Version : 4.5
Date: 2015
Language: English
Article no.: TDmlAX
BECKHOFF
Startup
Servo Drive AX5000
(1.5 A – 40 A)
Please read this document carefully before installing and commissioning the servo drive.
-04-01
-5000-0000-0200
1 Foreword BECKHOFF Drive Technology
Notes:
2 Version : 4.5 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 ............................................................................................................ 6
1.6 Documentation issue status ............................................................................... 6
1.7 Appropriate use .................................................................................................. 7
1.7.1 Dual Use (EU 1384/2014) .................................................................................. 7
1.8 Documented servo drives ................................................................................... 8
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 .............................................................................................. 14
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 - single-channel servo drive (AX51xx)....................................... 17
4.4.2.1 Single-phase connection .................................................................................. 17
4.4.2.2 Three-phase connection ................................................................................... 18
4.4.3 Electrical data - two-channel servo drive (AX52xx) .......................................... 19
4.4.3.1 Single-phase connection .................................................................................. 19
4.4.3.2 Three-phase connection ................................................................................... 19
4.4.4 Mechanical data (single-channel servo drive) .................................................. 20
4.4.5 Mechanical data (two-channel servo drive) ...................................................... 20
4.5 General overview (AX5101 – AX5112 and AX520x) ........................................ 21
4.6 General overview (AX5118, AX5125 und AX5140) .......................................... 22
4.7 Overview of connectors/terminal points ............................................................ 23
AX5000 Version : 4.5 3
1 Foreword BECKHOFF Drive Technology
4.7.1 X01 - wide voltage input ................................................................................... 23
4.7.2 X02 - DC link (AX5101 - AX5125 und AX520x) ................................................ 23
4.7.3 X02 - DC link (Only AX5140) ............................................................................ 23
4.7.4 X03 - 24 VDC supply ......................................................................................... 23
4.7.5 X04, X05 - EtherCAT connection ..................................................................... 24
4.7.6 X06 – Digital I/Os ............................................................................................. 24
4.7.7 X11 (channel A) , X21 (channel B) - feedback, high-resolution ........................ 25
4.7.8 X12 (channel A) , X22 (channel B) - resolver/hall ............................................ 25
4.7.9 X13 (channel A) , X23 (channel B) - motor connection (power) ....................... 26
4.7.10 X13 - motor connection (power - only AX5140) ................................................ 26
4.7.11 X14 (channel A), X24 (channel B)-motor brake, thermal contact, OCT ............ 26
4.7.12 X07 – internal and external brake resistor ........................................................ 27
4.8 Dimensions ...................................................................................................... 28
5 Installation .......................................................................................................... 30
5.1 Mechanical installation ..................................................................................... 30
5.1.1 Installation in the control cabinet ...................................................................... 30
5.1.1.1 Installation example - AX5101-AX5112 and AX5201-AX5206 ......................... 31
5.1.1.2 Installation example - AX5118, AX5125 and AX5140 ...................................... 31
5.2 Electrical installation ......................................................................................... 32
5.2.1 Mains supply connection (X01) ........................................................................ 33
5.2.1.1 External protection for individual devices, CE-compliant .................................. 33
5.2.1.2 Internal protection, CE-compliant ..................................................................... 33
5.2.1.3 External protection, UL-compliant .................................................................... 34
5.2.1.4 Internal protection, UL-compliant ..................................................................... 34
5.2.1.5 External drive system protection ...................................................................... 35
5.2.2 24 VDC - supply network connection (X03) ....................................................... 36
5.2.3 Connection of several servo drives to form a drive system .............................. 36
5.2.3.1 Connection example - module AX5901 and AX5911 (AX Bridge) .................... 37
5.2.3.2 Connection example - wiring in series without AX Bridge ................................ 38
5.2.4 Configuration example, general ....................................................................... 39
5.2.5 Connection diagram AX5101 – AX5112 and AX520x ...................................... 40
5.2.6 Connection diagram AX5118, AX5125 and AX5140 ........................................ 41
5.3 Motors and cables ............................................................................................ 42
6 Important information for commissioning ....................................................... 43
7 Project planning – important information ........................................................ 44
7.1 Drive train design ............................................................................................. 44
7.1.1 Control quality, mass inertia ratio and load connection .................................... 44
7.2 Energy management ........................................................................................ 44
7.3 EMC, earthing, screen connection and potential .............................................. 45
7.4 Control cabinet ................................................................................................. 45
8 Appendix ............................................................................................................ 46
8.1 Support and Service ......................................................................................... 46
8.1.1 Beckhoff's branch offices and representatives ................................................. 46
8.1.2 Beckhoff Headquarters..................................................................................... 46
8.1.3 Beckhoff Support .............................................................................................. 46
8.1.4 Beckhoff Service .............................................................................................. 46
4 Version : 4.5 AX5000
BECKHOFF Drive Technology 1 Foreword
Hazard to individuals!
