Beckhoff AX2090-BW5 Series Operator's manual

Documentation
External brake resistor AX2090-BW5x
Accessories for Beckhoff servo drive AX5000
1.3
2018-03-14
Version:
Date:

Table of content
External brake resistor AX2090-BW5x 3
Version: 1.3
Table of content
1 Foreword ....................................................................................................................................................5
1.1 Notes on the documentation........................................................................................................... 5
1.2 Documentation issue status............................................................................................................ 6
1.3 Appropriate use .............................................................................................................................. 6
2 For your safety...........................................................................................................................................7
2.1 Staff qualification ............................................................................................................................ 7
2.2 Description of symbols.................................................................................................................... 8
2.3 Safety rules..................................................................................................................................... 9
3 Product identification..............................................................................................................................10
4 Mechanical installation ...........................................................................................................................11
4.1 Mounting positions and distances................................................................................................. 11
5 Electrical installation...............................................................................................................................12
5.1 Important notes............................................................................................................................. 12
5.2 Connection the brake resistor....................................................................................................... 12
5.3 Cables........................................................................................................................................... 13
5.4 Temperature switch ...................................................................................................................... 14
5.5 Short-term capacity....................................................................................................................... 14
5.5.1 Duty cycle.........................................................................................................................14
5.5.2 Overload factor.................................................................................................................15
5.6 Overtemperature and continuous power at 100% duty cycle ....................................................... 15
6 Technical data..........................................................................................................................................16
7 Support and Service................................................................................................................................18

Table of content
External brake resistor AX2090-BW5x4 Version: 1.3

Foreword
External brake resistor AX2090-BW5x 5
Version: 1.3
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 documentation and the following notes and explanations are followed when installing
and commissioning the components.
It is the duty of the technical personnel to use the documentation published at the respective time of each
installation and commissioning.
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.
We reserve the right to revise and change the documentation at any time and without prior announcement.
No claims for the modification of products that have already been supplied may be made on the basis of the
data, diagrams and descriptions in 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
Copyright
© Beckhoff Automation GmbH & Co. KG, Germany.
The reproduction, distribution and utilization of this document as well as the communication of its contents to
others without express authorization are prohibited.
Offenders will be held liable for the payment of damages. All rights reserved in the event of the grant of a
patent, utility model or design.

Foreword
External brake resistor AX2090-BW5x6 Version: 1.3
1.2 Documentation issue status
Version Comment
1.3 Chapter update:
Appropriate use 1.3; For your safety 2; Product identification 3; Technical data 6
1.2 Chapter update:
5.5.1
1.1 General update
1.0 First published
1.3 Appropriate use
The brake resistors from the AX2090-BW5x-xxxx series are exclusively designed for direct application with
an AX5000 series servo drive or the AX5021 brake module. They are designed for installation as
components in electrical installations and machines together with the servo drive or the brake module, and
this is their only purpose.
WARNING
Caution – Risk of injury!
Basically, electronic devices are not fail-safe. The machine manufacturer is responsible for
ensuring that the connected motors and the machine are brought into a safe state in the
event of a fault in the drive system.
The external brake resistors of the AX2090-BW5x-xxxx series are able to convert the dynamic energy
generated during braking of a servomotor into heat. The series covers a wide continuous power and peak
power range. The built-in temperature switch enables the system to respond immediately to any overload of
the brake resistor through analysis in the AX5000 or the PLC. All brake resistors of the AX2090-BW5x-xxxx
series are UL and CSA approved.
Improper use
The external brake resistor AX2090-BW5x-xxxx 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 emissions must be complied with in residential
areas. The servo drives may only be installed in housings and control cabinets with appropriate shielding
attenuation.

For your safety
External brake resistor AX2090-BW5x 7
Version: 1.3
2 For your safety
Read the section on safety and heed the notices to protect yourself against personal injury and material
damages.
Liability limitations
All the components of the external brake resistor AX2090-BW5x-xxxx are supplied in certain hardware and
software configurations appropriate for the conditions of the application. Unauthorized modifications to the
hardware and/or software configurations other than those described in the documentation are not permitted,
and nullify the liability of Beckhoff Automation GmbH & Co. KG.
In addition, the following actions are excluded from the liability of Beckhoff Automation GmbH & Co.
KG:
• Failure to comply with this documentation
• Improper use
• Untrained personnel
• Use of unauthorized spare parts
2.1 Staff qualification
Only technical personnel with knowledge of control and automation technology may carry out any of the
illustrated work steps on the Beckhoff software and hardware, in particular on the external brake resistor
AX2090-BW5x-xxxx.
The technical personnel must have knowledge of drive technology and electrical systems and must also
know how to work safely on electrical equipment and machines.
This also includes:
• production planning and
• securing of the working environment (e.g. securing the control cabinet against being switched on
again).
The technical personnel must be familiar with the current and necessary standards and directives for the
automation and drive environment.

