Beckhoff XTS Standard Operating Instructions Manual

eXtended Tr ansport

System | XTS

05/06/2019 | Version 2.1

eXtended Transport

System | XTS

Operating instructions | EN

Table of contents

2 ─── Version: 2.1eXtended Transport System

Table of contents

Documentation notes .......................................................................................................................................... 4

Disclaimer ......................................................................................................................................................... 4

Version numbers............................................................................................................................................... 6

Scope of the documentation ............................................................................................................................. 6

Staff qualification............................................................................................................................................... 7

Safety and instruction ....................................................................................................................................... 8

Explanation of symbols ..................................................................................................................................... 8

Beckhoff Services ............................................................................................................................................. 9

For your safety................................................................................................................................................... 10

General safety instructions ............................................................................................................................. 10

Product overview............................................................................................................................................... 12

Name plate...................................................................................................................................................... 13

Type key ......................................................................................................................................................... 14

Product characteristics.................................................................................................................................... 15

Ordering options ............................................................................................................................................. 16

Intended use ................................................................................................................................................... 19

Technical data.................................................................................................................................................... 20

Definition ......................................................................................................................................................... 20

Data for operation and environment ............................................................................................................... 21

XTS Standard ................................................................................................................................................. 22

Dimensional drawings..................................................................................................................................... 23

Scope of supply ................................................................................................................................................. 40

Packaging ....................................................................................................................................................... 40

Transport and storage....................................................................................................................................... 41

Conditions ....................................................................................................................................................... 41

Long-term storage........................................................................................................................................... 41

Mechanical installation ..................................................................................................................................... 42

Preparation ..................................................................................................................................................... 42

Modules .......................................................................................................................................................... 46

Guide rails....................................................................................................................................................... 55

Mover .............................................................................................................................................................. 61

Electrical installation......................................................................................................................................... 66

Connection technology ................................................................................................................................... 66

Pin assignment of the power cable ................................................................................................................. 67

Earthing of the supply ..................................................................................................................................... 68

Earthing of the machine beds ......................................................................................................................... 69

Parallel connection of the modules ................................................................................................................. 71

parallel connection of the power supply.......................................................................................................... 73

Commissioning.................................................................................................................................................. 75

Before commissioning..................................................................................................................................... 75

During commissioning..................................................................................................................................... 75

Prerequisites during operation ........................................................................................................................ 76

After operation ................................................................................................................................................ 76

Maintenance and cleaning ................................................................................................................................ 77

Cleaning materials .......................................................................................................................................... 77

Intervals .......................................................................................................................................................... 78

Accessories........................................................................................................................................................ 79

Alignment gauge ............................................................................................................................................. 79

Rail on support................................................................................................................................................ 79

Table of contents

Version: 2.1 ─── 3eXtended Transport System

6-roller 50 mm mover...................................................................................................................................... 79

6-roller 70 mm mover...................................................................................................................................... 80

12-roller 50 mm mover.................................................................................................................................... 80

Decommissioning.............................................................................................................................................. 81

Disassembly.................................................................................................................................................... 81

Disposal .......................................................................................................................................................... 81

Index ................................................................................................................................................................... 82

Documentation notes

4 ─── Version: 2.1eXtended Transport System

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 P

®

, Safety over Ether-

CAT

®

, TwinSAFE

®

, XFC

®

and XTS

®

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

• DE102004044764

• DE102007017835

The TwinCAT technology is protected by patent rights through the

following registrations and patents with corresponding applications

and registrations in various other countries:

• EP0851348

• US6167425

EtherCAT

®

is a registered trademark and patented technology, li-

censed by Beckhoff Automation GmbH & Co. KG, Germany.