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.
Further and more detailed information regarding the individual sections and
CAUTION
An overview is provided on the inside of the rear cover, which can be folded out.
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.
safety can be found in the “AX5000 User manual” on the enclosed CD or
can be downloaded from our website at www.beckhoff.com. If you do not
have access to the “AX5000 User manual” please refrain from working on
the AX5000 and notify our support division.
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.
AX5000 Version : 4.5 5
1 Foreword BECKHOFF Drive Technology
Version
Comment
4.5
New chapter:
4.7.11; 5.2.1.1
4.4
Chapter-Update:
4.4.2; 4.4.3
4.3
New chapter:
1.5; 2.1.2; 4.3; 5.3; 8.1.2
4.2
Deleted chapter:
5.3
4.1
General revision
4.0
General revision on account of the cULus-Listing of the AX5000.
3.9
Chapter-Update:
4.7.4
3.8
Chapter-Update:
4.3; 4.4.1; 4.7.11; 7.5
3.7
Chapter-Update:
1.1; 4.4.4; 5.1.1.2
3.6
Chapter-Update:
2.2; 4.4.2.2; 4.6; 4.7.11
3.5
Chapter-Update:
6
3.4
Chapter-Update:
4.7.11
3.3
New chapter:
4.7.3
3.2
Chapter-Update:
4.7.2
3.1
Chapter-Update:
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.
1.6 Documentation issue status
5.2.5; 5.2.6
Chapter-Update:
1.7.1
Chapter-Update:
7.5
New chapter:
4.7.11; 5.2.1.1; 7.5
6 Version : 4.5 AX5000
BECKHOFF Drive Technology 1 Foreword
3.0
Chapter-Update:
1.8; 4.6; 4.7.9; 4.7.11; 7
2.5
Chapter-Update:
4.6.7; 6
2.4
Chapter-Update:
1.3; 1.4
2.3
Chapter-Update:
6
2.2
Chapter-Update:
2.2; 3.1; 4.6.6; 4.6.8; 5.1.1; 5.2.1.5
2.1
Chapter-Update:
4.1; 4.6.6; 5.2.3
2.0
General revision on account of the UL-Listing of the AX5000.
1.3
Chapter-Update:
1.1; 4.4.2.1; 4.4.2.2; 4.4.3.1; 4.4.3.2; 5.2.1; 5.2.1.1
1.2
General routine corrections
1.1
First edition
1.0
only german
Caution – Risk of injury!
brought into a safe state in the event of a fault in the drive system.
4.2.1; 4.4.2.2; 4.4.4; 4.8; 5.1.1.2; 5.2.1.1
New chapter:
1.1; 1.2; 1.5; 4.5; 5.2
New chapter:
2.2; 5.2.3.1
New chapter:
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 1384/2014)
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
AX5000 Version : 4.5 7
1 Foreword BECKHOFF Drive Technology
Council Regulation 428/2009 has been changed accordingly, Frequency inverters
(listed in item position 3A225) with „operating 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) can be used in consideration of Hardware
Versions with following drives:
• HW Version 1.0 (AX5xxx-0000-x0xx): Serial Number < 68.000
• HW Version 2.0 (AX5xxx-0000-x2xx): Serial Number < 140.000
• HW Version 2.0 (AX5xxx-0000-x21x)
Firmware versions with extension (Dual Use) can be used in consideration of Hardware
Versions with all drives
1.8 Documented servo drives
This documentation describes the following servo drives in the AX5000 range:
AX5101
AX5103
AX5106
AX5112
AX5118
AX5125
AX5140
AX5201
AX5203
AX5206
8 Version : 4.5 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
This symbol indicates important information about the UL-compliant.
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.
AX5000 Version : 4.5 9
2 Safety BECKHOFF Drive Technology
Serious risk of injury through high electrical voltage!
safe once the voltage has fallen 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 DC+ and
DC- terminals (X02) 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 GmbH.
• 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 "X02" after the servo drive has been disconnected from the
mains supply. After disconnecting the servo drive wait 5 minutes and
measure the voltage at the DC link contacts DC+ and DC-. The device is
WARNING
10 Version : 4.5 AX5000
• The surface temperature may exceed 50 °C, resulting in a risk of burns.
• 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
BECKHOFF Drive Technology 2 Safety
Hazard to individuals!
Directive in national legislation.
Hazard to devices and environment
- Do not touch the motor plug during operation of the AX5000.
• 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.).
- Place the servo drive on a conductive surface.
AX5000 Version : 4.5 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 of the AX5000 series 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 of the AX5000 series 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 : 4.5 AX5000
BECKHOFF Drive Technology 3 Guidelines and Standards
AX5000 with UL-Listing
AX5203 und AX5206
Drive system with UL-Listing!
