioned. To do this, remove all electrical connections and supply the servo amplifier for about 30 min. from 230V AC, single-phase, on terminals L2 / L3.

4.4 Maintenance / Cleaning

The devices do not require any maintenance, opening the devices invalidates warranty. Cleaning : — if the casing is dirty, clean with Isopropanol or similar

do not immerse or spray

— 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

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

AX2500 Product Manual 13

Package 06/2007 BECKHOFF

5 Package

5.1 Package supplied

If you order a AX2500 series amplifier from us, you will receive:

— AX250x or AX251x (master) — Mating connectors for X0, X1, X3, X6 — Protective cover for the axis-side (required only once per system) — Assembly and Installation Instructions — Setup software DRIVE.EXE and online documentation on CD-ROM or — AX252x (axis module) — Mating connector for X3, X6 — Short-form instructions

The mating SubD connectors are not part of the package supplied!

Accessories:

— Electrical add-on fan (for max. 2 axes, required for AX25x6) — Synchronous servomotor (linear or rotary) — Motor lead (pre-assembled), or motor cable as cut-off length + loose connectors

(motor- and amplifier-side)

— Feedback cable (pre-assembled) or both feedback connectors, loose with

feedback cable as cut-off length

— External regen resistor BAR(U) — Communication cable to PC (ð p.67) for parameterizing the master and any

attached axis modules

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

5.2 Nameplate

The nameplate depicted below is attached to the side of the servo amplifier.

Servo amplifier type

Typenbezeichnung

(must be ordered separately if required)

Eiserstr. 5 D-33415 Verl

Model Number

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

Ser.Nr

CommentsSerial number

E217428

Ser.No.

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

14 AX2500 Product Manual

BECKHOFF 06/2007 Package

5.3 Part number scheme

S406A0-NA

Family

S4 AX2500

Current rating

03 3A rms 06 6A rms

Voltage rating

A 230...400V 6 115...230V B no power supply

Expansions

NA no expansion PB PROFIBUS SE SERCOS EC ETHERCAT

Function

A Axis module M Master module

Comparison (without expansion) device name -> UL part number

Device Name UL Part Number

AX2503 S4036M-NA AX2506 S4066M-NA AX2513 S403AM-NA AX2516 S406AM-NA AX2523 S403BA-NA AX2526 S406BA-NA

AX2500 Product Manual 15

Technical description 06/2007 BECKHOFF

6 Technical description

6.1 Digital servo amplifiers in the series AX2500

Minimum complexity

up to 8 axes in a single system

only one power supply feed and one auxiliary voltage supply per system

shield connection directly on the servo amplifier

all axes in a system can be parameterized through a single interface

strongly reduced wiring expenditure by modular structure

simple mechanical structure on DIN rails

Standard version

2 supply voltage versions: AX250x up to 3x230VAC and

AX251x up to 3x400VAC

one size for the master and axis modules each, see page 35

analog input

fieldbus interface is integrated (standard: CANopen)

RS232 is integrated

pulse-direction interface is integrated

Supply power

directly off electrical supply input (master only, B6 rectifier bridge, integral power input filter and inrush circuit): 1 x 115V AC (AX250x only, unearthed operation is permitted) 3 x 115V AC (AX250x only, unearthed operation is permitted) 1 x 230V AC (AX250x only, unearthed operation is permissible) 3 x 230V AC (all types, unearthed operation is permissible) 3 x 400V AC (AX251x only, TN-system or TT-system with

earthed neutral point)

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

integrated interference suppression filter for the supply input (for category 2)

integrated interference suppression filter for the 24V auxiliary supply (for category 2)

all shielding connections directly on the amplifier

output stage IGBT module with isolated current measurement

Clock frequency can be switched from 8 to 16 kHz with

ASCII command (with power reduction, please contact

our customer support)

regen circuit internal regen resistor as standard,

external regen resistor if required

DC Bus link voltage 160...320V DC for AX250x

320...560V DC for AX251x

160...560V DC for AX252x

16 AX2500 Product Manual

BECKHOFF 06/2007 Technical description

Integrated safety

safe electrical separation to EN 50178 between the power input / motor connections

and the signal electronics, provided by appropriate creepage distances and complete electrical isolation

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

temperature monitoring of servo amplifier and motor (when using our motors with our

pre-assembled cables)

Auxiliary voltage 24V DC

electrically isolated via an external 24V DC PSU, e.g. with isolating transformer

Operation and parameter setting

with the comfortable setup software, via the serial interface of a PC to a single con

nection for all axes in a system

station address setting through two keys and a 3-digit LED status display on the

master

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 every application (250 µs)

integrated pulse direction interface, for connection of a servomotor to a stepper-motor control

evaluation of the resolver signals or sine/cosine signals from a high-resolution encoder

encoder emulation (incremental ROD 426-compatible or SSI)

Comfort functions

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

2 programmable digital outputs

freely programmable combinations of all digital signals

Options

PROFIBUS DP interface instead of CANopen, see page 69

SERCOS interface instead of CANopen, see page 70

EtherCat interface instead of CANopen, see page 71

AX2500 Product Manual 17

Technical description 06/2007 BECKHOFF

6.2 Technical data

6.2.1 Rated data

max. 230VAC max. 400VAC

Master

AX250

Rated data DIM 363636

Rated supply voltage V~

Max. installed load for S1 operation (in a multi-axis system)

kVA 7 12 —

1 x 115V

3 x 230V

-10%

+10%

Rated DC Bus link voltage V= 160 - 320 320 - 560 160 - 560 Rated output current

(rms value, ± 3%, @ 8kHz) Peak output current

(max. ca. 5s, ± 3%, @ 8kHz)

Arms

36*36*36*

9 12* 9 12* 9 12*

8 (can be switched to 16, with power re-

Clock frequency of output stage kHz

duction, please contact our customer sup

Overvoltage switch-off threshold V 450 750 — maximum load inductance mH 75 40 75 40 75 40 minimum load inductance mH 12 7.5 12 7.5 12 7.5 Form factor of the output current (rated conditions and min. load

— 1.01 inductance) Bandwidth of subordinate current controller Residual voltage drop at rated current Quiescent dissipation, output stage disabled Dissipation at rated current (without regen dissipation)

kHz > 1.2

V<5

W121512151215

W356035603040

Mechanical

Weight kg 3 1.7 Height, without connectors mm 230 267* 230 267* 230 267* Width mm 100 50 Depth, without connectors mm 240

Master

AX251

3 x 230V

3 x 400V

port)

Axis module

AX252

-10%

—

+10%

* with add-on ventilation, see page 36

18 AX2500 Product Manual

BECKHOFF 06/2007 Technical description

6.2.2 Inputs / Outputs

Analog input, 14-bit resolution V

common-mode voltage max. V Digital control inputs V low 0...7V, high 12...36V, 7mA Digital control outputs, open emitter V max. 30V, 10mA

BTB/RTO output, relay contacts

Auxiliary supply, electrically isolated, without holding brake, without fan Auxiliary supply, electrically isolated, with holding brake or fan (check voltage drop !) Min./max. output current for holding brake A 0.15 / 1.5

