Beckhoff AG1000 User manual

Operation Manual | EN
AG1000
Planetary gear unit
5/20/2021 | Version: 1.4

Table of content
AG1000 3Version: 1.4
Table of content
1 Foreword ....................................................................................................................................................5
1.1 Notes on the documentation..............................................................................................................5
1.2 Documentation issue status ..............................................................................................................6
1.3 Intended use .....................................................................................................................................6
2 Guidelines and Standards .......................................................................................................................7
3 For your safety...........................................................................................................................................8
3.1 Staff qualification ...............................................................................................................................8
3.2 Description of symbols ......................................................................................................................9
3.3 Instructions of the planetary gear unit AG1000-+PMxx ..................................................................10
4 Handling ...................................................................................................................................................12
4.1 Transport .........................................................................................................................................12
4.2 Packaging........................................................................................................................................12
4.3 Storage ............................................................................................................................................12
4.4 Maintenance / Cleaning...................................................................................................................13
4.4.1 Maintenance tasks........................................................................................................... 13
4.4.2 Commissioning after maintenance .................................................................................. 13
4.4.3 Notes on the lubricant used ............................................................................................. 14
4.4.4 Notes on the adhesive ..................................................................................................... 14
4.5 Disposal...........................................................................................................................................14
5 Product overview.....................................................................................................................................15
5.1 Scope of delivery AG1000...............................................................................................................15
5.2 Type plate AG1000..........................................................................................................................15
5.3 Type key AG1000............................................................................................................................15
6 Technical description..............................................................................................................................16
6.1 Gear unit configuration ....................................................................................................................16
6.2 Overview of the gear components...................................................................................................16
6.3 General technical data.....................................................................................................................16
6.4 Transport, assembly and disassembly ............................................................................................16
7 Mechanical installation ...........................................................................................................................17
7.1 Important notes................................................................................................................................17
7.2 Installing the planetary gear unit......................................................................................................18
7.2.1 Mounting the gear............................................................................................................ 18
8 Technical data of the planetary gear units............................................................................................19
8.1 PM052 .............................................................................................................................................20
8.1.1 Dimensional drawing PM052 ........................................................................................... 20
8.2 PM081 .............................................................................................................................................20
8.2.1 Dimensional drawing PM081 ........................................................................................... 20
9 Commissioning........................................................................................................................................21
9.1 Important notes................................................................................................................................21
9.2 Guide for commissioning the gear units ..........................................................................................22
9.3 Troubleshooting...............................................................................................................................23
10 Decommissioning....................................................................................................................................24

Table of content
AG10004 Version: 1.4
11 Support and Service................................................................................................................................25

Foreword
AG1000 5Version: 1.4
1 Foreword
1.1 Notes on the documentation
This description is only intended for the use of trained specialists in control and automation engineering who
are familiar with the applicable national standards.
It is essential that the documentation and the following notes and explanations are followed when installing
and commissioning the components.
It is the duty of the technical personnel to use the documentation published at the respective time of each
installation and commissioning.
The responsible staff must ensure that the application or use of the products described satisfy all the
requirements for safety, including all the relevant laws, regulations, guidelines and standards.
Disclaimer
The documentation has been prepared with care. The products described are, however, constantly under
development.
We reserve the right to revise and change the documentation at any time and without prior announcement.
No claims for the modification of products that have already been supplied may be made on the basis of the
data, diagrams and descriptions in this documentation.
Trademarks
Beckhoff®, TwinCAT®, EtherCAT®, Safety over EtherCAT®, TwinSAFE®, XFC® and XTS® are registered
trademarks of and licensed by Beckhoff Automation GmbH.
Other designations used in this publication may be trademarks whose use by third parties for their own
purposes could violate the rights of the owners.
Patent Pending
The EtherCAT Technology is covered, including but not limited to the following patent applications and
patents:
EP1590927, EP1789857, DE102004044764, DE102007017835
with corresponding applications or registrations in various other countries.
The TwinCAT Technology is covered, including but not limited to the following patent applications and
patents:
EP0851348, US6167425 with corresponding applications or registrations in various other countries.
EtherCAT® is registered trademark and patented technology, licensed by Beckhoff Automation GmbH,
Germany
Copyright
© Beckhoff Automation GmbH & Co. KG, Germany.
The reproduction, distribution and utilization of this document as well as the communication of its contents to
others without express authorization are prohibited.
Offenders will be held liable for the payment of damages. All rights reserved in the event of the grant of a
patent, utility model or design.