Please consult our Application Department with respect to the requirements
for a drive system with UL-Listing.
Fusing
AX5101
AX5103
AX5106
AX5201
AX5203
AX5206
AC supply (max.) *)
6 A
12 A
20 A
12 A
20 A
20 A
24 V supply (max.)
3 A
Brake resistor
electronic
Fusing
AX
5101
5103
5106
5112
5118
5125
5140
5201
5203
5206
AC suppl (max.)*)
6 A
12 A
20 A
20 A
35 A
45 A
80 A
12 A
20 A
20 A
24 V supply (max.)
3 AT
Brake resistor
elektronisch
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
AX5101, AX5103, AX5106, AX5112, AX5118, AX5125, AX5140, AX5201,
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.
Suitable for use on a circuit capable of delivering not more than 18000 rms symmetrical
amperes, 480 V maximum, when protected by RK5 class fuses.
Single-phase
*) Mains fuses according to type “RK5” must be used.
Three-phase
*) Mains fuses according to type “RK5” must be used.
AX5000 Version : 4.5 13
3 Guidelines and Standards BECKHOFF Drive Technology
When protected by RK5 class fuses:
Rated 80 A, min. 480 V
Canada!
by Beckhoff Automation.
AX5112
Rated 20 A, min. 480 V
AX5118
Rated 35 A, min. 480 V
AX5125
Rated 45 A, min. 480 V
AX5140
3.3.3 UL-specific notes
Use in a Pollution Degree 2 environment
Use 75 °C Copper Conductors min.
Control Board rating = 24 V
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 : 4.5 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:
X01: Mains input
X02: DC link
X03: DC power supply 24 V
X06: Digital inputs and outputs
X07: External brake resistor (only AX5140)
− Startup (this manual)
− Complete documentation on CD
AX5000 Version : 4.5 15
4 Product description BECKHOFF Drive Technology
Accessories with UL-Listing!
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
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 USA or Canada , please make sure
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
name
plate
16 Version : 4.5 AX5000
BECKHOFF Drive Technology 4 Product description
UL-Listing!
USA or Canada.
Ambient / operating conditions
Permissible values
Ambient temperature during operation
0 °C to +50 °C
Ambient temperature during transport /
storage
-25 °C to +70 °C
Air humidity
5 % to 95 %, non-condensing
Pollution degree
2 according to EN 60204/EN 50178
Corrosion protection
Normally not required.
measures must be agreed with the manufacturer.
Operating altitude
up to 1000 m above sea level
Installation position
vertical
Ventilation
Total device current ≤ 3 A: free convection
controlled fan
Protection class
IP 20
Vibration test (EN 60068-2-6)
Frequency range: 10-500 Hz
59-500 Hz = 1 g
Shock test (EN 60068-2-27)
Half sine wave amplitude: 5 g
(total 18)
Repetitive shock test (EN 60068-2-27)
Half sine wave amplitude: 5 g
(total 6000)
EMC
Category C3 - standard
Category C2, C1 - auxiliary filter required
Electrical data
AX5101
AX5103
AX5106
Rated output current
1.5 A
3 A
4.5 A
Minimum channel current at full current
resolution
Max. output current
(1)
4.5 A
7.5 A
13 A
Rated supply voltage
1x 100
-10%
– 240
+10% VAC
Max. DC link voltage
890 VDC
Rated apparent power
4.4 Technical data
It is essential to observe chapter 3.3 if you wish to operate an AX5000 in
4.4.1 Permissible ambient and operating conditions
Under extreme operating conditions separate
Total device current > 3 A: built-in temperature-
Amplitude: 10-58 Hz = 0,075 mm pk-pk
Duration: 30 ms
Number of shocks: 3 per axis and direction
Duration: 30 ms
Number of shocks: 1000 per axis and direction
4.4.2 Electrical data - single-channel servo drive (AX51xx)
4.4.2.1 Single-phase connection
0.35 A 1 A 1 A
AX5000 Version : 4.5 17
4 Product description BECKHOFF Drive Technology
Electrical data
AX5101
AX5103
AX5106
S1 mode (selection)
230 V
0.6 kVA
1.2 kVA
2.4 kVA
Power dissipation
(2)
35 W
50 W
85 W
Max. continuous braking power
(with internal brake resistor)
Max. braking power
(with internal brake resistor)
Min. brake resistor
(external brake resistor)
Max. braking power
(with external brake resistor)
Electrical data
AX
5101
5103
5106
5112
5118
5125
5140
Rated output current [A]
1,5 3 6
12
18
25
(1)
40
Minimum channel current [A]
at full current resolution
Max. output current
(3)
[A]
4,5
7,5
13
26
36
50
80
(4)
Rated supply voltage [VAC]
3x 100
-10%
– 480
+10%
(2)
Max. DC link voltage [VDC]
890
Rated apparent power [kVA]
480 V
1,2
2,5
5,0
10,0
15,0
20,8
33,3
Power dissipation
(5)
[W]
35
50
85
160
255
340
510
Max. continuous braking power [W]
