Beckhoff XTS Startup Manual
Documentation
eXtended Transport System Start-Up
Version:
Date:
1.2
2016-02-18
Table of content
Table of content
1 Foreword ....................................................................................................................................................5
1.1 Notes on the documentation............................................................................................................. 5
1.2 Documentation issue status.............................................................................................................. 6
1.3 Intended use ..................................................................................................................................... 6
2 Guidelines and Standards ........................................................................................................................7
3 Safety..........................................................................................................................................................8
3.1 General safety instructions ............................................................................................................... 8
3.1.1 Personnel qualification..........................................................................................................8
3.1.2 Description of safety symbols ...............................................................................................8
3.2 Special safety instructions ............................................................................................................... 9
3.3 Using in Ex environments ............................................................................................................... 10
4 Handling ...................................................................................................................................................11
4.1 Transport ........................................................................................................................................ 11
4.2 Packaging ....................................................................................................................................... 11
4.3 Storage ........................................................................................................................................... 12
4.4 Maintenance / Cleaning .................................................................................................................. 12
4.4.1 Replacement of the guide rollers ........................................................................................13
4.5 Disposal .......................................................................................................................................... 14
5 Product identification..............................................................................................................................15
5.1 Scope of supply .............................................................................................................................. 15
5.2 Type label ....................................................................................................................................... 15
5.3 Type key ......................................................................................................................................... 16
6 Technical description..............................................................................................................................18
6.1 General technical data.................................................................................................................... 18
6.1.1 Dimensions .........................................................................................................................19
6.1.2 Connection diagram XTS-Infeed.........................................................................................20
6.1.3 Connection overview...........................................................................................................21
6.2 Configuration ................................................................................................................................. 22
6.2.1 Basic functions....................................................................................................................22
6.2.2 Use of the basic functions...................................................................................................23
6.2.3 System length and curve function.......................................................................................23
6.3 Overview ........................................................................................................................................ 24
6.4 Overview of the components .......................................................................................................... 26
7 Installation................................................................................................................................................28
7.1 Mechanical installation.................................................................................................................... 28
7.2 Overview of the tightening torques ................................................................................................. 29
7.3 Mounting the movers on the guide rail............................................................................................ 31
7.4 The positioning system ................................................................................................................... 33
7.4.1 Zero point of the encoder system .......................................................................................33
7.4.2 Teaching the encoder system.............................................................................................34
7.4.3 Application simulation .........................................................................................................40
7.5 Collision avoidance......................................................................................................................... 41
7.5.1 Operating principle of collision avoidance........................................................................... 41
8 Technical data..........................................................................................................................................45
8.1 AT9011-0050-0550......................................................................................................................... 45
8.2 Technical drawing AT9011-0050-0550........................................................................................... 45
eXtended Transport System Start-Up 3
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Table of content
9 Support and Service................................................................................................................................46
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eXtended Transport System Start-Up4
Foreword
1 Foreword
1.1 Notes on the documentation
This description is only intended for the use of trained specialists in control and automation 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.
Disclaimer
The documentation has been prepared with care. The products described are, however, constantly under
development.
For that reason the documentation is not in every case checked for consistency with performance data,
standards or other characteristics.
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.
Trademarks
Beckhoff®, TwinCAT®, EtherCAT®, Safety over EtherCAT®, TwinSAFE®, XFC®and XTS® 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.
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.
EtherCAT® is registered trademark and patented technology, licensed by Beckhoff Automation GmbH,
Germany
Copyright
© Beckhoff Automation GmbH & Co. KG, Germany.
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.
eXtended Transport System Start-Up 5
Version: 1.2
Foreword
1.2 Documentation issue status
Issue Comment
1.2 Chapter update:
4.2; 4.5; 6.1.1; 6.1.2; 6.2.3; 6.4; 7.2; 7.5.1; 7.5.2
New and deleted chapter:
New: 4.4.1; 6.1.3
Deleted: 7.3
1.1 Chapter update:
3.2; 6.1; 6.1.1, 7.3
New chapter:
Technical data
1.0 First edition
1.3 Intended use
The linear eXtended Transport System (XTS) is designed for machines and equipment with the highest
demands on dynamics and positioning accuracy. All components of the eXtended Transport System (XTS)
are exclusively intended to be programmed and commissioned using the TwinCAT automation software
from Beckhoff Automation GmbH & Co. KG.
Caution - Risk of injury!
Electronic equipment is not fail-safe. In case of failure of the drive system, the machine
WARNING
manufacturer is responsible for ensuring that the connected components of the eXtended
Transport System (XTS) and the machine are brought into a safe state.
Commissioning of the eXtended Transport System (XTS)
The eXtended Transport System (XTS) must be commissioned based on the requirements
WARNING
All components of the eXtended Transport System (XTS) are installed exclusively in electrical systems or
machines. They may only be commissioned in connection with components of the eXtended Transport
System (XTS) and the previously designed plant. Furthermore, it is essential to take into account all
environmental conditions defined in this document before the eXtended Transport System (XTS) is
commissioned.
of the currently valid EU Machinery Directive. Furthermore, the client must ensure that all
components installed in the system have a valid serial number.
