Beckhoff XTS Startup Manual

Brand: Beckhoff

Model: XTS

Type: Startup Manual

Documentation

eXtended Transport System Start-Up

1.2

2016-02-18

Version:

Date:

Table of content

1 Foreword ....................................................................................................................................................5

1.1 Notes on the documentation............................................................................................................. 5

1.2 Documentation issue status.............................................................................................................. 6

1.3 Intended use ..................................................................................................................................... 6

2 Guidelines and Standards ........................................................................................................................7

3 Safety..........................................................................................................................................................8

3.1 General safety instructions ............................................................................................................... 8

3.1.1 Personnel qualification..........................................................................................................8

3.1.2 Description of safety symbols ...............................................................................................8

3.2 Special safety instructions ............................................................................................................... 9

3.3 Using in Ex environments ............................................................................................................... 10

4 Handling ...................................................................................................................................................11

4.1 Transport ........................................................................................................................................ 11

4.2 Packaging ....................................................................................................................................... 11

4.3 Storage ........................................................................................................................................... 12

4.4 Maintenance / Cleaning .................................................................................................................. 12

4.4.1 Replacement of the guide rollers ........................................................................................13

4.5 Disposal .......................................................................................................................................... 14

5 Product identification..............................................................................................................................15

5.1 Scope of supply .............................................................................................................................. 15

5.2 Type label ....................................................................................................................................... 15

5.3 Type key ......................................................................................................................................... 16

6 Technical description..............................................................................................................................18

6.1 General technical data.................................................................................................................... 18

6.1.1 Dimensions .........................................................................................................................19

6.1.2 Connection diagram XTS-Infeed.........................................................................................20

6.1.3 Connection overview...........................................................................................................21

6.2 Configuration ................................................................................................................................. 22

6.2.1 Basic functions....................................................................................................................22

6.2.2 Use of the basic functions...................................................................................................23

6.2.3 System length and curve function.......................................................................................23

6.3 Overview ........................................................................................................................................ 24

6.4 Overview of the components .......................................................................................................... 26

7 Installation................................................................................................................................................28

7.1 Mechanical installation.................................................................................................................... 28

7.2 Overview of the tightening torques ................................................................................................. 29

7.3 Mounting the movers on the guide rail............................................................................................ 31

7.4 The positioning system ................................................................................................................... 33

7.4.1 Zero point of the encoder system .......................................................................................33

7.4.2 Teaching the encoder system.............................................................................................34

7.4.3 Application simulation .........................................................................................................40

7.5 Collision avoidance......................................................................................................................... 41

7.5.1 Operating principle of collision avoidance...........................................................................41

8 Technical data..........................................................................................................................................45

8.1 AT9011-0050-0550......................................................................................................................... 45

8.2 Technical drawing AT9011-0050-0550........................................................................................... 45

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Table of content

9 Support and Service................................................................................................................................46

eXtended Transport System Start-Up4

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Foreword

1 Foreword

1.1 Notes on the documentation

This description is only intended for the use of trained specialists in control and automation engineering who

are familiar with the applicable national standards.

It is essential that the following notes and explanations are followed when installing and commissioning

these components.

The responsible staff must ensure that the application or use of the products described satisfy all the

requirements for safety, including all the relevant laws, regulations, guidelines and standards.

Disclaimer

The documentation has been prepared with care. The products described are, however, constantly under

development.

For that reason the documentation is not in every case checked for consistency with performance data,

standards or other characteristics.

In the event that it contains technical or editorial errors, we retain the right to make alterations at any time

and without warning.

No claims for the modification of products that have already been supplied may be made on the basis of the

data, diagrams and descriptions in this documentation.

Trademarks

Beckhoff

, TwinCAT

, EtherCAT

, Safety over EtherCAT

, TwinSAFE

, XFC

and XTS

are registered

trademarks of and licensed by Beckhoff Automation GmbH.