Foreword
AG10006 Version: 1.4
1.2 Documentation issue status
Origin of the document
This documentation was originally written in German. All other languages are derived from the German
original.
Product features
Only the product features specified in the current user documentation are valid. Further information given on
the product pages of the Beckhoff homepage, in emails or in other publications is not authoritative.
Version Comment
1.4 Chapter update:
Installing the planetary gear unit 7.2
New chapter:
Guidelines and Standards 2; For your safety 3
1.3 Chapter update:
Disposal 3.5
1.2 Chapter update:
1.0 Foreword; 2.0 Safety
1.1 Chapter update:
8.1
1.0 First edition
1.3 Intended use
The gear unit is used for transforming torques and speeds. It is suitable for all industrial applications that are
not covered by Article 2 of EC Directive 2002/95/EC (restriction of the use of certain hazardous substances
in electrical and electronic equipment).
The gear unit must not be operated in potentially explosive atmospheres. In food processing applications,
the gear unit may only be used beside or below the food area.
The gear unit is intended for mounting on Beckhoff stepper motors AS1000.
NOTE
Damage from improper use
Any use exceeding the maximum permissible speeds, torques and temperature is considered improper and
is therefore not permitted.

Guidelines and Standards
AG1000 7Version: 1.4
2 Guidelines and Standards
In addition to the safety instructions mentioned in this manual, the general statutory and other rules and
regulations for the prevention of accidents (e.g. personal protective equipment) and for environmental
protection must be followed.
CAUTION
Personal injuries!
The gear units are not products under the terms of the EC Machinery Directive. Operation of the gear units
in machines or systems is only permitted once the machine or system manufacturers has provided evi-
dence of CE conformity of the complete machine or system.

For your safety
AG10008 Version: 1.4
3 For your safety
Read the section on safety and heed the notices to protect yourself against personal injury and material
damages.
Liability limitations
All the components of the planetary gear units AG1000-+PMxx are supplied in certain hardware and
software configurations appropriate for the conditions of the application. Unauthorized modifications to the
hardware and/or software configurations other than those described in the documentation are not permitted,
and nullify the liability of Beckhoff Automation GmbH & Co. KG.
In addition, the following actions are excluded from the liability of Beckhoff Automation GmbH & Co.
KG:
• Failure to comply with this documentation
• Improper use
• Untrained personnel
• Use of unauthorized spare parts
3.1 Staff qualification
Only technical personnel with knowledge of control and automation technology may carry out any of the
illustrated work steps on the Beckhoff software and hardware, in particular of the planetary gear units
AG1000-+PMxx.
The technical personnel must have knowledge of drive technology and electrical systems and must also
know how to work safely on electrical equipment and machines.
This also includes:
• production planning and
• securing of the working environment (e.g. securing the control cabinet against being switched on
again).
The technical personnel must be familiar with the current and necessary standards and directives for the
automation and drive environment.

For your safety
AG1000 9Version: 1.4
3.2 Description of symbols
In this documentation the following symbols are used with an accompanying safety instruction or note. The
safety instructions must be read carefully and followed without fail!
Symbols that warn of personal injury:
DANGER
Serious risk of injury!
This is an extremely dangerous situation. Disregarding the safety notice will lead to serious permanent in-
juries or even death.
WARNING
Risk of injury!
This is a dangerous situation. Disregarding the safety notice may lead to serious injuries.
CAUTION
Personal injuries!
This is a dangerous situation. Disregarding the safety notice may lead to minor injuries.
Symbols that warn of damage to property or equipment:
NOTE
Warning of damage to property or the environment!
This notice indicates disturbances in the operational procedure that could damage the product or the envi-
ronment.
Symbols indicating further information or tips:
Tip or pointer!
This notice provides important information that will be of assistance in dealing with the product or
software. There is no immediate danger to product, people or environment.
UL note!
This symbol indicates important information regarding UL certification.

