Beckhoff eXtended Transport System User manual

XTS | eXtended Trans-
port System
Operating Instructions | EN
4/20/2020 | Version 2.2

Table of contents
Version: 2.2 ─── 3XTS
Table of contents
Documentation notes .......................................................................................................................................... 5
Disclaimer ......................................................................................................................................................... 5
Version numbers............................................................................................................................................... 7
Scope of the documentation ............................................................................................................................. 7
Staff qualification............................................................................................................................................... 8
Safety and instruction ..................................................................................................................................... 10
Explanation of symbols ................................................................................................................................... 10
Beckhoff Services ........................................................................................................................................... 12
For your safety................................................................................................................................................... 13
General safety instructions ............................................................................................................................. 13
Product overview............................................................................................................................................... 16
Name plate...................................................................................................................................................... 17
Type key ......................................................................................................................................................... 19
Product characteristics.................................................................................................................................... 21
Components.................................................................................................................................................... 22
Ordering options ............................................................................................................................................. 27
Special geometries ......................................................................................................................................... 29
Intended use ................................................................................................................................................... 31
Technical data.................................................................................................................................................... 32
Definition ......................................................................................................................................................... 32
Data for operation and environment ............................................................................................................... 33
XTS Standard ................................................................................................................................................. 34
Dimensional drawings..................................................................................................................................... 36
Scope of supply ................................................................................................................................................. 57
Packaging ....................................................................................................................................................... 57
Transport and storage....................................................................................................................................... 58
Conditions ....................................................................................................................................................... 58
Long-term storage........................................................................................................................................... 58
Mechanical installation ..................................................................................................................................... 59
Preparation ..................................................................................................................................................... 59
Modules .......................................................................................................................................................... 63
Guide rails....................................................................................................................................................... 72
Mover .............................................................................................................................................................. 79
Electrical installation......................................................................................................................................... 84
Connection technology ................................................................................................................................... 84
Pin assignment of the power cable ................................................................................................................. 85
Earthing of the supply ..................................................................................................................................... 86
Earthing of the machine beds ......................................................................................................................... 86
Fuse protection ............................................................................................................................................... 88
Commissioning.................................................................................................................................................. 93
Before commissioning..................................................................................................................................... 93
During commissioning..................................................................................................................................... 93
Prerequisites during operation ........................................................................................................................ 94
After operation ................................................................................................................................................ 94
Maintenance and cleaning ................................................................................................................................ 95
Cleaning materials .......................................................................................................................................... 95
Intervals .......................................................................................................................................................... 96
Accessories........................................................................................................................................................ 98
Alignment gauge ............................................................................................................................................. 98
Rail on support................................................................................................................................................ 98

Table of contents
4 ─── Version: 2.2XTS
6-roller 50 mm mover...................................................................................................................................... 98
6-roller 70 mm mover...................................................................................................................................... 99
12-roller 50 mm mover.................................................................................................................................... 99
ESD brushes................................................................................................................................................. 100
Fault correction................................................................................................................................................ 101
Motor modules .............................................................................................................................................. 101
TcIoXts object ............................................................................................................................................... 104
SoftDrive object............................................................................................................................................. 108
Decommissioning............................................................................................................................................ 110
Disassembly.................................................................................................................................................. 110
Disposal ........................................................................................................................................................ 111
Index ................................................................................................................................................................. 112

Documentation notes
Version: 2.2 ─── 5XTS
1.1Disclaimer
These operating instructions have been compiled with great care.
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®, EtherCAT
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 & Co. KG, Germany.

Documentation notes
6 ─── Version: 2.2XTS
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 and/or software configuration that go be-
yond 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: 2.2 ─── 7XTS
1.2Version numbers
Provision of revision levels
On request, you can obtain a list of revision levels for changes in
the operating instructions.
• Send your request 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 features
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.
1.3Scope of the documen-
tation
In addition to this documentation, the following documents are part
of the complete documentation:
XTS Definition
Original operating instructions;
this documentation
Description of the mechanical
and electrical parameters as well
as all information necessary for
the use of the XTS
Instruction leaflet Accompanying document with
general notes on handling the
XTS. This is included with every
product.

