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
BECKHOFF Drive Technology 3 Guidelines and Standards
AX5000 with UL-Listing
AX5160, AX5172, AX5190, AX5191, AX5192 und AX5193
Drive system with UL-Listing!
Please consult our Application Department with respect to the requirements
for a drive system with UL-Listing.
Fusing
AX5160
AX5172
AX5190
AX5191
AX5192
AX5193
AC supply (max.) *)
24 V supply (max.)
4 AT
10 AT
Brake resistor
electronic
3.3 UL-Listing in USA and Canada
The following servo drives from the AX5000 series have a UL-Listing and must bear the
CUS symbol
on the name plate. If you wish to operate an AX5000 in USA or Canada , please check that
there is a CUS symbol on the name plate.
Below is a list of the relevant chapters that are amended with respect to the UL-Listing.
Furthermore, UL-specific remarks are listed. It is essential to observe these specifications.
3.3.1 UL-specific chapter changes
“5.2.1 Mains supply connection (X01)”
AX5000 shall be connected only to a grounded wye-source where the
maximum voltage does not exceed 277 V to ground.
“5.2.3 Connection of several servo drives to form a drive system”
3.3.2 UL-specific chapter
“5.2.1.3 External protection, UL-compliant”
Integral solid state short circuit protection does not provide branch circuit protection. Branch
circuit protection must be provided in accordance with the Manufacture Instructions, National
Electrical Code and any additional local codes.
AX5160 and AX5172:
Suitable for use on a circuit capable of delivering not more than 5000 rms symmetrical
amperes, 480 V maximum. When protected by RK5 class fuses, rated 100 A maximum.
AX5190 - AX5193:
Suitable for use on a circuit capable of delivering not more than 10000 rms symmetrical
amperes, 480 V maximum. When protected by RK5 class fuses, rated 225 A maximum.
*) Mains fuses according to type “RK5” min. 480 V must be used.
3.3.3 UL-specific notes
Use in a Pollution Degree 2 environment
Use 75 °C Copper Conductors min.
Control Board rating = 24 V
AX5000 Version: 1.4 13
3 Guidelines and Standards BECKHOFF Drive Technology
Canada!
by Beckhoff Automation.
Drive intended for use over a range of motor sizes. Internal motor overload protection
level is adjustable:
The internal motor protection is parameterised via the IDN P-0-0062 “Thermal motor model”,
based on the value of the IDN S-0-0111 “Motor continuous stall current”. The IDN P-0-0062
“Time constant” is specified by the motor manufacturer and must be entered here. The IDN
P-0-0062 “Warning limit” (Default) is responsible for deciding when a warning is to be
generated. The IDN P-0-0062 “Error limit” (Default) is responsible for deciding when the
motor is to be switched off. The default values take into account the specific characteristics
of the servomotors.
In Canada use only in combination with unit AX2090-TS50, manufactured
3.4 Electrical isolation according to EN 50178 / VDE 160
The power section (motor connection, DC link connection and mains connection) and the
control unit are doubly insulated against each other, so that safe protection against
accidental contact is ensured at all terminals of the control unit without additional measures.
The air and creepage distances also meet the requirements of the above standard.
14 Version: 1.4 AX5000
BECKHOFF Drive Technology 4 Product description
X 5 Z Y b a d c X A -
Product line:
Servo Drives
Series:
5000
Number of channels:
channel
channel
Rated current per channel
channel units:
01, 03, 06, 12, 18, 25,
40, 60, 72, 90
channel units:
01, 03, 06
Version:
0 = Standard
1 = Customer
Hardware features:
00 = Standard
01 = Cold Plate
02 = Auxiliary fan
---
4 Product description
The servo drives of the AX5000 series are available as single- or multi-channel versions and
are optimised in terms of function and cost-effectiveness. In conjunction with EtherCAT, the
real-time Ethernet system, the integrated control technology offers minimum cycle times and
supports fast, highly dynamic positioning tasks.
4.1 Type code
1 = single-
2 = two-
Single-
or:
91 = 110 A
92 = 143 A
93 = 170 A
Two-
4.2 Scope of supply
-specific
The scope of delivery may vary depending on the ordered configuration. Before installing the
device please ensure that all ordered components were delivered and that they are
undamaged. In the event of any damage please contact the carrier immediately and
document the damage.
