Beckhoff AX8640-0000 Operating Instructions Manual

AX8000 | Multi-axis

servo system

Operating instructions | EN

4/24/2020 | Version 1.1

Order No.: TDmlAX-8000-0000-0201

Table of content

Version: 1.1 ─── 3AX8000

Table of content

Documentation notes .......................................................................................................................................... 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

Safety pictograms ........................................................................................................................................... 13

General safety instructions ............................................................................................................................. 14

Product overview............................................................................................................................................... 16

Power supply module...................................................................................................................................... 17

Axis module .................................................................................................................................................... 19

Capacitor module............................................................................................................................................ 21

Product characteristics.................................................................................................................................... 23

Ordering options ............................................................................................................................................. 24

Intended use ................................................................................................................................................... 26

Dual Use ......................................................................................................................................................... 27

Technical data.................................................................................................................................................... 28

Data for operation and environment ............................................................................................................... 28

Power supply modules.................................................................................................................................... 29

Axis modules................................................................................................................................................... 30

Capacitor module............................................................................................................................................ 31

Brake resistor [+]............................................................................................................................................. 31

Dimensional drawings..................................................................................................................................... 32

Scope of supply ................................................................................................................................................. 36

Packaging ....................................................................................................................................................... 37

Transport and storage....................................................................................................................................... 38

Conditions ....................................................................................................................................................... 38

Transport......................................................................................................................................................... 39

Long-term storage........................................................................................................................................... 39

Technical description........................................................................................................................................ 40

Installation position ......................................................................................................................................... 40

Residual current circuit breaker ...................................................................................................................... 40

Safe system stop ........................................................................................................................................... 40

Wide voltage range ......................................................................................................................................... 41

Dimensioning .................................................................................................................................................. 42

Display ............................................................................................................................................................ 45

Capacitor module............................................................................................................................................ 49

Mechanical installation ..................................................................................................................................... 50

Preparation ..................................................................................................................................................... 50

Modules .......................................................................................................................................................... 53

Electrical installation......................................................................................................................................... 56

Project planning .............................................................................................................................................. 56

Block diagrams ............................................................................................................................................... 58

Grounding ....................................................................................................................................................... 62

Power supply .................................................................................................................................................. 66

Voltage input ................................................................................................................................................... 67

Brake chopper................................................................................................................................................. 68

Table of content

4 ─── Version: 1.1AX8000

DC link ............................................................................................................................................................ 69

Fieldbus system .............................................................................................................................................. 70

Multi-feedback................................................................................................................................................. 71

Motor feedback OCT....................................................................................................................................... 74

Digital inputs ................................................................................................................................................... 75

Supply networks.............................................................................................................................................. 76

Fuse protection ............................................................................................................................................... 77

Commissioning.................................................................................................................................................. 81

Before commissioning..................................................................................................................................... 81

During commissioning..................................................................................................................................... 81

Prerequisites during operation ........................................................................................................................ 82

After operation ................................................................................................................................................ 82

Maintenance and cleaning ................................................................................................................................ 83

Intervals .......................................................................................................................................................... 83

Accessories........................................................................................................................................................ 84

Brake resistor.................................................................................................................................................. 84

Decommissioning.............................................................................................................................................. 85

Disassembly.................................................................................................................................................... 85

Disposal .......................................................................................................................................................... 86

Guidelines and Standards ................................................................................................................................ 87

Standards........................................................................................................................................................ 87

Guidelines ....................................................................................................................................................... 88

Test centers .................................................................................................................................................... 89

EU conformity ................................................................................................................................................. 89

UL certification ................................................................................................................................................ 90

Index ................................................................................................................................................................... 91

Documentation notes

Version: 1.1 ─── 5AX8000

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 & Co. KG, Germany.

Documentation notes

6 ─── Version: 1.1AX8000

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 and/or software configuration that go be-

yond 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.

Documentation notes

Version: 1.1 ─── 7AX8000

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:

AX8000 Definition

Translation of the original instruc-

tions;

this documentation

Description of the mechanical

and electrical parameters as well

as all information necessary for

the use, installation and mount-

ing of the AX8000 multi-axis

servo system

Commissioning under TwinCAT3 Commissioning tutorial under

TwinCAT3 including user infor-

mation on the TCDriveManager

2 and a description of the safety

function STO (Safe Torque Off)

over FSoE (Safety over Ether-

CAT)

CoE object description Documentation of the CAN over

EtherCAT objects with attribute

tables

Diagnostic messages Documentation of the error mes-

sages of the AX8000 multi-axis

servo system with attribute ta-

bles, problem descriptions and

possible solutions

AX2090-BW80-xxxx brake resis-

tors

Operating instructions for the use

and installation of the AX2090-

BW80 brake resistors as acces-

sories for the AX8000 multi-axis

servo system

Documentation notes

8 ─── Version: 1.1AX8000

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.

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 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

Documentation notes

Version: 1.1 ─── 9AX8000

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.

Documentation notes

10 ─── Version: 1.1AX8000

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

Pictograms and signal words are used in warning notices to make it

easier for you to find text passages:

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.

Documentation notes

Version: 1.1 ─── 11AX8000

Notes

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

Informations

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 Playstore 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.

Documentation notes

12 ─── Version: 1.1AX8000

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: 1.1 ─── 13AX8000

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.

2.1Safety pictograms

On Beckhoff products you will find attached or lasered safety pic-

tograms, which vary depending on the product. They serve to pro-

tect people and to prevent damage to the products. Safety pic-

tograms must not be removed and must be legible for the user.

Warning of high voltage!

The DC link capacitors and test contacts on all modules can carry

life-threatening voltages of over 875V

DC

.

