BECKHOFF AX5000 User Manual
Version: 1.4
Date: 2015
Language: English
Article no.: TDmlAX
BECKHOFF
Startup
Servo Drive AX5000
(60 A – 170 A)
Please read this document carefully before installing and commissioning the servo drive.
-03-18
-5160-0000-0200
1 Foreword BECKHOFF Drive Technology
Notes:
2 Version: 1.4 AX5000
BECKHOFF Drive Technology 1 Foreword
Chapter Page
Table of Contents – AX5000 Startup
1 Foreword ............................................................................................................... 5
1.1 Notes on the documentation ............................................................................... 5
1.2 Disclaimer ........................................................................................................... 5
1.3 Trademarks ........................................................................................................ 5
1.4 Patent Pending ................................................................................................... 5
1.5 Copyright ............................................................................................................ 5
1.6 Documentation issue status ............................................................................... 6
1.7 Appropriate use .................................................................................................. 6
1.7.1. Dual Use (EU 1382/2014) .................................................................................. 6
1.8 Documented servo drives ................................................................................... 7
2 Safety .................................................................................................................... 9
2.1 General safety instructions ................................................................................. 9
2.1.1 Safety rules ........................................................................................................ 9
2.1.2 Disclaimer ........................................................................................................... 9
2.1.3 Description of safety symbols ............................................................................. 9
2.1.4 Personnel qualification ..................................................................................... 10
2.2 Special safety instructions for AX5000 ............................................................. 10
3 Guidelines and Standards ................................................................................. 12
3.1 CE conformity ................................................................................................... 12
3.2 Electromagnetic compatibility ........................................................................... 12
3.3 UL-Listing in USA and Canada ......................................................................... 13
3.3.1 UL-specific chapter changes ............................................................................ 13
3.3.2 UL-specific chapter ........................................................................................... 13
3.3.3 UL-specific notes .............................................................................................. 13
3.4 Electrical isolation according to EN 50178 / VDE 160 ...................................... 14
4 Product description ........................................................................................... 15
4.1 Type code ......................................................................................................... 15
4.2 Scope of supply ................................................................................................ 15
4.2.1 Standard scope of supply ................................................................................. 15
4.2.2 Accessories ...................................................................................................... 16
4.3 Name plate ....................................................................................................... 16
4.4 Technical data .................................................................................................. 17
4.4.1 Permissible ambient and operating conditions ................................................. 17
4.4.2 Electrical data ................................................................................................... 18
4.4.3 Mechanical data ............................................................................................... 18
4.5 General overview (AX5160 and AX5172) ......................................................... 19
4.6 General overview (AX5190 and AX5191) ......................................................... 20
4.7 General overview (AX5192 and AX5193) ......................................................... 21
4.8 Overview of connectors/terminal points ............................................................ 22
4.8.1 X01 – voltage input ........................................................................................... 22
4.8.1.1 AX5160 and AX5172 ........................................................................................ 22
4.8.1.2 AX5190 and AX5191 ........................................................................................ 22
4.8.1.3 AX5192 and AX5193 ........................................................................................ 22
AX5000 Version: 1.4 3
1 Foreword BECKHOFF Drive Technology
4.8.2 X07 – External brake resistor ........................................................................... 22
4.8.2.1 AX5160 and AX5172 ........................................................................................ 22
4.8.2.2 AX5190 and AX5191 ........................................................................................ 23
4.8.2.3 AX5192 and AX5193 ........................................................................................ 23
4.8.3 X13 – Motor connection ................................................................................... 23
4.8.3.1 AX5160 and AX5172 ........................................................................................ 23
4.8.3.2 AX5190 and AX5191 ........................................................................................ 23
4.8.3.3 AX5192 and AX5193 ........................................................................................ 24
4.8.4 X02 – DC link system (currently not permissible!) ............................................ 24
4.8.4.1 AX5160 and AX5172 ........................................................................................ 24
