Beckhoff AG3210 Operating Instructions Manual

Brand: Beckhoff

Model: AG3210

Type: Operating Instructions Manual

AG3210 | Economy

planetary gear unit

Operating instructions | EN

10/18/2019 | Version 2.1

Table of content

Version: 2.1 ─── 3AG3210

Table of content

Documentation notes .......................................................................................................................................... 5

Disclaimer ......................................................................................................................................................... 5

Version numbers............................................................................................................................................... 7

Scope of the documentation ............................................................................................................................. 7

Staff qualification............................................................................................................................................... 8

Safety and instruction ....................................................................................................................................... 9

Explanation of symbols ..................................................................................................................................... 9

Beckhoff Services ........................................................................................................................................... 10

For your safety................................................................................................................................................... 11

General safety instructions ............................................................................................................................. 11

Product overview............................................................................................................................................... 13

Name plate...................................................................................................................................................... 14

Type key ......................................................................................................................................................... 14

Product characteristics.................................................................................................................................... 15

Ordering options ............................................................................................................................................. 16

Intended use ................................................................................................................................................... 16

Technical data.................................................................................................................................................... 17

Definitions ....................................................................................................................................................... 17

Data for operation and environment ............................................................................................................... 18

NP005 ............................................................................................................................................................. 20

NP015 ............................................................................................................................................................. 23

NP025 ............................................................................................................................................................. 26

NP035 ............................................................................................................................................................. 30

NP045 ............................................................................................................................................................. 34

Scope of supply ................................................................................................................................................. 37

Packaging ....................................................................................................................................................... 37

Transport and storage....................................................................................................................................... 38

Conditions ....................................................................................................................................................... 38

Transport......................................................................................................................................................... 38

Long-term storage........................................................................................................................................... 39

Technical description........................................................................................................................................ 40

Mounting position............................................................................................................................................ 40

Mechanical installation ..................................................................................................................................... 41

Motor............................................................................................................................................................... 41

Gear unit ......................................................................................................................................................... 44

Commissioning.................................................................................................................................................. 46

Before commissioning..................................................................................................................................... 46

During commissioning..................................................................................................................................... 46

Prerequisites during operation ........................................................................................................................ 47

After operation ................................................................................................................................................ 47

Maintenance and cleaning ................................................................................................................................ 48

Cleaning agents .............................................................................................................................................. 48

Intervals .......................................................................................................................................................... 49

Fault correction.................................................................................................................................................. 50

Decommissioning.............................................................................................................................................. 51

Disassembly.................................................................................................................................................... 51

Disposal .......................................................................................................................................................... 51

Table of content

4 ─── Version: 2.1AG3210

Guidelines and Standards ................................................................................................................................ 52

EU conformity ................................................................................................................................................. 52

RoHS .............................................................................................................................................................. 52

Index ................................................................................................................................................................... 53

Documentation notes

Version: 2.1 ─── 5AG3210

Documentation notes

Disclaimer

The documentation has been prepared with care. Beckhoff products

are subject to continuous further development.

We reserve the right to revise the documentation at any time and

without notice.

No claims for the modification of products that have already been

supplied may be made on the basis of the data, diagrams and de-

scriptions in this documentation.

Trademarks

Beckhoff

, TwinCAT

, EtherCAT

, EtherCAT G

, EtherCAT G10

EtherCAT P

, Safety over EtherCAT

, TwinSAFE

, XFC

, XTS

and

XPlanar

are registered and licensed brands of Beckhoff Automation

GmbH & Co. KG.

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.

Patents

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 & Co. KG, Germany.

Documentation notes

6 ─── Version: 2.1AG3210

Limitation of liability

All components of this product described in the original operating in-

structions are delivered in a hardware and software configuration,

depending on the application requirements. Modifications and

changes to the hardware and/or software configuration that go be-

yond the documented options are prohibited and nullify the liability

of Beckhoff Automation GmbH & Co. KG.

In addition, the following are excluded from the liability:

• Failure to comply with this documentation

• Improper use

• Use of untrained personnel

• Use of unauthorized spare parts

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 re-

serve all rights in the event of registration of patents, utility models

and designs.

