Beckhoff AX2000 User manual

Digital Servo Amplifier
AX2000
Assembly, Installation, Setup
Keep all product manuals as a product component
during the life span of the servo amplifier.
Pass all product manuals to future
users / owners of the servo amplifier.
Edition 02/06

Previous versions :
Edition Remarks
11/99 First edition
12/99 Option -AS- integrated, ground-bolt, master-slave
04/00 various corrections
06/00 Wiring diagrams electr. gearing, warning and error messages, recommended torque
08/00 Wiring diagram in chapter III.9.2 corrected
09/01 Options -I/O-14/08- and -2CAN - incorporated, hardware-description incorporated for PROFIBUS and
SERCOS, connector assignment corrected, LED-display corrected, error messages expanded
02/02 various corrections
09/02 corrections to US English, connection to diff. mains supply networks, block diagram to ch.III
09/03 several corrections, DeviceNet expansion card added, directives and standards page revised, new cover
design
02/06
Expansion cards updated, new sections on EtherCat and SynqNet, chapter l restructured, new sections on
motor chokes, Encoder power supply and encoder termination, various error corrections, new ordering
codes, Feedback section revised, BAR removed, new regen resistors BAR(U), cross section (awg)
WINDOWS is a registered trademark of Microsoft Corp.
HIPERFACE is a registered trademark of Max Stegmann GmbH
EnDat is a registered trademark of Dr. Johannes Heidenhain GmbH
Technical changes which improve the performance of the equipment may be made without prior notice !
Printed in the Federal Republic of Germany
All rights reserved. No part of this work may be reproduced in any form (by printing, photocopying, microfilm or any other method)
or stored, processed, copied or distributed by electronic means without the written permission of BECKHOFF Corporation.

1 General
1.1 About this manual ...................................................................................7
1.2 Symbols used in this manual ..........................................................................7
1.3 Abbreviations used in this manual ......................................................................8
2 Technical Description
2.1 Safety Instructions ..................................................................................9
2.2 Use as directed ....................................................................................10
2.3 European Directives and Standards ....................................................................11
2.4 CE conformance ...................................................................................11
2.5 UL and cUL- Conformance ...........................................................................12
2.6 Nameplate .......................................................................................13
2.7 Instrument description ..............................................................................13
2.7.1 Package supplied ............................................................................13
2.7.2 The digital servo amplifiers of the series AX2000 ....................................................14
2.8 Connection to different mains supply networks ...........................................................16
2.9 Components of a servo system .......................................................................17
2.10 Technical data ....................................................................................18
2.10.1 Recommended torque .........................................................................19
2.10.2 Fusing .....................................................................................19
2.10.2.1 Internal Fusing ...........................................................................19
2.10.2.2 External fusing ...........................................................................19
2.10.3 Allowable ambient conditions, ventilation, mounting position ...........................................19
2.10.4 Conductor cross-sections ......................................................................20
2.10.5 LED display .................................................................................20
2.11 Grounding system..................................................................................20
2.12 Control for motor-holding brake .......................................................................21
2.13 Regen circuit ......................................................................................22
2.14 Switch-on and switch-off behavior .....................................................................23
2.14.1 Stop function to EN 60204 (VDE 0113)............................................................24
2.14.2 Emergency Stop strategies .....................................................................24
3 Installation
3.1 Important instructions ...............................................................................25
3.2 Guide to installation and wiring ........................................................................26
3.3 Assembly ........................................................................................27
3.3.1 Dimensions .................................................................................28
3.4 Wiring ...........................................................................................29
3.4.1 Connection diagram ..........................................................................30
3.4.2 Example of connections for multi-axis system ......................................................31
3.4.3 Pin assignments .............................................................................32
3.4.4 Notes on connection techniques .................................................................33
3.4.4.1 Shielding connection to the front panel ........................................................33
3.4.4.2 Technical data for connecting cables .........................................................34
3.5 Setup software ....................................................................................35
3.5.1 General ....................................................................................35
3.5.1.1 Use as directed ..........................................................................35
3.5.1.2 Software description ......................................................................35
