Beckhoff XTS User manual

Operating Instructions | EN
XTS
eXtended Transport System
2022-05-05 | Version 3.1

Table of contents
Version: 3.1 ─── 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............................................................................................................................................... 15
Name plate ..................................................................................................................................................... 16
Type key ......................................................................................................................................................... 18
Product characteristics ................................................................................................................................... 21
Components ................................................................................................................................................... 22
Special geometries ......................................................................................................................................... 34
Track Management......................................................................................................................................... 36
Intended use ................................................................................................................................................... 41
Technical data.................................................................................................................................................... 42
Definition......................................................................................................................................................... 42
Data for operation and environment ............................................................................................................... 43
XTS Standard ................................................................................................................................................. 44
Dimensional drawings..................................................................................................................................... 46
Scope of supply ................................................................................................................................................. 79
Packaging ....................................................................................................................................................... 79
Transport and storage....................................................................................................................................... 80
Conditions....................................................................................................................................................... 80
Long-term storage .......................................................................................................................................... 80
Mechanical installation ..................................................................................................................................... 81
Preparation ..................................................................................................................................................... 81
Mounting the modules .................................................................................................................................... 93
Fitting the guide rails..................................................................................................................................... 104
Mounting the movers .................................................................................................................................... 112
Electrical installation....................................................................................................................................... 122
Connection technology ................................................................................................................................. 122
Pin assignment of the power cable............................................................................................................... 124
Earthing of the supply ................................................................................................................................... 127
Grounding of the machine beds.................................................................................................................... 129
Fuse protection ............................................................................................................................................. 130
Commissioning................................................................................................................................................ 135
Before commissioning .................................................................................................................................. 135
During commissioning .................................................................................................................................. 135
Prerequisites during operation...................................................................................................................... 136
After operation .............................................................................................................................................. 136
Maintenance and cleaning .............................................................................................................................. 137
Cleaning agents............................................................................................................................................ 137
Intervals ........................................................................................................................................................ 138
Maintenance work on the mover .................................................................................................................... 140
Roller replacement at AT9011-0050-x550.................................................................................................... 140
Roller replacement at AT9012-0050-x550.................................................................................................... 148

Table of contents
4 ─── Version: 3.1XTS
Roller replacement at AT9014-0055-x550.................................................................................................... 156
Roller replacement at AT9011-0070-x550.................................................................................................... 164
Roller replacement at AT9014-0070-x550.................................................................................................... 172
Replacing the magnetic plate set.................................................................................................................. 181
Replacing the encoder flag ........................................................................................................................... 186
Accessories...................................................................................................................................................... 188
Cables........................................................................................................................................................... 188
Adapter for cables......................................................................................................................................... 189
Connector cards ........................................................................................................................................... 189
Alignment gauge........................................................................................................................................... 189
Rail on support.............................................................................................................................................. 190
End cap......................................................................................................................................................... 190
ESD brushes................................................................................................................................................. 190
Roller set....................................................................................................................................................... 191
Torx keyT20................................................................................................................................................ 192
Tool set for replacing spring-loaded rollers................................................................................................... 193
Assembly tool for B23 connectors ................................................................................................................ 193
Magnetic plate set......................................................................................................................................... 194
Fault correction................................................................................................................................................ 197
Motor modules .............................................................................................................................................. 197
TcIoXts object ............................................................................................................................................... 200
SoftDrive object ............................................................................................................................................ 204
Decommissioning............................................................................................................................................ 206
Disassembly ................................................................................................................................................. 206
Disposal ........................................................................................................................................................ 207

Documentation notes
Version: 3.1 ─── 5XTS
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®, Ether-
CAT G10®, EtherCAT P®, Safety over EtherCAT®, TwinSAFE®,
XFC®, XTS® and XPlanar® are registered and licensed trademarks
of Beckhoff Automation GmbH.
The use of other brand names or designations by third parties may
lead to an infringement of the rights of the owners of the corre-
sponding designations.
1.1.2Patents
The EtherCAT technology is protected by patent rights through the
following registrations and patents with corresponding applications
and registrations in various other countries:
• EP1590927
• EP1789857
• EP1456722
• EP2137893
• DE102015105702
EtherCAT® is a registered trademark and patented technology, li-
censed by Beckhoff Automation GmbH.

Documentation notes
6 ─── Version: 3.1XTS
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: 3.1 ─── 7XTS
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.
1.3Scope of the documenta-
tion
In addition to this documentation, the following documents are part
of the complete documentation:
XTS Definition
Commissioning under Twin-
CAT3
Tutorial for commissioning under
TwinCAT3, including description
of the safety function STO; Safe
Torque Off via FSoE; Safety over
EtherCAT
Instruction leaflet Accompanying document with
general notes on handling the
XTS. This is included with every
product.

Documentation notes
8 ─── Version: 3.1XTS
1.4Staff qualification
1.4
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 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: 3.1 ─── 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

Documentation notes
10 ─── Version: 3.1XTS
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", [Page
13] in the documentation. Observe the warning notes in the chap-
ters so that you can handle and work properly and safely with the
product.
1.6Explanation of symbols
Various symbols are used for a clear arrangement:
► The triangle indicates instructions that you should execute
• The bullet point indicates an enumeration
[…] The square parentheses indicate cross-references to other
text passages in the document
[+] The plus sign in square brackets indicates ordering options
and accessories
1.6.1Pictograms
In order to make it easier for you to find text passages, pictograms
and signal words are used in warning notices:
DANGER
Failure to observe will result in serious or fatal injuries.
WARNING
Failure to observe may result in serious or fatal injuries.
CAUTION
Failure to observe may result in minor or moderate injuries.