Documentation notes

Version: 2.1 ─── 7AG3210

Version numbers

Origin of the document

These operating instructions were originally written in German. All

other languages are derived from the German original.

Product features

The product features specified in the latest version of the original

operating instructions are always applicable. Further information

given on the product pages of the Beckhoff homepage, in emails or

in other publications is not authoritative.

Issue Comment

2.1 Chapter revision

Documentation notes – Disclaimer; Technical data - Dimensional

drawings; Mechanical installation - Motor

2.0 Complete revision, new version

1.3 Chapter revision:

Technical data NP005 – NP045 8.1 – 8.5

New chapter:

Feather key 6.3.2

1.2 Chapter revision:

Technical data NP015 – NP035 8.2 – 8.4

(HIGH TORQUE – data supplemented / added)

1.1 Chapter revision:

Technical data NP005 – NP045 8.1 – 8.5

(rated torque at output added)

1.0 First edition

Scope of the documen-

tation

The complete documentation consists of the following documents:

AG3210-+NPxx Definition

Translation of the original instructions;

this documentation

Description of the mechanical and electri-

cal parameters as well as all information

necessary for the use of the gear unit

Gear unit information leaflet Accompanying document with general

notes on handling the gear units. It is in-

cluded with each product.

Documentation notes

8 ─── Version: 2.1AG3210

Staff qualification

These operating instructions are intended for trained control and au-

tomation specialists with knowledge of the applicable and required

standards and directives.

Qualified personnel must have knowledge of drive technology and

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

cal systems and machines. This includes knowledge of proper setup

and preparation of the workplace as well as securing the working

environment for other persons.

The documentation published at the time must be used for each in-

stallation and commissioning. The products must be used in compli-

ance with all safety requirements, including all applicable laws, regu-

lations, provisions and standards.

Designation of the target groups Explanation

Instructed person This target group has been informed about the possible dangers of improper use.

The assigned scope of duties is clearly defined. Training will be provided for any

tasks outside this scope. Instructions on the required protective measures and de-

vices were provided.

Trained user This target group meets all the requirements of an instructed person. In addition,

machine or plant-specific training has taken place at the machine builder or manu-

facturer.

Trained specialists Users who, based on their training, knowledge and experience, are able to assess

the tasks assigned to them and recognize potential hazards, are regarded as

trained specialists. Work experience over several years in a relevant field can also

be considered as part of the technical training.

Qualified electricians Qualified electricians are able to work on electrical machines or systems based on

their specialist training like university degree, apprenticeship or specialist training.

Possible sources of danger are automatically identified and avoided.

Qualified electricians are specially trained for the working environment and are fa-

miliar with the relevant standards and guidelines. Knowledge of control engineering

and automation is required. The provisions of the accident prevention regulations

must be complied with.

Customer service Customer service is provided by technicians who have been demonstrably trained

and authorized by Beckhoff or the machine manufacturer to work on the respective

machine or plant.

Documentation notes

Version: 2.1 ─── 9AG3210

Safety 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.

Explanation 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

Pictograms

Pictograms are used to identify important text passages:

The warning triangle indicates warning notes.

The possible consequences of failure to observe these include:

• Damage and/or serious injuries

• Fatal injuries

The warnings are shown at the points in the documentation where

it is important to observe them in order to prevent accidents and

injuries.

Notes are used for important information on the product

The possible 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.

Sample

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

ware.

Documentation notes

10 ─── Version: 2.1AG3210

Beckhoff Services

Beckhoff and the worldwide partner companies offer comprehensive

support and service.

Support

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

Training

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

Service

The Beckhoff Service Centre supports you in all aspects of after-

sales service for example the on-site service, repair service and

spare parts service.

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

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

E-mail: [email protected]

Web: www.beckhoff.de/service

Download 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

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: [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: 2.1 ─── 11AG3210

For your safety

General 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 / plant by the machine manufacturer. The documenta-

tion created by the machine manufacturer must be read.

Before operation

Keep the immediate surroundings clean

Keep your workplace and the immediate surroundings clean. Ensure

safe working. Prevent dirt from penetrating into the components.