3.5.1.3 Hardware requirements ....................................................................36
3.5.1.4 Operating systems........................................................................36
3.5.2 Installation under WINDOWS 95 / 98 / 2000 / ME / NT / XP ............................................36
AX2000 Installation manual 3
BECKHOFF 02/06 Contents
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4 Interfaces
4.1 Block diagram .....................................................................................37
4.2 Power supply .....................................................................................38
4.2.1 Mains supply connection (X0) ...................................................................38
4.2.2 24V auxiliary supply (X4).......................................................................38
4.2.3 DC bus link (X7) .............................................................................38
4.3 Motor connection with brake (X9) ......................................................................39
4.4 External regen resistor (X8) ..........................................................................39
4.5 Feedback ........................................................................................40
4.5.1 Resolver (X2) ...............................................................................40
4.5.2 Incremental encoder / sine encoder with Hall (X1) ...................................................41
4.5.3 Sine Encoder with EnDat or HIPERFACE (X1) ......................................................42
4.5.4 Incremental Encoder (X5) ......................................................................43
4.5.5 Sine Encoder without data channel (X1) ...........................................................44
4.6 Digital and analog inputs and outputs...................................................................45
4.6.1 Analog inputs (X3) ............................................................................45
4.6.2 Analog outputs (X3)...........................................................................46
4.6.3 Digital inputs (X3) ............................................................................47
4.6.4 Digital outputs (X3) ...........................................................................48
4.7 Encoder emulations ................................................................................49
4.7.1 Incremental encoder output - A quad B (X5) ........................................................49
4.7.2 SSI output (X5)..............................................................................50
4.8 Master-slave operation, encoder master control ..........................................................51
4.8.1 Connection to a AX master, 5V signal level (X5) ....................................................51
4.8.2 Connection to encoders with 24V signal level (X3) ...................................................52
4.8.3 Connection to a sine-cosine encoder (X1) .........................................................52
4.9 Interface for stepper-motor controls (pulse-direction) .......................................................53
4.9.1 Connection to stepper-motor controller with 5V signal level (X5) ........................................54
4.9.2 Connection to stepper-motor controller with 24V signal level (X3) .......................................54
4.10 RS232 interface, PC connection (X6) ...................................................................55
4.11 CANopen Interface (X6) .............................................................................56
5Setup
5.1 Important notes ....................................................................................57
5.2 Guide to Setup ....................................................................................58
5.3 Parameter setting ..................................................................................59
5.3.1 Multi-axis systems ............................................................................59
5.3.1.1 Node address for CAN-bus .................................................................59
5.3.1.2 Baud rate for CAN-bus ....................................................................59
5.3.2 Key operation / LED display ....................................................................60
5.3.2.1 Key operation............................................................................60
5.3.2.2 Status display ...........................................................................60
5.3.2.3 Standard menu structure ...................................................................61
5.3.2.4 Extended menu structure...................................................................61
5.4 Error messages ...................................................................................62
5.5 Warning messages .................................................................................63
6 Expansions / Accessories
6.1 Option -AS-, restart lock for personal safety ..............................................................65
6.1.1 Advantages of the -AS- option ..................................................................65
6.1.2 Functional description .........................................................................65
6.1.3 Block diagram ...............................................................................66
6.1.4 Signal diagram (sequence) .....................................................................66
6.1.5 Installation / Setup ............................................................................67
6.1.5.1 Safety instructions ........................................................................67
6.1.5.2 Functional test ...........................................................................67
6.1.5.3 Connection diagram.......................................................................67
6.1.6 Application examples .........................................................................68
6.1.6.1 Moving single axes or axis-groups in setting-up operation .........................................68
6.1.6.2 Switching off grouped axes with separate working areas ..........................................68
6.1.6.2.1 Control circuit.......................................................................68