Documentation notes
8 ─── Version: 2.2XTS
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.
Qualified personnel must have knowledge of drive technology and
electrical equipment as well as knowledge of safe working on electri-
cal systems and machines. This includes knowledge of proper setup
and preparation of the workplace as well as securing the working
environment 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
Version: 2.2 ─── 9XTS
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
Customer service
Customer service personnel and service personnel are verifiably
trained and authorized by Beckhoff or the machine manufacturer for
the work on the machine or plant.

Documentation notes
10 ─── Version: 2.2XTS
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
Pictograms and signal words in warning notices are used to identify
important text passages:
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
Version: 2.2 ─── 11XTS
Notes are used for important information on the product.
The possible 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.
Example
This symbol shows examples of how to use the product or soft-
ware.
QR code
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 Playstore 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
12 ─── Version: 2.2XTS
1.7Beckhoff Services
Beckhoff and its international partner companies offer comprehen-
sive support and service.
1.7.1Support
The Beckhoff Support offers technical advice on the use of individ-
ual Beckhoff products and system planning. Staff provide assistance
for programming and commissioning complex automation systems
and offer a comprehensive training program.
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 will find product information, software up-
dates, the TwinCAT automation suite, 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
Version: 2.2 ─── 13XTS
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.
2.1General 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/plant by the machine manufacturer.
Read the documentation prepared by the machine manufacturer.
2.1.1Before operation
Danger from magnetic fields
The magnetic fields of some of the components of the XTS are dan-
gerous to:
• people fitted with cardiac pacemakers
• persons with magnetically conducting implants
• implanted and external defibrillators
• magnetic data storage devices, chip cards with magnetic strips
and other electronic devices
Maintain a safety distance to all magnetic parts and prevent direct
contact between magnetic parts and parts that are sensitive to inter-
ference.
Observe the requirements of BGV B 11 for electromagnetic fields
(Germany) and applicable national regulations in other countries.
Use output voltages SELV / PELV
Operate all electronic modules and components in the drive system
only with a SELV (Safety Extra Low Voltage) or PELV (Protective
Extra Low Voltage) output voltage.
Keep the surroundings clean
Keep your workplace and the surrounding area clean. Ensure safe
working.
Secure the control cabinet
When working on machines, secure the control cabinet against inad-
vertent power-up.

For your safety
14 ─── Version: 2.2XTS
Do not use damaged components
Observe the specifications in the technical data during storage,
transport and operation. Do not use damaged components.
Check safety pictograms
Check whether the designated pictograms are on the product. Re-
place missing or illegible stickers.
Observe tightening torques
Install connections and components in compliance with the specified
tightening torques and check them regularly.
Earth electrical components or modules correctly
Do not touch electrical components or modules unless you are
wearing protective ESD clothing. Only walk on conductive floors.
Only use original packaging for further processing
When shipping, transporting, storing and packing, use the original
packaging or conductive materials.
2.1.2During operation
Observe the earthing concept
Special conditions need to be observed for the earthing of the XTS.
In every case, read the chapter: "Earthing of the power supply",
[Page86].
Do not work on live electrical parts
Ensure that the protective conductor is connected properly. Never
disconnect electrical connections while they are live. Only work on
the XTS when the voltage has dropped to < 10 V. Disconnect all
components from the mains and secure against reconnection.
Do not touch hot surfaces
Check cooling of the surfaces with a thermometer. Do not touch the
components during operation. Allow the components to cool down
for at least 15 minutes after switching off.
Avoid overheating
Operate the components according to the technical specifications.
Please refer to chapter: "Technical data". Provide for adequate cool-
ing and switch the components off immediately if the temperature is
too high.
Do not touch moving or rotating components
Do not touch moving or rotating components during operation. En-
sure that all parts / components on the machine / plant are firmly
seated.