Secure the control cabinet

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

ing switched on again.

Do not use defective gear units

Comply with the specifications in the technical data for storage,

transport and operation. Do not use damaged gear units.

Remove the feather key

If the planetary gear unit is operated without attachments on the out-

put or drive side and a feather key is present, remove it.

Observe tightening torques

Install connections and components in compliance with the specified

tightening torques and check them regularly. Use only calibrated

torque wrenches.

Ground electrical components or modules correctly

Only touch electrical components or modules when you are wearing

ESD protective clothing. Only walk on conductive floors.

Only use original packaging for further processing

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

packaging or conductive materials. Conductive materials are foam

or aluminum, for example.

For your safety

12 ─── Version: 2.1AG3210

During operation

Do not work on live electrical parts

Do not open gear units and components such as a motor or servo

drive if they are live. Ensure that the protective conductor is properly

connected. Never disconnect electrical connections while they are

live. Only work on the gear unit when the voltage on the electrically

conducting components has fallen below50V. Disconnect all com-

ponents from the mains and secure against reconnection.

Do not touch hot surfaces

Check with a thermometer that the surfaces have cooled down. Do

not touch the housing during and after operation. Allow the gear unit

to cool down for at least 15 minutes after switching off. Do not wear

rubberized gloves, as they could melt onto the skin at excessively

high temperatures.

Avoid overheating

Operate the gear unit under the technically specified conditions.

Please refer to chapter: Technical data. Ensure sufficient cooling

and shut the gear unit down immediately if the temperature is too

high.

Do not touch rotating components

Do not touch any rotating components during operation. Ensure that

all parts / components on the machine / plant are firmly seated.

After operation

Before working on components, make sure that they are de-en-

ergized

Carry out a voltage test and check all safety-relevant devices for

functionality. Secure the working environment and the control cabi-

net against inadvertent power-up. See chapter: Decommissioning.

No direct skin contact with solvents / lubricants

If used improperly, the solvents or lubricants employed can cause

skin irritations. Therefore, avoid direct skin contact.

Product overview

Version: 2.1 ─── 13AG3210

Product overview

Number Explanation

1 Gear housing

2 Holes for the attachment of the gear unit

3 Feather key [+]

4 Output shaft

5 Clamping hub

6 Holes for the motor attachment

7 Plug / mounting hole

8 Clamping bolt

9 Holes for the motor attachment

10 Holes for the attachment of the gear unit

11 Circlip

12 Adapter plate

Product overview

14 ─── Version: 2.1AG3210

3.1

Name plate

Typecode

Lubrication

Serialnumber

: 3400- 015- 1-3-1C1 AG NPT MF

: 100-1 TRIBOL GR PD

: 1234567

Made in Germany

BECKHOFF

Automation GmbH & Co. KG

Motor

DMF

: A 8301M

: 8

: 10/17

Huelshorstweg 20 - D-33415 Verl-Germany Phone: +49 5246 / 9 63-0 Fax: +49 5246 / 9 63 - 196 www.beckhoff.com [email protected]

1 2 3 4 5 6

Number Explanation

1 Gear unit type

2 Lubrication

3 Combined motor

4 Ratio

5 Data Matrix Code with Beckhoff TN

6 Country of manufacture

7 Date of manufacture

8 Serial number

3.2

Type key

AG3210 – NP005S – MF1 – 3 – 1C1 – AM803x Explanation

AG3210 Gear unit series

AG3210 = NP

NP005 Gear unit type

NP 005 / 015 / 025 / 035 / 045

S Execution

S = Standard

M Gear unit variant

M = Motor-mounted gear unit

F Gear unit version

F = Standard

A = HIGH TORQUE

1 No. of stages

1 = Single-stage

2 = Two-stage

3 Transmission ratio

See documentation

1 Drive form

0 = Smooth shaft

1 = Feather key DIN 6885 shape A

C Clamping hub identifying letter

Not freely selectable

Will be automatically selected on the basis of the motor to be selected

1 Torsional backlash

1 = Standard

AM803x Motor size

See documentation

Product overview

Version: 2.1 ─── 15AG3210

Product characteristics

Low-backlash planetary gear unit

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

Due to manufacturing in accordance with the quality standard ISO

9001, the gear units are of a high standard. The ball bearings are

lifetime-lubricated and maintenance-free.