4.8.4.2 AX5190 and AX5191 ........................................................................................ 24
4.8.4.3 AX5192 and AX5193 ........................................................................................ 25
4.8.5 X03 – 24 VDC supply ......................................................................................... 25
4.8.6 X04, X05 – EtherCAT connection .................................................................... 25
4.8.7 X06 – Digital I/Os ............................................................................................. 25
4.8.8 X11 – feedback, high-resolution ....................................................................... 26
4.8.9 X12 – resolver/hall ........................................................................................... 27
4.8.10 X14 – motor brake and thermal contact ........................................................... 27
4.9 Dimensions ...................................................................................................... 28
5 Installation .......................................................................................................... 29
5.1 Mechanical installation ..................................................................................... 29
5.1.1 Installation in the control cabinet ...................................................................... 30
5.1.2 Installation example ......................................................................................... 31
5.1.3 Installation of the shroud (optional) .................................................................. 32
5.2 Electrical installation ......................................................................................... 33
5.2.1 Mains supply connection (X01) ........................................................................ 34
5.2.1.1 External protection for individual devices, CE-compliant .................................. 34
5.2.1.2 External protection for individual devices, UL-compliant .................................. 34
5.2.2 24 VDC - supply network connection (X03) ....................................................... 35
5.3 Motors and cables ............................................................................................ 36
6 Important information for commissioning ....................................................... 37
7 Project planning – important information ........................................................ 38
7.1 Drive train design ............................................................................................. 38
7.1.1 Control quality, mass inertia ratio and load connection .................................... 38
7.2 Energy management ........................................................................................ 38
7.3 EMC, earthing, screen connection and potential .............................................. 39
7.4 Control cabinet ................................................................................................. 39
8 Appendix ............................................................................................................ 40
8.1 Support and Service ......................................................................................... 40
8.1.1 Beckhoff's branch offices and representatives ................................................. 40
8.1.2 Beckhoff Headquarters..................................................................................... 40
8.1.3 Beckhoff Support .............................................................................................. 40
8.1.4 Beckhoff Service .............................................................................................. 40
4 Version: 1.4 AX5000
BECKHOFF Drive Technology 1 Foreword
1 Foreword
1.1 Notes on the documentation
This description is only intended for trained specialists in control, automation and drive
engineering who are familiar with the applicable national standards. It is essential that the
following notes and explanations are followed when installing and commissioning these
components. The responsible staff must ensure that the application or use of the products
described satisfy all the requirements for safety, including all the relevant laws, regulations,
guidelines and standards. The "General safety instructions" and "Special safety instructions
for AX5000" sections are also essential.
1.2 Disclaimer
The documentation has been prepared with care. The products described are, however,
constantly under development. For this reason, the documentation may not always be have
been fully checked for consistency with the performance data, standards or other
characteristics described. In the event that it contains technical or editorial errors, we retain
the right to make alterations at any time and without warning. No claims for the modification
of products that have already been supplied may be made on the basis of the data,
diagrams and descriptions in this documentation.
1.3 Trademarks
Beckhoff®, TwinCAT®, EtherCAT®, Safety over EtherCAT®, TwinSAFE® and XFC® are
registered trademarks of and licensed by Beckhoff Automation GmbH.
Other designations used in this publication may be trademarks whose use by third parties
for their own purposes could violate the rights of the owners.
1.4 Patent Pending
The EtherCAT Technology is covered, including but not limited to the following patent
applications and patents:
EP1590927, EP1789857, DE102004044764, DE102007017835
with corresponding applications or registrations in various other countries.
The TwinCAT Technology is covered, including but not limited to the following patent
applications and patents:
EP0851348, US6167425 with corresponding applications or registrations in various other
countries.
1.5 Copyright
© Beckhoff Automation GmbH & Co. KG
The reproduction, distribution and utilization of this document as well as the communication
of its contents to others without express authorization are prohibited.
Offenders will be held liable for the payment of damages. All rights reserved in the event of
the grant of a patent, utility model or design.
AX5000 Version: 1.4 5
1 Foreword BECKHOFF Drive Technology
Version
Comment
1.4
New Chapter:
3.3; 4.3.; 4.4.2; 5.2.1.1
1.3
New Chapter:
1.5; 2.1.2; 4.3; 4.4.2; 8.2
1,2
Chapter-Update:
4.4.2; 4.5, 4.6, 4.7; 4.8.4, 5.1.1, 5.1.3; 5.2.1, 5.3
1,1
New Chapter:
1.8; 2.2; 3.1; 3.2; 4.5; 4.6; 4.8; 4.9; 5.1.1; 5.2
1,0
First edition
Caution – Risk of injury!
brought into a safe state in the event of a fault in the drive system.