For your safety
AG100010 Version: 1.4
3.3 Instructions of the planetary gear unit AG1000-
+PMxx
The safety instructions are designed to avert danger and must be followed during installation,
commissioning, production, troubleshooting, maintenance and trial or test assemblies.
The gear units of the AG1000 series are not designed for stand-alone operation and are always installed in a
machine or system. After installation the additional documentation and safety instructions provided by the
machine manufacturer must be read and followed.
CAUTION
Personal injuries
• Carefully read this manual before using the gear unit thoroughly, paying particular attention to the safety
instructions. In the event of any uncertainties please notify your sales office immediately and refrain from
working on the gear unit.
• Only trained, qualified personnel with good knowledge of drive technology may work on this gear unit.
• If a gear unit is installed in a machine it must not be commissioned until proof of compliance of the ma-
chine with the latest version of the EC Machinery Directive has been provided. This includes all relevant
harmonized standards and regulations required for implementation of this Directive in national legisla-
tion.
WARNING
Serious risk of injury through hot surfaces!
• The surface temperature of the AG1000 gears, may exceed 120 °C, resulting in a risk of burns.
• Avoid touching the housing during or shortly after operation.
• Allow the gear unit to cool down for at least 15 minutes after switching off.
• Use a thermometer to check whether the surface has cooled down sufficiently.
WARNING
Objects flung out by rotating components can cause serious injuries.
• Remove any items and tools in the vicinity of the gear unit before starting up the unit.
• Remove/secure the feather key (if present), if the gear unit is operated without attachments on the out-
put/drive side.
WARNING
Rotating components on the gear unit can pull in parts of the body and cause serious in-
jury or death.
• When the gear unit is running, keep sufficient distance to rotating machine parts.
• During assembly and maintenance work, secure the machine against restarting and unintentional move-
ments (such as uncontrolled lowering of lifting axes).
WARNING
A damaged gear unit can lead to accidents with risk of injury.
• Do not operate a gear unit that has been overloaded due to incorrect operation or a machine crash.
• Replace affected gear units, even if no external damage is visible.
NOTE
Loose or overloaded screw connections can damage the gear unit.
• Install and check all screw connections for which tightening torques are specified, using a calibrated
torque wrench.

For your safety
AG1000 11Version: 1.4
WARNING
Lubricants are flammable.
• Do not use a water jet for extinguishing flames.
• Suitable extinguishing media are powder, foam, water spray or carbon dioxide.
• Follow the safety instructions of the lubricant manufacturer.
CAUTION
Solvents and lubricants can cause skin irritations.
• Avoid direct skin contact.
NOTE
Solvents and lubricants can pollute soil and water.
• Cleaning solvents and lubricants must be used and disposed of properly.

Handling
AG100012 Version: 1.4
4 Handling
4.1 Transport
• No special mode of transport is prescribed for the gear unit.
• Only by qualified personnel.
• Only in the manufacturer's original packaging.
• Avoid hard shocks.
• If the packaging is damaged check the gear unit and any accessories for visible damage. Inform the
transport company and, if necessary, the manufacturer.
WARNING
Suspended loads may fall and cause serious injury or death.
• Never stand under suspended loads.
• Secure the gear unit with suitable fastenings (e.g. straps) prior to transport.
NOTE
Hard impacts, e.g. due to falling or dropping, may damage the gear unit.
• Use only lifting gear and load handling devices with sufficient load-bearing capacity.
• Do not exceed the permitted lifting weight.
• Set the gear unit down slowly.
4.2 Packaging
• Recyclable cardboard with inserts
• Dispose of the packaging materials at designated disposal sites.
Observe the relevant national disposal regulations
4.3 Storage
• The gear units must not be stored outdoors. The storage space must be adequately ventilated and dry.
• The gear units may only be stored in the original recyclable manufacturer's packaging.
• The gear units may only be stored in a horizontal position.
• Storage temperature: -30 °C to +60 °C in the original packaging
• Storage time: 2 years max.
Possible damage to the gear unit seals
If the gear units are stored at temperature ranges above 60°C or subjected to direct sunlight or ul-
traviolet light, the gear unit seals may become damaged. Storage temperatures of up to 85°C are
permitted for a maximum of 2 weeks. However, please note that even short-term storage at such
temperatures will result in premature ageing of the seals. Therefore, please check the seals before
commissioning the gear unit.

Handling
AG1000 13Version: 1.4
4.4 Maintenance / Cleaning
4.4.1 Maintenance tasks
4.4.1.1 Visual inspection
• Check the entire gear unit for external damage.
• Check the entire gear unit for leaks.
◦ In the installation position, check that no foreign media (e.g. oil) accumulate on the drive and
output shaft.
4.4.2 Commissioning after maintenance
• Clean the gear unit externally.
• Attach all safety devices.
• Perform a test run before releasing the gear unit again for operation.