Connections

Control signals — Combicon spring terminal Power supply — Power Combicon Motor — Combicon Resolver input — SubD 9pol. (socket) Incremental encoder input — SubD 15pol. (socket) PC interface — SubD 9pol. (plug) Encoder emulation, ROD/SSI — SubD 9pol. (plug)

n= number of axes

6.2.3 Recommended tightening torques

±10 ±10

V DC max. 30, AC max 42

mA 500

V 20-30 A n * 0.5 V 24 (-0% +15%)

A n * 2,5

Connector Tightening torque

X1, X3, X6 0.3 Nm X0 1.3 Nm Earthing bolts 3.5 Nm lower mounting bolt 3.5 Nm

6.2.4 Fusing

Internal fusing

Function

Auxiliary supply 24V 20 AM Regen resistor electronical

External fusing

Function Fusible cutouts or similar

AC supply F 24V supply F Regen resistor F

N1/2/3

H1/2

B1/2

16 A slow 20 A slow

6 A slow

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6.2.5 Ambient conditions, ventilation, mounting position

Storage, transport

ð p.13

Supply voltage tolerances

main power

AX250x

AX251x

min 1x115V min 3x115V min 3x230V

AC / max 1x230V

-10%

AC / max 3x230V

-10%

AC / max 3x400V

-10%

+10%

, 50/60 Hz

+10%

, 50/60 Hz

+10%

, 50/60 Hz

auxiliary supply

w/o brake and w/o fan with brake or with fan

Ambient temperature in operation

Humidity in operation

Site altitude

20 VDC ... 30 VDC 24 VDC (-0% +15%), check voltage drop

0...+45

C at rated conditions +45...+55°C with power derating 2.5% / K rel. humidity 85%, no condensation up to 1000m amsl without restrictions

1000...2500m amsl with derating 1.5% / 100m

Pollution level Pollution level 2 as per EN 60204 / EN 50178 Vibrations Noise emission

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

Enclosure protection IP 20 Mounting position

Ventilation

normally vertical ð p.34 AX25x3: free convection AX25x6: add-on fan (ð p.36)

Make sure that there is adequate forced ventilation in the closed control cabinet.

6.2.6 Conductor cross-sections

Technical requirements to cables ð p.41. Following EN 60204-1, we recommend :

AC connection Motor cables, max. 25m Resolver, motor thermostat, max.100m Encoder, motor thermostat, max. 50m Analog signals Control signals, BTB, DGND Holding brake (motor)

+24 V / XGND

To reach the max. permitted cable length, observe cable requirements ð p. 41.

6.3 LED display

A 3-digit LED display indicates the amplifier status after switching on the 24V supply (ð p.89).

1.5 mm², depending on the system fusing 1 mm², shielded, capacitance <150pF/m 4x2x0.25 mm², twisted pairs, shielded, capacitance <120pF/m 7x2x0.25 mm², twisted pairs, shielded, capacitance <120pF/m

0.25 mm² , twisted pairs, shielded

0.5 mm²

0.75 mm², shielded, check voltage drop max. 2.5 mm²

Check voltage drop and total current!

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6.4 Control for motor holding brake

A motor holding brake (24V, max.1.5 A) 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 (on the screen page for Motor): the setting is WITH. In the diagram below you can see the timing 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 amplifier is internally driven down a 10 ms ramp to 0. The brake output is switched on when a speed of 5 rpm is reached, at the latest after 5s (EMRGTO). The rise (f

) and fall (f

brH

) times of the holding brakes that are built into the motors vary

brL

for the different types of motor (see motor manual). A description of the interface can be found on page 48.

Personnel-safe operation of the holding brake requires an additional “make” contact in the brake circuit and a spark suppressor device (e.g. a varistor) in the recommended brake circuit:

AX2500

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6.5 Grounding system

AGND – ground reference for analog signals, internal analog ground DGND – ground reference for digital signals and auxiliary supply voltage,

optically isolated PGND — ground reference for position output The electrical isolation is indicated in the block diagram (ð p.43).

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. The regen resistor is switched in and out by the regen circuit. The switching thresholds for the regen circuit are adjusted to suit the supply voltage with the aid of the setup software. Our customer support can help you with the calculation of the regen power which is required. A description of the interface can be found on page 48 .

Internal regen resistor 33 W External regen resistor 33 W

Functional description

The regen circuit starts to respond when the DC Bus link voltage reaches the set value. 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 circuit will be switched off.

At the next internal check of the DC Bus link voltage (after a few milliseconds) an overvoltage will be detected and the servo amplifier will be switched off, with the error message overvoltage (ð p.90). The BTB/RTO contact (terminals X1/1,2) will be opened simultaneously (ð p.66).

Technical data

Supply voltage Rated data DIM Value

Upper switch-on threshold for regen circuit V 400 Switch-off threshold for regen circuit V 380

)W55

Bint

) max. kW 0,4

3 x 230 V

Continuous int. power in regen circuit (R Continuous ext. power in circuit (R Pulse power, internal (R Pulse power, external (R

max. 1s) kW 4.8

Bint

Bext

max. 1s) kW 4.8 External regen resistor Upper switch-on threshold for regen circuit V 720 Switch-off threshold for regen circuit V 680

)W80

Bint

) max. kW 0,6

3 x 400 V

Continuous int. power in regen circuit (R Continuous ext. power in circuit (R Pulse power, internal (R Pulse power, external (R

max. 1s) kW 16

Bint

Bext

max. 1s) kW 16 External regen resistor

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6.7 Switch-on/-off behavior

This chapter describes the switch-on and switch-off behavior of the AX25 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 soft ware: 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: War

ning n05 is output if an input phase is missing, and the motor current is limited to 4 A. The servo amplifier 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 instance.

l Error message if the servo amplifier is to bring the drive to a standstill: Error messa-

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

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 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 inter nal “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.

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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).

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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 con trol 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 (ACTFAULT=1).

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6.8 Stop / Emergency Stop Function to EN 60204

6.8.1 Stop: Standards

The Stop function is used to shut down the machine in normal operation. The Stop func tions 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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6.8.2 Emergency Stop: Standards

The emergency Stop function is used for the fastest possible shut-down of the machine in a dangerous 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 operate 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 opera

ting situations.

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 mechanical latching devices that do not require an external supply of energy, by counter-current braking 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 elec

tromechanical 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 hold ing brake fulfills the dynamic requirements, it must be taken into acount that this applica

tion will cause increased wear.

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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 (STOPMODE & ACTFAULT parameters set to 1). The switching sequence is unambig uously fixed by the circuit, and must be followed, to prevent undesirable error signals and failure of the servo amplifier.

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 cir cuit, as well as the control through the AX25xx, in order to meet Category 0.

Normally, 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 hold ing brake fulfills the dynamic requirements, it must be taken into acount that this applica tion will cause increased wear.

Circuit suggestion

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

AX2500

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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 AX2500 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 6.4) 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 sup ply and the holding brake are electrically isolated.

Should an internal AX2500 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)

AX2500

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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 fol lowing a time period set at the time relay.

