Beckhoff AL8200 User manual
Operating instructions | EN
AL8200
Magnetic Encoder system (MES) for Linear motors AL8000
4/6/2023 | Version 1.0
Table of contents
Version: 1.0 ─── 3AL8200
Table of contents
1 Documentation notes.................................................................................................................................. 5
1.1 Disclaimer ............................................................................................................................................. 5
1.1.1 Trademarks................................................................................................................................ 5
1.1.2 Patents....................................................................................................................................... 5
1.1.3 Limitation of liability.................................................................................................................... 6
1.1.4 Copyright.................................................................................................................................... 6
1.2 Version numbers ................................................................................................................................... 7
1.3 Scope of the documentation ................................................................................................................. 7
1.4 Staff qualification................................................................................................................................... 8
1.5 Safety and instruction............................................................................................................................ 10
1.6 Explanation of symbols ......................................................................................................................... 10
1.6.1 Pictograms ................................................................................................................................. 10
1.7 Beckhoff Services ................................................................................................................................. 12
1.7.1 Support services ........................................................................................................................ 12
1.7.2 Training offerings ....................................................................................................................... 12
1.7.3 Service offerings ........................................................................................................................ 12
1.7.4 Headquarters Germany ............................................................................................................. 12
1.7.5 Downloadfinder .......................................................................................................................... 13
2 For your safety ............................................................................................................................................ 14
2.1 General safety instructions.................................................................................................................... 14
2.1.1 Before operation ........................................................................................................................ 14
2.1.2 During operation ........................................................................................................................ 15
2.1.3 After operation ........................................................................................................................... 16
3 Product overview ........................................................................................................................................ 17
3.1 Name plate............................................................................................................................................ 18
3.2 Type key................................................................................................................................................ 18
3.3 Ordering options.................................................................................................................................... 19
3.3.1 Connection cable ....................................................................................................................... 19
3.4 Product characteristics.......................................................................................................................... 20
3.5 Intended use ......................................................................................................................................... 21
3.5.1 Improper use.............................................................................................................................. 21
4 Technical data ............................................................................................................................................. 22
4.1 Definitions ............................................................................................................................................. 22
4.1.1 Technical terms.......................................................................................................................... 22
4.2 Properties.............................................................................................................................................. 22
4.3 Dimensional drawings ........................................................................................................................... 23
5 Scope of supply........................................................................................................................................... 24
5.1 Packaging ............................................................................................................................................. 24
6 Transport and storage ................................................................................................................................ 25
6.1 Conditions ............................................................................................................................................. 25
6.2 Transport............................................................................................................................................... 25
6.3 Long-term storage................................................................................................................................. 25
7 Mechanical installation ............................................................................................................................... 27
Table of contents
4 ─── Version: 1.0AL8200
7.1 Requirements........................................................................................................................................ 27
7.2 Assembly............................................................................................................................................... 27
7.3 Verification ............................................................................................................................................ 28
8 Electrical installation .................................................................................................................................. 29
8.1 Connection technology.......................................................................................................................... 29
8.1.1 Cables........................................................................................................................................ 29
8.2 Connector assignment .......................................................................................................................... 30
8.2.1 AL8200-0000-0000 .................................................................................................................... 30
8.2.2 AL8200-0001-0000 .................................................................................................................... 30
9 Commutation and commissioning ............................................................................................................ 31
9.1 Commutation......................................................................................................................................... 31
9.2 Commissioning...................................................................................................................................... 32
10 Maintenance and cleaning.......................................................................................................................... 37
10.1 Cleaning agents .................................................................................................................................... 37
10.1.1 Not applicable ............................................................................................................................ 37
11 Accessories ................................................................................................................................................. 38
11.1 ZK4510-0020-xxxx ................................................................................................................................ 38
12 Decommissioning ....................................................................................................................................... 39
12.1 Disassembly.......................................................................................................................................... 39
12.2 Disposal ................................................................................................................................................ 40
12.2.1 Returning to the vendor ............................................................................................................. 40
13 Guidelines and Standards .......................................................................................................................... 41
13.1 Standards.............................................................................................................................................. 41
13.2 Guidelines ............................................................................................................................................. 41
13.3 Test centers .......................................................................................................................................... 41
13.4 EU conformity........................................................................................................................................ 42
13.5 CCC conformity..................................................................................................................................... 42
14 Notes ............................................................................................................................................................ 43
Documentation notes
Version: 1.0 ─── 5AL8200
1 Documentation notes
1.1 Disclaimer
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.