Documentation notes

Version: 2.1 ─── 5eXtended Transport System

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

Copyright

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

6 ─── Version: 2.1eXtended Transport System

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 update:

Technical data

2.0 Complete revision, new version

1.4 Chapter revision:

Scope of supply 5.1; General technical data 6.1; Structure of the XTS

6.2;

Mounting the movers on the guide rail 7.3; Teaching the encoder sys-

tem 7.4.2; Functional principle of the collision avoidance 7.5.1;

New chapter:

Error messages 8.3

1.3 Chapter revision:

3.2; 4.2; 4.3; 4.4; 4.4.1; 5.1; 6.1; 6.1.3; 6.2; 6.2.1.1; 6.2.1.2; 6.2.2; 6.2.3;

6.3; 6.4; 7.1; 7.2; 7.3; 7.4; 7.4.1; 7.4.2; 7.4.3

1.2 Chapter revision:

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 removed chapters:

New: 4.4.1; 6.1.3

Removed: 7.3

1.1 Chapter revision:

3.2; 6.1; 6.1.1, 7.3

New chapter:

Technical data

1.0 First edition

Scope of the documen-

tation

The complete documentation is divided into the following instruc-

tions:

XTS 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 XTS

Instruction leaflet Accompanying document with general

notes on handling the XTS

(included with each product)

Documentation notes

Version: 2.1 ─── 7eXtended Transport System

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 (university degree, apprenticeship, specialist training). Possi-

ble 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

8 ─── Version: 2.1eXtended Transport System

Safety and instruction

Read the contents, which refer to the activities that you have to

carry out with the product. Always read the chapter "For your

safety", [Page10] in the operating instructions. Observe the warn-

ing notes in the chapters so that you can handle and work properly

and safely with the product.

Explanation of symbols

Various symbols are used in the interest of clarity:

► 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 indicate different text categories:

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.

Example

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

ware.

QR code

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

Version: 2.1 ─── 9eXtended Transport System

Beckhoff Services

Beckhoff and its international partner companies offer comprehen-

sive support and service.

Support

Beckhoff Support offers technical advice on the use of individual

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 (on-site service, repair service, 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

10 ─── Version: 2.1eXtended Transport System

For your safety

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.

General safety instruc-

tions

This chapter provides you with instructions on safety when handling

the XTS. This system is not capable of stand-alone operation and is

therefore categorized as an incomplete machine. The XTS must be

installed in a machine/plant by the machine manufacturer. The doc-

umentation created by the machine manufacturer must be read.

Before operation

Danger from magnetic fields

The magnetic fields of some of the components of the XTS are dan-

gerous to:

• people fitted with cardiac pacemakers

• persons with magnetically conducting implants

• implanted and external defibrillators

• magnetic data storage devices, chip cards with magnetic strips

and other electronic devices

Maintain a safety distance of 500 mm to all magnetic parts and pre-

vent direct contact between magnetic parts and parts that are sensi-

tive to interference.

Observe the requirements of BGV B 11 for electromagnetic fields

(Germany) and applicable national regulations in other countries.

Use SELV/PELV output voltages

Operate all electronic modules and components in the drive system

only with a SELV (Safety Extra Low Voltage) or PELV (Protective

Extra Low Voltage) output voltage.

Keep the surroundings clean

Keep your workplace and the surrounding area clean. Ensure safe

working. Prevent the ingress of dirt into the XTS modules.

Secure the control cabinet

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

vertent power-up.

Do not use damaged modules

Observe the specifications in the technical data during storage,

transport and operation. Do not use damaged modules.

Check safety pictograms

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

place missing or illegible stickers.

Observe the 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 assemblies unless you are

wearing protective ESD clothing. Only walk on conductive floors.

For your safety

Version: 2.1 ─── 11eXtended Transport System

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.

During operation

Observe the earthing concept

Special conditions need to be observed for the earthing of the XTS.

Be sure to read the chapter "Earthing of the supply", [Page68].

Do not work on live electrical parts

Make sure the protective conductor is connected properly. Never

disconnect electrical connections while they are live. Only work on

the XTS when the voltage has dropped to < 10V. Disconnect all

components from the mains and secure against reconnection!

Do not touch hot surfaces

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

housing during and after operation. Allow the XTS to cool down for

at least 15 minutes after it is switched off.

Avoid overheating

Operate the XTS according to the technical specifications. Refer

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

and switch the XTS off immediately if the temperature is too high.

Do not touch rotating components

Do not touch any moving parts during the operation of the XTS. En-

sure 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",

[Page81].