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eXtended Transport System Start-Up6
2 Guidelines and Standards
Danger for persons, the environment or equipment
The components of the XTS are not products within the meaning of the EC Machinery Di-
CAUTION
rective. Operation of the XTS components in machines or systems is only permitted once
the machine or system manufacturers has provided evidence of CE conformity of the complete machine or system.
Guidelines and Standards
eXtended Transport System Start-Up 7
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Safety
3 Safety
3.1 General safety instructions
3.1.1 Personnel qualification
This description is only intended for trained specialists in control, automation and drive engineering who are
familiar with the applicable national standards.
3.1.2 Description of safety symbols
The following safety symbols and associated safety instructions are used in this document. These safety
instructions must be read and followed.
Serious risk of injury!
Failure to follow the safety instructions associated with this symbol directly endangers the
DANGER
life and health of persons.
WARNING
CAUTION
Attention
Note
Caution - Risk of injury!
Failure to follow the safety instructions associated with this symbol endangers the life and
health of persons.
Personal injuries!
Failure to follow the safety instructions associated with this symbol can lead to injuries to
persons.
Damage to the environment or devices!
Failure to follow the safety instructions associated with this symbol can lead to damage to
the environment or equipment.
Tip or pointer
This symbol indicates information that contributes to better understanding.
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eXtended Transport System Start-Up8
Safety
3.2 Special safety instructions
The safety instructions are designed to avert danger and must be followed during installation,
commissioning, production, troubleshooting, maintenance and trial or test assemblies. The XTS can operate
independently. Installation in a machine or system is not mandatory. During independent commissioning or
installation of the XTS in a machine or system, the documentation and safety instructions provided by the
machine manufacturer must be read and applied.
Caution - Risk of injury!
The XTS may only be installed by trained and qualified personnel. The qualified personnel
WARNING
WARNING
DANGER
must know the national accident prevention regulations and be able to apply them.
When working on the XTS, personal protective equipment (PPE) must be worn. In particular, safety boots must be worn!
Caution - Risk of injury through electric shock!
Bring the electrical environment (XTS, cabinet, etc.) into a safe, de-energized state before
installing or working on the XTS.
Acute risk of injury due to improper earthing!
The XTS must be earthed in accordance with the statutory provisions. Non-compliant earthing can cause acute injuries or death by electric shock.
Attention
Attention
CAUTION
Intended use!
The XTS starter kit may only be put into operation under consideration of currently valid EU
directives and standards, as well as the EC Machinery Directive in force at the time of commissioning.
Destruction of the XTS starter kit!
Ensure adequate ventilation and proper earthing of the cabinet. The permissible ambient
conditions are specified in the “Technical data” section. Failure to observe the specified
ambient conditions and improper earthing may cause damage to components of the XTS
starter kit. Furthermore, EMC problems can arise.
Risk of burns from hot surfaces!
The XTS issues a warning via TwinCAT if the operating temperature exceeds 65 °C. If the
temperature exceeds 75 °C, the system switches off automatically. In the event of an automatic shutdown, the surface temperature of the coils may exceed 105 °C. Acute risk of
burns!
Do not touch the components of the XTS during operation and shortly after operation. Wait
until all components have cooled sufficiently.
Use a thermometer to check the surface temperature of the components.
In cases that require touching of components directly after operation, use suitable safety
gloves to protect from burns. Wear heat-resistant clothing.
Danger from magnetic fields!
The Beckhoff XTS is equipped with permanent magnets at the guide rails and movers. The
field strength of the XTS results solely from the magnetic fields of these components. A
limit range of < 0.5 mT is reached in energized state at a radius of 150 mm, in non-energized state at a radius of 130 mm. The magnetic field poses a danger to persons and the
environment. Observe the regulations for magnetic fields in air transportation (IATA Packing Instruction 902). This applies to already installed magnets. Permanent magnets must
be stored in humid conditions. The use of permanent magnets in humid conditions (up to
95% relative humidity) can lead to corrosion and destruction of the permanent magnets.
eXtended Transport System Start-Up 9
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Safety
Note
Danger from magnetic fields!
In particular, the magnetic field poses a danger to:
• Persons with cardiac pacemakers (the magnetic field may cause the pacemaker to
switch to test mode and thus cause a cardiac arrest!)
• Persons with magnetically conductive implants
• Magnetic data storage devices
• Chip cards with magnetic strips, and
• Electronic devices
• Also keep in mind that the magnetic fields can influence implanted defibrillators and
make external defibrillators inoperable.
• Ensure a safety distance of 500 mm to all magnetic parts. Also, make sure that there is
no direct contact with magnetic components near parts that are susceptible to interference.
The national regulations and guidelines applicable in other countries must be followed!
Also note the requirements of BGV B 11 in connection with magnetic fields (BGV B 11
Section 14).