4.2.1 Standard scope of supply
− AX5000 in the performance class according to the order
− Connectors for:
X03: DC power supply 24 V
X06: Digital inputs and outputs
X14: Motor temperature sensor and brake
− Startup (this manual)
− Complete documentation on CD
AX5000 Version: 1.4 15
4 Product description BECKHOFF Drive Technology
Accessories with UL-Listing!
Listing, please make sure that the accessories also have a UL-Listing.
1
Catalog number
6
Output rated voltage
11
Customer-specific
2
Max. ambient temperature
7
Output rated current
12
wye-source only
3
Input rated voltage
8
Output frequency range
13
CE-Conform
4
Input rated current
9
Protection class
14
cULus - Listed
5
Input frequency
10
Serial number
Large
Small
name
plate
4.2.2 Accessories
A comprehensive list of accessories can be found in the complete Beckhoff catalogue or on
our website at www.beckhoff.com.
If you wish to operate an AX5000 in an economic area that requires a UL-
4.3 Name plate
The servo drive features two name plates. A comprehensive name plate can be found on the
right-hand side. An extract showing the main data can be found at the top of the servo drive.
name
plate
16 Version: 1.4 AX5000
BECKHOFF Drive Technology 4 Product description
UL-Listing!
economic area that requires a UL-Listing.
Ambient / operating conditions
Permissible values
Ambient temperature during operation
0 °C up to +40 °C
Up to 55 °C with reduced power (2 % / °C)
Ambient temperature during transport
-25 °C up to +70 °C
Ambient temperature during storage
-25 °C up to +55 °C
Air humidity
15 % up to 85 %, non-condensing
Pollution degree
2 according to EN 60664-1
Corrosion protection
Normally not required.
measures must be agreed with the manufacturer.
Operating altitude
up to 1000 m above sea level without reduced power.
power 1 % per 100 m.
Installation position
vertical
Ventilation
Built-in temperature-controlled fan
Protection class
IP 20 except the terminals (IP00)
EMC
Category C3 - standard
Category C2, C1 - auxiliary filter required
4.4 Technical data
It is essential to observe chapter 3.3 if you wish to operate an AX5000 in an
4.4.1 Permissible ambient and operating conditions
Under extreme operating conditions separate
Between 1000 m and max. 2000 m with reduced
AX5000 Version: 1.4 17
4 Product description BECKHOFF Drive Technology
Electrical Data
AX5160
AX5172
AX5190
AX5191
AX5192
AX5193
Rated output current
(1)
60 A
72 A
90 A
110 A
143 A
170 A
Minimum rated motor current
at full current resolution
Peak output current
120
(2)
144
(2)
180
(3)
165
(3)
215
(3)
255
(3)
Rated supply voltage
3x 400
-10%
– 480
+10% VAC
Max. DC link voltage
890 VDC
Rated apparent power
480 V
45 kVA
54 kVA
67 kVA
82 kVA
107 kVA
127 kVA
Power dissipation
(4)
830 W
1010 W
1300 W
1600 W
2100 W
2500 W
Min. brake resistor]
(external brake resistor)
Max. braking power
(external brake resistor)
Mains choke
(6)
AX2090-ND50-
---
---
0090
0110
0143
0170
Mains filter
(6)
AX2090-NF50
integrated
integrated
0100
0150
0150
0180
Mechanical data
AX5160
AX5172
AX5190
AX5191
AX5192
AX5193
Weight
ca.14 kg
ca.14 kg
ca.31 kg
ca.31 kg
ca.38 kg
ca.38 kg
Breite Width
190 mm
283 mm
283 mm
283 mm
283 mm
Height without plugs
345 mm
540 mm
540 mm
540 mm
540 mm
Depth without connectors/
accessories
259 mm
253 mm
253 mm
334 mm
334 mm
4.4.2 Electrical data
25 A 40 A 50 A 60 A 70 A 80 A
S1-mode (selection)
400 V
(5)
42 kVA
50 kVA
62 kVA
76 kVA
99 kVA
118 kVA
18 Ω 13 Ω 12 Ω 10 Ω 8,5 Ω 6,5 Ω
37 kW 52 kW 56 kW 67 kW 79 kW 103 kW
(1)
The rated current must be reduced by 10% when connecting rated voltage of 480V.
