Beckhoff AA3000 User manual

Operating instructions | EN
AA3000
Electric cylinders
1/17/2022 | Version 1.0

Table of contents
Version: 1.0 ─── 3AA3000
Table of contents
Documentation notes .......................................................................................................................................... 5
Disclaimer ......................................................................................................................................................... 5
Version numbers............................................................................................................................................... 7
Staff qualification............................................................................................................................................... 8
Safety and instruction ..................................................................................................................................... 10
Explanation of symbols ................................................................................................................................... 10
Beckhoff Services ........................................................................................................................................... 12
For your safety................................................................................................................................................... 13
Safety pictograms ........................................................................................................................................... 13
General safety instructions ............................................................................................................................. 14
Product overview............................................................................................................................................... 16
Name plate...................................................................................................................................................... 17
Type key ......................................................................................................................................................... 18
Product characteristics.................................................................................................................................... 19
Ordering options ............................................................................................................................................. 21
Intended use ................................................................................................................................................... 22
Technical data.................................................................................................................................................... 23
Definitions ....................................................................................................................................................... 23
Data for operation and environment ............................................................................................................... 25
AA3023 ........................................................................................................................................................... 27
AA3033 ........................................................................................................................................................... 29
AA3053 ........................................................................................................................................................... 31
Flange formats ................................................................................................................................................ 33
Scope of supply ................................................................................................................................................. 34
Packaging ....................................................................................................................................................... 34
Transport and storage....................................................................................................................................... 35
Conditions ....................................................................................................................................................... 35
Transport......................................................................................................................................................... 36
Long-term storage........................................................................................................................................... 37
Technical description........................................................................................................................................ 38
Mounting position............................................................................................................................................ 38
Feedback ........................................................................................................................................................ 39
Protection equipment ...................................................................................................................................... 40
Spindle end ..................................................................................................................................................... 41
Mechanical installation ..................................................................................................................................... 42
Flange mounting ............................................................................................................................................. 42
Output elements.............................................................................................................................................. 43
Electrical installation......................................................................................................................................... 44
Connection technology ................................................................................................................................... 44
Connector assignment .................................................................................................................................... 48
Commissioning.................................................................................................................................................. 49
Before commissioning..................................................................................................................................... 49
During commissioning..................................................................................................................................... 49
Prerequisites during operation ........................................................................................................................ 50
After operation ................................................................................................................................................ 50
Maintenance and cleaning ................................................................................................................................ 51
Cleaning agents .............................................................................................................................................. 51
Intervals .......................................................................................................................................................... 52

Table of contents
4 ─── Version: 1.0AA3000
Accessories........................................................................................................................................................ 55
Connection cables .......................................................................................................................................... 55
iTec extension................................................................................................................................................. 55
speedtec extension ......................................................................................................................................... 55
Pneumatic cylinder.......................................................................................................................................... 56
Fault correction.................................................................................................................................................. 57
Decommissioning.............................................................................................................................................. 61
Disassembly.................................................................................................................................................... 61
Disposal .......................................................................................................................................................... 62
Guidelines and Standards ................................................................................................................................ 63
Standards........................................................................................................................................................ 63
Guidelines ....................................................................................................................................................... 63
Test centers .................................................................................................................................................... 63
EU conformity ................................................................................................................................................. 64
CCC conformity............................................................................................................................................... 64
Index ................................................................................................................................................................... 65

Documentation notes
Version: 1.0 ─── 5AA3000
1.1Disclaimer
Beckhoff products are subject to continuous further development.
We reserve the right to revise the documentation at any time and
without notice. No claims for the modification of products that have
already been supplied may be made on the basis of the data, dia-
grams, and descriptions in this documentation.
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 Auto-
mation 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: 1.0AA3000
1.1.3Limitation of liability
All components of this product described in the original operating in-
structions are delivered in a hardware and software configuration,
depending on the application requirements. 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 comply with this documentation
• 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: 1.0 ─── 7AA3000
1.2Version numbers
Provision of revision levels
On request we can send you a list of revision levels for changes to
the documentation.
• Send your request to: [email protected]
Origin of the document
This documentation was originally written in German. All other lan-
guages are derived from the German original.
Product features
The valid product features are always those specified in the current
documentation. Further information given on the product pages of
the Beckhoff homepage, in emails or in other publications is not au-
thoritative.

Documentation notes
8 ─── Version: 1.0AA3000
1.3Staff qualification
1.3
This documentation is aimed at trained specialists working in control
technology and automation who have 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 documentation published at the time must be used for each in-
stallation and commissioning. The products must be used in compli-
ance with all safety requirements, including all applicable laws, regu-
lations, 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 builder 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: 1.0 ─── 9AA3000
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
10 ─── Version: 1.0AA3000
1.4Safety 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 doc-
umentation. Observe the warning notes in the chapters so that you
can handle and work properly and safely with the product.
1.5Explanation 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
1.5.1Pictograms
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
Version: 1.0 ─── 11AA3000
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. If your camera doesn't support this function
you can download a free QR code reader app for your smartphone.
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
12 ─── Version: 1.0AA3000
1.6Beckhoff Services
Beckhoff and its international partner companies offer comprehen-
sive support and service.
1.6.1Support
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
1.6.2Training
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
1.6.3Service
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
1.6.4Download 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
1.6.5Headquarters
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: 1.0 ─── 13AA3000
Read this chapter containing general safety information. Further-
more, the chapters in this documentation contain warning notices.
Always 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
Beckhoff products feature safety pictograms, either on stickers or
printed, which vary depending on the product. They serve to protect
people and to prevent damage to the products. Safety pictograms
must not be removed and must be legible for the user.
Warning of a hot surface
During and after operation there is a risk of burns at the motor hous-
ing due to hot surfaces over 60°C. Allow the motor housing to cool
down for the specified time, at least 15 minutes.
Avoid shocks to the shaft
Impacts on the shaft may cause the maximum permissible axial and
radial values to be exceeded. Optical encoder systems can thus be
destroyed.

