Beckhoff AX5021 Operator's manual

AX5000 Brake module AX5021
Documentation
1.3
2016-10-18
TDmlAX-5021-0000-0200
Version:
Date:
Order No.:

Table of content
Table of content
1 Foreword ....................................................................................................................................................4
2 Product overview.......................................................................................................................................5
2.1 AX5021 brake module ...................................................................................................................... 5
2.2 Electrical data ................................................................................................................................... 5
2.3 Mechanical data................................................................................................................................ 5
2.4 General overview.............................................................................................................................. 6
2.5 Pin strip assignment of X51 and X52................................................................................................ 6
2.6 Electrical connection (example)........................................................................................................ 7
2.7 Integration into TwinCAT .................................................................................................................. 8
2.8 Energy management ........................................................................................................................ 8
2.8.1 DC link ..................................................................................................................................8
2.8.2 Operation modes of the AX5021...........................................................................................9
2.8.3 Braking power diagnosis.....................................................................................................10
AX5000 Brake module AX5021 3
Version: 1.3

Foreword
1 Foreword
Appropriate use
The brake module may only be used together with servo drives of the AX51xx-xxxx-02xx or AX52xx-
xxxx-02xx series. These devices have serial numbers above 100.000. In addition to the AX5021, the drive
system must include at least two further servo drives from the AX5000 range.
Safety
Safety regulations
Please note the following safety instructions and explanations!
Product-specific safety instructions can be found on following pages or in the areas mounting, wiring,
commissioning etc.
DANGER
Caution – Danger of death!
Even when the AX5000 is disconnected from the mains voltage, dangerous voltage contin-
ues to be present at the “X02” terminals of the DC link for 15 minutes. Never touch the ter-
minals within this period.
WARNING
Caution – Risk of injury!
Electronic equipment is 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 servo drive.
Personnel qualification
This description is only intended for trained specialists in control, automation and drive engineering who are
familiar with the applicable national standards.
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.
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.
AX5000 Brake module AX50214 Version: 1.3

Product overview
2 Product overview
2.1 AX5021 brake module
Using a brake module it is possible to take up additional braking power in a drive system, because the
connection of an external brake resistor without a brake module in a drive system with devices up to max. 25
A rated current is not permissible. A further advantage is the simple installation and the small space
requirement of the brake module. The brake module is equipped with a complete DC link and an internal
brake resistor and enables the connection of an external brake resistor with the integrated brake chopper.
Several brake modules can be integrated into a drive system.
2.2 Electrical data
Electrcal data AX5021
int. Resistance1) [W] 150
int. Resistance2) [W] 14.000
ext. Resistance min. [Ω] 22
ext. Resistance3) [W] 6.000
ext. Resistance4) [W] max. 32.000
Power loss P [W] max. 250
Charging rate 24 VDC [A] 0.3 – 0.4
DC link capacity [µF] 705
1) Durability break power Prms
2) Peak break power Ppeak
3) Durability brake power Prms
4) Peak brake power Ppeak
2.3 Mechanical data
The external dimensions of the brake module are identical to the dimensions of the servo drives from the
AX5000 series up to 12 A.
Mechanical data AX5021
Weight ca. 4 kg
Width 92 mm
Height without connector 274 mm
Depth without connector / accessories 232 mm
299.2
60
AX5021 AX5206
93
8
Min. 100
Min.100
92
317.2
6.5
>2,5
M6
>277,6
277,6
AX5021
Control cabinet door Mounting plate
contuctible (zinced)
(Incl. plug and cable for feedback)
Cable duct
Cable duct
AX5000 Brake module AX5021 5Version: 1.3