The specified values are valid for output rotary frequency > 5Hz
(2)
I
for max. 3 s at max. 70% preload of rated current
eff
(3)
I
for max. 3 s at max. 70% preload of rated current
eff
(4)
S1 mode, incl. power supply unit, without brake chopper
(5)
Please contact our technical support if you are planning to use resistors with smaller
values
(6)
Required according to EN61800-3 (EMC product standard) C3 (industrial environment)
with motor cable length max. 25 m.
4.4.3 Mechanical data
18 Version: 1.4 AX5000
BECKHOFF Drive Technology 4 Product description
No
Designation
No
Designation
1
X4x – optional slot for expansion cards
9 X01 – mains supply 400 – 480 V
2
X3x – optional slot for safety card
10
X12 – feedback connection, resolver
3
X11 – feedback connection, encoder
11
Display
4
X06 – connection for digital inputs and outputs
12
Labeling field
5
Navigation rocker
13
X04 – socket for EtherCAT input
6
Labeling field
14
X14 – sensor for motor temperature
and brake
7
X05 – socket for EtherCAT output
15
Connection for external brake resistor
8
X03 – power supply 24 V DC input
DC link output (890 V DC voltage)
Max. 890 V DC voltage at the
DC link terminals. Dangerous
minutes after the device is
(Check voltage)
Motor connection (U,V,W,PE)
4.5 General overview (AX5160 and AX5172)
The servo drive illustrated below is an AX5172; the AX5160 is structurally similar
Item description:
DANGER
voltage may be present for
15
switched off. The device is
safe once the voltage has
fallen below 50 V.
AX5000 Version: 1.4 19
4 Product description BECKHOFF Drive Technology
No
Designation
No
Designation
1
X4x – optional slot for expansion cards
9 X14 – sensor for motor temperature
and brake
2
X3x – optional slot for safety card
10
DC link output (890 V DC voltage)
Connection for external brake resistor
3
X11 – feedback connection, encoder
11
Motor connection (U,V,W,PE)
4
X06 – connection for digital inputs and outputs
12
X04 – socket for EtherCAT input
5
Navigation rocker
13
Labeling field
6
Labeling field
14
Display
7
X05 – socket for EtherCAT output
15
X12 – feedback connection, resolver
8
X03 – power supply 24 V DC input
16
X01 – mains supply 400 – 480 V
Max. 890 V DC voltage at the
DC link terminals. Dangerous
minutes after the device is
(Check voltage)
4.6 General overview (AX5190 and AX5191)
Item description:
DANGER
20 Version: 1.4 AX5000
voltage may be present for
30
switched off. The device is
safe once the voltage has
fallen below 50 V.
BECKHOFF Drive Technology 4 Product description
No
Designation
No
Designation
1
X4x – optional slot for expansion cards
9 X14 – sensor for motor temperature
and brake
2
X3x – optional slot for safety card
10
X07 – External brake resistor
3
X11 – feedback connection, encoder
11
DC link output (890 V DC voltage)
4
X06 – connection for digital inputs and outputs
12
Motor connection (U,V,W,PE)
5
Navigation rocker
13
X04 – socket for EtherCAT input
6
Labeling field
14
Labeling field
7
X05 – socket for EtherCAT output
15
Display
8
X03 – power supply 24 V DC input
16
X12 – feedback connection, resolver
Max. 890 V DC voltage at the
DC link terminals. Dangerous
minutes after the device is
(Check voltage)
17
X01 – mains supply 400 – 480 V
4.7 General overview (AX5192 and AX5193)
Item description:
DANGER
AX5000 Version: 1.4 21
voltage may be present for
45
switched off. The device is
safe once the voltage has
fallen below 50 V.
4 Product description BECKHOFF Drive Technology
Terminal point
Connection
L1
Phase L1
L2
Phase L2
L3
Phase L3
PE
Protective conductor
Terminal point
Connection
L1
Phase L1
L2
Phase L2
L3
Phase L3
PE
Protective conductor
Terminal point
Connection
L1
Phase L1
L2
Phase L2
L3
Phase L3
PE
Protective conductor
Attention
Hazard to devices
Serious risk of injury through high electrical voltage!
off.
