Beckhoff AA3100 User manual

Operating instructions | EN
AA3100
Electric cylinders for compact drive technology
2024-01-31 | Version 1.0

Table of contents
Version: 1.0 ─── 3AA3100
Table of contents
1 Documentation notes.................................................................................................................................. 6
1.1 Disclaimer .......................................................................................................................................... 6
1.1.1 Trademarks ............................................................................................................................. 6
1.1.2 Patents .................................................................................................................................... 6
1.1.3 Limitation of liability ................................................................................................................. 7
1.1.4 Copyright ................................................................................................................................. 7
1.2 Version numbers ................................................................................................................................ 8
1.3 Staff qualification................................................................................................................................ 9
1.4 Safety and instruction......................................................................................................................... 11
1.5 Explanation of symbols ...................................................................................................................... 11
1.6 Beckhoff Services .............................................................................................................................. 13
1.6.1 Support services...................................................................................................................... 13
1.6.2 Training offerings..................................................................................................................... 13
1.6.3 Service offerings...................................................................................................................... 13
1.6.4 Headquarters Germany........................................................................................................... 14
1.6.5 Downloadfinder ....................................................................................................................... 14
2 For your safety ............................................................................................................................................ 15
2.1 Safety pictograms .............................................................................................................................. 15
2.2 General safety instructions................................................................................................................. 16
2.2.1 Before operation...................................................................................................................... 16
2.2.2 During operation...................................................................................................................... 17
2.2.3 After operation......................................................................................................................... 18
3 Product overview ........................................................................................................................................ 19
3.1 Name plate......................................................................................................................................... 20
3.2 Type key............................................................................................................................................. 21
3.3 Product characteristics....................................................................................................................... 22
3.4 Ordering options................................................................................................................................. 23
3.4.1 Integrated anti-twist protection [+] ........................................................................................... 23
3.4.2 Holding brake [+] ..................................................................................................................... 24
3.5 Intended use ...................................................................................................................................... 25
3.6 Improper use ...................................................................................................................................... 25
4 Technical data ............................................................................................................................................. 26
4.1 Definitions and technical terms .......................................................................................................... 26
4.2 Data for operation and environment................................................................................................... 27
4.2.1 General housing properties ..................................................................................................... 28
4.2.2 Environmental conditions ........................................................................................................ 28
4.2.3 Specifications for intended use ............................................................................................... 28
4.2.4 Switching thresholds for temperature shutdown ..................................................................... 28
4.2.5 Power derating ........................................................................................................................ 29
4.3 Size AA3123 ...................................................................................................................................... 30
4.3.1 Service life AA3123 ................................................................................................................. 31
4.3.2 Dimensional drawing AA3123 ................................................................................................. 32
4.4 Size AA3133 ...................................................................................................................................... 33
4.4.1 Service life AA3133 ................................................................................................................. 34

