Beckhoff AX8000 User manual

Operating instructions | EN
AX8000
Multi-axis servo system
3/15/2021 | Version 1.4
Order No.: TDmlAX-8000-0000-0201

Table of contents
Version: 1.4 ─── 3AX8000
Table of contents
Documentation notes .......................................................................................................................................... 5
Disclaimer ......................................................................................................................................................... 5
Version numbers............................................................................................................................................... 7
Scope of the documentation ............................................................................................................................. 8
Staff qualification............................................................................................................................................... 9
Safety and instruction ..................................................................................................................................... 11
Explanation of symbols................................................................................................................................... 11
Beckhoff Services ........................................................................................................................................... 13
For your safety................................................................................................................................................... 14
Safety pictograms ........................................................................................................................................... 14
General safety instructions ............................................................................................................................. 15
Product overview............................................................................................................................................... 17
Components.................................................................................................................................................... 17
Power supply module...................................................................................................................................... 21
Axis module .................................................................................................................................................... 23
Combined module........................................................................................................................................... 25
Capacitor module............................................................................................................................................ 27
Product characteristics.................................................................................................................................... 29
Ordering options ............................................................................................................................................. 30
Intended use ................................................................................................................................................... 32
Dual Use ......................................................................................................................................................... 33
Technical data.................................................................................................................................................... 34
Data for operation and environment ............................................................................................................... 34
Power supply module...................................................................................................................................... 35
Axis module .................................................................................................................................................... 37
Combined module........................................................................................................................................... 39
Capacitor module............................................................................................................................................ 41
Dimensional drawings..................................................................................................................................... 42
Scope of supply ................................................................................................................................................. 45
Packaging ....................................................................................................................................................... 46
Transport and storage....................................................................................................................................... 47
Conditions....................................................................................................................................................... 47
Transport......................................................................................................................................................... 48
Long-term storage........................................................................................................................................... 48
Technical description........................................................................................................................................ 49
Installation position ......................................................................................................................................... 49
Residual current circuit breaker ...................................................................................................................... 49
Safe system stop ........................................................................................................................................... 49
Wide voltage range......................................................................................................................................... 50
Dimensioning .................................................................................................................................................. 51
Display ............................................................................................................................................................ 54
Capacitor module............................................................................................................................................ 59
Mechanical installation ..................................................................................................................................... 60
Preparation ..................................................................................................................................................... 60
Modules .......................................................................................................................................................... 63
Electrical installation......................................................................................................................................... 66
Project planning .............................................................................................................................................. 66
Block diagrams ............................................................................................................................................... 68
Grounding ....................................................................................................................................................... 72
Power supply .................................................................................................................................................. 76

Table of contents
4 ─── Version: 1.4AX8000
Voltage input................................................................................................................................................... 78
External brake resistor.................................................................................................................................... 80
DC link ............................................................................................................................................................ 82
Fieldbus system.............................................................................................................................................. 82
Multi-feedback................................................................................................................................................. 83
Motor feedback OCT....................................................................................................................................... 86
Motor............................................................................................................................................................... 87
Holding brake OCT ......................................................................................................................................... 88
Digital inputs ................................................................................................................................................... 89
Supply networks.............................................................................................................................................. 90
Fuse protection ............................................................................................................................................... 97
Commissioning................................................................................................................................................ 101
Before commissioning................................................................................................................................... 101
During commissioning................................................................................................................................... 101
Prerequisites during operation...................................................................................................................... 102
After operation .............................................................................................................................................. 102
Maintenance and cleaning .............................................................................................................................. 103
Intervals ........................................................................................................................................................ 103
Accessories...................................................................................................................................................... 104
Brake resistor................................................................................................................................................ 104
Brake resistor IP65 ....................................................................................................................................... 104
Mains choke.................................................................................................................................................. 104
Decommissioning............................................................................................................................................ 105
Disassembly.................................................................................................................................................. 105
Disposal ........................................................................................................................................................ 106
Guidelines and Standards .............................................................................................................................. 107
Standards...................................................................................................................................................... 107
Guidelines..................................................................................................................................................... 108
Test centers .................................................................................................................................................. 109
EU conformity ............................................................................................................................................... 109
UL certification .............................................................................................................................................. 110
Notes................................................................................................................................................................. 111
Notes................................................................................................................................................................. 112
Notes................................................................................................................................................................. 113
Index ................................................................................................................................................................. 114