Terminal
point
Connection
RB +
External brake resistor +
RB -
External brake resistor -
4.8 Overview of connectors/terminal points
4.8.1 X01 – voltage input
4.8.1.1 AX5160 and AX5172
4.8.1.2 AX5190 and AX5191
4.8.1.3 AX5192 and AX5193
4.8.2 X07 – External brake resistor
Connect the PE connection of the external brake resistor at the central
grounding bar.
890 V DC voltage at the RB+ and RB- terminals. Dangerous voltage may
DANGER
4.8.2.1 AX5160 and AX5172
22 Version: 1.4 AX5000
be present at AX5160/AX5172 for 15 minutes, at AX5190/AX5191 for 30
minutes and at AX5192/AX5193 for 45 minutes after the device is switched
BECKHOFF Drive Technology 4 Product description
Terminal
point
Connection
RB +
External brake resistor +
RB -
External brake resistor -
Terminal
point
Connection
RB +
External brake resistor +
RB -
External brake resistor -
Terminal
point
Connection
U
Motor connection U
V+
Moto connection V
W
Motor connection W
PE
Protective conductor
Terminal
point
Connection
U
Motor connection U
V+
Moto connection V
W
Motor connection W
PE
Protective conductor
4.8.2.2 AX5190 and AX5191
4.8.2.3 AX5192 and AX5193
4.8.3 X13 – Motor connection
4.8.3.1 AX5160 and AX5172
4.8.3.2 AX5190 and AX5191
AX5000 Version: 1.4 23
4 Product description BECKHOFF Drive Technology
Terminal
point
Connection
U
Motor connection U
V+
Moto connection V
W
Motor connection W
PE
Protective conductor
Attention
Destruction of the AX5000!
Serious risk of injury through high electrical voltage!
off. (Check voltage)
Terminal
point
Connection
ZK +
Zk +
Currently not
permissible!
ZK –
Zk –
Terminal
point
Connection
ZK +
Zk +
Currently not
permissible!
ZK –
Zk –
4.8.3.3 AX5192 and AX5193
4.8.4 X02 – DC link system (currently not permissible!)
The DC link connection is currently not permissible.
890 V DC voltage at the DC link terminals. Dangerous voltage may be
DANGER
4.8.4.1 AX5160 and AX5172
present at AX5160/AX5172 for 15 minutes, at AX5190/AX5191 for 30
minutes and at AX5192/AX5193 for 45 minutes after the device is switched
4.8.4.2 AX5190 and AX5191
24 Version: 1.4 AX5000
BECKHOFF Drive Technology 4 Product description
Terminal
point
Connection
ZK +
Zk +
Currently not
permissible!
ZK –
Zk –
Terminal
point
Connection
Current consumption
Up +
24 V
- periphery
voltage)
Depending on the connected
X14, X24)
Us +
24 V
- system supply
60 A-72 A = 3 A
90 A-170 A = 10 A
GND
GND
Terminal point
Connection
X04 (IN)
incoming EtherCAT line
X05 (OUT)
outgoing EtherCAT line
CAUTION
Destruction of the AX5000!
Note
Output current
4.8.4.3 AX5192 and AX5193
4.8.5 X03 – 24 VDC supply
DC -0/+25%
(e.g. separate braking
DC ±25%
consumers (see X06 and
4.8.6 X04, X05 – EtherCAT connection
4.8.7 X06 – Digital I/Os
This connector is not designed for external power supply. It is supplied via
the 24 V supply (Up) of connector X03.
The specified output currents are maximum values. The actual values
depend on your current configuration.
AX5000 Version: 1.4 25
4 Product description BECKHOFF Drive Technology
Terminal point
Connection
Output current
24
Output voltage (Up 24 VDC +)
1 A max.
0
Input 0
1 Input 1
2
Input 2
3
Input 3
4
Input 4
5
Input 5
6
Input 6
7
Input 7 or output (configurable) (Up 24 VDC +)
0.5 A max.
0 V
Output voltage GND (-)
Pin
EnDAT / BiSS
Hiperface
Sin / Cos 1Vpp
TTL
1
SIN +
SIN +
SIN +
n.c. 2 GND_5 V
GND_9 V
GND_5 V
GND_5 V
3
COS +
COS +
COS +
n.c. 4 US_5 V *)
n.c.