1.6 Documentation issue status
5.2.1.2
Chapter-Update:
1.7.1
Chapter-Update:
4.7; 5.1.3; 5.3
Chapter-Update:
1.7 Appropriate use
The servo drives of the AX5000 series are exclusively designed for torque, speed and
position control of suitable asynchronous and synchronous three-phase current motors. The
maximum permissible effective motor voltage must be at least equal the effective mains
voltage fed into the servo drive.
The servo drives from the AX5000 series are designed for installation as components in
electrical systems or machines and may be operated only as integrated system or machine
components.
Electronic equipment is not fail-safe. The machine manufacturer is
WARNING
The servo drives may only be operated in enclosed control cabinets and in accordance with
the conditions described in the "Technical data" section.
responsible for ensuring that the connected motors and the machine are
1.7.1. Dual Use (EU 1382/2014)
As published on December 30, 2014 by EU Commission Delegated Regulation
1382/2014, standard frequency inverters – and with that also Beckhoff products AX5000 –
become newly classified Dual-Use items: the item list Annex I of the Dual-Use
Council Regulation 428/2009 has been changed accordingly, Frequency inverters
(listed in item position 3A225) with a „rotation field frequency of 600 Hz or more“ are now
export controlled items. As a consequence some modifications have to be noticed.
Firmware versions without extension “Dual-Use conform” can be used in consideration of
Hardware Versions with following drives only:
6 Version: 1.4 AX5000
BECKHOFF Drive Technology 1 Foreword
• HW Version 1.0 (AX5xxx-0000-x0xx): Serial Number < 68.000
• HW Version 2.0 (AX5xxx-0000-x20x) : Serial Number < 140.000
• HW Version 2.0 (AX5xxx-0000-x21x)
This firmware versions allow operation > 600 Hz rot. field frequency, shipment as single part
may be subject to export control regulations.
Firmware versions with extension “Dual-Use conform” can be used in consideration of
Hardware Versions with all drives. These versions support both rotational field frequency
bands (<600 Hz, >= 600 Hz) depending on product hardware.
For products with option „x21x“, shipment as single part may be subject to export control
regulations.
1.8 Documented servo drives
This documentation describes the following servo drives in the AX5000 range:
AX5160
AX5172
AX5190
AX5191
AX5192
AX5193
AX5000 Version: 1.4 7
1 Foreword BECKHOFF Drive Technology
Notes :
8 Version: 1.4 AX5000
BECKHOFF Drive Technology 2 Safety
DANGER
Acute risk of injury!
WARNING
Risk of injury!
CAUTION
Hazard to individuals!
Attention
Hazard to devices and environment
Note
Note or pointer
UL pointer
2 Safety
2.1 General safety instructions
2.1.1 Safety rules
Consider the following safety instructions and descriptions!
Product specific safety instructions are to be found on the following pages or in the areas
mounting, wiring, commissioning etc..
2.1.2 Disclaimer
All the components are supplied in particular hardware and software configurations
appropriate for the application. Modifications to hardware or software configurations other
than those described in the documentation are not permitted, and nullify the liability of
Beckhoff Automation GmbH & Co. KG.
2.1.3 Description of safety symbols
The following safety symbols with a adjoining safety advise are used in this manual. You
have to read the adjoining safety advice carefully and adhere it strictly.
If you do not adhere the safety advise adjoining this symbol, there is
immediate danger to life and health of individuals!
If you do not adhere the safety advise adjoining this symbol, there is
danger to life and health of individuals!
If you do not adhere the safety advise adjoining this symbol, there is
obvious hazard to individuals!
If you do not adhere the notice adjoining this symbol, there is obvious
hazard to materials and environment.
This symbol indicates information that contributes to better understanding.
This symbol indicates important information about the UL-compliant.
AX5000 Version: 1.4 9
2 Safety BECKHOFF Drive Technology
Serious risk of injury through high electrical voltage!
below 50 V.
Serious risk of injury through hot surfaces!
sufficiently.
WARNING
Danger of injury due to uncontrolled movements!
2.1.4 Personnel qualification
This description is only intended for trained specialists in control, automation and drive
engineering who are familiar with the applicable national standards.
2.2 Special safety instructions for AX5000
The safety instructions are designed to avert danger and must be followed during
installation, commissioning, production, troubleshooting, maintenance and trial or test
assemblies.