Other designations used in this publication may be trademarks whose use by third parties for their own

purposes could violate the rights of the owners.

Patent Pending

The EtherCAT Technology is covered, including but not limited to the following patent applications and

patents:

EP1590927, EP1789857, DE102004044764, DE102007017835

with corresponding applications or registrations in various other countries.

The TwinCAT Technology is covered, including but not limited to the following patent applications and

patents:

EP0851348, US6167425 with corresponding applications or registrations in various other countries.

EtherCAT

is registered trademark and patented technology, licensed by Beckhoff Automation GmbH,

Germany

The reproduction, distribution and utilization of this document as well as the communication of its contents to

others without express authorization are prohibited.

patent, utility model or design.

eXtended Transport System Start-Up 5

Version: 1.2

Foreword

1.2 Documentation issue status

Issue Comment

1.2 Chapter update:

4.2; 4.5; 6.1.1; 6.1.2; 6.2.3; 6.4; 7.2; 7.5.1; 7.5.2

New and deleted chapter:

New: 4.4.1; 6.1.3

Deleted: 7.3

1.1 Chapter update:

3.2; 6.1; 6.1.1, 7.3

New chapter:

Technical data

1.0 First edition

1.3 Intended use

The linear eXtended Transport System (XTS) is designed for machines and equipment with the highest

demands on dynamics and positioning accuracy. All components of the eXtended Transport System (XTS)

are exclusively intended to be programmed and commissioned using the TwinCAT automation software

from Beckhoff Automation GmbH & Co. KG.

WARNING

Caution - Risk of injury!

Electronic equipment is not fail-safe. In case of failure of the drive system, the machine

manufacturer is responsible for ensuring that the connected components of the eXtended

Transport System (XTS) and the machine are brought into a safe state.

WARNING

Commissioning of the eXtended Transport System (XTS)

The eXtended Transport System (XTS) must be commissioned based on the requirements

of the currently valid EU Machinery Directive. Furthermore, the client must ensure that all

components installed in the system have a valid serial number.

All components of the eXtended Transport System (XTS) are installed exclusively in electrical systems or

machines. They may only be commissioned in connection with components of the eXtended Transport

System (XTS) and the previously designed plant. Furthermore, it is essential to take into account all

environmental conditions defined in this document before the eXtended Transport System (XTS) is

commissioned.

eXtended Transport System Start-Up6

Version: 1.2

Guidelines and Standards

2 Guidelines and Standards

CAUTION

Danger for persons, the environment or equipment

The components of the XTS are not products within the meaning of the EC Machinery Di-

rective. Operation of the XTS components in machines or systems is only permitted once

the machine or system manufacturers has provided evidence of CE conformity of the com-

plete machine or system.

eXtended Transport System Start-Up 7

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Safety

3 Safety

3.1 General safety instructions

3.1.1 Personnel qualification

This description is only intended for trained specialists in control, automation and drive engineering who are

familiar with the applicable national standards.

3.1.2 Description of safety symbols

The following safety symbols and associated safety instructions are used in this document. These safety

instructions must be read and followed.

DANGER

Serious risk of injury!

Failure to follow the safety instructions associated with this symbol directly endangers the

life and health of persons.

WARNING

Caution - Risk of injury!

Failure to follow the safety instructions associated with this symbol endangers the life and

health of persons.

CAUTION

Personal injuries!

Failure to follow the safety instructions associated with this symbol can lead to injuries to

persons.

Attention

Damage to the environment or devices!

Failure to follow the safety instructions associated with this symbol can lead to damage to

the environment or equipment.

Note

Tip or pointer

This symbol indicates information that contributes to better understanding.

eXtended Transport System Start-Up8

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Safety

3.2 Special safety instructions

The safety instructions are designed to avert danger and must be followed during installation,

commissioning, production, troubleshooting, maintenance and trial or test assemblies. The XTS can operate

independently. Installation in a machine or system is not mandatory. During independent commissioning or

installation of the XTS in a machine or system, the documentation and safety instructions provided by the

machine manufacturer must be read and applied.