US_5 V *)
US_5 V *)
5
DX + (Data)
DX + (Data)
n.c.
B +
6
n.c.
US_9 V *)
n.c.
n.c.
7
n.c.
n.c.
REF Z
REF Z
8
CLK + (Clock)
n.c.
n.c.
A + 9 REFSIN
REFSIN
REFSIN
n.c.
10
GND_Sense
n.c.
GND_Sense
GND_Sense
11
REF COS
REF COS
REF COS
n.c.
12
US_5 V Sense
n.c.
US_5 V Sense
US_5 V Sense
13
DX - (Data)
DX - (Data)
n.c.
B -
14
n.c.
n.c.
Z +
Z +
15
CLK - (Clock)
n.c.
n.c.
A -
4.8.8 X11 – feedback, high-resolution
*) The max. output current per channel is 0,25 A
26 Version: 1.4 AX5000
BECKHOFF Drive Technology 4 Product description
Feedback system
Resolver
Analog Hall sensor
1
Temperature
1300 Ω ± 3%
n.c.
2
AGND
n.c.
3
COS - (S3)
n.c.
4
SIN - (S4)
n.c.
5
REF - (R2)
n.c.
6
n.c.
SIN 1Vpp
7
n.c.
-120° oder -90° 1Vpp *
8
n.c.
Us_9 V (supply)
9
Temp._GND
n.c.
10
COS + (S1)
n.c.
11
SIN + (S2)
n.c.
12
REF + (R1)
n.c.
13
n.c.
REFSIN 1 Vpp
14
n.c.
REF -120° oder -90° 1Vpp *
15
n.c.
GND (supply)
Terminal point
Connection
Output current
T-
Temp. - *
T+
Temp. + *
PE
Signal pair screen
B-
Brake GND
B+
Brake (Up) +
2.2 A max.
Note
Output current
4.8.9 X12 – resolver/hall
Pin
(only PTC, Klixon or
bimetal!)
Switchpoint:
*) The angle must be configured
4.8.10 X14 – motor brake and thermal contact
*) Switch, KTY 83-1xx or KTY 84-1xx
The specified output current is the maximum value. The actual value
depends on your current configuration.
AX5000 Version: 1.4 27
4 Product description BECKHOFF Drive Technology
AX A [mm]
B
[mm]
C
[mm]
C1
[mm]
D
[mm]
H
[mm]
H1
[mm]
H2
[mm]
T
[mm]
Fastening
screw
5160
158
190
380 8 6,5
345
398
16,5
259
4 x M5
5172
158
190
380 8 6,5
345
398
16.5
259
4 x M5
5190
200
280
582
10 9 540
603
10
254
4 x M8
5191
200
280
582
10 9 540
603
10
254
4 x M8
5192
200
280
575
10 9 540
600
20
335
4 x M8
5193
200
280
575
10 9 540
600
20
335
4 x M8
4.9 Dimensions
The specified measurements relate to the actual device, without connectors and cables. The
fitting dimensions for control cabinet installation can be found in section "Mechanical
installation Installation examples".
AX5160, AX5172, AX5190, AX5191, AX5192, AX5193
28 Version: 1.4 AX5000
BECKHOFF Drive Technology 5 Installation
Caution – Risk of injury!
• Safety boots must be worn.
WARNING
Caution - Risk of injury through electric shock!
Destruction of the servo drive!
• It is essential to adhere to the required distances (see diagrams below).
5 Installation
• The servo drives may only be installed by trained, qualified personnel.
WARNING
5.1 Mechanical installation
Attention
The qualified personnel must know and comply with the national accident
prevention regulations.
De-energise all electrical components (servo drive, control cabinet, etc.)
before commencing the installation or deinstallation.
• Always install the servo drive vertically.
• Provide adequate ventilation for the servo drive. The permissible ambient
conditions are specified in the "Technical data" section.
AX5000 Version: 1.4 29
5 Installation BECKHOFF Drive Technology
AX
G
[mm]
M
[mm]
H3
[mm]
5160 and 5172
≥ 300
4 x M5
445
5190 and 5191
≥ 300
4 x M8
640
5192 and 5193
≥ 500
4 x M8
640
WARNING
Caution - Risk of injury through electric shock!