Documentation notes
Version: 1.4 ─── 5AX8000
1.1Disclaimer
Beckhoff products are subject to continuous further development.
We reserve the right to revise the operating instructions 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 these operating instruc-
tions.
1.1.1Trademarks
Beckhoff®, TwinCAT®, EtherCAT®, EtherCAT G®, Ether-
CAT G10®, EtherCAT P®, Safety over EtherCAT®, TwinSAFE®,
XFC®, XTS® and XPlanar® are registered and licensed trademarks
of Beckhoff Automation GmbH.
The use of other brand names or designations by third parties may
lead to an infringement of the rights of the owners of the corre-
sponding designations.
1.1.2Patents
The EtherCAT technology is protected by patent rights through the
following registrations and patents with corresponding applications
and registrations in various other countries:
• EP1590927
• EP1789857
• EP1456722
• EP2137893
• DE102015105702
EtherCAT® is a registered trademark and patented technology, li-
censed by Beckhoff Automation GmbH.

Documentation notes
6 ─── Version: 1.4AX8000
1.1.3Limitation of liability
All components in this product as described in the operating instruc-
tions are delivered in a specific configuration of hardware and soft-
ware, depending on the application regulations. Modifications and
changes to the hardware or software configuration that go beyond
the documented options are prohibited and nullify the liability of
Beckhoff Automation GmbH & Co. KG.
The following is excluded from the liability:
• Failure to observe these operating instructions
• Improper use
• Use of untrained personnel
• Use of unauthorized spare parts
1.1.4Copyright
© Beckhoff Automation GmbH & Co. KG, Germany
The copying, distribution and utilization of this document as well as
the communication of its contents to others without express autho-
rization is prohibited. Offenders will be held liable for the payment of
damages.
We reserve all rights in the event of registration of patents, utility
models and designs.

Documentation notes
Version: 1.4 ─── 7AX8000
1.2Version numbers
Provision of revision levels
On request, you can obtain a list of revision levels for changes in
the operating instructions.
• Send requests to: [email protected]
Origin of the document
These operating instructions were originally written in German. All
other languages are derived from the German original.
Product properties
Only the product properties specified in the current operating in-
structions are valid. Further information given on the product pages
of the Beckhoff homepage, in emails or in other publications is not
authoritative.

Documentation notes
8 ─── Version: 1.4AX8000
1.3Scope of the documen-
tation
Apart from these operating instructions, the following documents are
part of the overall documentation:
AX8000 Definition
Commissioning under TwinCAT3 Commissioning tutorial under
TwinCAT3 including user infor-
mation on the TCDriveManager
2 and a description of the safety
function STO (Safe Torque Off)
over FSoE (Safety over Ether-
CAT)
CoE object description Documentation of the CAN over
EtherCAT objects with attribute
tables
Diagnostic messages Documentation of the error mes-
sages of the AX8000 multi-axis
servo system with attribute ta-
bles, problem descriptions and
possible solutions
AX2090-BW80
brake resistors
Operating instructions for the use
and installation of the AX2090-
BW80 brake resistors as acces-
sories for the AX8000 multi-axis
servo system
AX2090-BW65
brake resistors IP65
Operating instructions for the use
and installation of the AX2090-
BW65 brake resistors with the
protection class IP65 as acces-
sories for the AX8000 multi-axis
servo system
AX2090-ND80
mains chokes
Operating instructions for the use
and installation of the AX2090-
ND80 mains chokes as acces-
sories for the AX8000 multi-axis
servo system
AX2090-TT80
isolating transformers
Data sheet with mechanical and
electrical data as well as initial in-
formation on the use of the
AX2090-TT80 isolating trans-
formers as accessories for the
AX8000 multi-axis servo system

Documentation notes
Version: 1.4 ─── 9AX8000
1.4Staff qualification
1.4
These operating instructions are intended for trained control and au-
tomation specialists with knowledge of the applicable and required
standards and directives.
Specialists must have knowledge of drive technology and electrical
equipment as well as knowledge of safe working on electrical sys-
tems and machines. This includes knowledge of proper setup and
preparation of the workplace as well as securing the working envi-
ronment for other persons.
The operating instructions published at the respective time of each
installation and commissioning is to be used. The products must be
used in compliance with all safety requirements, including all appli-
cable laws, regulations, provisions and standards.
Instructed person
Instructed persons have a clearly defined task area and have been
informed about the work to be carried out. Instructed persons are fa-
miliar with:
• the necessary protective measures and protective devices
• the intended use and risks that can arise from use other than for
the intended purpose
Trained person
Trained persons meet the requirements for instructed persons.
Trained persons have additionally received training from the ma-
chine manufacturer or vendor:
• machine-specific or
• plant-specific
Trained specialists
Trained specialists have received specific technical training and
have specific technical knowledge and experience. Trained special-
ists can:
• apply relevant standards and directives
• assess tasks that they have been assigned
• recognize possible hazards
• prepare and set up workplaces