WARNING

Caution - Risk of injury!

The XTS may only be installed by trained and qualified personnel. The qualified personnel

must know the national accident prevention regulations and be able to apply them.

When working on the XTS, personal protective equipment (PPE) must be worn. In particu-

lar, safety boots must be worn!

WARNING

Caution - Risk of injury through electric shock!

Bring the electrical environment (XTS, cabinet, etc.) into a safe, de-energized state before

installing or working on the XTS.

DANGER

Acute risk of injury due to improper earthing!

The XTS must be earthed in accordance with the statutory provisions. Non-compliant earth-

ing can cause acute injuries or death by electric shock.

Attention

Intended use!

The XTS starter kit may only be put into operation under consideration of currently valid EU

directives and standards, as well as the EC Machinery Directive in force at the time of com-

missioning.

Attention

Destruction of the XTS starter kit!

Ensure adequate ventilation and proper earthing of the cabinet. The permissible ambient

conditions are specified in the “Technical data” section. Failure to observe the specified

ambient conditions and improper earthing may cause damage to components of the XTS

starter kit. Furthermore, EMC problems can arise.

CAUTION

Risk of burns from hot surfaces!

The XTS issues a warning via TwinCAT if the operating temperature exceeds 65 °C. If the

temperature exceeds 75 °C, the system switches off automatically. In the event of an auto-

matic shutdown, the surface temperature of the coils may exceed 105 °C. Acute risk of

burns!

Do not touch the components of the XTS during operation and shortly after operation. Wait

until all components have cooled sufficiently.

Use a thermometer to check the surface temperature of the components.

In cases that require touching of components directly after operation, use suitable safety

gloves to protect from burns. Wear heat-resistant clothing.

Danger from magnetic fields!

The Beckhoff XTS is equipped with permanent magnets at the guide rails and movers. The

field strength of the XTS results solely from the magnetic fields of these components. A

limit range of < 0.5 mT is reached in energized state at a radius of 150 mm, in non-ener-

gized state at a radius of 130 mm. The magnetic field poses a danger to persons and the

environment. Observe the regulations for magnetic fields in air transportation (IATA Pack-

ing Instruction 902). This applies to already installed magnets. Permanent magnets must

be stored in humid conditions. The use of permanent magnets in humid conditions (up to

95% relative humidity) can lead to corrosion and destruction of the permanent magnets.

eXtended Transport System Start-Up 9

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Safety

Danger from magnetic fields!

In particular, the magnetic field poses a danger to:

• Persons with cardiac pacemakers (the magnetic field may cause the pacemaker to

switch to test mode and thus cause a cardiac arrest!)

• Persons with magnetically conductive implants

• Magnetic data storage devices

• Chip cards with magnetic strips, and

• Electronic devices

• Also keep in mind that the magnetic fields can influence implanted defibrillators and

make external defibrillators inoperable.

• Ensure a safety distance of 500 mm to all magnetic parts. Also, make sure that there is

no direct contact with magnetic components near parts that are susceptible to interfer-

ence.

The national regulations and guidelines applicable in other countries must be followed!

Also note the requirements of BGV B 11 in connection with magnetic fields (BGV B 11

Section 14).

Note

Liability for further transport!

Please note that all components of the XTS starter kit may only be forwarded in the original

packaging supplied by Beckhoff. The use of other packaging for further transport would

void all liability and warranty claims against Beckhoff Automation GmbH & Co. KG.

3.3 Using in Ex environments

WARNING

The use of the XTS in potentially explosive atmospheres – Directive 94/9/EC

– is not permitted!

eXtended Transport System Start-Up10

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Handling

4 Handling

4.1 Transport

• The XTS starter kit may only be transported by qualified personnel and in the manufacturer's original

packaging.