Circuit suggestion

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

AX2500

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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:

= n x 20mA + L x 1mA/m at 8kHz clock frequency at the output stage

leak

= n x 20mA + L x 2mA/m at a 16kHz clock frequency at the output stage

leak

(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. Use the PE terminal X0/3 and the PE bolt in order to fulfil this requirement.

The following measures can be used to minimise leakage currents. — Reduce the length of the engine cable — Use low-capacity cables (see p.41) — Remove external EMC filters (radio-interference suppressors are integrated)

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 AX2500 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 shorter than 5 m) we recommend that each servo amplifier be protected individually using a 30mA residual-current circuit-breaker which is sensitive to all currents.

Protection against "indirect contact" (personal fire protection) for stationary and mobile equipment, as well as for "direct contact". Protection against "indirect contact" (personal fire protection) for stationary equipment

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

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6.9.3 Isolating transformers

If protection against indirect contact is absolutely essential despite a higher leakage cur rent, or if an alternative form of shock-hazard protection is sought, the AX2500 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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7 Mechanical Installation

7.1 Important notes

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

components 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 control

cabinet or use heat exchanger. Note the conditions on page 20.

Take care that the servo amplifier and motor are properly earthed. Do not use pain

ted (non-conductive) mounting plates.

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

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

Not more than 7 axis modules can be connected to a master module.

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 control cabinet. Observe page 20.

Site

Ventilation

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

Check that the ventilation of the servo amplifier is unimpeded and keep within the permitted ambient temperature ð p.20 . Keep the required space clear above and below the servo amplifier ð p.34.

Mount the servo amplifier on mounting rails (DIN-rails) on the

Mounting

Grounding,

Shielding

conductive, earthed mounting plate in the control cabinet and mount the necessary add-on fans (ð p.36)

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

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7.3 Mounting

Material: 2 mounting rails to EN60715, min. length = system width + 40mm,

make sure there is a conductive connection to the mounting plate

Mount the protective cover (7mm) on the left side of the system.

Tools required: Screwdriver with approx. 5 mm blade width

AX2500

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7.4 Dimensions

AX250x and AX251x

AX252x

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7.5 Add-on fan

Electrical add-on fan for two axes to achieve rated power even under unfavourable ambi ent conditions, required for AX25x6.

To mount the fan, just hook it in the designated slots at the bottom of the AX2500 and screw the fixing bolt into the thread in the housing. The electrical connection takes place automatically when mounting the fan.

Please consider that a mounted fan increases the required space underneath the amplifier! (Þ p. 34)

The drawing below shows, how the fan should be mounted. With an odd number of axes (master included), the fan must also cover the power supply unit at the master.

Single master

Master with 1 Axis module

Master with 2 Axis modules

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8 Electrical Installation

8.1 Important notes

Not more than 7 axis modules can be connected to a master module.

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

current of the units. Carry out the wiring according to the instructions on page 39.

Make sure that the maximum permissible rated voltage at the terminals for L1, L2, L3

and +R conditions (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. Use the AX251x only on an earthed 3-phase supply system. Use the amplifier only to drive a synchronous servomotor.

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

20 cm. This improves the interference immunity required by EMC regulations. If a motor power cable is used which includes cores for brake control, the brake control cores must be separately shielded. Earth the shielding at both ends (ð p.45).

, –DC is not exceeded by more than 10%, even in the most unfavourable

Bext

Install all heavy-current cables with an adequate cross-section, as per EN 60204-1

(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.

Only in this way is the monitoring of the servo amplifier assured.

Install all shielding with large area (low impedance) connections, with metallised con-

nector housings or shield connection clamps where possible. Notes on connection techniques can be found on page 40.

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

Any other alterations will invalidate the warranty.

Caution Never disconnect the electrical connections to the servo amplifier while it is live. 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 (+R

/-DC) and wait until the voltage has fallen below 40V.

Bext

Control and power connections can still be live, even when the motor is not rotating.

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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 selection

Grounding,

Shielding

Wiring — Route power leads separately from control cables

Select cables according to EN 60204-1, ð p.20

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

— Wire the BTB/RTO contact in series into the safety loop — Connect the digital control inputs to the servo amplifier — Connect up AGND — Connect the analog setpoint, if required — Connect the feedback unit (resolver or encoder) — If required, connect the encoder emulation — If required, connect the fieldbus — Connect the motor cable

Connect shielding to EMC connectors at the motor end, and the shielding lug at the amplifier end

— Connect motor-holding brake, with shielding to EMC

connector at the motor end, and to shielding lug at the

amplifier end — If required, connect the external regen resistor (with fusing) — Connect the auxiliary supply

(maximum permissible voltages ð p.20) — Connect main power supply

(maximum permissible voltages ð p.20) — Connect PC (ð p.67).

Check

Make a final check of the wiring carried out against the wiring diagrams that 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 appropriate 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 (lock-out, warning signs etc.). The individual voltages will be switched on for the first time during commissioning.

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

Use the following wiring and connection diagrams : Overview:

Master module : Page 45

Axis module : Page 46 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 Digital&Analog I/Os : Page 63ff RS232 / PC : Page 67 Fieldbus:

CAN interface : Page 68

PROFIBUS interface : Page 69

SERCOS interface : Page 70

EtherCAT interface : Page 71 Multiaxis systems : Page 87

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

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8.3.2 Shield connection on the front panel

The pre-assembled cables for AX2500 are provided with an over all metal ferrule at the amplifier end that is electrically connected to the shielding.

Thread a cable tie through each slot in the shielding strip (front panel) of the servo amplifier.

AX2500

Tighten up the cable ties so that the shielding ferrule and the sheathing of the cable is pressed down tightly against the shielding strip.

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8.3.3 Requirements to cables

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

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 (polyesteraphthalate, code 12Y)

Capacitance

Motor cable less than 150 pF/m RES/encoder cable less than 120 pF/m

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8.4 Components of a servo system

Control / PLC

24V supply

motor

fuses

drive contactor

terminals

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8.5 Block diagram

The block diagram below just provides an overview.

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8.6 Connector assignments

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8.7 Connection diagram AX250x and AX251x (overview)

Follow the safety instructions (ð p.9) and the use as directed (ð p.10) !

AX250x/AX251x

ðp.51ff

ð p.63

ð p.50

ð p.65

ð p.48

ð p.56

ð p.67

ð p.66

ð p.47

ð p.48

ð p.68

ð p.47

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8.8 Connection diagram AX252x (overview)

Follow the safety instructions (ð p.9) and the use as directed (ð p.10) !

AX252x

ðp.51ff

ð p.63

ð p.50

ð p.65

ð p.48

ð p.56

ð p.68

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8.9 Power supply, master only

8.9.1 Mains supply connection (X0)

Three-phase supplies

Directly to earthed supply, filter is integrated, fusing (e.g. fusible cut-outs) to be provided by the user (ð p.19).

AX2500

for AX250x

for AX251x

Single-phase supplies

Directly to supply, filter is integrated, fusing (e.g. fusible cut-outs) to be provided by the user (ð p.19).

AX2500

8.9.2 24V auxiliary voltage (X0)

— Electrically isolated supply from an external 24 V DC PSU, e.g. with isolating

transformer

— Required current rating (ð p.19)

Observe summarized current and voltage drop!