For your safety
Version: 2.2 ─── 15XTS
2.1.3After operation
De-energize and switch off components before working on
them
Carry out a voltage test and check all safety-relevant devices for
functionality. Secure the working environment and the control cabi-
net against inadvertent power-up. See chapter: "Decommissioning",
[Page110].

Product overview
16 ─── Version: 2.2XTS
3
1
2
3
4
5
6
7
8
9
Number Explanation
1 Curved rail
2 Straight guide rail with lock
3 Mover
4 Lock
5 Name plate
6 Machine bed
7 Straight guide rail without lock
8 Straight module
9 Curved module

Product overview
Version: 2.2 ─── 17XTS
3.1Name plate
3.1
16
Automation GmbH & Co.KG
Huelshorstweg 20
33415 Verl / Germany
www.beckhoff.com
Made in Germany
AT2000-0250
XTS Drive 250 mm
2000 002082
ECAT Run
Link / Act
48V | 16A
24V | 4A
Number Explanation
1 Link / Act status LED
2 EtherCAT status LED
3 cURus approval
4 Product designation
5 Module length
6 DataMatrix code
7 Serial number
8 Module type
9 RoHS conformity
10 CE conformity
11 24V | 4A power supply status LED
12 48V | 16A power supply status LED
13 Firmware and hardware revision
14 XML sensor PCB revision number
15 XML motor PCB revision number
16 Date of manufacture - week/year

Product overview
18 ─── Version: 2.2XTS
3.1.1DataMatrix code
3.1.1
The DataMatrix code can be found on all movers and modules. If
there is no BTN number under the DataMatrix code, you can read it
out via the DataMatrix code.
For example, you can read the DataMatrix code with the camera of
your smartphone or tablet. If your camera does not support this fea-
ture, you can download a free QR code reader app or barcode
reader app for your smartphone. Use the Appstore for Apple operat-
ing systems or the Google Playstore for Android operating systems.
Internet access is not required to use the app and to read out these
DataMatrix codes.
Example scan on a straight module
This example shows how to read the BTN number on a smart-
phone screen after a scan.
► Take a photo of DataMatrix code 1
► Read BTN number 2 from the screen of your end device via the
camera app or the reader app

Product overview
Version: 2.2 ─── 19XTS
3.2Type key
3.2.1Module
AT 20 xx – xxxx – 000x Explanation
AT Product line
AT = drive technology
20 Product type
2 = module
xx Module variants
00 = straight
01 = straight with supply
20 = 22.5° outside curve
21 = 22.5° outside curve with supply
25 = - 22.5° inside curve
26 = - 22.5° inside curve with supply
40 = 45.0° curve
41 = 45.0° curve with supply
50 = 180° curve, clothoid
xxxx Product length
Module length in mm
000x Execution
2 = Black Line
3 = Standard with supply, UL-certified
4 = Black Line with supply, UL-certified
The ordering detail is not extended with standard mod-
ules.
3.2.2Mover
AT 901 x – 00x0 – x 550 Explanation
AT Product line
AT = drive technology
901 Product type
901 = mover
x Roller variants
1 = mover,6 rollers
2 = mover,12 rollers
00x0 Product length
Mover length in mm
5 = 50 mm
7 = 70 mm
x Magnetic plate set
0 = Standard
1 = Mover 1

Product overview
20 ─── Version: 2.2XTS
3.2.3Guide rail
AT 9x xx – xxxx – 0070 Explanation
AT Product line
AT = drive technology
9x Product type
0 = without lock
1 = with lock
xx Rail variants
00 = straight
20 = 22.5° outside curve
25 = - 22.5° inside curve
40 = 45° curve
50 = 180° curve, clothoid
42 = 360° full circle consisting of four elements with
one lock
xxxx Product length
Rail length in mm
0070 When using a 70 mm mover AT9011-0070-0550, ap-
pend -0070 to the order details.