For your safety
External brake resistor AX2090-BW5x8 Version: 1.3
2.2 Description of symbols
In this documentation the following symbols are used with an accompanying safety instruction or note. The
safety instructions must be read carefully and followed without fail!
Symbols that warn of personal injury:
DANGER
Serious risk of injury!
This is an extremely dangerous situation. Disregarding the safety notice will lead to serious
permanent injuries or even death.
WARNING
Risk of injury!
This is a dangerous situation. Disregarding the safety notice may lead to serious injuries.
CAUTION
Personal injuries!
This is a dangerous situation. Disregarding the safety notice may lead to minor injuries.
Symbols that warn of damage to property or equipment:
Attention
Warning of damage to property or the environment!
This notice indicates disturbances in the operational procedure that could damage the
product or the environment.
Symbols indicating further information or tips:
Note
Tip or pointer!
This notice provides important information that will be of assistance in dealing with the
product or software. There is no immediate danger to product, people or environment.
UL note!
This symbol indicates important information regarding UL certification.

For your safety
External brake resistor AX2090-BW5x 9
Version: 1.3
2.3 Safety rules
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 and guidelines.
DANGER
Serious risk of injury through electric shock!
Due to the DC link capacitors dangerous voltage (> 890VDC) may persist at the DC link con-
tacts “ZK+ and ZK- (DC+ and DC-)“ and “RB+ and RB-“ after the servo drive has been dis-
connected from the mains supply. After disconnecting the servo drive wait at AX5101 -
AX5125 and AX520x; 5 minutes, at AX5140/AX5160/AX5172; 15 minutes, at AX5190/
AX5191; 30 minutes and at AX5192/AX5193; 45 minutes and measure the voltage at the
DC link contacts ZK+ and ZK- (DC+ and DC-). The device is safe once the voltage has
fallen below 50 V.
WARNING
Caution - Risk of injury through hot surfaces!
The temperature of the brake resistor housing surface may reach over 200 °C. Please en-
sure that the housing has cooled down below 40 °C before touching it.
UL-Listing!
It is essential to observe directives and standards if you wish to operate an AX5000 in an
economic area that requires a UL-Listing.

Product identification
External brake resistor AX2090-BW5x10 Version: 1.3
3 Product identification
Scope of supply
The scope of delivery may vary depending on the ordered configuration. Before installing the device please
ensure that all ordered components were delivered and that they are undamaged. In the event of any
damage please contact the carrier immediately and document the damage.
The scope of supply always includes:
• Brake resistor of the appropriate performance class
• Technical documentation (this documentation)
• Packaging
Name plate
Figure Pos.-No. Description
1 Type power at 40 °C
2 Resistance
3 Switching temperature
4 Product no
5 Barcode
6 UL-Recognized Component – certification
7 CE – certification
8 E no.
9 Serial no.
10 Catalog no.
Type key
Figure Pos.-No. Description
1 Drive Technology Acessories
2 BW = brake resistor
3 Servo drive AX5000
4 0 = AX5000 up to 12 A rated channel current
1 = AX5118 up to AX5140
2 = AX5160 up to AX5172
3 = AX5190 up to AX5191
4 = AX5192 up to AX5193
5 AX5000

Mechanical installation
External brake resistor AX2090-BW5x 11
Version: 1.3
4 Mechanical installation
4.1 Mounting positions and distances
(A) = vertical installation is only permitted according to the diagram (terminal box facing downwards).
(B) = horizontal installation
Assignment of the device classes
AX2090-BW50-xxxx
AX2090-BW51-1000
AX2090-BW51-3000 and AX2090-BW51-6000
AX2090-BW52-3000 and AX2090-BW52-6000
AX2090-BW53-3000 and AX2090-BW53-6000
AX2090-BW54-3000 and AX2090-BW54-6000
For all mounting positions the following minimum distances must be adhered to:
200 mm to adjacent components, walls etc. and 300 mm to components, ceilings etc. above. If the device is
installed vertically (A), the minimum distance to components, floors etc. below is 200 mm in order to allow
unobstructed flow of air to the brake resistor.

