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