Handling
AG100014 Version: 1.4
4.4.3 Notes on the lubricant used
Lubricant used
All gear units are lubricated for life at the factory. The lubricant used is a grease.
4.4.4 Notes on the adhesive
Inserted adhesive
The sun wheel of the gear unit is factory glued to the motor shaft of the AS1000 series. The em-
ployed Adhesives WEICONLOCK AN 306-48 (D) and WEICONLOCK AN 306-60 (D) are anaerobic
Sealants. These include dangerous ingredients such as:
• acrylic acid (<3%)
• methacrylic acid (> 10%)
• 2-hydroxyethyl methacrylate (<20%)
• cumene hydroperoxide (1%) and
• methacrylic acid ester (<20%)
Further information on the adhesives is available directly from the manufacturer:
Adhesive WEICONLOCK AN306-48 / 60 (D)
WEICON GmbH & Co. KG, Königsberger Str. 255
D-48045 Münster
Tel.: +49 (0)251 / 93 22-0
www.weicon.com
4.5 Disposal
National regulations
Observe the relevant national disposal regulations.
Supplementary information on replacing the adapter plate and disassembly and disposal of the gear unit is
available from our service department:
• The device should be disposed of by a certified disposal company. Addresses can be obtained from
our service department.
• Metal parts can be sent for metal recycling.
In accordance with the WEEE 2012/96/EG Directives we take old devices and accessories back for
professional disposal, provided the transport costs are taken over by the sender.
Send the devices with the note “For disposal” to:
Beckhoff Automation GmbH & Co. KG
Huelshorstweg 20
D-33415 Verl

Product overview
AG1000 15Version: 1.4
5 Product overview
5.1 Scope of delivery AG1000
• Check the completeness of the delivery against the delivery note.
• Missing parts or damage should be reported immediately in writing to the carrier, the insurance
company and / or Beckhoff Automation.
5.2 Type plate AG1000
Beckhoff Automation GmbH
AG1000 - + PM81-4-06/01
Fert.-Datum:
Made in Germany
39/15
Production information
Gear type
Manufacturing date
Calender week/year
5.3 Type key AG1000
AG1000 PMxx x-+ .
Gear series
AG1000 = PM
Gear type
PM 52
(only AS1030/AS1050)
PM 81
( AS1060)only
Gear ratio
4 = 1:4 (exactly 3,7 as a fraction 63/17)
7 = 1:7 (exactly 6,75 as a fraction 27/4)

Technical description
AG100016 Version: 1.4
6 Technical description
6.1 Gear unit configuration
The devices of the AG1000-PMxxxx series are planetary gear units. They can be used in any installation
position. The gears are lubricated lifetime and have an unbalance can Pinion. Furthermore, they are firmly
connected to the output shaft. Input and output are coaxial. The shafts rotate in the same direction. The
planetary gears are characterized by high efficiency. Also, the gearboxes of the series AG1000 high torque
transmission with small installation space.
6.2 Overview of the gear components
Gear components
C
B
D
A
A Gear housing
B Output shaft
C Adapter plate
6.3 General technical data
The maximum permissible speeds and torques can be found in our catalog or on our website at
http://www.beckhoff.de.
6.4 Transport, assembly and disassembly
Recommendations for trouble-free operation and long service life
• Ensure adequate convection of the gear unit.
• Ensure adequate heat dissipation from the gear unit via the output flange.
• The gear unit may heat up due to the motor and other external heat sources. Acquaint yourself
with the motor temperature and external influences that may occur during operation.
• Note the protection class of the gear unit and the resulting constraints.
Preparing the installation
The drive and output sides are treated with a corrosion inhibitor to protect from corrosion. Ensure that the
installation instructions are enclosed with the gear unit and remove the corrosion inhibitor, once you have
read up on handling hazardous substances.

Mechanical installation
AG1000 17Version: 1.4
7 Mechanical installation
7.1 Important notes
CAUTION
Damage to persons and devices
Observe the general and special safety instructions.
The gear unit can be used in any gear unit.
NOTE
Assembly sequence
Always follow the assembly sequence described below in order to avoid damage.
The fastening screws are not included and must be provided by the customer. Pertinent information can be
found in the individual assembly steps.
NOTE
Compressed air may damage gear unit seals.
Do not use compressed air for cleaning the gear unit.
NOTE
In rare cases, leaks ("sweating") may occur at the drive in gear units with grease lubrica-
tion (see type plate).
• To avoid "sweating", we recommend sealing the areas between
ðadapter plate, drive housing and gear unit and
ðadapter plate and motor
ðwith a surface seal adhesive (e.g. Loctite® 573 or 574).
• For further information please contact our customer service.
• Clean the following components with a clean, lint-free cloth and a grease-dissolving, non-aggressive
cleaning agent:
◦ all surfaces in contact with adjacent components
◦ Centering
◦ the motor shaft
◦ the internal diameter of the socket
◦ the spacer sleeve inside and outside
• In addition, check the contact surfaces for damage and foreign particles.