(with internal brake resistor)
Max. braking power [kW]
(with internal brake resistor)
Min. brake resistor [Ω]
(external brake resistor)
Max. braking power [kW]
(external brake resistor)
120 V
0.3 kVA
50 W 50 W 150 W
(1)
I
for max. 7 s
eff
(2)
S1 mode, including power supply unit, without brake chopper
4.4.2.2 Three-phase connection
0,35 1 1 6 8 12 18
S1-mode (selection)
120 V
230 V
400 V
0,3
0,6
1,0
0,6
1,2
2,1
1,2
2,4
4,2
0.6 kVA
14 kW
47 Ω
15 kW
2,5
4,8
8,3
3,4
7,2
12,5
1.2 kVA
4,8
10,0
17,3
8,3
16,0
27,7
50 50 150 90 200 200 150
14 26 26 26
47 47 47 30 22 22 22
15 15 15 23,5 32 32 32
(1)
cULus = 24 A
(2)
cULus = AX5118 und AX5125 = 3 x 480 VAC
(3)
I
for max. 7 s
eff
(4)
I
for max. 7 s, if rotating field frequency >3 Hz at max. 40°C
eff
(5)
S1 mode, including power supply unit, without brake chopper
(4)
Brake resistor < 22 Ω –> Please consult our Application Department
18 Version : 4.5 AX5000
± 10%
(4)
BECKHOFF Drive Technology 4 Product description
Electrical data
AX5201
AX5203
AX5206
Rated output current / channel
1.5 A
3 A
6 A
Minimum channel current at full current
resolution
Maximum rated channel current
3 A
4.5 A
9 A
Total rated output current
3 A
4.5 A
9 A
Max. output current
(1)
/channel
5 A
10 A
13 A
Max. output current
(1)
total device
current
Rated supply voltage
1x 100
-10%
– 240
+10% VAC
Max. DC link voltage
890 VDC
Rated apparent power
230 V
1.2 kVA
2.4 kVA
4.8 kVA
Power dissipation
(2)
55 W
85 W
160 W
Max. continuous braking power
(with internal brake resistor)
Max. braking power
(with internal brake resistor)
Min. brake resistor
(external brake resistor)
Max. braking power
(with external brake resistor)
Electrical data
AX5201
AX5203
AX5206
Rated output current per channel
1.5 A
3 A
6 A
Minimum channel current at full current
resolution
Maximum rated channel current
3 A
6 A
9 A
Total rated output current
3 A
6 A
12 A
Max. output current
(1)
/channel
5 A
10 A
13 A
Peak output current
(1)
total device
current
Rated supply voltage
3x 100
-10%
– 480
+10% VAC
Max. DC link voltage
890 VDC
Rated apparent power
120 V
0.6 kVA
1.2 kVA
2.5 kVA
4.4.3 Electrical data - two-channel servo drive (AX52xx)
4.4.3.1 Single-phase connection
0.35 A 1 A 1 A
10 A 20 A 26 A
S1 mode (selection)
120 V
0.6 kVA
50 W 150 W 90 W
(1)
I
for max. 7 s
eff
(2)
S1 mode, including power supply unit, without brake chopper
4.4.3.2 Three-phase connection
0.35 A 1 A 1 A
10 A 20 A 26 A
1.2 kVA
14 kW
47 Ω
15 kW
2.5 kVA
S1 mode (selection)
AX5000 Version : 4.5 19
4 Product description BECKHOFF Drive Technology
Electrical data
AX5201
AX5203
AX5206
230 V
480 V
1.2 kVA
2.5 kVA
2.4 kVA
5.0 kVA
4.8 kVA
10.0 kVA
Power dissipation
(2)
55 W
85 W
160 W
Max. continuous braking power
(with internal brake resistor)
Max. braking power
(with internal brake resistor)
Min. brake resistor
(external brake resistor)
Max. braking power
(with external brake resistor)
Mechanical data
AX
5101
5103
5106
5112
5118
5125
5140
Weight [kg]
ca. 4
ca. 4
ca. 5
ca. 5
ca. 11
ca. 11
ca. 13
Width [mm]
92
185
Height without plugs [mm]
274
Depth without connectors/ [mm]
accessories
232
Mechanical data
AX5201
AX5203
AX5206
Weight
approx. 5 kg
approx. 6 kg
approx. 6 kg
Width
92 mm
Height without plugs
274 mm
Depth without connectors / accessories
232 mm
400 V
2.1 kVA
4.2 kVA
50 W 150 W 90 W
(1)
I
for max. 7 s
eff
(2)
S1 mode, including power supply unit, without brake chopper
4.4.4 Mechanical data (single-channel servo drive)
4.4.5 Mechanical data (two-channel servo drive)
8.3 kVA
14 kW
47 Ω
15 kW
20 Version : 4.5 AX5000
BECKHOFF Drive Technology 4 Product description
Item description:
No
Designation
1
X11 – feedback connection, encoder
2
X12 – feedback connection, resolver
3
X21 – feedback connection, encoder
channel B (only for two-channel unit)
4
X22 – feedback connection, resolver
channel B (only for two-channel unit)
5
X3x – optional slot for safety card
X4x – optional slot for expansion cards
6
Navigation rocker
7
Status LED for EtherCAT output
8
Labeling field
9
X05 – socket for EtherCAT output
10
X03 – power supply 24 V DC input
11
X14 – sensor for motor temperature and brake
12
X24 – sensor for motor temperature and brake
channel B (only for two-channel unit)
13
X23 – motor connection (U, V, W, PE)
channel B (only for two-channel unit)
14
X13 – motor connection (U, V, W, PE)
15
X01 – mains supply 100 – 480 V
16
X02 – DC link output
Connection for the external brake resistor
17
890 V DC voltage at the DC link
below 50 V.