Table of contents
4 ─── Version: 1.0AA3100
4.4.2 Dimensional drawing AA3133 ................................................................................................. 35
5 Scope of supply........................................................................................................................................... 36
5.1 Packaging .......................................................................................................................................... 36
6 Transport and storage ................................................................................................................................ 37
6.1 Conditions .......................................................................................................................................... 37
6.2 Transport............................................................................................................................................ 38
6.2.1 Transport AA3123 and AA3133 .............................................................................................. 39
6.3 Long-term storage.............................................................................................................................. 39
7 Technical description ................................................................................................................................. 40
7.1 Installation position............................................................................................................................. 40
7.2 Temperature sensor LPTC-600 ......................................................................................................... 42
7.3 Spindle end ........................................................................................................................................ 43
8 Mechanical installation ............................................................................................................................... 44
8.1 Flange mounting ................................................................................................................................ 44
8.2 Fastening the end of the spindle ........................................................................................................ 45
9 Electrical installation .................................................................................................................................. 47
9.1 Power / feedback connection ............................................................................................................. 47
9.1.1 Pin assignment itec® (OCT).................................................................................................... 48
9.2 Connect the motor cable .................................................................................................................... 48
9.2.1 Establish the itec® plug connection ........................................................................................ 49
9.3 Select motor cables............................................................................................................................ 50
9.4 Select extension cable ....................................................................................................................... 50
10 Commissioning ........................................................................................................................................... 51
10.1 Before commissioning........................................................................................................................ 51
10.1.1 System requirements .............................................................................................................. 51
10.1.2 Mechanical and electrical requirements .................................................................................. 52
10.1.3 Testing the holding brake [+] ................................................................................................... 52
10.2 During commissioning........................................................................................................................ 53
10.2.1 Electric cylinder with integrated anti-twist protection [+].......................................................... 53
10.2.2 Electric cylinder without integrated anti-twist protection [+]..................................................... 54
10.3 During operation................................................................................................................................. 55
10.4 After operation.................................................................................................................................... 56
11 Maintenance and cleaning.......................................................................................................................... 57
11.1 Maintenance....................................................................................................................................... 57
11.2 Maintenance intervals ........................................................................................................................ 58
11.3 Lubrication of the spindle drive .......................................................................................................... 59
11.4 Cleaning ............................................................................................................................................. 61
12 Accessories ................................................................................................................................................. 63
12.1 Mechanical accessories ..................................................................................................................... 63
13 Fault correction ........................................................................................................................................... 64
14 Decommissioning ....................................................................................................................................... 68
14.1 Disassembly....................................................................................................................................... 68
14.2 Disposal ............................................................................................................................................. 69

Table of contents
Version: 1.0 ─── 5AA3100
14.2.1 Returning to the vendor........................................................................................................... 69
15 Guidelines and Standards .......................................................................................................................... 70
15.1 Standards........................................................................................................................................... 70
15.2 Guidelines .......................................................................................................................................... 70
15.3 Test centers ....................................................................................................................................... 70
15.4 EU conformity..................................................................................................................................... 71
15.5 CCC conformity.................................................................................................................................. 72
Index ............................................................................................................................................................. 73

Documentation notes
6 ─── Version: 1.0AA3100
1 Documentation notes
1.1 Disclaimer
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.
1.1.1 Trademarks
Beckhoff®, TwinCAT®, TwinCAT/BSD®, TC/BSD®, EtherCAT®, Ether-
CAT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.
1.1.2 Patents
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
Version: 1.0 ─── 7AA3100
1.1.3 Limitation 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
1.1.4 Copyright
© 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
8 ─── Version: 1.0AA3100
1.2 Version 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.

Documentation notes
Version: 1.0 ─── 9AA3100
1.3 Staff qualification
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 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
10 ─── Version: 1.0AA3100
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: 1.0 ─── 11AA3100
1.4 Safety 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 warnings in the chapters so that
you can handle and work with the product as intended and safely.
1.5 Explanation 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 brackets indicate cross-references to other text
passages in the document.
[1] The number in the square brackets refers to the position in the
adjacent figure.
[+] The plus sign in square brackets indicates ordering options
and accessories.
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: 1.0AA3100
NOTICE
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.
Examples
This symbol shows examples of how to use the product or software.
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
Version: 1.0 ─── 13AA3100
1.6 Beckhoff Services
Beckhoff and its international partner companies offer comprehen-
sive support and service.
www.beckhoff.com/en-en/support/global-availability/
1.6.1 Support services
The Beckhoff Support offers technical advice on the use of individ-
ual Beckhoff products and system planning. The support engineers
offer you competent assistance, for comprehension questions as
well as for commissioning.
+495246963-157
[email protected]
www.beckhoff.com/en-en/support/our-support-services/
1.6.2 Training offerings
Training in Germany takes place at the Beckhoff branches or, after
consultation, at the customer's premises. Beckhoff offers both face-
to-face and online training courses.
+495246963-5000
[email protected]
www.beckhoff.com/en-en/support/training-offerings/
1.6.3 Service offerings
The Beckhoff service experts support you worldwide in all areas of
after-sales service.
+495246963-157
[email protected]
www.beckhoff.com/en-en/support/our-service-offerings/