6.1.6.2.2 Mains supply circuit ..................................................................69
4 AX2000 Installation manual
Contents 02/06 BECKHOFF
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6.2 Expansion Cards ..................................................................................70
6.2.1 Guide to installation of expansion cards ...........................................................70
6.2.2 Expansion card -I/O-14/08- .....................................................................71
6.2.2.1 Front view ..............................................................................71
6.2.2.2 Technical data ...........................................................................71
6.2.2.3 Light emitting diodes (LEDs) ................................................................71
6.2.2.4 Select motion task number (Sample)..........................................................71
6.2.2.5 Connector assignments ....................................................................72
6.2.2.6 Connection diagram.......................................................................73
6.2.3 Expansion cards -PROFIBUS- ..................................................................74
6.2.3.1 Front view ..............................................................................74
6.2.3.2 Connection technology ....................................................................74
6.2.3.3 Connection diagram.......................................................................74
6.2.4 Expansion card -SERCOS- .....................................................................75
6.2.4.1 Front view ..............................................................................75
6.2.4.2 Light emitting diodes (LEDs) ................................................................75
6.2.4.3 Connection technology ....................................................................75
6.2.4.4 Connection diagram.......................................................................76
6.2.4.5 Modifying the station address ...............................................................76
6.2.4.6 Modifying the baud rate and optical power .....................................................76
6.2.5 Expansion card -DEVICENET- ..................................................................77
6.2.5.1 Front view ..............................................................................77
6.2.5.2 Connection technology ....................................................................77
6.2.5.3 Connection diagram.......................................................................77
6.2.5.4 Combined module/network status-LED ........................................................78
6.2.5.5 Setting the station address (device address)....................................................78
6.2.5.6 Setting the transmission speed ..............................................................78
6.2.5.7 Bus cable ...............................................................................79
6.2.6 Expansion card -ETHERCAT- ...................................................................80
6.2.6.1 Front view ..............................................................................80
6.2.6.2 LEDs ..................................................................................80
6.2.6.3 Connection diagram.......................................................................80
6.2.7 Expansion card -SYNQNET- ....................................................................81
6.2.7.1 Front view ..............................................................................81
6.2.7.2 NODE ID Switch .........................................................................81
6.2.7.3 Node LED table .........................................................................81
6.2.7.4 SynqNet Connection, Connector X21B/C (RJ-45)................................................81
6.2.7.5 Digital inputs/outputs, connector X21A (SubD 15-pin, socket) ......................................82
6.2.7.6 Connection diagram digital inputs/outputs, connector X21A ........................................82
6.2.8 Expansion module -2CAN- .....................................................................83
6.2.8.1 Installation ..............................................................................83
6.2.8.2 Front View ..............................................................................83
6.2.8.3 Connection technology ....................................................................83
6.2.8.4 Connector assignments ....................................................................84
6.2.8.5 Connection diagram.......................................................................84
6.3 Accessories ......................................................................................85
6.3.1 External 24V DC / 5A supply ....................................................................85
6.3.2 External 24V DC / 20A supply ...................................................................86
6.3.3 External regen resistor BAR(U) ..................................................................87
6.3.4 Motor choke box 3YLN ........................................................................88
6.3.5 Power Supply SINCOS ........................................................................89
6.3.6 Terminating adapter for encoder cables ...........................................................89
6.3.7 Hall Dongle .................................................................................90
7 Appendix
7.1 Transport, storage, maintenance, disposal...............................................................91
7.2 Removing faults/warnings............................................................................92
7.3 Glossary .........................................................................................94
7.4 Index ............................................................................................96
AX2000 Installation manual 5
BECKHOFF 02/06 Contents
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6 AX2000 Installation manual
02/06 BECKHOFF

1 General
1.1 About this manual
This manual describes the digital servo amplifiers of the AX2000series
(standard version, 1.5 to 20 Amps nominal current).