18
X04 – socket for EtherCAT input
19
Labeling field
20
Status LED for EtherCAT input
21
Display
22
X06 – connection for digital inputs and outputs
4.5 General overview (AX5101 – AX5112 and AX520x)
The servo drive shown below is a two-channel device. Components that are only available
for the second channel are identified in the item description.
(890 V DC voltage)
terminals. Dangerous voltage may
WARNING
AX5000 Version : 4.5 21
be present for 5 minutes after the
device is switched off. The device
is safe once the voltage has fallen
4 Product description BECKHOFF Drive Technology
No
Designation
No
Designation
1
X11 – feedback connection, encoder
11
X07 – external brake resistor
(only AX5140)
2
X12 – feedback connection, resolver
12
X13 – motor connection (U, V, W, PE)
3
X3x – optional slot for safety card
X4x – optional slot for expansion cards
13
X01 – mains supply 100 – 480 V
4
Navigation rocker
14
X02 – DC link output
(only AX5118 u. AX5125)
5
Status LED for EtherCAT output
15
X04 – socket for EtherCAT input
6
Labeling field
16
Labeling field
7
X05 – socket for EtherCAT output
17
Status LED for EtherCAT input
8
X03 – power supply 24 V DC input
18
Display
9
Max. 890 V DC voltage at the
DC link terminals. Dangerous
fallen below 50 V.
19
X06 – connection for digital inputs and outputs
10
X14 – sensor for motor temperature and brake
4.6 General overview (AX5118, AX5125 und AX5140)
The servo drive illustrated below is an AX5140; the devices with 18 A or 25 A are structurally
similar apart from pos. 11 "X07" (external brake resistor).
Item description:
(890 V DC voltage)
Connection for the external brake resistor
WARNING
voltage may be present for 5
minutes after the device is
switched off. The device is
safe once the voltage has
22 Version : 4.5 AX5000
BECKHOFF Drive Technology 4 Product description
Connection
Tightening
torque
3-phase
1-phase
L1
Phase L1
Phase L1
L2
Phase L2
not used
L3/ N
Phase L3
Neutral conductor
PE
Protective conductor
Terminal point
Connection
Tightening
torque
DC+
DC link +
external brake resistor
and drive system
DC –
DC link –
Terminal point
Connection
Tightening
torque
DC+
DC link +
DC –
DC link –
Serious risk of injury through high electrical voltage!
Remove the white hexagon plugs only if you wire the terminal points again.
Terminal
point
Connection
Current
consumption
Tightening
torque
Up +
24 V
- periphery
voltage)
Depending on the
(see X06 and X14,X24)
Us +
24 V
- system
rated current)
-12 A = 0.4 A – 0.8 A
40 A = 1,6 A
GND
GND
4.7 Overview of connectors/terminal points
4.7.1 X01 - wide voltage input
Terminal point
0,5 -0,6 Nm
4.7.2 X02 - DC link (AX5101 - AX5125 und AX520x)
0,5 -0,6 Nm
4.7.3 X02 - DC link (Only AX5140)
only for drive system 1,2 -1,5 Nm
890 V DC voltage at the DC link terminals. Dangerous voltage may be
WARNING
present for 5 minutes after the device is switched off.
Remove the connector only if you want to build a drive system with a AXBridge.
4.7.4 X03 - 24 VDC supply
DC -0/+25%
(e.g. separate braking
DC ±25%
supply (depending on
AX5000 Version : 4.5 23
connected consumers
0,5 – 0,6 Nm
18 A - 25A = 1,1 A
4 Product description BECKHOFF Drive Technology
Terminal point
Connection
X04 (IN)
incoming EtherCAT line
X05 (OUT)
outgoing EtherCAT line
CAUTION
Destruction of the AX5000!