Product overview

16 ─── Version: 2.1AG3210

Ordering options

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

arately. The listed components cannot be retrofitted.

3.4.1

Feather key

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.

Intended use

The planetary gear units from the AG3210-+NPxx series may be op-

erated exclusively for the activities foreseen and defined in this doc-

umentation, taking into account the prescribed environmental condi-

tions.

The components are to be installed in electrical systems or ma-

chines and only put into operation as integrated components of the

system or machine.

The thermal protection contact incorporated in the motor windings

must be analyzed and monitored on a regular basis.

The gear unit is intended for attachment to motors under the follow-

ing conditions:

• motors of the design B5

• at least a concentricity tolerance or axial run-out tolerance ac-

cording to EN 50347

• a cylindrical shaft end with the tolerance class h6 to k6

Read the complete documentation for the planetary gear unit:

• Translation of the original instructions

• Translation of the original operating instructions for the

synchronous servo motors AM8000 & AM8500

• Complete machine documentation provided by the machine

manufacturer

Non-observance of the documentation content may result in dam-

age to the product and exclusion of liability.

Improper use

Any use exceeding the permissible values specified in the Technical

data is considered improper and therefore prohibited!

The Beckhoff planetary gear units from the AG3210-+NPxx series

are not suitable for use in the following areas:

• ATEX zones without suitable housing

• Areas with aggressive environments, for example aggressive

gases or chemicals

The relevant standards and directives for EMC interference emis-

sions must be complied with in residential areas. The planetary gear

units may only be installed in housings with appropriate shielding at-

tenuation.

Technical data

Version: 2.1 ─── 17AG3210

Technical data

Below you will find definitions of terms, environmental conditions,

operating details and technical data for the planetary gear units.

4.1

Definitions

All data, with the exception of the voltage constant, are based on

40°C ambient temperature and 100K overtemperature of the wind-

ing. The data can have a tolerance of +/- 10%.

When attaching a gear unit, the performance may be reduced by up

to 20%. The flange of the motor used for heat dissipation is fitted

with a gear unit that generates heat during operation. The loss in

performance therefore has thermal reasons.

Technical Term Symbol

[Unit]

Definition

Equivalent force on the output F

2_eq

[N] The equivalent force on the output describes the force that is relevant for dimensioning

the gear unit.

Equivalent application torque T

2_eq

[Nm] The equivalent application torque describes the for torque that is relevant for dimension-

ing the gear unit.

Dimensioning factor f

The dimensioning factor describes the influence of the daily operating time and the oper-

ating factor on the application torque.

Operating mode factor K

The operating mode factor describes the influence of duty cycle, number of cycles and

dynamics on the application torque.

Mass moment of inertia;

based on the drive

[kgcm²] The mass moment of inertia is a measure for the tendency of a body to maintain its mo-

tion state, whether at rest or in motion.

Running noise L

[dB (A)] Low running noise of an application is becoming increasingly important for environmental

and health reasons. The gear ratio and speed affect the running noise.

In general, the following rule applies:

Higher speed = louder running noise

Higher transmission ratio = quieter running noise

Maximum radial force F

[N] The radial force is the force component that acts at right angles to the output shaft or par-

allel to the output flange. It acts perpendicular to the axial force and can have an axial

distance x

to the shaft shoulder or the shaft flange. This distance acts as lever arm. The

lateral force generates a bending moment.

Maximum torque at the output T

[Nm] Represents the maximum torque that can be transferred by the gear unit. This value may

be lower, depending on application-specific boundary conditions.

EMERGENCY STOP torque T

2Emerg

[Nm] The EMERGENCY STOP torque is the maximum permitted torque at the gear unit out-

put. It may be reached up to 1000 times during the service life of the gear unit and must

never be exceeded.

Technical data

18 ─── Version: 2.1AG3210

Data for operation and

environment

Operate the gear units only under the specified environmen-

tal conditions

Operate the gear units only in accordance with the specifications

for operation and the environment listed in this chapter. This en-

sures a long service life and proper operation.