Electrical installation
External brake resistor AX2090-BW5x12 Version: 1.3
5 Electrical installation
5.1 Important notes
DANGER
Serious risk of injury through electric shock!
Only staff qualified and trained in electrical engineering are allowed to wire up the brake re-
sistors.
• Check the assignment of the servo drive and the brake resistor. Compare the rated
voltage and the rated current of the devices.
• Always make sure that the brake resistors are de-energized during assembly and
wiring, i.e. no voltage may be switched on for any piece of equipment which is to be
connected. Ensure that the control cabinet remains turned off (barrier, warning signs
etc.). The individual voltages will only be turned on again during commissioning.
• Due to the DC link capacitors, the DC link contacts "ZK+ and ZK- (DC+ and DC-)" and
"RB+ and RB-" may be subject to dangerous voltages exceeding 890VDC, even after the
servo drive was disconnected from the mains supply.
Wait 5 minutes for the AX5101 - AX5125 and AX520x; 15 minutes for the AX5140/
AX5160/AX5172; 30 minutes for the AX5190/AX5191; 45 minutes for the AX5192/
AX5193 after disconnecting, and measure the voltage at the DC links "ZK+ and ZK-
(DC+ and DC-)". The device is safe once the voltage has fallen below 50 V.
5.2 Connection the brake resistor
Remove the two screws (1) and remove the cover (2) in direction of the arrow. Connect an adequately
dimensioned cable (see chapter "Cables") to the connections (3) of the resistor and the earthing stud (5) and
take it out of the terminal box through the strain-relief assembly (9). Ensure adequate strain relief with the
two screws (8). Connect the other side of the cable to the DC link contact connector "X2" of the AX5000. The
connector is supplied with the AX5000. Connect the earthing cable to the earthing conductor of the control
cabinet.
Connect an adequately dimensioned cable to the potential-free N/C contact (4) of the temperature switch
and take it out of the terminal box through the strain-relief assembly (7) (see chapter "Temperature switch").
Ensure adequate strain relief with the nut (6).
Install the cover (2) in reverse order.

Electrical installation
External brake resistor AX2090-BW5x 13
Version: 1.3
5.3 Cables
Beckhoff offers pre-assembled cables for safe, faster and flawless installation of the motors. Beckhoff cables
have been tested with regard to the materials, shielding and connectors used. They ensure proper
functioning and compliance with statutory regulations such as EMC, UL etc. The use of other cables may
lead to unexpected interference and invalidate the warranty.
WARNING
Caution - Fire hazard!
The brake resistors can reach temperatures of almost 200 °C. Therefore, ensure adequate
thermostability of the cables! Cables with inadequate thermostability can cause a cable fire!
Attention
EMC safety
Use only shielded cables.
Type Brake resistor Temperature switch
[mm2] [AWG] [mm2] [AWG]
AX2090-BW50-0300 1,5 16 0.75 18
AX2090-BW50-0600 1,5 16 0.75 18
AX2090-BW50-1600 1,5 16 0.75 18
AX2090-BW51-1000 2,5 12 0.75 18
AX2090-BW51-3000 2,5 12 0.75 18
AX2090-BW51-6000 2,5 12 0.75 18
AX2090-BW52-3000 4,0 12 0.75 18
AX2090-BW52-6000 4,0 12 0.75 18
AX2090-BW53-3000 6,0 12 0.75 18
AX2090-BW53-6000 6,0 12 0.75 18
AX2090-BW54-3000 6,0 12 0.75 18
AX2090-BW54-6000 6,0 12 0.75 18
We recommend wire end sleeves.

Electrical installation
External brake resistor AX2090-BW5x14 Version: 1.3
5.4 Temperature switch
Attention
Destruction of the brake resistor!
The temperature switch is exclusively used for temperature monitoring. The brake resistor
is not switched off.
The temperature switch has a potential-free N/C contact, which enables immediate response to any overload
of the brake resistor through analysis in the AX5000 or the PLC. Connect the cable directly to a free input of
plug "X06". Then parameterize it such that the AX5000 stops the motor(s) with an emergency ramp or the
PLC reads and processes this input.
Type Switching temperature Switching current
24 VDC or 230 VAC
[°C] [A]
AX2090-BW50-0300 180 2
AX2090-BW50-0600 180 2
AX2090-BW50-1600 180 2
AX2090-BW51-1000 180 2
AX2090-BW51-3000 85 2
AX2090-BW51-6000 85 2
AX2090-BW52-3000 85 2
AX2090-BW52-6000 85 2
AX2090-BW53-3000 85 2
AX2090-BW53-6000 85 2
AX2090-BW54-3000 85 2
AX2090-BW54-6000 85 2
5.5 Short-term capacity
Brake resistors are usually not operated continuously, but only exposed to short-time duty. In the following
section the permitted short-term capacity is calculated based on the continuous power, overload factor and
duty cycle.
5.5.1 Duty cycle
The duty cycle is a relative value that depends on the switch-on time (ton) and the cycle time. Cycle times up
to 120 sec. are used directly in the calculation. Should the cycle time exceed 120 sec., the maximum
relevant cycle time of 120 sec. is used in the calculation.
Sample 1
Ton = 60 s
Cycle time = 280 s
Duty cycle = 50%
Sample 2
Ton = 40 s
Cycle time = 100 s
Duty cycle = 40 %
Note
Further information of external brake resistors:
For further information on the configuration and diagnostics of external brake resistors,
please refer to the function description of the servo drive AX5000: “Diagnostic of external
brake resistors”.