Note
Output current
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 (-)
4.7.5 X04, X05 - EtherCAT connection
4.7.6 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.
24 Version : 4.5 AX5000
BECKHOFF Drive Technology 4 Product description
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 -
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)
4.7.7 X11 (channel A) , X21 (channel B) - feedback, high-resolution
*) The max. output current per channel is 0,25 A
4.7.8 X12 (channel A) , X22 (channel B) - resolver/hall
Pin
(only PTC, Klixon or
bimetal!)
Switchpoint:
*) The angle must be configured
AX5000 Version : 4.5 25
4 Product description BECKHOFF Drive Technology
Terminal point
Connection
U
Motor connection U
V+
Motor connection V
W
Motor connection W
PE
Protective conductor
Shroud
Screen
Terminal point
Connection
U
Motor connection U
V+
Motor connection V
W
Motor connection W
PE
Protective conductor
Shroud
Screen
Grounding shield!
due to a poor shield connection of the motor.
Terminal point
Connection
Output current
T-
Temp. - *
T+
Temp. + *
PE
Signal pair screen
B-
Brake GND
B+
Brake (Up) +
1.5 A max.
4.7.9 X13 (channel A) , X23 (channel B) - motor connection (power)
(AX5101 - AX5125 und AX520x)
4.7.10 X13 - motor connection (power - only AX5140)
The grounding shield of the motor is connected via the shield plate in the
Attention
motor connector. Please tighten the knurled screws of the motor connector
with a screwdriver. It is possible that some feedback problems may caused
4.7.11 X14 (channel A), X24 (channel B)-motor brake, thermal contact, OCT
AX5000-xxxx-0000 (Hardware 1)
*) Switch, KTY 83-1xx or KTY 84-1xx
26 Version : 4.5 AX5000
BECKHOFF Drive Technology 4 Product description
Terminal point
Connection
Output current
T-
OCT – and temperature
T+
OCT + and temperature
PE
Signal pair screen
B-
Brake GND
B+
Brake (Up) +
2.2 A max.
Note
Output current
Terminal point
Connection
PE
Protective conductor
+ RB
External brake resistor +
+ R
Bint
Internal brake resistor +
– RB
Brake resistor GND
Operation of AX5140
"FD4B – undervoltage"
AX5000-xxxx-0200 (Hardware 2)
The specified output current is the maximum value. The actual value
depends on your current configuration.
4.7.12 X07 – internal and external brake resistor
(Only AX5140)
Commissioning the AX5140 can only be carried out when the terminal
Note
points "+R
resistor is connected (terminal points "+R
" and "+RB" are bypassed (delivery state) or an external brake
Bint
" and "-RB"). If these measures
B
are not taken then the AX5140 will be stopped with the error message
AX5000 Version : 4.5 27
4 Product description BECKHOFF Drive Technology
4.8 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".
AX5118, AX5125 and AX5140 AX5101-AX5112 / AX5201-AX5206
All dimensions are in mm
28 Version : 4.5 AX5000
BECKHOFF Drive Technology 4 Product description
AX5000
without AX bridge
AX5000
with AX bridge
All dimensions are in mm
AX5000 Version : 4.5 29
5 Installation BECKHOFF Drive Technology
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).
WARNING
Caution - Risk of injury through electric shock!
Attention
Grounding!
5 Installation
• The servo drives may only be installed by trained, qualified personnel.
WARNING
5.1 Mechanical installation
Attention
5.1.1 Installation in the control
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.
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 : 4.5 AX5000
BECKHOFF Drive Technology 5 Installation
5.1.1.1 Installation example - AX5101-AX5112 and AX5201-AX5206
5.1.1.2 Installation example - AX5118, AX5125 and AX5140
AX5000 Version : 4.5 31
5 Installation BECKHOFF Drive Technology
UL-Listing!
USA or Canada.
Serious risk of injury through electric shock!
voltage has fallen below 50 V.
Caution – Risk of injury through electric shock!
the motor is prevented from rotating by the internal brake.
Destruction of the equipment!
“IDN-Description”).
5.2 Electrical installation
It is essential to observe chapter 3.3 if you wish to operate an AX5000 in
Due to the DC link capacitors dangerous voltage may persist at the DC link
DANGER
WARNING
contacts "X02" after the servo drive has been disconnected from the mains
supply. After disconnecting the servo drive wait 5 minutes and measure the
voltage at the DC link contacts DC+ and DC-. The device is safe once the
• 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
32 Version : 4.5 AX5000
motors.
• When the AX5000 is disconnected from the mains supply (emergency
stop, mains contactor etc.), wait at least 3 minutes before starting again
or query the status of the IDN "P-0-0205" (see documentation of the
BECKHOFF Drive Technology 5 Installation
Connection to the standard mains supply (TT/TN) with earthed centre is
www.beckhoff.com.