Documentation notes
Version: 3.1 ─── 11XTS
Notes
Notes are used for important information on the product. The possi-
ble consequences of failure to observe these include:
• Malfunctions of the product
• Damage to the product
• Damage to the environment
Information
This sign indicates information, tips and notes for dealing with the
product or the software.
Examples
This symbol shows examples of how to use the product or soft-
ware.
QR codes
This symbol shows a QR code, via which you can watch videos or
animations. Internet access is required in order to use it.
You can read the QR code, for example, with the camera of your
Smartphone or Tablet PC. If your camera doesn't support this func-
tion you can download a free QR code reader app for your Smart-
phone. Use the appropriate app distribution platform for your smart-
phone operating system.
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: 3.1XTS
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. The employees support
you in the programming and commissioning of complex automation
systems.
Hotline: [phone]
Fax: [phone]
e-mail: [email protected]
Web: www.beckhoff.de/support
1.7.2Training
Training in Germany takes place in our training center at the Beck-
hoff headquarters in Verl, at branch offices or, by arrangement, at
the customer's premises.
Hotline: [phone]
Fax: [phone]
e-mail: [email protected]
Web: www.beckhoff.de/training
1.7.3Service
The Beckhoff Service Center supports you with after-sales services
such as on-site service, repair service or spare parts service.
Hotline: [phone]
Fax: [phone]
e-mail: [email protected]
Web: www.beckhoff.de/service
1.7.4Download area
In the download area you can obtain product information, software
updates, the TwinCAT automation software, documentation and
much more.
Web: www.beckhoff.de/download
1.7.5Headquarters
Beckhoff Automation GmbH & Co. KG
Hülshorstweg 20
33415 Verl
Germany
Phone: [phone]
Fax: [phone]
e-mail: [email protected]
Web: www.beckhoff.de
The addresses of the international Beckhoff branch offices can be
found on the Beckhoff website: http://www.beckhoff.de

For your safety
Version: 3.1 ─── 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 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.
2.1.1Before 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: 3.1XTS
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 GND concept
Special conditions need to be observed for the grounding of the
XTS. In every case, read the chapter: Grounding of the power sup-
ply.
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.
Refer here to the chapter: "Technical data". Provide for adequate
cooling and switch the components off immediately if the tempera-
ture 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.
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206].

Product overview
Version: 3.1 ─── 15XTS
3
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
16 ─── Version: 3.1XTS
3.1Name plate
3.1
Item number Explanation
1 Product designation
2 Link / Act status LED
3 Status LED ECAT Run
4 CE conformity
5 UKCA marking
6 EAC marking
7 cURus approval
8 WEEE compliance
9 EtherCAT marking
10 24V | 4A power supply status LED
11 48V | 16A power supply status LED
12 Firmware and hardware revision
13 XML sensor PCB revision number
14 XML motor PCB revision number
15 BTN number
16 DataMatrix code
17 Date of manufacture - week/year

Product overview
Version: 3.1 ─── 17XTS
3.1.1DataMatrix code
3.1.1
The Data Matrix code can be found on all movers and modules. If
there is no BTN number under the Data Matrix code, you can read it
out via the Data Matrix code.
For example, you can read the Data Matrix 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 appropriate app distribu-
tion platform for your smartphone operating system.
Internet access is not required to use the app and to read out these
Data Matrix codes.
Example scan on a straight module
This example shows how to read the BTN number on a smart-
phone screen after a scan.
► Scan the Data Matrix code[1]
► Read the BTN number[1] from the screen of your end device via
the camera or the reader app

Product overview
18 ─── Version: 3.1XTS
3.2Type key
3.2.1Motor modules
AT 20xx–0xxx–000x Explanation
AT Product area
AT = drive technology
20 Product type
20 = module
xx Module variants
00 = straight
01 = straight with supply
02 = straight with connector*
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
42 = 45.0° curve with connector*
50 = 180.0° curve, clothoid
0xxx Product length
Module length in mm
233 = 233mm
249 = 249mm
250 = 250mm
500 = 500mm
000x Execution
2 = Black Line
3 = Standard with supply, UL-certified
4 = Black Line with supply, UL-certified
The ordering information is not extended with standard
modules.
* The connector can be rotated on the name plate side by default. The connector with ordering option
ZX2002-0001 can be rotated on the feedback side of the module.

Product overview
Version: 3.1 ─── 19XTS
3.2.2Mover
AT 901x-00xx-yz50 Explanation
AT Product area
AT = drive technology
901 Product type
901 = mover
x Roller variants
1 = mover,6 rollers
2 = mover,12 rollers
4 = mover, 6 rollers, 2 of which are spring-loaded
00xx Product length
Mover length in mm
50 = 50 mm
55 = 55 mm
70 = 70 mm
y Magnetic plate set
0 = Standard
1 = Mover 1
z Magnetic poles of the magnetic plate set
4 = 4 poles
5 = 5 poles
50 Length of the magnetic plate set
50 = 50mm

Product overview
20 ─── Version: 3.1XTS
3.2.3Guide rails
AT 9xxx–xxxx–00xx Explanation
AT Product area
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 = 45.0° curve
50 = 180.0° curve, clothoid
42 = 360.0° full circle consisting of four elements
with one lock
xxxx Product length
Rail length in mm
0249 = 249mm
0250 = 250mm
0500 = 500mm
0750 = 750mm
…
2250 = 2250mm
2500 = 2500mm
00xx Extension of the ordering information by
0055 = when using 55mm movers
AT9014‑0055‑x550
0070 = when using 70mm movers
AT9011‑0070‑x550
0170 = when using 70mm movers
AT9014‑0070‑x550
For standard guide rails the ordering information is not
extended.