In this manual you can find information about:
lGeneral Chapter 1
lTechnical description Chapter 2
lAssembly / installation Chapter 3
lInterfaces Chapter 4
lSetup Chapter 5
lExpansions / Accessories Chapter 6
lTransport, storage, maintenance, disposal Chapter 7
A more detailed description of the expansion cards which are currently available and the digital
connection to automation systems can be found on the accompanying CD-ROM in Acrobat-Reader
format (system requirements: WINDOWS with Internet browser, Acrobat Reader) in English,
German, Italian and French versions.
You can print this documentation on any standard printer. A printed copy of the documentation is
available from us at extra cost.
This manual makes the following demands on qualified personnel :
Transport : only by personnel with knowledge in handling electrostatically
sensitive components.
Installation : only by electrically qualified personnel
Setup : only by personnel with extensive knowledge of electrical
engineering / drive technology
1.2 Symbols used in this manual
Danger to personnel
from electricity and its
effects
Danger to maschinery,
general warning
Important
notes
ðp. see page lspecial emphasis
AX2000 Installation manual 7
BECKHOFF 02/06 General

1.3 Abbreviations used in this manual
The abbreviations used in this manual are explained in the table below.
Abbrev. Meaning
AGND Analog ground
AS Restart Lock, option
BTB/RTO Ready to operate
CAN Fieldbus (CANopen)
CE Communité Européenne (EC)
CLK Clock signal
COM Serial interface for a PC-AT
DGND Digital ground
DIN German Institute for industrial Standards
Disk Magnetic storage (diskette, hard disk)
EEPROM Electrically erasable programmable memory
EMC Electromagnetic compatibility
EMI Electromagnetic interference
EN European standard
ESD Electrostatic discharge
F-SMA Fiber Optic Cable connector according to IEC 60874-2
IEC International Electrotechnical Commission
IGBT Insulated Gate Bipolar Transistor
INC Incremental Interface
ISO International Standardization Organization
LED Light-emitting diode
MB Megabyte
NI Zero pulse
NSTOP Limit-switch input for CCW rotation (left)
PELV Protected low voltage
PGND Ground for the interface
PSTOP Limit-switch input for CW rotation (right)
PWM Pulse-width modulation
RAM Volatile memory
Rregen (RB) Regen resistor
RBext External regen resistor
RBint Internal regen resistor
RES Resolver
ROD 426 (EEO) A quad B encoder
PLC Programmable logic controller
SRAM Static RAM
SSI Synchronous serial interface
UL Underwriters Laboratory
VAC AC voltage
VDC DC voltage
VDE Verein deutscher Elektrotechniker
XGND Ground for the 24V supply
8 AX2000 Installation manual
General 02/06 BECKHOFF

2 Technical Description
2.1 Safety Instructions
lOnly properly qualified personnel are permitted to perform activities such as trans-
port, installation, setup and maintenance. Properly qualified persons are those who
are familiar with the transport, assembly, installation, setup and operation of the pro-
duct, and who have the appropriate qualifications for their job. The qualified person-
nel must know and observe:
IEC 364 and CENELEC HD 384 or DIN VDE 0100
IEC-Report 664 or DIN VDE 0110
National Accident Prevention Regulations or BGV A3
lRead this documentation before carrying out installation and setup. Incorrect hand-
ling of the servo amplifier can lead to personal injury or material damage. It is vital
that you keep to the technical data and information on connection requirements (on
the nameplate and in the documentation).
lThe servo amplifiers contain electrostatically sensitive components which may be
damaged by incorrect handling. Ground yourself before touching the servo amplifier
by touching any unpainted metal surface. Avoid contact with highly insulating mater-
ials (artificial fabrics, plastic film etc.). Place the servo amplifier on a conductive sur-
face.
lThe manufacturer of the machine must generate a hazard analysis for the machine,
and take appropriate measures to ensure that unforeseen movements cannot cause
injury or damage to any person or property.
lDo not open the units. Keep all covers and switchgear cabinet doors closed during
operation. Otherwise there are deadly hazards, with the possibility of severe danger
to health or material damage.