Fire hazard through short circuit!
drives feature integrated self-protection.
Fusing
AX5101
AX5103
AX5106
AX5201
AX5203
AX5206
AC supply *)
10 A
10 A
16 A
10 A
16 A
20 A
24 V supply *)
5 A
Brake resistor
electronic
Fusing
AX
5101
5103
5106
5112
5118
5125
5140
5201
5203
5206
AC supply *)
6 AT
6 A
10 A
20 A
35 A
35 A
50 A
10 A
10 A
20 A
24 V supply
*)
5 A
Brake resistor
elektronisch
Circuit
Fuse
24 V - system voltage
3.4 AF
24 V - peripheral voltage
electronic
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 between single-phase 100 V
three-phase 100 V
AC -10%
- 480 V
AC +10%
.
described below. Details for connections to other supply systems (e.g. ITmains supply, isolating transformer etc.) can be found in the “AX5000 User
Note
single-phase 100
manual” on the enclosed CD or can be downloaded from our website at
-10%
- 240
+10% VAC
three-phase 100
5.2.1.1 External protection for individual devices, CE-compliant
• The following data refer to individual devices. Please note the total
CAUTION
current of all connected devices in a multi-axis system.
• The recommended fuses are designed for line protection. The servo
Single-phase
AC -10%
- 240 V
-10%
AC +10%
- 480
and
+10% VAC
*) Application class "gG" mains fuses according to IEC 60269 with characteristic “T” or
"C" type automatic circuit breakers must be used.
Three-phase
*) Application class "gG" mains fuses according to IEC 60269 with characteristic “T” or
"C" type automatic circuit breakers must be used.
5.2.1.2 Internal protection, CE-compliant
AX5000 Version : 4.5 33
5 Installation BECKHOFF Drive Technology
Fusing
AX5101
AX5103
AX5106
AX5201
AX5203
AX5206
AC supply (max.) *)
6 A
12 A
20 A
12 A
20 A
20 A
24 V supply (max.)
3 A
Brake resistor
electronic
Fusing
AX
5101
5103
5106
5112
5118
5125
5140
5201
5203
5206
AC suppl (max.)*)
6 A
12 A
20 A
20 A
35 A
45 A
80 A
12 A
20 A
20 A
24 V supply (max.)
3 A
Brake resistor
elektronisch
When protected by RK5 class fuses:
Rated 80 A, min. 480 V
Circuit
Fuse
24 V - system voltage
3.4 AF
24 V - peripheral voltage
electronic
Brake resistor
electronic
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.
Suitable for use on a circuit capable of delivering not more than 18000 rms symmetrical
amperes, 480 V maximum, when protected by RK5 class fuses.
Single-phase
*) Mains fuses according to type “RK5” must be used.
Three-phase
*) Mains fuses according to type “RK5” must be used.
AX5112
Rated 20 A, min. 480 V
AX5118
Rated 35 A, min. 480 V
AX5125
Rated 45 A, min. 480 V
AX5140
5.2.1.4 Internal protection, UL-compliant
34 Version : 4.5 AX5000
BECKHOFF Drive Technology 5 Installation
Special requirements for a drive system
requirements for a drive system with UL-Listing.
5.2.1.5 External drive system protection
Rule of thumb: Determine the total device rated current, multiply by correction factor and
round it up to the next higher standard level.
Example: 1 x AX5103 + 2 x AX5201 + 2 x AX5203
3 A + 6 A
Please consult our Application Department with respect to the special
+ 12 A = 21 x 1,1 = 23,1 A selected 25 A
AX5000 Version : 4.5 35
5 Installation BECKHOFF Drive Technology
Note
If one transformer is used for the 24 VDC power supply, the connections US
Drive system with UL-Listing!
Please consult our Application Department with respect to the requirements
for a drive system with UL-Listing.
Hazard to the equipment
≠
contactor etc.).
Danger for persons and equipment
AX Bridge is limited to 85 A.
Attention
Destruction of the external brake resistor
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
5.2.3 Connection of several servo drives to form a drive system
• The connection sequence of the devices is not arbitrary. The total rated
Attention
current of the device must decrease from the power supply.
AX5112-AX5203-AX5106-AX5201 = OK; AX5201-AX5112-AX5203
• All devices in a drive system are always to be disconnected from and
reconnected to the mains supply together (emergency stop, mains
Note the total rated current of the connected devices.
CAUTION
According to CE the current carrying capacity of power busbars of the
An external brake resistor may not be connected to the X02 terminal point
(DC link) in a drive system. Use an external brake module AX5021 for this.