Attention
Grounding!
5.1.1 Installation in the control cabinet
The mounting plate must be earthed according to the statutory regulations.
If the ground connection of the AX5000 is not done as specified it is
possible to get trouble with some EMC issues.
30 Version: 1.4 AX5000
BECKHOFF Drive Technology 5 Installation
AX
F
[mm]
E
[mm]
5160 and 5172
≥ 180
20
5190 and 5191
≥ 180
40
5192 and 5193
≥ 180
40
5.1.2 Installation example
AX5000 Version: 1.4 31
5 Installation BECKHOFF Drive Technology
1. Remove the screws 1
2. Position the shroud at the
5.1.3 Installation of the shroud (optional)
(Don’t use again.)
ground of the servo drive.
3. Mount the shroud with the
screws 2.
(Take the new delivered
screws.)
4. Connect the lines at the terminals.
5. Connect the shield of the lines at the connecting links 3.
32 Version: 1.4 AX5000
BECKHOFF Drive Technology 5 Installation
UL-Listing!
It is essential to observe chapter 3.3 if you wish to operate an AX5000 in an
economic area that requires a UL-Listing.
Serious risk of injury through electric shock!
50 V.
Caution – Risk of injury through electric shock!
the motor is prevented from rotating by the internal brake.
Destruction of the equipment!
documentation of the “IDN-Description”) before starting again or
5.2 Electrical installation
Due to the DC link capacitors dangerous voltage may persist at the DC link
DANGER
WARNING
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 below
• Before installation, wiring and commissioning it is essential to read the
section on "Safety".
• Before installing, uninstalling or connecting the servo drive and the
motors please note the following:
- Remove all relevant mains fuses.
- Switch off the main system switch and secure it with a lock.
- Put up a warning sign.
• The control and power connections for the motors may be live, even if
• Check the rated voltage and current of the servo drive and the connected
Attention
AX5000 Version: 1.4 33
motors.
• When the AX5000 is disconnected from the mains supply (emergency
stop, mains contactor etc.), query the status of the IDN "P-0-0205" (see
5 Installation BECKHOFF Drive Technology
Note
Connection to the standard mains supply (TT/TN) with earthed centre is
CAUTION
Fire hazard through short circuit!
Fusing
AX5160
AX5172
AX5190
AX5191
AX5192
AX5193
AC supply *)
80 AT
100 AT
125 AT
160 AT
200 AT
224 AT
24 V supply
4 AT
10 AT
Brake resistor
electronic
CAUTION
Fire hazard through short circuit!
Fusing
AX5160
AX5172
AX5190
AX5191
AX5192
AX5193
AC supply (max.) *)
24 V supply (max.)
4 AT
10 AT
Brake resistor
electronic
5.2.1 Mains supply connection (X01)
The servo drives of the AX5000 series are equipped with a wide voltage input "X01" and can
be connected to voltage systems three-phase 400 V
described below. Connections to other supply systems are not permissible.
Three-phase 400
-10%
- 480
AC -10%
- 480 V
+10% VAC
AC +10%
.
5.2.1.1 External protection for individual devices, CE-compliant
The recommended fuses are designed for line protection. The servo drives
feature integrated self-protection.
*) Application class "gG" mains fuses according to IEC 60269 or "C" type automatic
circuit breakers must be used.
5.2.1.2 External protection for individual devices, UL-compliant
The recommended fuses are designed for line protection. The servo drives
feature integrated self-protection.
*) Mains fuses according to type “RK5” min. 480 V must be used.
34 Version: 1.4 AX5000
BECKHOFF Drive Technology 5 Installation
Note
If one transformer is used for the 24 VDC power supply, the connections US
5.2.2 24 VDC - supply network connection (X03)
The 24 VDC connection "X03" is used for supplying control electronics and periphery with
DC voltage. The control electronics and the periphery can be supplied separately with two
different voltage sources.
and UP must be bridged, in order to ensure that both the control electronics
and the periphery are supplied.