Product overview
2.4 General overview
No. Name
1 Navigation rocker
2 Labelling field
3 X05 - socket for EtherCAT output
4 X03 – power supply 24 V DC
Input
5 X52 - connection of the temperature monitor
and the fan of the
external brake resistor
6 X51 - connection of the external brake
resistor
7 X01 – mains supply
 100 – 480 V
8 X02 – DC link output
(890 V DC voltage).
9
DANGER
Max. voltage 890 V DC at the
DC link terminals (X02). Once
the device has been switched
off dangerous voltage will still
be present for a further 15
minutes. The device is safe
once the voltage has fallen
below 50 V.
10 X04 - socket for EtherCAT input
11 Display
2.5 Pin strip assignment of X51 and X52
No. Name
1T- = input of the temperature measurement
sensor of the external brake resistor
2T+ = input of the temperature measurement
sensor of the external brake resistor
3PE = protective conductor
4F- = output to the fan controller
of the external brake resistor
5F+ = output to the fan controller
of the external brake resistor
6PE = protective conductor
7B- = output to the controller of
the external brake resistor
8B+ = output to the controller of
the external brake resistor
Please refer to the servo drive ‘Startup’ manual for the pin assignments of the remaining inputs and outputs.
Note
Temperature rise in the external brake resistor
The temperature rise of the external brake resistor should be monitored continuously via
temperature contacts (1) and (2).
AX5000 Brake module AX50216 Version: 1.3

Product overview
2.6 Electrical connection (example)
DANGER
Serious risk of injury through high electrical voltage!
Due to the DC link capacitors dangerous voltage may persist at the DC link contacts "X02"
after the servo drive has been disconnected from the mains supply. Wait 5 minutes after
disconnection and measure the voltage on the DC link contacts DC+ and DC-. The device
is safe once the voltage has fallen below 50 V.
The example below describes the brake module and several servo drives, which are linked via AX-Bridge
modules to make up a drive system. We recommend that the brake module be placed in the first position
with the AX-Bridge power supply module (AX5901) and after that the servo drives with decreasing rated
current; we assume here that the most powerful servo drive also releases the greatest brake energy.
Attention
Damage to devices
Please analyze your application. The brake module should always be placed directly be-
side the servo drive that releases the greatest brake energy. This rule should also be ap-
plied if several brake modules are used in a drive system.
Pos. Name Pos. Name
1 PC with TwinCAT and PLC 6 Patch cable
2 Output terminal 7 Control cable from the output terminal
2A Output "8" of the servo drive digital I/Os 7A Control cable from output ‘8’ of the servo drive digital I/
Os
3 Brake module 8 Mains fuses
4 Servo drive (with the greatest brake energy) 9 Mains contactor
5 Servo Drives
CAUTION
Uncontrolled movements!
If the drive system is disconnected from the mains due to a mains failure, all axes of the
drive system make uncontrolled movements. Take suitable measures to ensure than no
persons are endangered during this time. Vertical axes are particularly dangerous.
AX5000 Brake module AX5021 7
Version: 1.3

Product overview
2.7 Integration into TwinCAT
The brake module can be integrated in the TwinCAT
System Manager as a completely normal I/O device
(1) and is parameterized (3) with the TCDrive
Manager (2).
Power Management
Configuration in the TC Drive Manager
Pos. Name Pos. Name
1 Power management 6 Activation / deactivation of the internal brake resistor
2 Mains voltage selection 7 External brake resistor parameter list
3 Phase monitoring (deactivate for single-phase mains) 8 0 = Deactivation of the external brake resistor
(not recommended)
1 = Standard energy management with external
brake resistor
2 = Energy management with external
brake resistor (standalone)
4 Delay time until the phase monitoring responds (acti-
vate if mains is unclean)
9 Enabling / disabling the fan of the external brake resis-
tor and setting the switching thresholds Switch on
Level: Percentage specification of the rated capacity
value of the external brake resistor.Switch on Temp.:
Max. temperature value for the external brake resistor
in "°C".
5 Internal brake resistor parameter list
2.8 Energy management
Intelligent energy management ensures that energy is distributed evenly to the DC links and the internal
brake resistors when devices are used commonly in the drive system. This reliably prevents the undesirable
permanent load of only one device.
2.8.1 DC link
The connected servomotors are supplied with energy from the DC link. It serves as an energy storage and
first needs to be charged up after switching the device on, before it can supply the servomotors. The DC link
is designed such that it can take up and store a certain degree of surplus energy from the motor (brake
energy) and subsequently supply the motor again with this stored energy. If the upper limit of the energy
storage is reached, the brake chopper feeds any further brake energy into the internal or external brake
resistor, where it is converted into heat; it is then no longer available for the further operation of the motor.
The voltage is taken and evaluated as the indicator for the current energy level of the DC link. As soon as
the brake resistors have also reached their energy limit, the error ‘FD4C, DC link – overvoltage’ appears and
the energy flow to and from the motor is interrupted, i.e. the motor makes uncontrolled movements.
In a drive system, the DC links of the individual devices are connected so that the energy level of all devices
is the same, regardless of which motor the brake energy is currently being fed back from. In many cases
these feedbacks do not happen at the same time, and without a DC link system, for example, a device
would be at the limit and would already have to "destroy" energy in a brake resistor, even though other
devices could still store energy in the DC link. In a DC link connection the energy could be stored, since the
DC link of all linked devices would be loaded first, before the energy in the brake resistors would be
converted to heat.
AX5000 Brake module AX50218 Version: 1.3