Electrical installation
External brake resistor AX2090-BW5x 15
Version: 1.3
5.5.2 Overload factor
Calculation formula
Short-term capacity = continuous power x overload factor
5.6 Overtemperature and continuous power at 100% duty
cycle
If your application requires a higher continuous power than the specified nominal capacity, you can accept
this state if a higher brake resistor temperature is permitted. The following diagram shows the
overtemperature v. the continuous power.
Normal operating range,
max. 130%
Permitted operating range,
max. 160%
Inadmissible operating range,
more than 160%
This operating range is recommended for
maximum service life and error-free opera-
tion.
This operating range is still permitted, al-
though it results in shorter service life with
higher failure probability
In this operating range there is a risk of de-
struction of the brake resistor through over-
heating. Due to the high temperatures the
adjacent components are also at risk.
Attention
Destruction of the brake resistor and adjacent components
Always ensure adequate ventilation of the brake resistor, since the temperatures of the
housing surface may exceed 200 °C.

Technical data
External brake resistor AX2090-BW5x16 Version: 1.3
6 Technical data
Dimensions
Type1) Type power
[W] * at 40 °C
Resistance
[Ω]
O
[mm
]
R
[mm]
H
[mm]
M
[mm]
U
[mm]
Weight
[kg]
AX5000
AX2090-BW50-0300 300 47 349 92 120 230 64 2 AX5x01-AX5112
AX2090-BW50-0600 600 47 549 92 120 430 64 3 AX5x01-AX5112
AX2090-BW50-1600 1600 47 649 185 120 530 150 5,8 AX5x01-AX5112
AX2090-BW51-1000 1000 23 749 92 120 630 64 4 AX5118-AX5140
AX2090-BW51-3000 3000 23,4 490 355 255 380 270 8 AX5118-AX5140
AX2090-BW51-6000 6000 23,2 490 455 255 380 370 12 AX5118-AX5140
AX2090-BW52-2000 3000 13,2 490 355 255 380 270 8 AX5160-AX5172
AX2090-BW52-6000 6000 13,0 490 455 255 380 370 12 AX5160-AX5172
AX2090-BW53-3000 3000 10,2 490 355 255 380 270 8 AX5190-AX5191
AX2090-BW53-6000 6000 10 490 455 255 380 370 12 AX5190-AX5191
AX2090-BW54-3000 3000 6,6 490 355 255 380 270 8 AX5192-AX5193
AX2090-BW54-6000 6000 6,5 490 455 255 380 370 12 AX5192-AX5193
*) 4% decrease in performance per 10K temperature difference
1) All external brake resistor have the protection class IP20

Technical data
External brake resistor AX2090-BW5x 17
Version: 1.3
Technical drawings

Support and Service
External brake resistor AX2090-BW5x18 Version: 1.3
7 Support and Service
Beckhoff and their partners around the world offer comprehensive support and service, making available fast
and competent assistance with all questions related to Beckhoff products and system solutions.
Beckhoff's branch offices and representatives
Please contact your Beckhoff branch office or representative for local support and service on Beckhoff
products!
The addresses of Beckhoff's branch offices and representatives round the world can be found on her internet
pages:
http://www.beckhoff.com
You will also find further documentation for Beckhoff components there.
Beckhoff Headquarters
Beckhoff Automation GmbH & Co. KG
Huelshorstweg 20
33415 Verl
Germany
Phone: [phone]
Fax: [phone]
e-mail: [email protected]
Beckhoff Support
Support offers you comprehensive technical assistance, helping you not only with the application of
individual Beckhoff products, but also with other, wide-ranging services:
• support
• design, programming and commissioning of complex automation systems
• and extensive training program for Beckhoff system components
Hotline: [phone]
Fax: [phone]
e-mail: [email protected]
Beckhoff Service
The Beckhoff Service Center supports you in all matters of after-sales service:
• on-site service
• repair service
• spare parts service
• hotline service
Hotline: [phone]
Fax: [phone]
e-mail: [email protected]