• Avoid shocks, particularly at the corners of the packaging.

• If the packaging is damaged, check the XTS starter kit for visible damage. Inform the transport

company and, if necessary, the manufacturer.

CAUTION

Damage to the device due to improper transport!

When transporting the XTS starter kit ensure that all specifications are met. In particular,

jerky and fast movements should be avoided.

4.2 Packaging

• Motor modules in recyclable cardboard packaging*

• Magnet holders in recyclable cardboard packaging with foam inserts*

• Movers in recyclable cardboard packaging with bubble wrap*

*only single packaging.

Shipping of the XTS starter kit

Contents of the Starter Kit include

• Fully Assembled and tested XTS (item 4)

• Control Cabinet with all necessary equipment

(item 3)

Both are secured in the shipping crate to prevent

movement during transport.

Warning Pinch Point!

When opening/closing the case keep hands clear of

the area between the lid of the crate (1) and the side

of the crate (2) two People are required to lift/lower

the lid!

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Handling

4.3 Storage

Requirement Characteristic value

Climate category 2K3 according to EN 60721

Storage temperature -25°C to +85°C

Permissible relative humidity 15% - 95%, no condensation

Store only in the original recyclable manufacturer's packaging.

4.4 Maintenance / Cleaning

Maintenance

The XTS motor modules are maintenance-free!

WARNING

Observe the ambient commissioning conditions!

Make sure that the XTS is stored and electrically operated only under the specified condi-

tions.

The XTS movers are not maintenance-free!

WARNING

Destruction of the rails!

The guide rollers of movers must be checked at regular intervals. Remove any dirt or other

foreign material that may have accumulated on the guide rollers during operation. Failure to

comply with regular maintenance can lead to increased wear of the guide rollers, as well as

damage to the rails.

Note

Rail maintenance

The rails can be lubricated lightly. This increases the life of the guide rollers. The following

lubricants are suitable for this purpose:

• Vaseline according to DAB 10 (German Pharmacopoeia 10)

• Vaseline spray

• Silicone spray

• PTFE spray

• If the rails are cleaned for maintenance, re-lubricate them with one of the lubricants

listed above. For further specifications please contact the Beckhoff applications depart-

ment.

eXtended Transport System Start-Up12

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Handling

Cleaning

The XTS modules are sealed according to protection class IP65. They are not protected against aggressive

substances. Clean the modules regularly to protect them against rust and corrosion. Use only Isopropanol.

WARNING

Damage to motor modules

If damage to the motor modules has occurred, please contact Beckhoff Automation GmbH

& Co. KG immediately!

WARNING

Damage to the guide rollers

Make sure that the rails are free from dirt and metallic particles. A dirty rail can significantly

reduce the service life of the guide rollers.

4.4.1 Replacement of the guide rollers

Installation manual

Loosen the roller axel nut

• Use a 1.5mm Allen Key hold to hold the screw

in place. (2)

• Loosen and remove the nut using a 5.5mm

socket wrench/spanner (1)

The Screw (2) must be held in place to prevent it

from turning with the Socket.

Removal of the components

• Pull out the screw that is the shaft of the roller

(2) and take with it

• the Roller (4)

• the washer (5)

• the nut (1)

Caution! When removing the screw (2) be sure to

pull it straight out from the hole in the mover body (6)

in order to prevent damage to the threads. Do not tilt

it.

eXtended Transport System Start-Up 13

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Handling

Exchange the Roller

After all the components have been removed, from

the mover body, the roller can be replaced.

Reassemble the Components

• Insert the screw (2) through

• the Roller (4) then

• the washer (5)

• Push the screw through the hole of the mover

body and fix it in place with the nut (6)

Caution! To prevent damage to the threads, take

care to insert the screw (2) straight into the mover

body (6). Do not tilt the screw.

Tighten the Roller axel nut.

• Use a 1.5mm Allen key hold the screw (2) in

place.

