Beckhoff AG2250 Operating Instructions Manual

Operating instructions | EN

AG2250

Planetary gear unit

29.05.2020 | Version 2.0

Table of content

Version: 2.0 ─── 3AG2250

Table of content

Notes of the documentation ............................................................................................................................... 5

Disclaimer ......................................................................................................................................................... 5

Version numbers............................................................................................................................................... 7

Scope of the documentation ............................................................................................................................. 7

Staff qualification............................................................................................................................................... 8

Safety and instruction ..................................................................................................................................... 10

Explanation of symbols ................................................................................................................................... 10

Beckhoff Services ........................................................................................................................................... 12

For your safety................................................................................................................................................... 13

General safety instructions ............................................................................................................................. 13

Product overview............................................................................................................................................... 15

Standard gear unit .......................................................................................................................................... 15

Right-angle gear unit....................................................................................................................................... 16

Name plate...................................................................................................................................................... 17

Type key ......................................................................................................................................................... 18

Product characteristics.................................................................................................................................... 19

Ordering options ............................................................................................................................................. 20

Intended use ................................................................................................................................................... 21

Technical data.................................................................................................................................................... 22

Definitions ....................................................................................................................................................... 22

Data for operation and environment ............................................................................................................... 24

PLE040 ........................................................................................................................................................... 25

WPLE040........................................................................................................................................................ 30

PLE060 ........................................................................................................................................................... 36

WPLE060........................................................................................................................................................ 41

PLE080 ........................................................................................................................................................... 47

WPLE080........................................................................................................................................................ 52

PLE120 ........................................................................................................................................................... 58

WPLE120........................................................................................................................................................ 63

PLE160 ........................................................................................................................................................... 69

Scope of supply ................................................................................................................................................. 72

Packaging ....................................................................................................................................................... 72

Transport and storage....................................................................................................................................... 73

Conditions ....................................................................................................................................................... 73

Transport......................................................................................................................................................... 73

Long-term storage........................................................................................................................................... 74

Technical description........................................................................................................................................ 75

Mounting position............................................................................................................................................ 75

Mechanical installation ..................................................................................................................................... 76

General tightening torques.............................................................................................................................. 76

Motor on gear unit........................................................................................................................................... 77

Gear unit to machine....................................................................................................................................... 80

Commissioning.................................................................................................................................................. 82

Before commissioning..................................................................................................................................... 82

During commissioning..................................................................................................................................... 83

Prerequisites during operation ........................................................................................................................ 83

After operation ................................................................................................................................................ 83

Maintenance and cleaning ................................................................................................................................ 84

Cleaning agents .............................................................................................................................................. 84

Intervals .......................................................................................................................................................... 86

Table of content

4 ─── Version: 2.0AG2250

Fault correction.................................................................................................................................................. 87

Decommissioning.............................................................................................................................................. 88

Disassembly.................................................................................................................................................... 88

Disposal .......................................................................................................................................................... 89

Guidelines and Standards ................................................................................................................................ 90

EU conformity ................................................................................................................................................. 90

RoHS .............................................................................................................................................................. 90

Index ................................................................................................................................................................... 91

Notes of the documentation

Version: 2.0 ─── 5AG2250

1.1Disclaimer

Beckhoff products are subject to continuous further development.

We reserve the right to revise the operating instructions at any time

and without prior announcement. 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 these operating instruc-

tions.

1.1.1Trademarks

Beckhoff®, TwinCAT®, EtherCAT®, EtherCAT G®, EtherCAT

G10®, EtherCAT P®, Safety-over-EtherCAT®, TwinSAFE®, XFC®,

XTS® and XPlanar® are registered and licensed trademarks of

Beckhoff Automation GmbH.

The use of other brand names or designations by third parties may

lead to an infringement of the rights of the owners of the corre-

sponding designations.

1.1.2Patents

The EtherCAT technology is protected by patent rights through the

following registrations and patents with corresponding applications

and registrations in various other countries:

• EP1590927

• EP1789857

• EP1456722

• EP2137893

• DE102015105702

EtherCAT

®

is a registered trademark and patented technology, li-

censed by Beckhoff Automation GmbH.