36 Version : 4.5 AX5000
OK
BECKHOFF Drive Technology 5 Installation
CAUTION
Hazard to inviduals through electric shock
Hazard to inviduals and equipment
current and must comply with EN60204-1.
Terminal points
Conductor design
max. Conductor
cross-section
Tightening torque
L1-L3, PE
single wire
10 mm2
2,2 Nm
L1-L3, PE
flnely stranded with
wire end sleeves
16 mm2
2,2 Nm
L1-L3, PE
flnely stranded /
stranded
25 mm2
2,2 Nm
5.2.3.1 Connection example - module AX5901 and AX5911 (AX Bridge)
This connection option enables a safe system to be set up very quickly. The modules are
attached to plug contacts X01, X02 and X03, the relevant slides are pushed to the left and
screwed tight. According to CE the current carrying capacity of power busbars of the
AX Bridge is limited to 85 A.
Move all busbar sliders to the left limit stop in order to ensure full current
carrying capacity. Then tighten all screws with a torque of 2.2 Nm.
Please ensure that the connection line for the AX5901 supply module is
CAUTION
The supply connection is established as described in sections 5.2.1 and 5.2.2.
Information of the terminal points
adequately dimensioned. The dimensioning depends on the total rated
AX5000 Version : 4.5 37
5 Installation BECKHOFF Drive Technology
Hazard to inviduals and equipment
• Avoid phase reversal between the devices!
5.2.3.2 Connection example - wiring in series without AX Bridge
Wire the relevant connections using individual cables.
• Please ensure that the final supply network connection cable is
CAUTION
adequately dimensioned. The dimensioning depends on the total rated
current and must comply with EN60204-1.
• To establish a DC link system wire the X02 connections with a suitable
cable. Voltages up to 890 V may be present.
• The connectors are designed for a maximum current of 41 A and a
maximum conductor cross-section of 6 mm².
The supply connection is established as described in sections 5.2.1 and 5.2.2.
38 Version : 4.5 AX5000
BECKHOFF Drive Technology 5 Installation
5.2.4 Configuration example, general
AX5000 Version : 4.5 39
5 Installation BECKHOFF Drive Technology
5.2.5 Connection diagram AX5101 – AX5112 and AX520x
40 Version : 4.5 AX5000
BECKHOFF Drive Technology 5 Installation
5.2.6 Connection diagram AX5118, AX5125 and AX5140
AX5000 Version : 4.5 41
5 Installation BECKHOFF Drive Technology
Motor choke
AX5101 - AX5112 a.AX52xx
AX5118 a. AX5125
AX5140
C21)
C3
C22)
C3
C2
C3
Without
< 25 m
< 25 m
< 25 m
< 25 m
-
< 35 m
AX2090MD50-0012
< 100 m
< 100 m
- - - - AX2090-
MD50-0025
-
-
< 50 m
< 50 m
-
-
Motor choke
AX5101 - AX5112 a.AX52xx
AX5118 a. AX5125
AX5140
C21)
C3
C22)
C3
C2
C3
Without
< 20 m
< 20 m
< 20 m
< 20 m
-
< 35 m
AX2090MD50-0012
< 100 m
< 100 m
- - - - AX2090-
MD50-0025
-
-
< 50 m
< 50 m
-
-
Note
We recommend that feedback wires and motor wires used have the same
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.
Maximum cable length (including extensions) for a rated motor voltage up to 400 V
1)
For compliance with EN 61800-3 only with mains filter AX2090-NF50-0014.
2)
For compliance with EN 61800-3 only with mains filter AX2090-NF50-0032.
In exceptional cases (sensitive sensors, etc.) it can be necessary to use a motor choke even
for motor cable lengths < 25 m.
Maximum cable length (including extensions) for a rated motor voltage up to 480 V
1)
For compliance with EN 61800-3 only with mains filter AX2090-NF50-0014.
2)
For compliance with EN 61800-3 only with mains filter AX2090-NF50-0032.
In exceptional cases (sensitive sensors, etc.) it can be necessary to use a motor choke even
for motor cable lengths < 20 m.
length.
42 Version : 4.5 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 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 : 4.5 43
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. If the mains supply does not meet the
specifications for operation of the AX5000, then isolating transformers, mains chokes, mains
filters or other measures may be required. An energy efficient drive system operates in a
drive system with a shared DC link and shared internal and possibly also external brake
resistors or brake modules. If you are already using similar drive systems, the AX5000 offers
a convenient diagnostic system for determining the load on the brake resistors and for
transferring the values. Previous experience with drive systems shows that in such a system
much smaller or even no external brake resistors / brake modules need to be used.
44 Version : 4.5 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 pre-assembled Beckhoff motor and feedback cables as these are optimally adapted to
the drive system and reduce interference to a minimum. Ensure that the connectors are
properly connected: this applies to the motor connector in particular.
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 : 4.5 45
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
46 Version : 4.5 AX5000
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