The servo drives of the AX5000 series are not designed for stand-alone operation and must
always be installed in a machine or system. After installation the additional documentation
and safety instructions provided by the machine manufacturer must be read and followed.
• Never open the servo drive when it is live. Wait until the DC link
WARNING
capacitors are discharged. The voltage measured between the “ZK+ and
ZK-“ and “RB+ and “RB-“ terminals must have fallen below 50 V.
Opening the device (with the exception of expansion card slots)
invalidates all warranty and liability claims against Beckhoff Automation.
• Negligent, improper handling of the servo drive and bypassing of the
safety devices can lead to personal injury or death through electric
shock.
• Ensure that the protective conductor is connected properly.
• Disconnect the servo drive from the mains supply and secure it against
reconnection before connecting or disconnecting the pluggable terminals.
• Disconnect the servo drive from the mains supply and secure it against
reconnection before working on electrical parts with a voltage > 50 V.
• Due to the DC link capacitors dangerous voltage may persist at the DC
link contacts “ZK+ and ZK-“ and “RB+ and RB-“ after the servo drive has
been disconnected from the mains supply. After disconnecting the servo
drive wait at AX5160/AX5172 15 minutes, at AX5190/AX5191 30 minutes
and at AX5192/AX5193 45 minutes and measure the voltage at the DC
link contacts ZK+ and ZK-. The device is safe once the voltage has fallen
• The surface temperature may exceed 50 °C, resulting in a risk of burns.
WARNING
• Avoid touching the case during or shortly after operation.
• Leave the servo drive to cool down for at least 15 minutes after it is
switched off.
• Use a thermometer to check whether the surface has cooled down
Read and take note of chapter 6 ‘Important information for commissioning’
each time before commissioning the AX5000
10 Version: 1.4 AX5000
BECKHOFF Drive Technology 2 Safety
Hazard to individuals!
Directive in national legislation.
Hazard to devices and environment
- Place the servo drive on a conductive surface.
• Carefully read this manual before using the servo drive thoroughly,
CAUTION
Attention
paying particular attention to the safety instructions. In the event of any
uncertainties please notify your sales office immediately and refrain from
working on the servo drive.
• Only well trained, qualified electricians with sound knowledge of drive
equipment may work on the device.
• During the electrical installation it is essential to ensure that the correct
fuses/protective circuit breakers are used between the mains supply and
the servo drive. Further information can be found in the "Electrical
installation" section.
• If a servo drive is installed in a machine it must not be commissioned
until proof of compliance of the machine with the latest version of the EC
Machinery Directive has been provided. This includes all relevant
harmonised standards and regulations required for implementation of this
• During installation it is essential to ensure that the specified ventilation
clearances and climatic conditions are adhered to. Further information
can be found in the "Technical data" and "Mechanical installation"
sections.
• If the servo drive is operated in contaminated ambient air, the cooling
openings must be checked regularly for blockage. These checks should
be carried out several times per day.
• The servo drives contain components at risk from electrostatic discharge
caused by improper handling:
- Please ensure you are electrostatically discharged before touching
the servo drive directly.
- Avoid contact with highly insulating materials
(synthetic fibres, plastic film etc.).
AX5000 Version: 1.4 11
3 Guidelines and Standards BECKHOFF Drive Technology
Hazard to individuals!
conformity of the complete machine or system.
3 Guidelines and Standards
3.1 CE conformity
The servo drives AX5160, AX5172, AX5190, AX5191,AX5192 and AX5193 comply with the
• EC Low-Voltage Directive, 2006/95/EC
Applied harmonised standards:
61800-5-1
Servo drives are not covered by the EC Machinery Directive. Operation
CAUTION
3.2 Electromagnetic compatibility
The servo drives AX5160, AX5172, AX5190, AX5191,AX5192 and AX5193 comply with the
• 2004/108/EC EMC Directive
Applied harmonised standards:
IEC / EN 61000-4-2
IEC / EN 61000-4-3
IEC / EN 61000-4-4
IEC / EN 61000-4-5
IEC / EN 61000-4-6
IEC / EN 61000-6-1
IEC / EN 61000-6-2
IEC / EN 61000-6-3
IEC / EN 61000-6-4
IEC / EN 61800-3
of the servo drives in machines or systems is only permitted once the
machine or system manufacturers has provided evidence of CE
12 Version: 1.4 AX5000
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