Notes of the documentation

6 ─── Version: 2.0AG2250

1.1.3Limitation of liability

All components in this product as described in the operating instruc-

tions are delivered in a specific configuration of hardware and soft-

ware, depending on the application regulations. Modifications and

changes to the hardware or software configuration that go beyond

the documented options are prohibited and nullify the liability of

Beckhoff Automation GmbH & Co. KG.

The following is excluded from the liability:

• Failure to observe these operating instructions

• Improper use

• Use of untrained personnel

• Use of unauthorized spare parts

1.1.4Copyright

The copying, distribution and utilization of this document as well as

the communication of its contents to others without express autho-

rization is prohibited. Offenders will be held liable for the payment of

damages.

We reserve all rights in the event of registration of patents, utility

models and designs.

Notes of the documentation

Version: 2.0 ─── 7AG2250

1.2Version numbers

Provision of revision levels

On request, you can obtain a list of revision levels for changes in

the operating instructions.

• Send your request to: [email protected]

Origin of the document

These operating instructions were originally written in German. All

other languages are derived from the German original.

Product features

Only the product properties specified in the current operating in-

structions are valid. Further information given on the product pages

of the Beckhoff homepage, in emails or in other publications is not

authoritative.

1.3Scope of the documen-

tation

Apart from these operating instructions, the following documents are

part of the overall documentation:

Documentation Definition

Gear unit information leaflet Accompanying document with

general notes on handling the

gear units Included with each

product.

Notes of the documentation

8 ─── Version: 2.0AG2250

1.4Staff qualification

1.4

These operating instructions are intended for trained control and au-

tomation specialists with knowledge of the applicable and required

standards and directives.

Specialists must have knowledge of drive technology and electrical

equipment as well as knowledge of safe working on electrical sys-

tems and machines. This includes knowledge of proper setup and

preparation of the workplace as well as securing the working envi-

ronment for other persons.

The operating instructions published at the respective time of each

installation and commissioning is to be used. The products must be

used in compliance with all safety requirements, including all appli-

cable laws, regulations, provisions and standards.

Instructed person

Instructed persons have a clearly defined task area and have been

informed about the work to be carried out. Instructed persons are fa-

miliar with:

• the necessary protective measures and protective devices

• the intended use and risks that can arise from use other than for

the intended purpose

Trained person

Trained persons meet the requirements for instructed persons.

Trained persons have additionally received training from the ma-

chine manufacturer or vendor:

• machine-specific or

• plant-specific

Trained specialists

Trained specialists have received specific technical training and

have specific technical knowledge and experience. Trained special-

ists can:

• apply relevant standards and directives

• assess tasks that they have been assigned

• recognize possible hazards

• prepare and set up workplaces

Notes of the documentation

Version: 2.0 ─── 9AG2250

Qualified electricians

Qualified electricians have comprehensive technical knowledge

gained from a course of study, an apprenticeship or technical train-

ing. They have an understanding of control technology and automa-

tion. They are familiar with relevant standards and directives. Quali-

fied electricians can:

• independently recognize, avoid and eliminate sources of danger

• implement specifications from the accident prevention regula-

tions

• assess the work environment

• independently optimize and carry out their work

Customer service

Customer service personnel and service personnel are verifiably

trained and authorized by Beckhoff or the machine manufacturer for

the work on the machine or plant.

Notes of the documentation

10 ─── Version: 2.0AG2250

1.5Safety and instruction

Read the contents that refer to the activities you have to perform

with the product. Always read the chapter For your safety in the op-

erating instructions. Observe the warning notes in the chapters so

that you can handle and work properly and safely with the product.

1.6Explanation of symbols

Various symbols are used for a clear arrangement:

► The triangle indicates instructions that you should execute

• The bullet point indicates an enumeration

[…] The square parentheses indicate cross-references to other

text passages in the document

[+] The plus sign in square brackets indicates ordering options

and accessories

1.6.1Pictograms

In order to make it easier for you to find text passages, pictograms

and signal words are used in warning notices:

DANGER

Failure to observe will result in serious or fatal injuries.

WARNING

Failure to observe may result in serious or fatal injuries.

CAUTION

Failure to observe may result in minor or moderate injuries.

Notes of the documentation

Version: 2.0 ─── 11AG2250

Notes

Notes are used for important information on the product. The possi-

ble consequences of failure to observe these include:

• Malfunctions of the product

• Damage to the product

• Damage to the environment

Information

This sign indicates information, tips and notes for dealing with the

product or the software.