Supply through via one transformer Supply via two transformers
AX5000 Version: 1.4 35
5 Installation BECKHOFF Drive Technology
Note
Motor chokes
Motor choke
AX5160
AX5172
AX5190
1)
AX5191
2)
AX5192
2)
AX5193
3)
C2
C3
C2
C3
C2
C3
C2
C3
C2
C3
C2
C3
AX2090
ND50-0060
AX2090
ND50-0072
AX2090
ND50-0090
AX2090
ND50-0110
AX2090
ND50-0143
AX2090
ND50-0170
5.3 Motors and cables
With longer motor cables the resulting commutation currents can affect the control quality
and lead to EMC faults. Use the tables below to check whether motor chokes or mains filters
have to be used in your application. When selecting the control cabinet ensure that there is
adequate space for motor chokes, mains filters, etc.
Lay the power and signal cables in separate metal cable ducts or, if both types of cable use
the same metal cable duct, make sure there is an earthed metal dividing wall between the
cables.
For the series AX5160 up to AX5193 motor chokes are not required.
Maximum cable length (including extensions) for a rated motor voltage up to 480 V
4)
5)
- - - - - - - - - -
4)
- -
- - - - 10 m 25 m - - - - - -
- - - - - - 10 m 25 m - - - -
5)
- - - - - - - -
- - - - - - - - 10 m 25 m - -
- - - - - - - - - - 10 m 25 m
1)
For compliance with EN 61800-3 only with mains filter AX2090-NF50-0100.
2)
For compliance with EN 61800-3 only with mains filter AX2090-NF50-0150.
3)
For compliance with EN 61800-3 only with mains filter AX2090-NF50-0180.
4)
Without line choke up to max. 10m
5)
Without line choke up to max. 25m
36 Version: 1.4 AX5000
BECKHOFF Drive Technology 6 Important information for commissioning
Caution – Risk of injury!
brought into a safe state in the event of a fault in the drive system.
Increased attention in the case of vertical axes!
mean the sudden falling down of a load in this case.
6 Important information for commissioning
Electronic equipment is not fail-safe. The machine manufacturer is
WARNING
Please be aware each time before commissioning the AX5000 that connected motors can
make uncontrolled movements, which cannot always be prevented even by the AX5000’s
integrated diagnostic system, or may permit uncontrolled movements until the diagnostic
system responds. Analyse your system and take suitable precautions to prevent damage
being caused by these uncontrolled movements.
Potential causes of uncontrolled movements:
The diagnostic system of the AX5000 is equipped with complex plausibility checks, which
constantly monitor installation, operation, parameterisation and operation and, if necessary,
interrupt them with a diagnostic message. The points listed below are naturally also
monitored as standard, but it is not possible to include all eventualities; therefore, with
respect to the following points, you must always consider whether the driven axes can only
perform permissible movements.
• Incorrect commutation results (e.g. during wake & shake), It is essential to observe
chapter “AX5000 User manualcommissioningcommutation methodscommutation
error “F2A0”” on our Homepage.
• Specific caution with synchronous motors of third parties: always execute the
command „P-0-0166“ without load when changing the motor or feedback or when
changing the SysMan-file (.TSM) and evaluate the result. Correct the commutation offset if
applicable., as described in chapter
“AX5000 User manual Commissioning Commutation methods”.
• Input of invalid parameters
• Measuring transducer and/or signal transducer defective or incorrectly adjusted
• Cables defective or not adequately screened
• Incorrectly attached sensors
responsible for ensuring that the connected motors and the machine are
When commissioning vertical axes, the risk consideration described above
CAUTION
AX5000 Version: 1.4 37
is to be carried out with particular care. An uncontrolled movement can
7 Project planning – important information BECKHOFF Drive Technology
Control quality / Dynamics
Mass inertia ratio
Good
up to 3:1
Average
up to 5:1
Bad
up to 10:1
7 Project planning – important information
The more thoroughly a machine or plant project is thought through in advance, the less risk
there is of having to carry out expensive modifications during or after commissioning. This
applies to both the mechanical and electrical design. This section can only give a rough
overview of electrical design. Further information can be found in the publication "Project
planning aid” under Downloads on our website at www.beckhoff.com
7.1 Drive train design
Application, servo drive, motors and gear mechanism must be adapted to each other so that
there is an adequate safety margin for all components as a degree of sluggishness appears
over time due to high temperatures or wear. Make sure that the components in the working
area of the system have adequate reserves so that the working life is not impaired and the
necessary control quality can be maintained.