• With a 5.5mm Socket tighten the nut (1) to a

torque of 2.4Nm

The screw (2) must be held in place to prevent it from

turning with the nut.

4.5 Disposal

In accordance with the WEEE 2002/96/EC Directives we take old devices and accessories back for

professional disposal, provided the transport costs are taken over by the sender. Send the devices with the

note “For disposal” to:

Beckhoff Automation GmbH & Co. KG

Service-Center

Stahlstraße 31

33415 Verl

eXtended Transport System Start-Up14

Version: 1.2

Product identification

5 Product identification

5.1 Scope of supply

Check the completeness of the delivery against your delivery note.

Missing parts or damage should be recorded immediately and reported to the carrier, the insurance and/or

Beckhoff Automation GmbH & Co. KG.

The standard scope of supply includes:

• XTS-Starter Kit

• Control cabinet

• Connection cables

• Control PC

• Switch mode power supply units for 24 V and 48 V

• Software licenses (TwinCAT/TC3/XTS Extension)

• Commissioning of the XTS (this manual)

5.2 Type label

eXtended Transport System Start-Up 15Version: 1.2

Product identification

5.3 Type key

*Content of the XTS-Starterkit

eXtended Transport System Start-Up16

Version: 1.2

Product identification

*Content of the XTS-Starterkit

eXtended Transport System Start-Up 17

Version: 1.2

Technical description

6 Technical description

6.1 General technical data

Environmental influences XTS

Ambient temperature -10 °C – +40 °C

If ambient temperatures exceeding +40 °C are expected, it is essential to contact

the Beckhoff applications department.

Transport and storage temperature -25 °C - +85 °C

Permissible relative humidity 15 % - +95 %, no condensation

Contamination level EN 60204 / EN 50178 Level 2

Corrosion protection Normally not required. Under extreme operating conditions, special measures

may be imposed by the production.

Installation altitude Between 1000 m and 2500 m, the performance reduces by 1.5% per 100 m.

Installation position Vertical installation position of the starter kit and housing

Other installation positions are possible for further individual XTS components

Ventilation XTS via convection

Protection class IP65

Note

Ventilation of the machine bed!

To improve system utilization, it is strongly recommend to actively or passively cool the ma-

chine bed of the XTS. For further information on cooling please contact the Beckhoff appli-

cations department!

System properties XTS

Max. force 100 N at standstill

Payload 80 N at 2 m/s

Continuous force 30 N (at approx. 30 °C temperature increase between motor / mounting frame)

Velocity 4 m/s at 48 V

supply

Acceleration > 100 m/s² (without payload)

Synchronization accuracy < ± 0.15

1*)

mm at 1.5 m/s within a straight module

Absolute accuracy < ± 0.25

2*)

mm within a straight module

Repeatability (unidirectional) < ± 10 µm (standstill)

Mover length 50 mm in direction of movement (AT9011)

Mover weight Approx. 350 g (complete mover without attachments)

Maximum system length > 10 m (dependent on computing power, no system limit)

Occurring temperature during operation /

storage temperature

0…< +105 °C

3*)

/ -25 °C…+85 °C

Protection class IP 65

Approvals CE

Vibration/shock resistance Conforms to EN60068-2-6/EN 60068-2-27

EMC immunity/emission Conforms to EN61000-6-2/EN 61000-6-4

1*)

The synchronization accuracy is primarily dependent on the mechanical stiffness and the load on the

mover. The controller setting and the mechanical offset between the modules must also be taken into

account.

2*)

Typically achievable absolute accuracy; this may be exceeded in case of significant thermal warming of

the module (∆ϑ ≥ 30°C) or lack of parallelism or orthogonality of the encoder flag to the motor module.