Product overview

12 ─── Version: 2.1eXtended Transport System

3

Product overview

1

2

3

4

5

6

7

8

9

Number Explanation

1 Curved rail

2 Straight guide rail with gate

3 Mover

4 Gate

5 Name plate

6 Machine bed

7 Straight guide rail without lock

8 Straight module

9 Curved module

Product overview

Version: 2.1 ─── 13eXtended Transport System

3.1

Name plate

Automation GmbH & Co.KG

Huelshorstweg 20

33415 Verl / Germany

www.beckhoff.com

Made in Germany

AT2000-0250

XTS Drive 250 mm

2000 002082

ECAT Run

Link / Act

48V | 16A

24V | 4A

Number Explanation

1 Link / Act status LED

2 EtherCAT status LED

3 cURus approval

4 Product designation

5 Module length

6 Serial number

7 Module type

8 RoHS conformity

9 CE conformity

10 24V | 4A power supply status LED

11 48V | 16A power supply status LED

12 Firmware and hardware revision

13 XML sensor PCB revision number

14 XML motor PCB revision number

15 Date of manufacture - week/year

Product overview

14 ─── Version: 2.1eXtended Transport System

3.2

Type key

Module

AT 20 xx – xxxx – 000x Explanation

AT Product line

AT = drive technology

20 Product type

2 = module

xx Module variants

00 = straight

01 = straight with supply

20 = 22.5° curve

21 = 22.5° curve with supply

25 = -22.5° curve

26 = -22.5° curve with supply

40 = 45° curve

41 = 45° curve with supply

50 = 180° curve (clothoid)

xxxx Product length

Module length in mm

000x Execution

2 = Black Line

3 = Standard with supply (UL-certified)

4 = Black Line with supply (UL-certified)

Mover

AT 901 x – 00x0 – x 550 Explanation

AT Product line

AT = drive technology

901 Product type

901 = mover

x Roller variants

1 = mover,6 rollers

2 = mover,12 rollers

00x0 Product length

Mover length in mm

5 = 50 mm

7 = 70 mm

x Magnetic plate set

0 = Standard

1 = Mover 1

Guide rail

AT 9x xx – xxxx – 0070 Explanation

AT Product line

AT = drive technology

9x Product type

0 = with lock

1 = without lock

xx Rail variants

00 = straight

20 = straight with supply

25 = 22.5° curve

40 = 22.5° curve with supply

50 = -22.5° curve

42 = -22.5° curve with supply

xxxx Product length

Module length in mm

(0070) When using a 70 mm mover AT9011-0070-0550, append -0070 to

the order details.

Product overview

Version: 2.1 ─── 15eXtended Transport System

Product characteristics

Permanent magnets

Permanent magnets made of a hard magnetic material are built into

the XTS movers. The permanent magnets develop high forces even

in small designs. They enable the precise and highly dynamic posi-

tioning of the XTS movers.

More modular travel path

You have the possibility to choose from a wide variety of module ge-

ometries and to assemble them together as you wish. This allows

different machine forms to be implemented.

Rail system

You have the possibility to select the best combination from several

rail systems and movers for every application.

Armature short circuit brake

In the case of an emergency stop the movers can optionally be de-

celerated by means of an armature short circuit.

Integrated power electronics

The entire power electronics is integrated in the modules. To supply

the modules you need a 24V control voltage and a 48V load volt-

age.

Software-based control

The XTS is controlled by a software-based cascade control. The

control loop structure is stored in the XTS drivers and is calculated

cyclically on the control IPC. You do not need any additional drive

software.

Programming according to IEC61131-3

The standardized "Motion Control function blocks" according to the

PLC Open standard IEC61131-3 are available for the programming

of the XTS.

Product overview

16 ─── Version: 2.1eXtended Transport System

Ordering options

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

arately.

Mover 1 magnetic plate

set

The special magnetic plate set is outwardly recognizable by the en-

graving on the magnetic plate set and an imprint on the encoder

flag. The Mover 1 functionality is used for the unambiguous identifi-

cation of the individual movers.

50 mm mover

The XTS mover with the Mover 1 magnetic plate set [+] is available

as a 50mm mover with 6 or 12 guide rollers.

70 mm mover

The XTS mover with the Mover 1 magnetic plate set [+] is available

as a 70 mm mover with 6 guide rollers.

Individual magnetic plate set

The Mover 1 magnetic plate set [+] is individually available for Beck-

hoff 50mm and 70mm movers as well as for external movers.