If you do not adhere to the permissible specifications for the oper-

ation and the environment, this can lead, for example, to icing of

the seal and damage to the gear unit.

Beckhoff products are designed for operation under certain environ-

mental conditions, which vary according to the product. The follow-

ing specifications must be observed for operation and environment

in order to achieve the optimum service life of the products.

Environmental requirements

Climate category 2K3 according to EN 60721

Ambient temperature at operation 0°C to +40°C; extended temperature range

Ambient temperature at transport and storage Maximum fluctuation 20 K/hour:

-25°C to +70°C

Permissible air humidity at operation 95% relative humidity, no condensation

Permissible air humidity at transport and storage 5% to 95% relative humidity, no condensation

Specifications for intended use

Protection class IP 64

Paint finish grey RAL 7016

Direction of rotation Drive side and output side in the same direction

Lubrication Lifetime lubricated; >20,000 hrs

Mounting position See chapter: "Technical description", [Page40]

Maintenance intervals See chapter: "Maintenance and cleaning", [Page48]

Gear unit design

Reducing the rated input speed

For higher ambient temperatures the rated input speed must be

reduced.

The two speeds that are relevant for the gear unit design are the

maximum rated speed and the drive speed. The maximum permitted

rated speed (n

1max

) may not be exceeded. Cycle operation is dimen-

sioned based on this value.

The permitted mean drive speed (n

) must not be exceeded during

continuous operation. The rated speed is limited by the housing

temperature, which may not exceed 90°C. The value specified in

the technical data applies at an ambient temperature of +20°C.

Technical data

Version: 2.1 ─── 19AG3210

Feather key [+]

Dimensional data for the feather keys [+] are given in the following

table:

AG3210-+ 1-stage 2-stage

NP005

NP015

NP025

NP035

NP045

Technical data

20 ─── Version: 2.1AG3210

4.3

NP005

Mechanical data 1-stage 2-stage

Transmission ratio i

Further transmission ratios on enquiry

4 5 7 8 10 16 20 25 28 35 40 50 64 70 100

Efficiency under full load ŋ [%] 97 95

Mass moment of inertia J

[kgcm²]

in relation to the drive

0.02 to 0.14 0.02 to 0.13

Running noise

[dB/A]

i = 10 / n

= 3000 rpm without load

≤ 58

Weight including adapter plate

m [kg] 0.7 – 1.2 0.9 – 1.6

Torques and speeds

Rated torque at the output T

[Nm] 5.1 6.5 6.0 5.1 6.5 5.1 6.5 5.1 6.5 6.0 6.5 6.0

Maximum acceleration torque T

[Nm]

maximum 1000 cycles per hour

11 14 13 11 14 11 14 11 14 13 14 13

Maximum torque T

[Nm] 18 22 21 18 22 18 22 18 22 21 22 21

Emergency stop torque

2Emerg

[Nm] 26

Average drive speed

[rpm]

T

& 20°C ambient temperature

3800 4300 4000 4300

Maximum drive speed n

1Max

[rpm] 10000

No-load running torque T

012

[Nm] 0.1 0.009 0.008 0.11 0.1 0.1 0.009 0.008

Torsion and forces

Maximum torsional backlash j

[arcmin] Standard ≤ 10 Standard ≤ 13

Maximum torsional rigidity C

t21

[Nm/arcmin]

1.2 0.85 1.2 0.85 1.2 0.85

Maximum axial force

2AMax

[N] 700

Maximum radial force

2RMax

[N] 800

Temperature[°C]

Maximum housing temperature + 90

Ambient temperature -15 to + 40

Clamping hub diameter [mm]

Standard 8 Z; 9 A; 11 B

Large 14 C

a) 1000 x possible during gear unit lifetime, maximally T

2Emerg

is permissible at T

> T

2Emerg

b) in relation to the shaft center at the output, n

= 150 rpm

c) dependent on the clamping hub diameter and selected adapter plate

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Model: AG3210

Type: Operating Instructions Manual

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Beckhoff AG3210 Operating Instructions Manual

Beckhoff AG3210 Operating Instructions Manual

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