7.1.1 Control quality, mass inertia ratio and load connection
Control quality is dependent on the parameters "mass inertia ratio" and "load connection":
The "Control quality / dynamics" is primarily affected by the mass moment of inertia: a poor
"Control quality / dynamic" due to an unfavourable mass moment of inertia cannot be
improved even with a very good load connection. Likewise, however, a good "Control quality
/ dynamic" due to a favourable mass moment of inertia can be reduced through a poor load
connection.
7.2 Energy management
If the quality of the mains supply is impaired due to wide fluctuations in voltage, then both
the servo drive specification and the speed range of the motor will need to be considered.
With a positive tolerance for voltage fluctuation the upper limit value of the wide voltage
input of the AX5000 needs to be taken into account. With a negative tolerance of the voltage
fluctuation it must be checked whether the decrease in speed caused by the low voltage is
permissible. With these motors what is known as field weakening operation (check
availability) of the servo drive may provide a solution.
38 Version: 1.4 AX5000
BECKHOFF Drive Technology 7 Project planning – important information
7.3 EMC, earthing, screen connection and potential
The AX5000 corresponds to EMC category "C3" (industrial sector) in terms of conducted
interference emissions. If you wish to use components which comply with a higher category
you can limit the AX5000 conducted interference emissions with the aid of additional filters
to such a degree that this complies with the EMC category "C2" (residential and industrial
environment) or "C1" (residential environments).
Ensure that there is adequate earthing (large-area low-impedance connection) of all relevant
components (incl. control cabinet). The AX5000 incl. periphery, control cabinet, machine bed
and motors must be at the same potential, as the AX5000 control quality will suffer under
differing potentials and operational malfunction may result. Using the screen connection for
potential equalisation is not permitted. If you are unable to provide a uniform reference
potential you need to lay potential equalisation cables of adequate dimensions.
Smooth operation is only guaranteed by faultless screen connections of the cables. The
screens must be applied generously at both ends and must on no account be disconnected.
Use Beckhoff motor and feedback cables as these are optimally adapted to the drive system
and reduce interference to a minimum. Ensure that the connectors and cables are properly
connected.
7.4 Control cabinet
The dimensions of the control cabinet must be sufficient to accommodate all components
with the specified distances. Remember that high temperatures may necessitate forced
cooling. Position the control cabinet as close as possible to the machine so that the motor
cables can be as short as possible.
In addition, the control cabinet should have an earthed metal rear panel to which the
AX5000 incl. periphery are attached so that safe earthing can be guaranteed. If you are
unable to guarantee these conditions you need to earth the AX5000 and the relevant
components using an approved cable of adequate size.
AX5000 Version: 1.4 39
8 Appendix BECKHOFF Drive Technology
8 Appendix
8.1 Support and Service
Beckhoff and their partners around the world offer comprehensive support and service,
making available fast and competent assistance with all questions related to Beckhoff
products and system solutions.
8.1.1 Beckhoff's branch offices and representatives
Please contact your Beckhoff branch office or representative for local support and service on
Beckhoff products!
The addresses of Beckhoff's branch offices and representatives round the world can be
found on her internet pages: http://www.beckhoff.com
You will also find further documentation for Beckhoff components there.
8.1.2 Beckhoff Headquarters
Beckhoff Automation GmbH & Co. KG
Hülshorstweg 20
33415 Verl
Germany
Phone: +49(0)5246/963-0
Fax: +49(0)5246/963-198
E-Mail: info@beckhoff.com
8.1.3 Beckhoff Support
Support offers you comprehensive technical assistance, helping you no only with the
application of individual Beckhoff products, but also with other, wide-ranging services:
• Support
• Design, programming and commissioning of complex automation systems
• Extensive training program for Beckhoff system components
Hotline : +49(0)5246/963-157
Fax : +49(0)5246/963-9157
E-Mail : support@beckhoff.com
8.1.4 Beckhoff Service
The Beckhoff Service Center supports you in all matters of after-sales service:
• On-site service
• Repair service
• Spare parts service
Hotline : +49(0)5246/963-460
Fax : +49(0)5246/963-479
E-Mail : service@beckhoff.com
40 Version: 1.4 AX5000
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