Examples

This symbol shows examples of how to use the product or soft-

ware.

QR-Codes

This symbol shows a QR code, via which you can watch videos or

animations. Internet access is required in order to use it.

You can read the QR code, for example, with the camera of your

Smartphone or Tablet PC. If your camera doesn't support this func-

tion you can download a free QR code reader app for your Smart-

phone. Use the Appstore for Apple operating systems or the

Google Play Store for Android operating systems.

If you cannot read the QR code on paper, make sure that the light-

ing is adequate and reduce the distance between the reading de-

vice and the paper. In the case of documentation on a monitor

screen, use the zoom function to enlarge the QR code and reduce

the distance.

Notes of the documentation

12 ─── Version: 2.0AG2250

1.7Beckhoff Services

Beckhoff and the worldwide partner companies offer comprehensive

support and service.

1.7.1Support

The Beckhoff Support offers technical advice on the use of individ-

ual Beckhoff products and system planning. Staff provide assistance

for programming and commissioning complex automation systems

and offer a comprehensive training program.

Hotline: +49(0)5246/963-157

Fax: +49(0)5246/963-199

E-mail: [email protected]

Web: www.beckhoff.de/support

1.7.2Training

Training in Germany takes place in our training center at the Beck-

hoff headquarters in Verl, at branch offices or, by arrangement, at

the customer's premises.

Hotline: +49(0)5246/963-5000

Fax: +49(0)5246/963-95000

E-mail: [email protected]

Web: www.beckhoff.de/training

1.7.3Service

The Beckhoff Service Center supports you with after-sales services

such as on-site service, repair service or spare parts service.

Hotline: +49(0)5246/963-460

Fax: +49(0)5246/963-479

E-mail: [email protected]

Web: www.beckhoff.de/service

1.7.4Download area

In the download area you will find product information, software up-

dates, the TwinCAT automation suite, documentation and much

more.

Web: www.beckhoff.de/download

1.7.5Headquarters

Beckhoff Automation GmbH & Co. KG

Hülshorstweg 20

33415 Verl

Germany

Phone: +49(0)5246/963-0

Fax: +49(0)5246/963-198

E-mail: [email protected]

Web: www.beckhoff.de

The addresses of the international Beckhoff branch offices can be

found on the Beckhoff website: http://www.beckhoff.de

For your safety

Version: 2.0 ─── 13AG2250

Read this chapter containing general safety information. The chap-

ters in these operating instructions also contain warning notices. Al-

ways observe the safety instructions for your own safety, the safety

of other persons and the safety of the product.

When working with control and automation products, many dangers

can result from careless or incorrect use. Work particularly thor-

oughly, not under time pressure and responsibly towards other peo-

ple.

2.1General safety instruc-

tions

This chapter provides you with instructions on safety when handling

the gear units. They cannot run independently. The gear units are

therefore regarded as incomplete machines. They must be installed

in a machine or plant by the machine manufacturer. The documen-

tation created by the machine manufacturer must be read.

2.1.1Before operation

Keep the surroundings clean

Keep your workplace and the surrounding area clean. Ensure safe

working.

Secure the control cabinet

When working on machines, secure the control cabinet against be-

ing switched on again.

Do not use defective gear units

Adhere to the specifications from the technical data for storage,

transport and operation. Do not use defective gear units.

Remove feather key

Remove the existing feather key if the planetary gear unit is oper-

ated without attachments on the input or output side.

Observe tightening torques

Mount and repeatedly check connections and components, comply-

ing with the prescribed tightening torques.

Earth electrical components or modules correctly

Touch electrical components or assemblies only when wearing ESD

protective clothing. Move only on a conductive floor.

Only use original packaging for further processing

When shipping, transporting, storing and packing, use the original

packaging or conductive materials.

For your safety

14 ─── Version: 2.0AG2250

2.1.2During operation

Do not work on live electrical components

Do not open any gear unit or other components when live. Ensure

that the protective conductor is connected properly. Never loosen

electrical connections when live. Only work on the gear unit when

the voltage on the electrically conducting components has fallen be-

low 50 V. Disconnect all components from the mains and secure

them against being switched on again.

Do not touch hot surfaces

Check the cooling of the surfaces with a thermometer. Do not touch

the components during and after operation. Allow the components to

cool down for at least 15minutes after switching off.

Avoid overheating

Operate the components according to the technical specifications.