— Integrated EMC filter for the 24 V auxiliary supply

AX2500

for AX250x

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8.10 DC Bus link (X0)

Can be connected in parallel with further, identical masters (via terminals -DC and RB

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 AX2500 must not exceed 24 A.

Use unshielded single cores (2.5mm²) with a max. length of 200 mm. Use shielded cables for longer lengths.

8.11 Motor connection with brake (X6)

Max. admisible length of the motor cable is 25 m.

AX2500

ext

8.12 External regen resistor (X0), master only

Remove the plug-on link between terminals X0/5 (-RB) and X0/4 (+R

AX2500

bint

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8.13 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, information will be fed back to the servo amplifier using digital or analog means.

AX2500 supports the most common types of feedback device whose functions must be assigned 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

One Feedback

Two Feedbacks

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

The table below provides an overview of the supported feedback types, their corresponding parameters 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 X5 SinCos Encoder BISS X2 SinCos Encoder ENDAT X2 SinCos Encoder HIPERFACE X2 SinCos Encoder w/o data channel X2 SinCos Encoder + Hall X2 RS422 5V X4 Sensorless (w/o feedback) - - 10*

motor FBTYPE motor FBTYPE

externally

ASCII Parameter

EXTPOS GEARMODE

Commu-

tation

XXX XX

Wiring

diagram

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

Speed

control

Position-

control

FBTYPE

0, 3 20* 3, 4 2, 3

6, 7 (16*)

11*

8*, 9*

electr.

gearing

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

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

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8.13.1 Resolver (X5)

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 AX2500 and evaluated there.

If lead lengths of more than 25 m are planned, please consult our customer support.

FBTYPE: 0, 3

AX2500

SubD9

12-pin round

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8.13.2 Sine encoder 5V with BISS (X2)

Connection of a single- or multiturn sine-cosine encoder (5V) with BISS interface as feed back (from firmware revision 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 X2 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): 350 kHz FBTYPE: 20

AX2500

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8.13.3 Sine Encoder with EnDat 2.1 or HIPERFACE (X2)

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

The thermostat contact in the motor must be connected via the encoder cable to the AX2500 and evaluated there. All signals are connected using our pre-assembled encoder connection cable.

If lead lengths of more than 25 m are planned, please consult our customer support.

Frequency limit (sin, cos): 350 kHz Encoder with EnDat: FBTYPE 3, 4 Encoder with HIPERFACE: FBTYPE 2, 3

AX2500

SubD15

17-pin round

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8.13.4 Sine Encoder without data channel (X2)

Connection of a sine-cosine encoder without data channel as feedback. Every time the 24V auxiliary voltage is switched on, the amplifier needs start-up information for the posi tion 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 must be connected via the encoder cable to X2 and evaluated there.

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

Frequency limit (sin, cos): 350 kHz

Encoder type FBTYPE Remarks

SinCos 5V 6 MPHASE from EEPROM SinCos 5V 7 MPHASE with wake & shake

Resolver+SinCos5V 16

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

Commutation with resolver, Speed&Position with Encoder

AX2500

SubD 15

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8.13.5 Incremental or sine encoder with hall sensors (X2)

Feedback devices (incremental or sine-cosine), which don't deliver an absolute informa tion for commutation, can be used as complete feedback system combined with an addi tional Hall encoder. All signals are connected to X2.

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

Frequency limit (A, B): 350 kHz

RS422 with Hall: FBTYPE 12 Encoder with Hall: FBTYPE 11

AX2500

SubD15

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8.13.6 Incremental Encoder (X4)

An incremental encoder can be used as standard motor feedback.

Every time the 24V auxiliary voltage is switched on, the amplifier needs start-up informa tion 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 ampli fier's EEPROM.

The thermostat contact in the motor must be connected to X2 (see p.52) or X5 (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.

Frequency limit (A, B): 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).

AX2500

SubD 9

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8.14 Electronic Gearing, Master-slave operation

In the case of the “electronic gearing” functionality (see setup software and description of GEARMODE 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 connect 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 X4 Incremental Encoder 24V X3 Sine/Cosine Encoder X2 SSI Encoder X4 Pulse and Direction 5V X4 Pulse and Direction 24V X3

* adjustable via terminal screen of the setup software

The following table shows the allowed feedback combinations:

Secondary Feedback for Position control/Following Primary Feedback

Resolver (X5)

FBTYPE= 0

Sine Encoder (X2)

FBTYPE= 2,4,6,7,20

Encoder & Hall (X2)

FBTYPE= 11,12

RS422 Encoder (X4)

FBTYPE= 8,9

Sensorless

FBTYPE= 10 -

Sine Encoder

(X2)

EXTPOS= 1,2,3

GEARMODE=

6,8,9,16

FPGA= 0

ENCMODE= 0

--- -

Increm. Encoder 5V/24V (X4/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

Wiring

diagram

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

Pulse&Direct. 5V/24V (X4/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

GEARMODE

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

6, 8*, 9*, 16*

7*, 17*

4, 14* 1, 11*

SSI Encoder (X4)

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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8.14.1 Connection to a AX2500 master, 5 V signal level (X4)

You can link several AX2500 amplifiers in master-slave operation (encoder follower).

Up to 16 slave amplifiers can be controller by the master via the encoder output. The SubD connector X4 is used for this purpose.

Frequency limit: 1 MHz, transition speed tv £ 0.1 µsec

AGND (terminal X3/1) must be connected to the ground of the control system!

AX2500

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

You can use this interface to set up the AX2500 as a slave following an encoder with a 24V signal level (master-slave operation). This application uses the digital inputs DIGITAL-IN 1 and 2 on connector X3.

Frequency limit: 100 kHz, transition speed tv £ 0.1 µsec

AGND (terminal X3/1) must be connected to the ground of the control system!

AX2500

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8.14.3 Connection to a sine-cosine encoder master (X2)

You can set up the AX2500 as a slave following a sine/cosine encoder (master-slave operation). This application uses the SubD connector X2.

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

Frequency limit (sin, cos): 350 kHz

AGND (terminal X3/1) must be connected to the ground of the control system!

AX2500

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8.14.4 Connection to a SSI encoder (X4)

You can set up the AX2500 as a slave following a synchronous serial absolute-encoder (master-slave operation). This application uses the SubD connector X4. 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 MHz

AGND (terminal X3/1) must be connected to the ground of the control system!

AX2500

8.14.5 Connection to stepper motor controllers (pulse and direction)

You can 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 limit frequency! Using an A quad B encoder provides better EMC noise immunity.

Speed profile and signal diagram

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8.14.5.1 Step/Direction with 5 V signal level (X4)

Connection of the servo amplifier to a stepper motor control witha5Vsignal level. The SubD connector X4 is used for this purpose. Frequency limit: 1 MHz

AGND (terminal X3/1) must be connected to the ground of the control system!

AX2500

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

Connection of the servo amplifier to a stepper motor control with a 24 V signal level. The digital inputs DIGITAL-IN 1 and 2 on connector X3 are used for this purpose. Frequency limit: 100 kHz

AGND (terminal X3/1) must be connected to the ground of the control system!