Documentation notes
10 ─── Version: 1.4AX8000
Qualified electricians
Qualified electricians have comprehensive technical knowledge
gained from a course of study, an apprenticeship or technical train-
ing. They have an understanding of control technology and automa-
tion. They are familiar with relevant standards and directives. Quali-
fied electricians can:
• independently recognize, avoid and eliminate sources of danger
• implement specifications from the accident prevention regula-
tions
• assess the work environment
• independently optimize and carry out their work

Documentation notes
Version: 1.4 ─── 11AX8000
1.5Safety and instruction
Read the contents that refer to the activities you have to perform
with the product. Always read the chapter For your safety in the op-
erating instructions. Observe the warning notes in the chapters so
that you can handle and work properly and safely with the product.
1.6Explanation of symbols
Various symbols are used for a clear arrangement:
► The triangle indicates instructions that you should execute
• The bullet point indicates an enumeration
[…] The square parentheses indicate cross-references to other
text passages in the document
[+] The plus sign in square brackets indicates ordering options
and accessories
1.6.1Pictograms
In order to make it easier for you to find text passages, pictograms
and signal words are used in warning notices:
DANGER
Failure to observe will result in serious or fatal injuries.
WARNING
Failure to observe may result in serious or fatal injuries.
CAUTION
Failure to observe may result in minor or moderate injuries.

Documentation notes
12 ─── Version: 1.4AX8000
Notes
Notes are used for important information on the product. The possi-
ble consequences of failure to observe these include:
• Malfunctions of the product
• Damage to the product
• Damage to the environment
Information
This sign indicates information, tips and notes for dealing with the
product or the software.
Examples
This symbol shows examples of how to use the product or soft-
ware.
QR-Codes
This symbol shows a QR code, via which you can watch videos or
animations. Internet access is required in order to use it.
You can read the QR code, for example, with the camera of your
Smartphone or Tablet PC. If your camera doesn't support this func-
tion you can download a free QR code reader app for your Smart-
phone. Use the Appstore for Apple operating systems or the
Google Play Store for Android operating systems.
If you cannot read the QR code on paper, make sure that the light-
ing is adequate and reduce the distance between the reading de-
vice and the paper. In the case of documentation on a monitor
screen, use the zoom function to enlarge the QR code and reduce
the distance.

Documentation notes
Version: 1.4 ─── 13AX8000
1.7Beckhoff Services
Beckhoff and the worldwide partner companies offer comprehensive
support and service.
1.7.1Support
The Beckhoff Support offers technical advice on the use of individ-
ual Beckhoff products and system planning. The employees support
you in the programming and commissioning of complex automation
systems.
Hotline: [phone]
Fax: [phone]
E-mail: [email protected]
Web: www.beckhoff.de/support
1.7.2Training
Training in Germany takes place in our training center at the Beck-
hoff headquarters in Verl, at branch offices or, by arrangement, at
the customer's premises.
Hotline: [phone]
Fax: [phone]
E-mail: [email protected]
Web: www.beckhoff.de/training
1.7.3Service
The Beckhoff Service Center supports you with after-sales services
such as on-site service, repair service or spare parts service.
Hotline: [phone]
Fax: [phone]
E-mail: [email protected]
Web: www.beckhoff.de/service
1.7.4Download area
In the download area you can obtain product information, software
updates, the TwinCAT automation software, documentation and
much more.
Web: www.beckhoff.de/download
1.7.5Headquarters
Beckhoff Automation GmbH & Co. KG
Hülshorstweg 20
33415 Verl
Germany
Phone: [phone]
Fax: [phone]
E-mail: [email protected]
Web: www.beckhoff.de
The addresses of the international Beckhoff branch offices can be
found on the Beckhoff website: http://www.beckhoff.de

For your safety
14 ─── Version: 1.4AX8000
Read this chapter containing general safety information. The chap-
ters in these operating instructions also contain warning notices. Al-
ways observe the safety instructions for your own safety, the safety
of other persons and the safety of the product.
When working with control and automation products, many dangers
can result from careless or incorrect use. Work particularly thor-
oughly, not under time pressure and responsibly towards other peo-
ple.
2.1Safety pictograms
On Beckhoff products you will find attached or lasered safety pic-
tograms, which vary depending on the product. They serve to pro-
tect people and to prevent damage to the products. Safety pic-
tograms must not be removed and must be legible for the user.
Warning of high voltage!
The DC link capacitors and test contacts on all modules may carry
hazardous voltages up to 848VDC.