Please refer to chapter: "Technical data". Provide for sufficient cool-

ing. Switch the components off immediately if the temperature is too

high.

Do not touch any moving or rotating components

Do not touch any moving or rotating parts during operation. Fasten

all parts or components on the machine or plant.

2.1.3After operation

De-energize and switch off components before working on

them

Check the functionality of all safety-relevant devices. Carry out a

voltage test. Secure the working environment and the control cabi-

net against being switched on again. See chapter: Decommissioning

No direct skin contact with solvents or lubricants

In case of improper use, the solvents or lubricants used can lead to

skin irritations. Therefore, avoid direct skin contact.

Product overview

Version: 2.0 ─── 15AG2250

3.1Standard gear unit

3.1

Number Explanation

1 Gear housing

2 Clamping bolt

3 Clamping hub

4 Holes for the attachment of the gear unit

5 Adapter plate

6 Holes for the motor attachment

7 Feather key [+]

8 Output shaft with center bore

9 Holes for the motor attachment

10 Plug; mounting hole

11 Holes for the attachment of the gear unit

Product overview

16 ─── Version: 2.0AG2250

3.2Right-angle gear unit

3.2

Number Explanation

1 Plug; mounting hole

2 Adapter plate

3 Gear housing

4 Holes for the attachment of the gear unit

5 Feather key [+]

6 Holes for the motor attachment

7 Output shaft with center bore

8 Holes for the motor attachment

9 Clamping bolt

10 Clamping hub

11 Holes for the attachment of the gear unit

Product overview

Version: 2.0 ─── 17AG2250

3.3Name plate

3.3

Number Explanation

1 Gear unit type

2 Order number

3 Serial number

4 Data Matrix Code with Beckhoff BTN

5 Country of manufacture

6 Date of manufacture

Product overview

18 ─── Version: 2.0AG2250

3.4Type key

AG2250 -+ [W]PLE040S - MF1 - 3 - 1C1 -

AM813x

Explanation

AG2250 Gear unit series

AG2250 = PLE planetary gear unit

[W]PLE Gear type

PLE = Standard

W = Right-angle gear unit

040 Size

040

060

080

120

160

S Lubrication

S = Standard

M Gear unit variant

M = Motor-mounted gear unit

F Gear unit version

F = Standard

1 No. of stages

1 = single-stage

2 = two-stage

3 = three-stage

3 Ratio

See documentation

1 Type of output

0 = smooth shaft

1 = feather key DIN 6885 shape A

C Clamping hub identifying letter

Not freely selectable

Is selected on the basis of the motor to be mounted

1 Torsional backlash

1 = Standard

AM813x Motor size

See documentation

Product overview

Version: 2.0 ─── 19AG2250

3.5Product characteristics

Wide range of possible applications

Due to the manufacturing-related and application-related freedom of

movement, you have the possibility to install the planetary gear unit

in a variety of ways in the machine or plant. The planetary gear unit

can be used in any installation position. The gear units are delivered

in the "M" variant for motor attachment.

Motor centering via the mounted clamping hub

Due to centering via the mounted clamping hub the motor cannot be

radially stressed. The planetary gear unit can be adapted to various

motor types with the adapter flange and a spacer sleeve.

The bearing of the output shaft is designed for high breakdown

torques and high axial forces.

Maintenance-free ball bearings

The gear units are of a high quality standard due to manufacturing

according to ISO 9001. The ball bearings are lifetime-lubricated and

maintenance-free.

Product overview

20 ─── Version: 2.0AG2250

3.6Ordering options

Order options are defined by the type key and must be ordered sep-

arately. The listed components cannot be retrofitted.

3.6.1Right-angle gear unit

3.6.1

The gear units from the AG2250 series are available as a standard

version "PLE" and as an angle version "WPLE".

In the case of right-angle gear units, the input shaft and output shaft

are arranged in different directions to each other. The right-angle

gear unit version, for example, is perfectly suited for dynamic multi-

axis systems and limited installation space.

This ordering option as a right-angle gear unit is available for all

gear units from the series up to size 120.

3.6.2Feather key

3.6.2

A feather key transmits torque to an output element.

The gear units are available with feather key groove and inserted

feather key according to DIN 6885.

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Beckhoff AG2250 Operating Instructions Manual

Beckhoff AG2250 Operating Instructions Manual

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