1.6mm encoder flag for non-Beckhoff movers

The use of the 1.6 mm-thick encoder flag is recommended for non-

Beckhoff movers. The Mover 1 magnetic plate set with pre-mounted

1.6 mm encoder flag is available under the following article number:

• AT9001-1550-1640

Product overview

Version: 2.1 ─── 17eXtended Transport System

Guide rails

In addition to the modules you need a rail system, which consists of

different guide rails. The guide rails are available in different lengths

and angles.

Straight guide rails

Straight guide rails are available in the following lengths, with or

without gate cover:

Available lengths

250 mm 1500mm

500mm 1750mm

750mm 2000mm

1000mm 2250mm

1250mm 2500mm

Curved guide rails

Curved guide rails are available in various angle sizes.

22.5° guide rails

These guide rails are available in angles of +22.5° and -22.5°.

The assembly of this angle is possible in combination with a straight

module and a 22.5° module. Two 22.5° modules cannot be installed

one behind the other.

45° guide rails

You can implement 45° angles with these guide rails.

These guide rails are suitable for a combination of a straight module

with a 45° module.

Product overview

18 ─── Version: 2.1eXtended Transport System

90° guide rails

90° guide rails are available to you for different applications.

You can install these guide rails in case of an arrangement of a

straight module with two consecutive 45° modules.

180° guide rails

You have the possibility to extend the 90° guide rails to 180° with

these additional guide rails.

360° guide rails

You have the possibility to implement a 360° system with lock cover.

Product overview

Version: 2.1 ─── 19eXtended Transport System

Intended use

The XTS may be operated exclusively for the activities foreseen and

defined in this documentation, taking into account the prescribed en-

vironmental conditions.

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.

All components of the XTS are intended to be programmed and put

into operation only with the help of the Beckhoff TwinCAT automa-

tion software.

Read the entire drive system documentation

This consists of:

• Translation of the original instructions

• Translation of the original instructions for the control computer

• 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 Standard XTS is not suitable for use in the following areas:

• in ATEX zones without a suitable housing

• in areas with aggressive environments (e.g. aggressive gases or

chemicals)

The relevant standards and directives for EMC interference emis-

sions must be complied with in residential areas. The XTS may only

be installed in a plant with a housing for corresponding shielding at-

tenuation.

Technical data

20 ─── Version: 2.1eXtended Transport System

Technical data

Below you will find definitions of terms, environmental conditions,

operating details and technical data for the XTS.

Definition

All details relate to an ambient temperature of 40 °C. The data can

have a tolerance of +/- 10%.

Technical term Symbol/

unit

Definition

Nominal force F

0

[N] Nominal force that a mover can continuously apply.

Force constant K

F

[N/A] Specification of how much force in N the mover generates with a certain mover cur-

rent.

The equation is F

0

= I

0Mover

x K

F

Voltage constant K

E

[Vs/m] Induced motor EMF related to 1 m/s as a peak sine value on a motor coil.

Thermal time constant tTH [min] Specification of the heating time of the cold module when loaded with the nominal

force until 63% of the maximum overtemperature is reached. This temperature rise

happens in a much shorter time when the motor is loaded with the peak current.

Absolute accuracy [mm] Specification of the difference between an expected set position and the mean value

of the actual position resulting from approaching the set position from different direc-

tions (multi-directional). The absolute accuracy is valid within a module and is de-

fined as the difference between the set position and the actual position of the posi-

tioning system.

Standstill repeatability [mm] Specification of how accurately the system positions when approaching a position

from the same direction (unidirectional). The standstill repeatability is to be evaluated

as the average difference between the actual position and the set position and is the

most important measure for the assessment of a positioning system. It defines the

variance around the mean value with a large number of positionings.

The variance of the positions is illustrated by the "Gauss distribution" or normal distri-

bution. The standstill repeatability is defined by three standard deviations (3σ) with a

probability of 99.74%.

Synchronization accuracy [mm] Specification of the fluctuations that the system exhibits in the position (lag error) dur-

ing a position-controlled movement at a constant set speed. The synchronization ac-

curacy depends on the mechanical rigidity, the applied load on the movers, the con-

troller settings, the set speed and also any mechanical offset between the modules.

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Beckhoff XTS Standard Operating Instructions Manual

Beckhoff XTS Standard Operating Instructions Manual

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