BECKHOFF AX2500 User Manual
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
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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.
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-
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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
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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
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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
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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.
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The manufacturer of the machine must produce a hazard analysis for the ma-
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chine and take appropriate measures to ensure that unforeseen movements do
not result in personal injury or material damage.
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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.
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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.
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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
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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
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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
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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
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premises, then additional filter measures must be implemented by the user.
The AX2500 family of servo amplifiers is only intended to drive specific brushless
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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.
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The servo amplifiers may only be operated in a closed control cabinet, taking into
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account the ambient conditions defined on page 20. Ventilation or cooling measures
may be required to keep the temperature below 45°C.
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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).
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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.).
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Not more than 7 axis modules can be connected to a master module.
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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).
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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.
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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
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BECKHOFF 06/2007 Handling
4 Handling
4.1 Transport
Transport only by qualified personnel in the manufacturer’s original packaging
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Avoid shocks
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Transport temperature -25 to +70°C, max. rate of change 20°C/hour
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Transport humidity max. 95% relative humidity, no condensation
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The servo amplifiers contain electrostatically sensitive components which can
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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
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form the shipper and the manufacturer.
4.2 Packaging
Recyclable cardboard with inserts
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Dimensions AX252x (HxWxD) 100x300x270 mm
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AX250x/AX251x (HxWxD) 150x300x270 mm
Labelling instrument label on outside of box
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4.3 Storage
l Storage only in the manufacturer’s original recyclable packaging
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Max. stacking height: 8 cartons
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Storage temp. –25 to +55°C, max. rate of change 20°C/hr
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Humidity relative humidity max. 5...95%, no condensation
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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
U
CUS
L
®
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
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only one power supply feed and one auxiliary voltage supply per system
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shield connection directly on the servo amplifier
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all axes in a system can be parameterized through a single interface
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strongly reduced wiring expenditure by modular structure
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simple mechanical structure on DIN rails
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Standard version
2 supply voltage versions: AX250x up to 3x230VAC and
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AX251x up to 3x400VAC
one size for the master and axis modules each, see page 35
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analog input
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fieldbus interface is integrated (standard: CANopen)
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RS232 is integrated
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pulse-direction interface is integrated
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Supply power
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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)
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fusing (e.g. fusible cutout) provided by the user
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integrated interference suppression filter for the supply input (for category 2)
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integrated interference suppression filter for the 24V auxiliary supply (for category 2)
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all shielding connections directly on the amplifier
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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)
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regen circuit internal regen resistor as standard,
external regen resistor if required
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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
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and the signal electronics, provided by appropriate creepage distances and complete
electrical isolation
Soft-start, overvoltage detection, short-circuit protection, phase-failure monitoring
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temperature monitoring of servo amplifier and motor (when using our motors with our
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pre-assembled cables)
Auxiliary voltage 24V DC
electrically isolated via an external 24V DC PSU, e.g. with isolating transformer
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Operation and parameter setting
with the comfortable setup software, via the serial interface of a PC to a single con
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nection for all axes in a system
station address setting through two keys and a 3-digit LED status display on the
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master
fully programmable via RS232 interface
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Completely digital control
digital current controller (space vector pulse-width modulation, 62.5 µs)
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freely programmable digital speed controller (62.5 µs or 250 µs)
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integral position controller, with adaptation possibilities for every application (250 µs)
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integrated pulse direction interface, for connection of a servomotor to a
stepper-motor control
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evaluation of the resolver signals or sine/cosine signals from a high-resolution
encoder
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encoder emulation (incremental ROD 426-compatible or SSI)
Comfort functions
l
4 programmable digital inputs
(two are normally defined as limit-switch inputs)
l
2 programmable digital outputs
l
freely programmable combinations of all digital signals
Options
l
PROFIBUS DP interface instead of CANopen, see page 69
l
SERCOS interface instead of CANopen, see page 70
l
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%
to
+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
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
to
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
AX2500 Product Manual 19
Technical description 06/2007 BECKHOFF
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
o
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!
20 AX2500 Product Manual
BECKHOFF 06/2007 Technical description
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
AX2500 Product Manual 21
Technical description 06/2007 BECKHOFF
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
W
33
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
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
W
33
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
Bext
max. 1s) kW 16
External regen resistor
22 AX2500 Product Manual
BECKHOFF 06/2007 Technical description
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
l
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.
-
AX2500 Product Manual 23
Technical description 06/2007 BECKHOFF
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).
24 AX2500 Product Manual
BECKHOFF 06/2007 Technical description
6.7.2 Behavior in the event of an error (with standard setting)
The behavior of the servo amplifier always depends on the current setting of a number of
different parameters (e.g., ACTFAULT, VBUSMIN, VELO, STOPMODE, etc.; see online
help). The diagram shows the startup procedure and the procedure that the internal 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).
AX2500 Product Manual 25
Technical description 06/2007 BECKHOFF
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.
-
26 AX2500 Product Manual
BECKHOFF 06/2007 Technical description
6.8.2 Emergency Stop: Standards
The emergency Stop function is used for the fastest possible shut-down of the machine
in a 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
l
ting situations.
the energy supply to any drive machinery that could cause dangerous situations
l
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.
l
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.
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.
-
AX2500 Product Manual 27
Technical description 06/2007 BECKHOFF
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
28 AX2500 Product Manual
BECKHOFF 06/2007 Technical description
6.8.4 Implementation of the Stop Category 1
Bringing the motor to a standstill by interrupting the mains supply and using controlled
electronic braking (STOPMODE & ACTFAULT parameters set to 1). The 24 V supply
for the 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
-
AX2500 Product Manual 29
Technical description 06/2007 BECKHOFF
6.8.5 Implementation of the Stop Category 2
The machine receives an operational stop (disable) command and brakes the drive using
the set braking ramp (STOPMODE & ACTFAULT parameters set to 1).
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. In this case, there is no interruption of the elec
trical supply.
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
30 AX2500 Product Manual
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