AX2500

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8.15 Encoder emulations

8.15.1 Incremental encoder output - A quad B (X4)

The incremental-encoder interface is part of the package supplied. Select the encoder function ROD (screen page “Encoder”, funktion ENCMODE). 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 as two signals, A and B, with 90° phase difference and a zero pulse. The resolu tion (lines before quadrature) can be changed with the RESOLUTION parameter:

Encoder function Feedback system Resolution Zero position

Resolver 256...4096

ROD (1)

Encoder

ROD interpolation (3) Encoder

256...524288

... 219)

...27TTL

2 lines per sine line

one per revolution (only if A=B=1) one per revolution (only if A=B=1) analog pass through X2 to X4

You can also adjust and store the position of the zero pulse within one mechanical turn (parameter NI-OFFSET). The ground reference for the interface is PGND.

PGND must always be connected to the control ground. The max. admissible cable length is 10 m.

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

AX2500

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8.15.2 SSI output (X4)

The SSI interface (synchronous serial absolute-encoder emulation) is part of the package supplied. Select encoder function ROD (“Encoder” screen page).

The servo amplifier calculates the motor shaft position from the cyclic-absolute signals of the resolver or encoder. From this information a SSI date (after Stegmann patent specifi cation DE 3445617C2) is provided.

28 bits are transferred. The 12 leading data bits contains the number of revolutions. The following max. 16 bits contain the resolution and are not variable.

The following table shows the allocation of the SSI date:

Revolution Resolution

111098765432101514131211109876543210

The signal sequence can be output in Gray code or in Binary (standard) code (parameter SSI-CODE). The servo amplifier can be adjusted to the clock frequency of your SSI-eval uation through the SSI-TIMEOUT parameter (cycle time 1.3 µs or 10 µs).

The ground reference for the interface is PGND.

PGND must always be connected to the control ground.

Connection and signals for the SSI interface : The count direction is UP when the motor shaft is rotating clockwise (looking at the end of the motor shaft).

AX2500

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8.16 Digital and analog inputs and outputs

8.16.1 Analog input (X3)

The servo amplifier has a programmable input for analog setpoints. AGND (X3/1) must always be joined to the CNC-GND of the controls to provide a ground reference.

Technical data

— 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 supplementary — Update rate: 62.5 µs

AX2500

Input Analog-IN (terminals X3/2-3)

Input voltage max. ± 10 V, 14-bit resolution, scalable Standard setting: Speed Setpoint

Fixing the direction of rotation

Standard setting: clockwise rotation of the motor shaft (looking at shaft end)

with positive voltage on terminal X3/3 (+ ) against X3/2(-)

To reverse the direction of rotation you can swap the connections to terminals X3/2-3 or change the DIRECTION parameter in the SPEED screen.

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8.16.2 Digital inputs (X3)

All digital inputs are electrically isolated through optocouplers.

Technical data

— Reference ground is digital-GND (DGND, terminal X1/4,5 on the master) — The logic is dimensioned for +24V/7mA(PLC-compatible) — H-level from +12...36V/7mA,L-level from 0...7V/0mA — Update rate: Software:250 µs / Hardware: 2 µs

AX2500

You can use the digital inputs PSTOP / NSTOP / DIGITAL-IN1 and DIGITAL-IN2 to initiate pre-programmed functions that are stored in the servo amplifier. You will find a list of the pre-programmed functions in the Online Help. If an input has to be re-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 for the servo amplifier must be switched off and then on again (to reset the amplifier software).

Limit-switches PSTOP / NSTOP

Terminals X3/6 and X3/7 are used to connect limit switches. They are deactivated upon delivery. If these inputs are not needed for the connection of limit switches, then they can be used for other input functions.

Limit-switch positive/negative (PSTOP / NSTOP, terminals X3/6 and X3/7), high level in normal operation (fail-safe for cable break). A low signal (open) inhibits the corresponding direction of rotation.

DIGITAL-IN 1 / DIGITAL-IN 2

You can link the digital inputs at terminals X3/4 (DIGITAL-IN 1) and X3/5 (DIGITAL-IN2) with a pre-programmed function.

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8.16.3 Digital outputs (X3)

Technical characteristics

— Ground reference is Digital-GND (DGND, terminal X1/4,5 on the master) — Alle digital outputs are floating — DIGITAL-OUT1 and 2 : Open-collector, max. 30 V DC, 10 mA — Update rate: 250 µs

AX2500

Programmable digital outputs DIGITAL-OUT1/2:

You can use the digital outputs DIGITAL-OUT1 (terminal X3/8) and DIGITAL-OUT2 (terminal X3/9) to output messages from pre-programmed functions that are stored in the servo amplifier. A list of the pre-programmed functions can be found in the Online Help. 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 switched off and on again (to reset the amplifier software).

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8.16.4 Digital I/O on the Master (X1)

Technical characteristics

— Ground reference is Digital-GND (DGND, terminal X1/4,5) — The logic is dimensioned for +24V/7mA(PLC-compatible) — H-level from +12...36V/7mA,L-level from 0...7V/0mA

BTB/RTO: Relay output, max. 30 V DC or 42 V AC, 0.5 A

AX2500

ENABLE input

The output stage of the servo amplifier is activated by the enable signal (terminal X1/3, input 24V, active-high). In the inhibited state (low signal) the motor which is attached does not have any torque.

Ready-to-operate contact BTB/RTO

Operational readiness (terminals X1/1 and X1/2 ) is signalled via a floating relay contact. The contact is closed when all servo amplifiers in the system are ready for operation. This 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 90.

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8.17 RS232 interface, PC connection (X8), master only

The setting of the operating, position control, and motion-block parameters, can be car ried out by using the setup software on an ordinary commercial PC.

Connect the PC interface (X8) of the servo amplifier while the supply to the equipment

is switched off via a null-modem cable to a serial interface on the PC.

Do not use a null-modem link cable!

The interface has the same potential as the internal logic, and uses AGND as the ground reference.

The interface is selected and set up in the setup software. Further notes can be found on page 74 .

AX2500

Interface cable between the PC and servo amplifiers of the

(View: front view of the built-in SubD connectors, this corresponds to looking at the solder side of the SubD connector on the cable.)

AX2500 series:

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8.18 Fieldbus connection

8.18.1 CANopen interface (X7)

The interface for connection to the CAN bus (default: 500 kbps). The master is fitted with a CAN input. All axis modules in the system are connected to this through the internal bus. The last axis module has a CAN output, where the CAN bus either continues to other bus participants or is terminated by a termination resistor.

The integrated profile is based on the communication profile CANopen DS301 and the drive profile DS402. The following functions are available in connection with the inte grated position controller: Jogging with variable speed, homing, 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 at the same potential as the internal logic, and uses AGND as the ground reference.

AGND must be connected to the control system ground for potential equalization!

AX2500

CAN bus cable

To meet ISO 11898 you should use a bus cable with a 120 W characteristic impedance. 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 mea sured, but they must not be assumed to be limits:

Cable data: Characteristic impedance 100-120 W

Cable capacitance max. 60 nF/km Conductor loop resistance 159.8 W/km

Cable length, depending on the transmission rate

Transmission rate / kbps max. cable length / m

1000 20

500 70 250 115

Lower cable capacitance (max. 30 nF/km) and lower lead resistance (loop: 115 W/km) make it possible to transmit over longer distances.