For your safety

14 ─── Version: 1.1AX8000

2.2General safety instruc-

tions

This chapter provides you with instructions on safety when handling

the product. This product is not capable of stand-alone operation

and is therefore categorized as an incomplete machine. The product

must be installed in a machine/plant by the machine manufacturer.

Read the documentation prepared by the machine manufacturer.

2.2.1Before 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 inad-

vertent power-up.

Do not use damaged components

Observe the specifications in the technical data during storage,

transport and operation. Do not use damaged components.

Check safety pictograms

Check whether the designated pictograms are on the product. Re-

place missing or illegible stickers.

Observe tightening torques

Install connections and components in compliance with the specified

tightening torques and check them regularly.

Earth electrical components or modules correctly

Do not touch electrical components or modules unless you are

wearing protective ESD 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.

For your safety

Version: 1.1 ─── 15AX8000

2.2.2During operation

Avoid contact with DC link DC+ and DC-

Measure the voltage on the DC link test contacts DC+ und DC-. Ob-

serve the following delay times after disconnecting from the mains

supply:

• AX8620 and AX8640 30 minutes

• AX8108, AX8118 and AX8206 30 minutes

Do not work on live electrical parts

Do not open the multi-axis servo system when it is live. Ensure that

the protective conductor is properly connected. Never disconnect

electrical connections while they are live. Only work on the multi-

axis servo system when the voltage has dropped to < 50V. Discon-

nect all components from the mains and secure against reconnec-

tion.

Do not touch hot surfaces

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

components during 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.

Refer here to the chapter: "Technical data". Provide for adequate

cooling and switch the components off immediately if the tempera-

ture is too high.

Do not touch moving or rotating components

Do not touch moving or rotating parts during operation. Ensure that

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

2.2.3After operation

De-energize and switch off components before working on

them

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".

Product overview

16 ─── Version: 1.1AX8000

3

Number Explanation

1 Housing

2 Display; in case of 2-channel modules: left channel 1, right channel 2

3 Digital inputs X15, channel A and X25, channel B

4 Feedback connection X21 and X22; optional

5 Quick coupling 24V

DC

; AX bridge

6 EtherCAT connection

7 Quick coupling, DC link and protective earth PE; AX bridge

8 8-pin motor connector X23, channel B; U, V, W, PE, T+ / OCT+, T- / OCT-, B+

and B-

9 8-pin motor connector X13, channel A; U, V, W, PE, T+ / OCT+, T- / OCT-, B+

and B-

10 AX-Bridge: DC link, FE

11 AX-Bridge: 24V

DC

12 Fieldbus EtherCAT input X04

13 Fieldbus EtherCAT output X05

14 10-pin input terminal X01; DC, 24V, supply network, PE and external brake re-

sistor

15 Earthing bolt

16 Test contact DC link DC-

17 Test contact DC link DC+

18 Test contact GND

19 Test contact +24V

DC

Product overview

Version: 1.1 ─── 17AX8000

3.1Power supply module

3.1.1Name plate

3.1.1

Number Explanation

1 Order number

2 Serial number

3 Rated input voltage

4 Rated input current

5 Input frequency

6 Maximum ambient temperature

7 Rated output voltage

8 Rated output current

9 Date of manufacture

10 QR code

11 EtherCAT conformity

12 cULus approval

13 EAC conformity

14 CE approval

Product overview

18 ─── Version: 1.1AX8000

3.1.2Type key

AX 8x yz-a b c d-0000 Explanation

AX Product line

Servo drive

8 Series

AX8000

x Supply

6

In combination with "a"

yz Rated output current

20 = 7A

DC

- single-phase supply

20 = 20A

DC

- three-phase supply

40 = 40A

DC

- three-phase supply

a Supply

0 = three-phase 200 to 480V

AC

1 = single-phase or three-phase 100 to 240V

AC

b Reserved

0 = Standard

c Hardware features

0 = Standard

d Execution

0 = Standard

Product overview

Version: 1.1 ─── 19AX8000

3.2Axis module

3.2.1Name plate

3.2.1

9 10

12

11

13

1

2

3

4

5

6

8

7

Input rated voltage : 680 V ( )DC UL

: 875 V ( -Link max.)DC DC

Max. amb. temp. : 55 °C

Catalog No. : 8206-0000-0000 AX

Serial # : 000000100

Output rated voltage : 3 0V - mains voltage PH AC

Output rated current : 2 x 6 A

Output frequency range : 0 - 599 Hz

Manufacturing date : 2017 / 02

Made in Germany

Ind. Cond. E.q.

41GE

BECKHOFF

Phone: + 49 52 46 / 9 63 - 0

Fax. : + 49 52 46 / 9 63 - 198

www.beckhoff.com [email protected]

Huelshorstweg 20

D-33415 Verl

Germany

Automation GmbH & Co. KG

Number Explanation

1 Order number

2 Serial number

3 Rated input voltage

4 Maximum ambient temperature

5 Rated output voltage

6 Rated output current

7 Output frequency range

8 Date of manufacture

9 QR code

10 EtherCAT conformity

11 cULus approval

12 EAC approval

13 CE conformity

Product overview

20 ─── Version: 1.1AX8000

3.2.2Type key

AX 8x yz-a b c d-0000 Explanation

AX Product line

Servo drive

8 Series

AX8000

x Axis module

1 = single-channel servo axis

2 = two-channel servo axis

yz Rated channel current

08 = 1 x 8A

18 = 1 x 18A

06 = 2 x 6A

a DC link voltage

0 = 0 to 875V

DC

b Safety function

0 = No safety function

1 = Safety functions, see "Ordering options", [Page24]

2 = Safety functions, see "Ordering options", [Page24]

c Hardware features

0 = OCT

1 = EnDat 2.2, BiSS C; Multi-Feedback Interface

d Execution

0 = Standard

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