BECKHOFF AX5000 User Manual

0 (0)

Startup

Servo Drive AX5000

(60 A – 170 A)

Please read this document carefully before installing and commissioning the servo drive.

Version: 1.4

Date: 2015-03-18

Language: English

Article no.: TDmlAX-5160-0000-0200

BECKHOFF

1 Foreword

BECKHOFF Drive Technology

Notes:

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

Version: 1.4

AX5000

BECKHOFF Drive Technology

1 Foreword

1.1Notes 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.

1.2Disclaimer

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.

1.3Trademarks

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.

1.4Patent 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.

1.5Copyright

The reproduction, distribution and utilization of this document as well as the communication of its contents to others without express authorization are prohibited.

AX5000

Version: 1.4

1 Foreword

BECKHOFF Drive Technology

1.6Documentation issue status

Version	Comment
1.4	New Chapter:
	5.2.1.2
	Chapter-Update:
	3.3; 4.3.; 4.4.2; 5.2.1.1
1.3	New Chapter:
	1.7.1
	Chapter-Update:
	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:
	4.7; 5.1.3; 5.3
	Chapter-Update:
	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

1.7Appropriate 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.

		Caution – Risk of injury!
		Electronic equipment is not fail-safe. The machine manufacturer is
	WARNING	responsible for ensuring that the connected motors and the machine are
	WARNING	brought into a safe state in the event of a fault in the drive system.

The servo drives may only be operated in enclosed control cabinets and in accordance with the conditions described in the "Technical data" section.

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:

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.

1.8Documented servo drives

This documentation describes the following servo drives in the AX5000 range:

AX5160

AX5172

AX5190

AX5191

AX5192

AX5193

AX5000

Version: 1.4

1 Foreword	BECKHOFF Drive Technology
Notes :

Version: 1.4

AX5000

BECKHOFF Drive Technology

2 Safety

2.1General safety instructions

2.1.1Safety 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..

2.1.2Disclaimer

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.

2.1.3Description 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.

	Acute risk of injury!
	If you do not adhere the safety advise adjoining this symbol, there is
DANGER	immediate danger to life and health of individuals!
DANGER

	Risk of injury!
	If you do not adhere the safety advise adjoining this symbol, there is
WARNING	danger to life and health of individuals!
WARNING

	Hazard to individuals!
	If you do not adhere the safety advise adjoining this symbol, there is
CAUTION	obvious hazard to individuals!
CAUTION

	Hazard to devices and environment
	If you do not adhere the notice adjoining this symbol, there is obvious
Attention	hazard to materials and environment.
Attention

	Note or pointer
	This symbol indicates information that contributes to better understanding.
Note

UL pointer

This symbol indicates important information about the UL-compliant.

AX5000

Version: 1.4

2 Safety

BECKHOFF Drive Technology

2.1.4Personnel qualification

This description is only intended for trained specialists in control, automation and drive engineering who are familiar with the applicable national standards.

2.2Special 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.

Serious risk of injury through high electrical voltage!

• 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 below 50 V.

	Serious risk of injury through hot surfaces!
	• 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
	sufficiently.

	Danger of injury due to uncontrolled movements!
	Read and take note of chapter 6 ‘Important information for commissioning’
WARNING	each time before commissioning the AX5000
WARNING

10 Version: 1.4 AX5000

BECKHOFF Drive Technology

2 Safety

Hazard to individuals!

• Carefully read this manual before using the servo drive thoroughly,

CAUTION 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 Directive in national legislation.

Hazard to devices and environment

• During installation it is essential to ensure that the specified ventilation

Attention 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.).

-Place the servo drive on a conductive surface.

AX5000

Version: 1.4

3 Guidelines and Standards

BECKHOFF Drive Technology

3 Guidelines and Standards

3.1CE 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

Hazard to individuals!

Servo drives are not covered by the EC Machinery Directive. Operation

of the servo drives in machines or systems is only permitted once the CAUTION machine or system manufacturers has provided evidence of CE

conformity of the complete machine or system.

3.2Electromagnetic 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

Version: 1.4

AX5000

+ 28 hidden pages