(Characteristic impedance 150 ± 5 WÞterminating resistance 150 ± 5 W).

For EMC reasons, the SubD connector housing must fulfill the following conditions:

— metal or metallized housing — provision for connecting the cable shielding within the housing,

large-area connections

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8.18.2 PROFIBUS interface (X7), option

This section describes the PROFIBUS interface for AX2500. Information on the range of functions and the software protocol can be found in the man ual “Communication profile PROFIBUS-DP”. The selection of cables, cable routing, shielding, bus connectors, bus termination and propagation times are described in the “Setup guidelines for PROFIBUS-DP/FMS” from PNO, the PROFIBUS User Organization.

AX2500

Use only identical cable types of one manufacturer.

Recommendations for 1.5 MBit/s and 3 MBit/s

1.5 MBit/s 3 MBit/s

max 32 axes per segment max 32 axes per segment

Recommendations for 6 MBit/s and 12 MBit/s

For long-term reliability of the system with 6 MBit/s and 12 MBit/s we recommend to connect the segments with repeaters and to use one AX2500-Master per segment only (see example).

6 MBit/s

12 MBit/s

max 8 axes(1 master) per segment max 8 axes(1 master) per segment

8 x AX2500

6 x AX2500

Master

4 x AX2500

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8.18.3 SERCOS interface (X7), option

This section describes the SERCOS interface of the AX2500. Information on the range of functions and the software protocol can be found in the manual “IDN Reference Guide SERCOS”.

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

8.18.3.1 Light emitting diodes (LEDs)

Indicates whether SERCOS telegrams are being correctly received. In the final

Err

Communication Phase 4 this LED should flicker, since cyclical telegrams are being received. Indicates that SERCOS telegrams are being transmitted. In the final Communi cation Phase 4 this LED should flicker, since cyclical telegrams are being trans mitted. 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, 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.

8.18.3.2 Connection diagram

Layout of the SERCOS bus system in ring topology, with optical fibre cables (schematic).

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8.18.4 EtherCat interface (X7), option

This section describes the EtherCat interface of the AX2500. Information on the range of functions and the software protocol can be found in the EtherCat documentation (actually in process).

8.18.4.1 EtherCat connection, connector X7A/B (RJ-45)

Connection to the EtherCat network with RJ-45 connectors (IN and OUT interfaces).

8.18.4.2 Connection diagram

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This page has been deliberately left blank.

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9 Setup

9.1 Important notes

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

The procedure for commissioning is described as an example. Depending on the applica tion, a different procedure may be appropriate or necessary. In multi-axis systems, com mission each servo amplifier individually.

Before setting up, 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.

Check that all connection components that are live in operation are safely protected against bodily contact. The equipment produces potentially lethal voltages up to 800 V. Never undo the electrical connections to the servo amplifier while it is live. Capacitors can still have dangerous residual charges up to 300 seconds after switching off the supply voltage. The heat sink and front panel of the amplifier can reach temperatures up to 80°C in operation. Check the heat sink temperature. Wait until the heat sink has cooled down to 40°C before touching it

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 230 V AC to the terminals L1 / L2. This will re-form the capacitors.

Further information on commissioning: The adaptation of parameters and their effects on the control loop behaviour are described in the online help of the setup software. The commissioning of the fieldbus interface is described in the corresponding manual. 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 DRIVE.EXE for the AX2500 digital servo amplifiers.

We offer training and familiarization courses on request.

9.2.1.1 Use as directed

The operator software is intended to be used for altering and storing the operating param eters for the AX2500 series of servo amplifiers. The attached servo amplifier is commis sioned with the assistance of the software - during this process the drive can be con trolled 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.

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 operator software. The PC is connected to the servo amplifier by a null-modem (serial, ð p.67) cable. The setup software provides the communication between the PC and AX2500.

You will find the setup software on the accompanying CD-ROM and in the download section of our website.

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

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

Sets of data can be stored on data media (archived) and loaded again. You can also print out the data sets.

We provide you with motor-specific default sets of data for all the reasonable combina tions 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 sup ports you in each situation.

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9.2.1.3 Hardware requirements

The PC interface (X6, RS232) of the master is connected to a serial interface on 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 98 / 2000 / ME / NT4.0 / XP Graphica adapter : Windows compatible, color Drives : Hard disk (10 MB free space)

CD-ROM drive Main memory : at least 8 MB Interface : one free serial interface (COM1... 10)

9.2.1.4 Operating systems

WINDOWS 98 / 2000 / ME / NT / XP

DRIVE.EXE can work under WINDOWS 98 / 2000 / ME / XP or WINDOWS NT 4.0.

Emergency operation is possible with an ASCII terminal-emulation. Interface setting: 9600 bps, databit 8, stopbit 1,no parity, no handshake

Unix, Linux

DRIVE.EXE does not work under Unix and Linux.

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

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

Installation

Insert the CD-ROM into a free drive.

Autostart activated: The start screen of the CD-ROM pops up. Click on the link to the Setup Software and follow the instructions.

Autostart deactivated: Click on START (task bar), then on Run. Enter the program call x:\index.htm (where x is the drive letter for the CD drive). Click on OK and then on the link to the Setup Software and follow the instructions.

Connection to the serial interface of the PC

Connect the interface cable to a serial interface on your PC and the PC interfaces (X8) of the AX2500 (ð p.67).

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9.3 Quickstart, drive test

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 down load the latest editions from our website):

Product Manual (this manual)

Depending on the installed fieldbus interface you need one of these documents:

CANopen Communication Profile Manual

PROFIBUS DP Communication Profile Manual

l 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.

ENC

1 2 3

Enable

24V ON

RES

24V DC

Motor-Power

Motor

Feedback

Motor-Power

Motor

Feedback

Power ON

Power

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9.3.2 Connect

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

X8 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 cur

rent class (e.g. for 3 A) . If the power supply voltage is switched on, too, a lea ding P is displayed (e.g. for Power, 3 A).

If a fault code ( ) or a warning ( ) or a status message (./_ / E/S) appears in the display, you will find the description on page 90ff. If there is fault, fix the problem.

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

You can work offline or online with

"Multidrive" must be activated in the menu "Communication"!

DRIVE.EXE. We work online now. Select the interface where the servo amplifier is connected to.

The software tries to communicate with the drive and to upload the para

meters. If it's not successful, you recei ve this error message:

- wrong interface chosen

- wrong connector chosen at the servo amplifier

Frequent causes:

- interface is used by another software

- 24 V auxiliary voltage for the servo amplifier not working

- interface cable broken or wrong wiring

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

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If communication works, the drive selection screen appears:

Now parameters are transmitted from the servoamplifier to the computer. Then you see the start screen.

Make sure, that the amplifier is disabled (Input HW-Enable connector X1 pin 3 must be 0 V or open)!

9.3.3 Important Screen Elements

Help Function

In der Online-Hilfe finden Sie detaillierte Informationen zu allen Parametern, die vom Servoverstärker verarbeitet werden können.