For your safety
14 ─── Version: 1.0AA3000
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.
Do not use defective or damaged electric cylinders
Observe the specifications in the technical data during storage,
transport, and operation. Check electric cylinder for damage. Do not
use damaged electric cylinders.
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
Version: 1.0 ─── 15AA3000
2.2.2During operation
Do not work on live electrical parts
Do not open the motor while it is live. Ensure that the protective con-
ductor is properly connected. Never disconnect electrical connec-
tions while they are live. Only work on the motor when the voltage
has dropped to < 50V. Disconnect all components from the mains
and secure against reconnection.
Observe grease leakage at the spindle drive
Check the spindle drive for leaking grease. In every case, read the
chapter: "Lubrication". Avoid contamination of the environment with
the escaping grease.
Avoid surface temperatures above 200°C
Avoid surface temperatures of over 200°C in the immediate vicinity
of the spindle drive.
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 motor according to the technical specifications. Refer
here to the chapter: "Technical data". Activate and monitor the tem-
perature contact of the motor. Provide for sufficient cooling. Switch
off the motor immediately if the temperature is too high.
Do not touch any moving or rotating components
Do not touch any moving or rotating components. Fasten all parts or
components on the machine or plant.
Keep travel path clear and do not enter area
Keep the travel path of the piston rod clear when operating the elec-
tric cylinder. Maintain a safety distance of 25 cm from all moving
parts in the travel range.
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. Observe the chapter: "Decommissioning"
No direct skin contact with solvents or lubricants
In case of improper use, the solvents or lubricants used can lead to
skin irritations. Therefore, avoid direct skin contact.

Product overview
16 ─── Version: 1.0AA3000
3
Item number Explanation
1 Motor shaft
2 Bleeding
3 Screw lubrication
4 Power / feedback connection
5 Housing
6 4x mounting holes front and rear

Product overview
Version: 1.0 ─── 17AA3000
3.1Name plate
3.1
Item number Explanation
1 Motor type
2 Continuous force
3 Nominal velocity
4 Standstill current
5 Nominal voltage
6 Nominal output
7 Insulation class
8 Protection class
9 Safety Integrity Level
10 Beckhoff Traceability Number; BTN
11 Data-Matrix Code
12 Additional information standard
13 CE conformity
14 Disposal according to WEEE directive
15 Country of manufacture

Product overview
18 ─── Version: 1.0AA3000
3.2Type key
AA3 t u v – w-x-y-z-0000 Explanation
AA3 Product area
Electric cylinder
t Motor series
0 = standard
u Flange size
2 = 58mm
3 = 75mm
5 = 110mm
v Overall length
3 = standard
w Spindle pitch and anti-twist protection
1 = pitch 5 mm without anti-twist protection
2 = pitch 5 mm with anti-twist protection
3 = pitch 10 mm without anti-twist protection
4 = pitch 10 mm with anti-twist protection
5 = pitch 20 mm without anti-twist protection
6 = pitch 20 mm with anti-twist protection
9 = special pitch
x Stroke length
2 = 150mm
3 = 200mm
4 = 250mm
9 = special stroke
y Feedback system
H = OCT multi-turn 24-bit, SIL 2
z Holding brake
0 = without holding brake
1 = 24V holding brake
0 Versions
0 = standard
1 = special variant
000 Not defined
3.2.1Compatibility
Information on compatibility with ISO 15552; pneumatic cylinders
Beckhoff flange size Standard cylinder sizes [mm]
F2 Ø 40
F3 Ø 63
F3 Ø 100

Product overview
Version: 1.0 ─── 19AA3000
3.3Product characteristics
Ball screw
The direct-drive ball screw translates the rotation of the motor into a
linear motion.
Internal anti-twist protection
The internal anti-twist protection supports the torque and ensures
that the rotational movement of the rotor is converted into a linear
movement of the spindle.
Neodymium permanent magnets
The magnets installed in the motor are permanent magnets.
Neodymium is a hard magnetic material that enables the precise
and highly dynamic positioning of the motors.
Three-phase stator winding
The three-phase winding in the stator reduces the amount of mate-
rial required while maintaining the same electrical output. All phase
angles are 120°.
Electronic commutation in the servo drive
The commutation of the motor is done electronically. The three coil
turns are supplied from a bridge circuit.
Thermal contacts
A thermal contact LPTC-600 is installed to monitor and measure the
winding temperature and to protect the motor against overheating.
This can be read out by the user.
Temperature warning and switch-off:
• Motor warning temperature at 120°C
• Motor switch-off temperature at 140°C

Product overview
20 ─── Version: 1.0AA3000
Holding brake [+]
The motors can be equipped as an option with permanent magnet
holding brakes. These operate according to the quiescent current
principle and open at a voltage of 24VDC +6/-10% with > 10,000,000
switching cycles.
The installed holding brake is not suitable for service braking, since
there is no monitoring for wear and functionality by the servo drive
and the configuration. This applies in particular to vertical axes.
Safety measures for vertical axes must be applied
When operating vertical axes, appropriate additional measures
must be taken; for example, including but not only:
• additional redundant brake units
• mechanical safeguards or interlocks
• attachment of a balancing weight
Permanent magnet holding brakes alone are not approved for the
protection of persons. In consideration of ISO 13849-1 and
13849-2, additional precautions must be taken for personal protec-
tion.