Liability for further transport!
Please note that all components of the XTS starter kit may only be forwarded in the original
packaging supplied by Beckhoff. The use of other packaging for further transport would
void all liability and warranty claims against Beckhoff Automation GmbH & Co. KG.
3.3 Using in Ex environments
The use of the XTS in potentially explosive atmospheres – Directive 94/9/EC
– is not permitted!
WARNING
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eXtended Transport System Start-Up10
4 Handling
4.1 Transport
• The XTS starter kit may only be transported by qualified personnel and in the manufacturer's original
packaging.
• Avoid shocks, particularly at the corners of the packaging.
• If the packaging is damaged, check the XTS starter kit for visible damage. Inform the transport
company and, if necessary, the manufacturer.
Damage to the device due to improper transport!
When transporting the XTS starter kit ensure that all specifications are met. In particular,
jerky and fast movements should be avoided.
CAUTION
4.2 Packaging
• Motor modules in recyclable cardboard packaging*
• Magnet holders in recyclable cardboard packaging with foam inserts*
• Movers in recyclable cardboard packaging with bubble wrap*
Handling
*only single packaging.
Shipping of the XTS starter kit
Contents of the Starter Kit include
• Fully Assembled and tested XTS (item 4)
• Control Cabinet with all necessary equipment
(item 3)
Both are secured in the shipping crate to prevent
movement during transport.
Warning Pinch Point!
When opening/closing the case keep hands clear of
the area between the lid of the crate (1) and the side
of the crate (2) two People are required to lift/lower
the lid!
eXtended Transport System Start-Up 11
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Handling
4.3 Storage
Requirement Characteristic value
Climate category 2K3 according to EN 60721
Storage temperature -25°C to +85°C
Permissible relative humidity 15% - 95%, no condensation
Store only in the original recyclable manufacturer's packaging.
4.4 Maintenance / Cleaning
Maintenance
The XTS motor modules are maintenance-free!
Observe the ambient commissioning conditions!
Make sure that the XTS is stored and electrically operated only under the specified condi-
WARNING
tions.
The XTS movers are not maintenance-free!
Destruction of the rails!
The guide rollers of movers must be checked at regular intervals. Remove any dirt or other
WARNING
foreign material that may have accumulated on the guide rollers during operation. Failure to
comply with regular maintenance can lead to increased wear of the guide rollers, as well as
damage to the rails.
Rail maintenance
The rails can be lubricated lightly. This increases the life of the guide rollers. The following
Note
lubricants are suitable for this purpose:
• Vaseline according to DAB 10 (German Pharmacopoeia 10)
• Vaseline spray
• Silicone spray
• PTFE spray
• If the rails are cleaned for maintenance, re-lubricate them with one of the lubricants
listed above. For further specifications please contact the Beckhoff applications department.
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eXtended Transport System Start-Up12
Handling
Cleaning
The XTS modules are sealed according to protection class IP65. They are not protected against aggressive
substances. Clean the modules regularly to protect them against rust and corrosion. Use only Isopropanol.
Damage to motor modules
If damage to the motor modules has occurred, please contact Beckhoff Automation GmbH
WARNING
& Co. KG immediately!
Damage to the guide rollers
Make sure that the rails are free from dirt and metallic particles. A dirty rail can significantly
WARNING
reduce the service life of the guide rollers.
4.4.1 Replacement of the guide rollers
Installation manual
Loosen the roller axel nut
• Use a 1.5mm Allen Key hold to hold the screw
in place. (2)
• Loosen and remove the nut using a 5.5mm
socket wrench/spanner (1)
The Screw (2) must be held in place to prevent it
from turning with the Socket.
Removal of the components
• Pull out the screw that is the shaft of the roller
(2) and take with it
• the Roller (4)
• the washer (5)
• the nut (1)
Caution! When removing the screw (2) be sure to
pull it straight out from the hole in the mover body (6)
in order to prevent damage to the threads. Do not tilt
it.
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Handling
Exchange the Roller
After all the components have been removed, from
the mover body, the roller can be replaced.
Reassemble the Components
• Insert the screw (2) through
• the Roller (4) then
• the washer (5)
• Push the screw through the hole of the mover
body and fix it in place with the nut (6)
Caution! To prevent damage to the threads, take
care to insert the screw (2) straight into the mover
body (6). Do not tilt the screw.
Tighten the Roller axel nut.
• Use a 1.5mm Allen key hold the screw (2) in
place.
• With a 5.5mm Socket tighten the nut (1) to a
torque of 2.4Nm
The screw (2) must be held in place to prevent it from
turning with the nut.
4.5 Disposal
In accordance with the WEEE 2002/96/EC Directives we take old devices and accessories back for
professional disposal, provided the transport costs are taken over by the sender. Send the devices with the
note “For disposal” to:
Beckhoff Automation GmbH & Co. KG
Service-Center
Stahlstraße 31
33415 Verl
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eXtended Transport System Start-Up14
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