The master and axis modules, recognized in the sys tem, with its station address and name are listed. The master module is separately characterized. Doubleclick on the amplifier, which you want to work with. You can select additional other axis modules later to show them in parallel at the screen and parameterize them (Multidrive function).

Key F1 Menu Bar ? / Online HTML Help

Tool Bar

Save to EEPROM, required if you changed parameters.

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

Status Bar

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 soft ware.

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9.3.4 Basic Setup

On the start screen click "Basic Setup" button.

Regen Resistor: Change only if you use an external regen resistor. Most applications

don't need an external 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.

Address: Adjust for master amplifier only (= highest address of the drive system, see p.86)

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 (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.

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 appears. 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 ampli fier's RAM now (takes some seconds). When this is done, you have to accept the changed configuration with "Yes" or to discard the changes in the appearing screen. If you click "Yes", the parameters are sa ved in the EEPROM and the amplifier makes a coldstart (reset). This takes some seconds.

On the start screen, click "Feedback" button.

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9.3.6 Feedback

Press function key F12 (disable) before changing feedback parameters.

Feedback Type:

Select the feedback type used.

Leave all other fields unchanged.

If Software Enable is active, a warning ap pears. The configuration change cannot be performed. Click OK on the warnings, press F12 (SW disable) and start the Feedback procedure again.

If everything was ok, the same procedure (parameter 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. Depend ing 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 sym-

bol 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 iconl .

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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 X1 pin 3].

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, 3 A).

Click the icon "Oscilloscope" :

l 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. The 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.

The Reset button can be used to clear some actual error messages. A description of errors/warnings can be found on p. 90.

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 integrated command reference.

Click the icon

"Monitor"

The Monitor screen shows all important electrical and mechanical actual values.

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9.4 Multi-axis systems

All the axes in a system can be parameterized through the RS232 interface in the master. To do this, there is an internal connection between the master and the axis modules. The PC cable only has to be connected to the master. The internal address assignment is carried out automatically, so that it is only necessary to set up the basic station address for the master.

Axismodule 1

Axismodule 2

Axismodule 3

X8/PC

9.4.1 Station Address

Adjust the address of the master with the setup software. The addresses of the axis modules are then assigned automatically.

After changing the station address it is necessary to turn off the 24 V auxiliary supply, and then turn it on again.

Starting at the master, descending addresses are assigned automatically to the axis mod ules. The following table shows an example with one master and three axis modules according to the graphics above:

Axis Address Remark

Master 10 Master address, set by user Axis module 3 9

Axis module 1 7

The highest permitted master address is 128. When choosing the master address, please consider that at least address 1 will be assigned to the last (leftmost) axis module. In CAN and PROFIBUS field bus systems the automatically assigned addresses must not match the address of other nodes.

Master

COMx

RS232

assigned automaticallyAxis module 2 8

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9.4.2 Example of connections for multi-axis system

Follow the safety instructions (ð p.9) and the use as directed (ð p.10) !

AX250x / AX251x

AX252x

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9.5 Key pad controls and status displays

Two keys are fitted in the operating panel of the master. Here you can enter the basic address for the system and call up status information on all the axes that are connected.

9.5.1 Operating

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 on the axis module

Each axis module is fitted with 2 LEDs that provide a quick indication of the instrument status.

LED

red green Interpretation

lit off axis is not ready for operation (fault)

blinking off a warning has been generated

off lit axis is ready for operation, and enabled off blinking axis is ready for operation, but not enabled

blinking blinking axis is selected for editing by the master

A detailed display of the warnings and faults can be called up in the display on the master ( ð p.89).

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9.5.3 Status display on the master

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9.6 Error messages

Any errors that 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, the out put stage being switched off (motor loses all torque), and the holding brake is activated.

Number Designation Explanation A/I/P/E ... F00

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 cleared without a reset, by using the ASCII command CLRFAULT. If only one of these errors is present and the RESET button or the I/O RESET function is used, only the CLRFAULT command will be executed.

Status Messages Status messages, no error, see p. 89 Status Message Updating the startup configuration no error no error on the selected axis module

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 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 A phase is missing in the mains supply power feed Slot fault Slot error (hardware fault on interface card) Handling error Software error on the interface card reserved reserved CAN-bus off Severe CAN bus communication error Warning Warning is displayed as fault Commutation error Commutation error Limit switch Homing error (hardware limit switch activated) reserved reserved

External Trajectory

Sercos Error only in SERCOS systems Emergency timeout Timeout emergency stop Macro Macro program error System Error system software not responding correctly

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

Internal amplifier supply voltages are out of tolerance

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

External position profile generator created a step, that exceeded 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 the Online help chapter "Trouble-Shooting".

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9.7 Warning messages

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

Number Designation Explanation A/I/P/E ... 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 result in a controller shut-down of the drive (braking by emergency stop ramp)

Status Messages Status messages, no error, see p. 89 Status Message Updating the startup configuration 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

reserved reserved

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 Wrong GMT data Wrong "Graphical Motion Task" data PLC program error For details see plc code max. motor temperatur reached 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

Range overflow on motion task data

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 the Online help chapter "Trouble-Shooting".

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9.8 Trouble Shooting

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 support can give you further assistance with problems.

Fault possible causes Measures to remove the fault

HMI message: communication fault

motor does not rotate

motor oscillates

drive reports following error

motor overheating

drive too soft

drive runs roughly

axis drifts at setpoint = 0V

wrong cable used

—

cable plugged into wrong posi

—

tion in servo amplifier or PC wrong PC interface selected

—

servo amplifier not enabled

—

break in setpoint cable

—

motor phases swapped

—

brake not released

—

drive is mechanically blocked

—

no. of motor poles set incor

—

rectly — feedback set up incorrectly — gain too high (speed controller) — shielding in feedback cable has

a break — AGND not wired up —I

rms

or I

is set to low

peak

— setpoint ramp is too long —I

rms/Ipeak

—

Kp (speed controller) too low —

Tn (speed controller) too high

—

PID-T2 too high —

T-Tacho too high —

Kp (speed controller) too high —

Tn (speed controller) too low

—

PID-T2 too low —

T-Tacho too low —

offset not correctly adjusted for

set too high — reduce I

analog setpoint provision —

AGND not joined to the

CNC-GND of the controls

use null-modem cable

—

plug cable into the correct so

—

ckets 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

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

(keep

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10 Appendix

10.1 Glossary

C clock Clock signal

common-mode voltage The maximum amplitude of a disturbance (on both

inputs) which a differential input can eliminate

continuous power of regen circuit Mean power which can be dissipated in the

regen circuit

counts Internal count pulses, 1 pulse = 1/2

current controller Regulates the difference between the current

setpoint and the actual value to 0 Output : power output voltage

D DC Bus link Rectified and smoothed power voltage

disable Removal of the enable signal (0 V or open)

E earth short electrical connection between a phase and

the protective earth (PE)

enable Enable signal for the servo amplifier (+24 V)