For your safety
Version: 1.4 ─── 15AX8000
2.2General safety instruc-
tions
This chapter provides you with instructions on safety when handling
the product. This product is not capable of stand-alone operation
and is therefore categorized as an incomplete machine. The product
must be installed in a machine or plant by the machine manufac-
turer. Read the documentation prepared by the machine manufac-
turer.
2.2.1Before operation
Protective equipment
Do not remove or bypass any protective devices. Check all protec-
tive devices before operation. Make sure that all emergency
switches are present at all times and can be reached by you and
other people. People could be seriously or fatally injured by unpro-
tected machine parts.
Shut down and secure the machine or plant
Shut down the machine or plant. Secure the machine or plant
against being inadvertently started up.
Correctly ground electrical components or modules
Avoid electric shocks due to improper grounding of electrical compo-
nents or modules. Ground all conductive components according to
the specifications in the chapters "Electrical Installation" and "Me-
chanical Installation".
Keep the immediate environment clean
Keep your workplace and the surrounding area clean. Ensure safe
working.
Check safety pictograms
Check whether the designated pictograms are on the product. Re-
place missing or illegible stickers.
Observe tightening torques
Mount and repeatedly check connections and components, comply-
ing with the prescribed tightening torques.
Use the original packaging only
When shipping, transporting, storing and packing, use the original
packaging or conductive materials.

For your safety
16 ─── Version: 1.4AX8000
2.2.2During operation
Observe the discharge times of the capacitors
Observe the following delay times after disconnecting from the
mains supply:
• AX8620 and AX8640 30 minutes
• AX8108, AX8118 and AX8206 30 minutes
• AX8525 and AX8540 30 minutes
Do not work on live electrical parts
Do not open the multi-axis servo system while it is live. Measure the
voltage on the DC link test contacts DC+ und DC-. Only work on the
multi-axis servo system when the voltage has dropped to < 50 V.
Ensure that the protective conductor is connected properly. Never
loosen electrical connections when live. Disconnect all components
from the mains and secure them against being switched on again.
Do not touch hot surfaces
Check the cooling of the surfaces with a thermometer. Do not touch
the components during and immediately after operation. Allow the
components to cool sufficiently after switching off.
Avoid overheating
Operate the components according to the technical specifications.
Please refer to chapter: "Technical data". Provide for sufficient cool-
ing. Switch the components off immediately if the temperature is too
high.
2.2.3After operation
De-energize and switch off components before working on
them
Check the functionality of all safety-relevant devices. Secure the
working environment. Secure the machine or plant against being in-
advertently started up. See chapter: "Decommissioning"

Product overview
Version: 1.4 ─── 17AX8000
3.1Components
3.1.1Power supply modules
3.1.1
Number Explanation
1 Housing
2 Display
3 Fieldbus EtherCAT input X04
4 Fieldbus EtherCAT output X05
5 Quick coupling 24VDC; AX bridge
6 Quick coupling, DC link and protective earth PE; AX bridge
7 10-pin input terminal X01;
DC, 24V, supply network, PE and external brake resistor
8 Grounding bolt
9 Test contact DC link DC-
10 Test contact DC link DC+
11 Test contact GND
12 Test contact +24VDC

Product overview
18 ─── Version: 1.4AX8000
3.1.2Axis modules
3.1.2
Number Explanation
1 Digital inputs X15, channel A and X25, channel B
2 Feedback connection X11 and X21; optional
3 Quick coupling 24VDC; AX bridge
4 EtherCAT connection
5 Quick coupling, DC link and protective earth PE; AX bridge
6 8-pin motor connector X23,
channel B; U, V, W, PE, T+ / OCT+, T- / OCT-, B+ and B-
7 8-pin motor connector X13,
channel A; U, V, W, PE, T+ / OCT+, T- / OCT-, B+ and B-
8 AX-Bridge: DC link, FE
9 AX-Bridge: 24VDC

Product overview
Version: 1.4 ─── 19AX8000
3.1.3Combined modules
3.1.3
Number Explanation
1 Fieldbus EtherCAT input X04
2 Fieldbus EtherCAT output X05
3 Display
4 X15 digital inputs / TwinSAFE STO connection
5 Optional: X11 encoder feedback connection
6 Quick coupling 24VDC; AX bridge
7 Quick coupling, DC link and protective earth PE; AX bridge
8 Grounding bolt
9 Housing

Product overview
20 ─── Version: 1.4AX8000
Number Explanation
10 X01 connection – mains supply and DC link
11 X02 connection – external brake resistor
12 X14 connection – holding brake, motor temperature / OCT
13 X13 plug – motor connection
14 X03 connection – 24VDC