lDuring operation, servo amplifiers, according to their degree of enclosure protection,
may have uncovered live components. Control and power connections may be live,
even if the motor is not rotating.
lServo amplifiers may have hot surfaces during operation. Since the front panel is
used for cooling, it can reach temperatures above 80°C (176°F).
lNever undo the electrical connections to the servo amplifier while it is live. There is a
danger of electric arcing with damage to contacts and danger to persons.
lWait at least five minutes after disconnecting the servo amplifier from the mains
supply voltage before touching live sections of the equipment (e.g. contacts) or
undoing connections. Capacitors can still have dangerous voltages present up to five
minutes after switching off the supply voltages. To be sure, measure the voltage in
the DC bus link circuit and wait until it has fallen below 40V.
AX2000 Installation manual 9
BECKHOFF 02/06 Technical Description

2.2 Use as directed
The servo amplifiers are components which are built into electrical equipment or machines, and can
only be used as integral components of such equipment.
The manufacturer of the machine must generate a hazard analysis for the machine, and take
appropriate measures to ensure that unforeseen movements cannot cause injury or damage to any
person or property.
The AX2000 family of servo amplifiers can be connected directly to symmetrically earthed
(grounded) three-phase industrial mains supply networks [TN-system, TT-system with earthed
(grounded) neutral point, not more than 5000 rms symmetrical amperes, 480VAC maximum].
The servo amplifiers must not be operated directly on power supply networks >230V without an
earth (ground) or with an asymmetrical earth (ground).
Connection to different mains supply networks (with additional isolating transformer) ðp.16.
Periodic overvoltages between outer conductor (L1, L2, L3) and housing of the servo amplifier may
not exceed 1000V (peak value).
Transient overvoltages (< 50µs) between the outer conductors may not exceed 1000V.
Transient overvoltages (< 50µs) between outer conductors and housing may not exceed 2000V.
If the servo amplifiers are used in residential areas, or in business or commercial premises, then
additional filter measures must be implemented by the user.
The AX2000 family of servo amplifiers is only intended to drive specific brushless
synchronous servomotors, with closed-loop control of torque, speed and/or position. The rated volt-
age of the motors must be at least as high as the DC bus link voltage of the servo amplifier.
The servo amplifiers may only be operated in a closed switchgear cabinet, taking into account the
ambient conditions defined on page 19 and the dimensions shown on page 27. Ventilation or cool-
ing may be necessary to prevent enclosure ambient from exceeding 45°C (113°F).
Use only copper wire. Wire size may be determined from EN 60204 (or table 310-16 of the NEC
60°C or 75°C column for AWG size).
We only guarantee the conformance of the servo amplifiers with the standards for industrial areas
(page 11), if the components (motors, cables, amplifiers etc) are delivered by BECKHOFF.
Option -AS-, restart lock for personnel safety
The -AS- restart lock is exclusively intended to provide safety for personnel, by preventing the
restart of a system. To achieve this personnel safety, the wiring of the safety circuits must meet the
safety requirements of EN60204, EN292 and EN 954-1.
The -AS- restart lock must only be activated,
— when the motor is no longer rotating (setpoint = 0V, speed = 0rpm, enable = 0V).
Drives with a suspended load must have an additional safe mechanical blocking
(e.g. by a motor-holding brake).
— when the monitoring contacts (KSO1/2 and BTB/RTO) for all servo amplifiers are
wired into the control signal loop (to recognize a cable break).
The -AS- restart lock may only be controlled by a CNC if the control of the internal safety relay is
arranged for redundant monitoring.
The -AS- restart lock must not be used if the drive is to be made inactive for the following reasons :
1. - cleaning, maintenance and repair operations
- long inoperative periods
In such cases, the entire system should be disconnected from the supply by the personnel,
and secured (main switch).
2. - emergency-stop situations
In an emergency-stop situation, the main contactor is switched off
(by the emergency-stop button or the BTB-contact in the safety circuit).Safety instructions
10 AX2000 Installation manual
Technical Description 02/06 BECKHOFF