F fieldbus interface CANopen, PROFIBUS, SERCOS, EtherCat

free convection Free movement of air for cooling

G GRAY-code Special format for representing binary numbers

H holding brake Brake in the motor, which should only be used

when the motor is at standstill

I I²t threshold Monitoring of the r.m.s. current that is actually

required

incremental encoder interface Position signalling by 2 signals with 90° phase

difference, not an absolute position output

input drift Temperature and age-dependent alteration of an

analog input

Ipeak, peak current The effective value of the peak current

Irms, effective current The r.m.s. value of the continuous current

K Kp, P-gain Proportional gain of a control loop

L limit speed Maximum value for speed normalization at ±10 V

limit-switch Switch limiting the traverse path of the machine;

implemented as n.c. (break) contact

M machine The complete assembly of all connected parts or

devices, of which at least one is movable

motion-block Set of all the position control parameters

which are required for a motion task

multi-axis system Machine with several driven axes

N natural convection Free movement of air for cooling

O optocoupler Optical connection between two electrically

independent systems

turn

-1

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P P-controller Control loop with purely proportional behaviour

phase shift Compensation for the lag between the electro-

magnetic and magnetic fields in the motor

PID-controller Control loop with proportional, integral and

differential behaviour

PID-T2 Filter time constant for the speed controller output

position controller Regulates the difference between the position

setpoint and the actual position to 0 Output : speed setpoint

potential isolation electrically decoupled

power contactor System protection device with phase monitoring

pulse power of the regen circuit Maximum power which can be dissipated in the

regen circuit

R regen circuit Converts superfluous energy, which is fed back

during braking, into heat in the regen resistor

reset New start of the microprocessor

reversing mode Operation with a periodic change of direction

ROD-interface Incremental position output

S servo amplifier Control device for regulating the speed, torque

and position of a servomotor

setpoint ramps Limits for the rate of change of the speed

setpoint

short-circuit here: electrically conductive connection between

two phases

speed controller Regulates the difference between the speed

setpoint and the actual value to 0 Output : current setpoint

SSI-interface Cyclic-absolute, serial position output

supply filter Device to divert interference on the power supply

cables to PE

T T-tacho, tachometer time constant Filter time constant in the speed feedback of

the control loop

tachometer voltage Voltage proportional to the actual speed

thermostat Temperature-sensitive switch built into the

motor winding

Tn, I-integration time Integral section of a control loop

Z zero pulse Output once per turn from incremental encoders,

used to zero the machine

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10.2 Index

! 24V aux. supply, interface ........47

A Abbreviations ...............8

Ambient conditions ............20

B BISS interface ..............51

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

Brake...................21

BTB/RTO................. 66

C CANopen interface ............ 68

CE conformity .............. 12

Commissioning.............. 73

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

Connector assignments .........44

Control signals ..............63

D DC Bus link, interface ..........48

Dimensions................35

Display, LED ...............20

Disposal .................13

E Earthing

installation ..............38

wiring diagram ............ 45

Enclosure protection ...........20

Encoder

interface ............... 52

interface Master-Slave ........56

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

Error messages .............90

EtherCat interface ............ 71

F Fan.................... 36

Fieldbus interface ............68

Forming ................. 73

Fusing ..................19

G Glossary .................93

Ground symbol ..............39

Grounding system ............22

Guide

electrical installation .........38

mechanical installation ........33

H Hall, interface ..............54

Hardware requirements ......... 75

I Incremental encoder, interface ......55

Inputs

ANALOG IN .............63

DIGI-IN 1/2 ..............64

enable ................ 66

encoder................ 52

Encoder for Master Slave ......56

NSTOP ................64

power supply .............47

PSTOP ................64

resolver................50

Installation

electrical ...............37

mechanical ..............33

software ...............75

K Key operation .............. 88

L Leakage current .............31

LED display ............... 88

Limit-switch inputs ............64

M Maintenance ............... 13

Master-Slave ............... 56

Motor, interface .............48

Mounting .................34

Mounting position ............ 20

Multi-axis systems

connection example .........87

parameterization ...........86

N Nameplate ................14

Noise emission ..............20

NSTOP, interface ............ 64

O Operating systems ............75

Options..................17

Outputs

BTB/RTO ............... 66

DIGI-OUT 1/2 ............65

encoder emulations .........61

P Package supplied ............14

Packaging ................13

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

PC connection ..............67

PC interface cable ............67

Pollution level .............. 20

PROFIBUS interface ...........69

PSTOP, interface ............64

Pulse/direction, interface .........59

Q Quickstart, drive test ...........76

R regen circuit ............... 22

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

Regen resistor

external interface. ..........48

techn. data ..............22

Resolver ................. 50

ROD, interface ..............61

RS232/PC, interface ...........67

S Safety instructions .............9

SERCOS interface ............70

Setpoint input ..............63

Setup software ..............74

Shield connection ............40

Shielding

installation ..............38

wiring diagram ............ 45

Sine-cosine encoder, interface ......53

Site altitude................20

SSI, interface............... 62

Stacking height.............. 13

Standards ................11

Status display ..............88

Storage.................. 13

Supply connection, interface .......47

Supply voltage .............. 20

Switch on/off behavior ..........23

Symbols ..................7

System components, summary .....42

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T Technical data ..............18

ambient conditions ..........20

cables ................ 41

conductor cross sections .......20

connections..............19

fusing ................. 19

rated data ..............18

tightening torques ..........19

Technical description...........16

Tightening torques, connectors .....19

Transport.................13

Trouble shooting .............92

U Use as directed

servo amplifier ............ 10

setup software ............ 74

V Ventilation

installation ..............33

techn. data ..............20

Vibrations ................20

W Warning messages............ 91

Wiring .................. 39

Wiring diagram

axis module..............46

master ................45

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This page has been deliberately left blank.

AX2500 Product Manual 97

BECKHOFF AX2500 User Manual

Specifications and Main Features

Frequently Asked Questions

User Manual

BECKHOFF 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

2.2 Use as directed

Mains voltage Servo amplifier

BECKHOFF 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 / Cleaning

4.5 Disposal

5 Package

5.1 Package supplied

5.2 Nameplate

5.3 Part number scheme

Technical description 06/2007 BECKHOFF

6 Technical description

6.1 Digital servo amplifiers in the series AX2500

Options

6.2 Technical data

6.2.1 Rated data

Rated data DIM 363636

6.2.2 Inputs / Outputs

Connections

6.2.3 Recommended tightening torques

6.2.4 Fusing

6.2.5 Ambient conditions, ventilation, mounting position

Site altitude

Pollution level Pollution level 2 as per EN 60204 / EN 50178 Vibrations Noise emission

Enclosure protection IP 20 Mounting position

6.2.6 Conductor cross-sections

6.3 LED display

6.4 Control for motor holding brake

6.5 Grounding system

6.6 Regen circuit

6.7 Switch-on/-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

BECKHOFF 06/2007 Mechanical Installation

7 Mechanical Installation

7.1 Important notes

7.2 Guide to mechanical installation

7.3 Mounting

7.4 Dimensions

7.5 Add-on fan

8 Electrical Installation

8.1 Important notes

Electrical Installation 06/2007 BECKHOFF

8.2 Guide to electrical installation

8.3 Wiring

8.3.1 Important notes

8.3.2 Shield connection on the front panel

8.3.3 Requirements to cables