Product overview
2.8.2 Operation modes of the AX5021
It can be assumed that a brake module is used only if the brake energy cannot be dissipated despite a DC
link system and internal brake resistors. The brake module can be operated in two different operation
modes, which have a direct influence on the energy management. The operation modes can be selected
when using the external brake resistor. The following sketches show the storage capacity of the DC link of
the individual devices in relation to the operation modes.
Default operation mode 1 - Ext. brake resistor enabled (system / standard)
In this operation mode the capacity of the DC link of
the brake module is reduced by approx. 10%. At
90% DC link load the brake chopper then directs
the generated braking energy to the external brake
resistor and, when this has reached its capacity
limit, into the internal brake resistor. In this case the
brake energy is first fed into the brake module,
since the brake choppers in the other servo drives
are only activated at 100% utilization of the DC link.
This operation mode is set as the default, because
no further configuration of the devices in the DC
link system is necessary apart from the basic
configuration of the brake module. If the external
brake resistor of the brake module is mounted
outside the control cabinet, then the thermal load in
the control cabinet is also lower.
AX5000 Brake module AX5021 9
Version: 1.3

Product overview
Default operation mode 2 - Ext. brake resistor enabled (standalone brake chopper)
In this case the capacity of the DC links is fully
utilized. This operation mode must be selected and,
apart from the basic configuration of the brake
module, the internal brake resistors of the devices
in the DC link system should be deactivated, as
otherwise the thermal load in the control cabinet will
also increase. In order to reduce the thermal load
further, it is a good idea to mount an external brake
resistor on the brake module outside the control
cabinet.
2.8.3 Braking power diagnosis
The current continuous output of the brake resistor can be read via the IDNs P-0-0209 (int. brake resistor)
and P-0-0210 (ext. brake resistor). The unit is watts. Loads above 90% of the continuous output of the brake
resistor should be avoided. The IDNs can be read cyclically as process data.
The current impulse energy load of the brake resistor can be read via the IDNs P-0-0218 (int. brake resistor)
and P-0-0219 (ext. brake resistor). It is specified in % with one decimal place. Loads above 90% should be
avoided. The IDNs can be read cyclically as process data.
The maximum energy values since the last reset are stored in IDNs P-0-0220 (int. brake resistor) and
P-0-0221 (ext. brake resistor). The values can be reset by entering zero. Duty cycle corresponds to 100
seconds. The energy values are monitored at the specified intervals (100 ms, 1 s, 10 s, 20 s, 40 s and 100
s). The values for 100 s correspond to the continuous output. The maximum values should be approx. 10%
below the resistor limits (P-0-0207 or P-0-0208). If a current energy value exceeds the limit value of a brake
resistor, this brake resistor is not enabled. In a drive systems or in a configuration with active internal
chopper the other brake resistors have to absorb the energy. If this is not possible the DC link voltage will
continue to increase until an overvoltage error occurs, followed by disabling of the axes with "Torque off". It is
therefore important to ensure that adequate braking power is available in the systems, in order to avoid
uncontrolled movements of the axes. The diagnostics should cover the whole system. If not enough reserve
capacity is available, an external brake resistor with a higher output should be selected. If the performance
limit is still reached, several AX5021 may be used.
Note
Energy balance
The energy balance is affected positively whenever an axis requires energy and another
axis produces generative energy (braking energy). This rule should be observed in all appli-
cations.
AX5000 Brake module AX502110 Version: 1.3