Mechanical installation
AG100018 Version: 1.4
7.2 Installing the planetary gear unit
For installation of the planetary gear at the stepper motor please note the following:
• The planetary gear of the AG1000-xxxx series are supplied with a separate adapter shaft and
integrated sun wheel.
• Slide the adapter shaft onto the stepper motor shaft up to the end stop and secure it with a heat
resistant, industrial adhesive (e.g. WEICONLOCK AN306-60).
• Before applying the adhesive to the adapter shaft, clean the motor shaft with a suitable solvent.
• A cotter pin (not included) can be inserted through the mounting hole.
• Slide the gear unit onto the motor shaft. Screw the gear flange to the motor flange. Ensure the screws
are tightened evenly to avoid tensions in the component.
7.2.1 Mounting the gear
Order of assembly:
• Clean the motor shaft and the sun wheel with isopropanol. Remove all dirt particles from the motor
shaft or sun wheel. Carefully dry all the components.
• Wet the sun wheel and the motor shaft with the adhesive WEICONLOCK AN 306-60. Make sure that
the adhesive is evenly distributed over the complete motor shaft.
NOTE
Damage to the gear unit!
When wetting the motor shaft, make sure that no adhesive runs into the interior of the component! There is
a danger of components sticking and impairing the function of the gear unit!
Hardening time of the adhesive!
WEICONLOCK AN 306-60 is an anaerobic adhesive. It hardens immediately on contact with metal
and the exclusion of oxygen. Note that the components can no longer be moved after gluing. The
adhesive is completely hardened after 10 to 15 minutes.
• Now wet the threaded holes of the gear unit with a screw-locking compound. Make sure that all threads
are completely wetted.
• Push the motor onto the gear unit and fix both components.
• Now fasten the gear unit to the motor with the four hex socket-head screws. Tighten the screws
diagonally. Observe the specified tightening torque.
Sun wheel Gear AG1000
Stepper motor AS1000
Through thread
Through hole
Mounting screws
Motor shaft

Technical data of the planetary gear units
AG1000 19Version: 1.4
8 Technical data of the planetary gear units
Beckhoff offers planetary gears for stepper motors in order to increase the torque or to improve the mass
inertia ratio. Stepper motors whose flanges have dimensions of 56 mm or above can be fitted with low-play
planetary gears.
AG1000-+PM052.00x AG1000-+PM081.00x
Rated torque 4 Nm 20 Nm
Acceleration torque 6 Nm 30 Nm
Gear play ≤ 0,7° ≤ 0,5°
Max. radial power 200 N 400 N
Max. axial power 60 N 80 N
Stepper motors AS1030 and AS1050 AS1060
Fastening screws 4 x M4 4 x M6
Tightening torque 2.8 Nm 9 Nm
Operating temperature -30 °C at + 120°C
Protection class DIN EN 60529
Operating factor CB = 1,0 (3h/day)
x = ratio 4 (3.7 exactly or 63/17 as a fraction), ratio 7 (6.75 exactly or 27/4 as a fraction)
Gear rim and planet wheels in steel design, straight-toothed. Lubricant Klübersynth GE14-151

Technical data of the planetary gear units
AG100020 Version: 1.4
8.1 PM052
8.1.1 Dimensional drawing PM052
Ø12 h7
Ø32 h8
3
4
25
±
0.7
73.8
±
0.6
Installation dimension
at motor flange
8.3
+0.3
Ø52
Ø
40
56
47.14
Ø6.35 H7+0.015
Ø38.1 H7+0.025
Father key DIN 6885 - A 4x4x16
Ztr. DIN 332 - D M4
M5x10
M4
8.2 PM081
8.2.1 Dimensional drawing PM081
-0.25
+0.006
-0.01
102.1±0.6 49±0.7
5
5.5
Ø81
Ø73F7
14H7
86
Ø65
69,6
Ø19 h7
Ø50
Installation dimension 13.5+0.15
at motor flange
15
Ztr. DIN 332 - D M6
Father key DIN 6885 _ A 6x6x28
M5x12
M6x10