Documentation notes
14 ─── Version: 1.0AA3100
1.6.4 Headquarters Germany
Beckhoff Automation GmbH & Co. KG
Hülshorstweg 20
33415 Verl, Germany
+495246963-0
[email protected]
www.beckhoff.com/en-en/
A detailed overview of the Beckhoff locations worldwide can be
found at:
www.beckhoff.com/en-en/company/global-presence/
1.6.5 Downloadfinder
In the Download finder you will find configuration files, technical doc-
umentation and application reports to download.
www.beckhoff.com/documentations

For your safety
Version: 1.0 ─── 15AA3100
2 For your safety
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.
2.1 Safety pictograms
You will find safety symbols on Beckhoff products and packaging.
The symbols may be glued, printed, or lasered on and may vary de-
pending on the product. They serve to protect people and to prevent
damage to the products. Safety symbols may not be removed and
must be legible for the user.
Warning of hot surface
During and after operation, there is a risk of burns on the housing of
the electric cylinder due to hot surfaces above 60 °C. Allow the
housing of the electric cylinder to cool down for at least 15minutes.
Avoid impacts on the spindle end
Impacts on the spindle end can exceed the permissible forces in ax-
ial and radial direction. Internal components such as the integrated
anti-twist protection[+], the ball screw or the encoder system can be
damaged or destroyed as a result.

For your safety
16 ─── Version: 1.0AA3100
2.2 General safety instructions
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.
2.2.1 Before operation
Correctly ground electrical components or modules
Avoid electric shocks due to improper grounding of electrical compo-
nents or modules. Ground all conductive components as specified in
the chapters: "Electrical installation", [Page47] and "Mechanical in-
stallation", [Page44].
Do not use defective or damaged electric cylinders
Adhere to the specifications from the technical data for storage,
transport, and operation. Check electric cylinder for damage. Do not
use damaged electric cylinders.

For your safety
Version: 1.0 ─── 17AA3100
2.2.2 During operation
Do not work on live electrical parts
Do not open any electric cylinders while they are live. Ensure that
the protective conductor is properly connected. Never loosen electri-
cal connections when live. Only work on electric cylinders when the
device is switched off. Disconnect all components from the mains
and protect them against unintentional reconnection.
Check for grease leakage at the spindle drive
Check the spindle drive for leaking grease and remove the grease
from the spindle environment. Please also refer to chapter "Clean-
ing", [Page61]
Avoid excessive greasing of the spindle and contamination of the
environment with the escaping grease. Ensure that you read the
chapter "Lubrication of the spindle drive", [Page59].
Avoid temperatures above 200°C near the spindle
Avoid surface temperatures of over 200°C in the immediate vicinity
of the spindle drive. Escaping grease could liquefy completely at
high temperatures.
Adequately shield hot surfaces to protect them from accidental con-
tact and possible grease leakage.
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 electric cylinder within the technical specifications.
Please refer to chapter "Switching thresholds for temperature shut-
down", [Page 28]. Activate and monitor the temperature sensor of
the electric cylinder. Provide for sufficient cooling. Switch off the
electric cylinder 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 spindle drive clear when operating the
electric cylinder. Maintain a safety distance of at least 25cm from all
moving parts in the travel range.

For your safety
18 ─── Version: 1.0AA3100
2.2.3 After 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",
[Page68].
No direct skin contact with solvents or lubricants
In case of improper use, the solvents or lubricants used can lead to
skin irritations. Avoid direct skin contact.

Product overview
Version: 1.0 ─── 19AA3100
3 Product overview
1
5
8
2
3
2
2
4
2
6
7
Item number Explanation
1 Spindle end
2 Threaded holes for mounting
3 Pressure equalization element
4 Screw plug for lubrication
5 Power/feedback connection
6 Safety pictograms
7 Name plate
8 Housing

Product overview
20 ─── Version: 1.0AA3100
3.1 Name plate
1
2
3
4
7
5
6
8 9 10 11 12
13
14
15
16
Item number Explanation
1 Product number
2 Continuous force
3 Nominal velocity
4 Standstill current
5 Nominal voltage
6 Nominal output
7 Insulation class
8 Protection class
9 Brake type
10 Safety Integrity Level
11 Beckhoff Traceability Number (BTN)
12 DataMatrix code
13 Additional information standard
14 CE conformity
15 WEEE compliance
16 Country of manufacture