3*)

Please note the special safety instructions for the XTS on page 8 of this manual!

eXtended Transport System Start-Up18

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Technical description

Electrical data XTS

Supply voltage Control voltage 24 V

, power supply 50 V

Current consumption Power supply: 16 A rated current

Power consumption control voltage (24 V) Motor modules: 30 W/m (communication, electronics,

displacement measurement)

Length per infeed Typically 1 m – max. 3 m (depending on computing power)

Power consumption per mover approx. 30 W at 2 m/s constant speed

approx. 60 W at 4 m/s constant speed

approx. 60 W at a peak acceleration of 10 m/s² and a mass

of 1 kg

approx. 300 W at a peak acceleration of 50 m/s² and a

mass of 1 kg

Note

Length per infeed!

The length per infeed is application-dependent. For precise dimensioning of the power sup-

ply please contact the Beckhoff applications department.

Note

Energy recovery from the XTS

The XTS is capable of energy recovery. If kinetic energy is fed back during an emergency

stop, measures should be taken to avoid voltage overshoot, and associated premature

auto-shutdown of the motor modules. For further information please contact the Beckhoff

applications department.

6.1.1 Dimensions

Module Width at the ma-

chine bed

Width at the

track connection

Height Depth

Straight motor module

AT2001-0250

39.1 mm 22.1 mm 96 mm 250 mm

Straight line motor module with power

supply

AT2001-0250

39.1 mm 22.1 mm 96 mm 250 mm

Curved motor module 180° (clothoid)

AT2050-0500

39.1 mm 22.1 mm 306.5 mm 204.2 mm

Distance between movers and modules

The air gap between the magnet and the motor should by 0.85 mm on each side. Important: The magnets

must not touch the motor modules of the XTS!

The air gap between the encoder flag and the sensor should be 0.9 mm. A tolerance range of 0.4 mm – 1.4

mm applies (as of December 2015).

Important: Under no circumstances must the encoder flag touch the sensors of the motor modules!

eXtended Transport System Start-Up 19

Version: 1.2

Technical description

6.1.2 Connection diagram XTS-Infeed

24V Power supply

48V

GND

24V

PE connection port

of the module body

EtherCAT

line

48V Power supply

Control cabinet earth

Circuit diagram 48 V negative not grounded:

Do not ground the negative side of the 48V DC Bus

Power Supply! The adjacent diagram describes the

current distribution in the individual conductors. Inside

the module the negative 24V and negative 48V

cables are connected together. If the 48V minus is

not grounded the current for each circuit remains on

its conductors. The current for the 24V control power

remains on the 0.75mm wires to and from the

module. The current for the 48V power remains on

the 2.5mm 48V wires to and from the module. The

grounding of the DC Bus circuit is not necessary. The

EN60204-1 Standard chapter 9.4.3.1 (ground faults)

describes that the control circuits must be grounded

to ensure a machine cannot start with a broken cable.

Load circuits are not affected.

Circuit diagram 48 V minus grounded:

If the negative side of the 48V power supply is

grounded, the following situation occurs as described

by the adjacent diagram. Again, the -48V and -24V

lines are connected internally in the modules. If the

negative side of the 48V power supply is also

grounded, -24V wire (0.75mm) and the -48V wire

(2.5mm) act in parallel for the return path. This will

overload the -24V (0.75mm) wire. The +48V wire

(2.5mm) will carry the 48V load circuit current to the

module, the +24V wire (0.75mm) will carry the 24V

Control circuit current to the module. On the return

side, the -24V (0.75mm) wire will carry half of the

sum of the 48V load circuit current and the 24V

control circuit current. The -48V (2.5mm) wire will

carry the other half of the sum of the currents. The

0.75mm wire does have a slightly higher resistance

(0.042Ohm/m) than the 2.5mm (0.013Ohm/m) wire

but the difference is so small it can be omitted.

eXtended Transport System Start-Up20

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Beckhoff XTS Startup Manual

Brand: Beckhoff

Model: XTS

Type: Startup Manual

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Beckhoff XTS Startup Manual

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