1.1.1 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 by third parties of other brand names or trademarks con-
tained in this documentation may lead to an infringement of the
rights of the respective trademark owner.
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
6 ─── Version: 1.0AL8200
1.1.3 Limitation 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
1.1.4 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
Version: 1.0 ─── 7AL8200
1.2 Version 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.
1.3 Scope of the documentation
Apart from these operating instructions, the following documents are
part of the overall documentation:
Document Definition
AL8000 Translation of the origi-
nal instructions
Description of the mechanical
and electrical characteristics as
well as all the information re-
quired for operating the motors
Documentation notes
8 ─── Version: 1.0AL8200
1.4 Staff qualification
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 ─── 9AL8200
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: 1.0AL8200
1.5 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 doc-
umentation. Observe the warning notes in the chapters so that you
can handle and work properly and safely with the product.
1.6 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 parentheses indicate cross-references to other
text passages in the document
[+] The plus sign in square brackets indicates ordering options
and accessories
1.6.1 Pictograms
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 ─── 11AL8200
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: 1.0AL8200
1.7 Beckhoff Services
Beckhoff and its international partner companies offer comprehen-
sive support and service. A detailed overview of our worldwide tech-
nical support is online available at global availability.
Web: www.beckhoff.com/en-en/support/global-availabil-
ity/
1.7.1 Support services
The Beckhoff Support offers technical advice on the use of individ-
ual Beckhoff products and system planning. Our support engineers
provide competent support whether the customer has general ques-
tions or needs help with a specific installation.
Hotline: +495246963-157
Mail: [email protected]
Web: www.beckhoff.com/en-en/support/our-support-ser-
vices/
1.7.2 Training offerings
We offer worldwide training courses for our products and technolo-
gies, always concentrating on direct local resources for our cus-
tomers. Please note that we offer both traditional classroom and on-
line training courses to best suit your needs.
Hotline: +495246963-5000
Mail: [email protected]
Web: www.beckhoff.com/en-en/support/training-offer-
ings/
1.7.3 Service offerings
Our experts stand ready to provide support worldwide in all areas of
after-sales service.
Hotline: +495246963-460
Mail: [email protected]
Web: www.beckhoff.com/en-en/support/our-service-of-
ferings/
1.7.4 Headquarters Germany
Beckhoff Automation GmbH & Co. KG
Hülshorstweg 20
33415 Verl, Germany
Phone: +495246963-0
Mail: [email protected]
Web: www.beckhoff.com/en-en/
A detailed overview of our worldwide locations is online available at
global presence.
Web: www.beckhoff.com/en-en/company/global-pres-
ence/
For your safety
14 ─── Version: 1.0AL8200
2 For your safety
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.
2.1 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.
2.1.1 Before 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.
Danger from magnetic fields
Magnetic fields on individual components of the AL8000 linear ser-
vomotors pose a risk to:
• persons with cardiac pacemakers or implanted or external defib-
rillators
• persons with magnetically conducting implants
• 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.
Danger due to magnetic attraction
The magnetic plates contain permanent magnets and attract other
ferromagnetic objects. The high attractive forces cannot be con-
trolled by hand.
Ensure a safety distance of at least 25 cm from the magnetic plate
to other ferromagnetic parts, e.g. iron.
Observe the requirements of BGV B 11 for electromagnetic fields
(Germany) and applicable national regulations in other countries.
For your safety
Version: 1.0 ─── 15AL8200
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.
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.
Avoid spalling of the sealing compound due to hard knocks
In case of improper use or due to hard knocks, the sealing com-
pound can spall and the product can be damaged.
Use the original packaging only
Use the original packaging for dispatch, transportation, storage and
packing.
2.1.2 During operation
Do not work on live electrical parts
Ensure that the protective conductor is connected properly. Measure
the voltage on the DC link test contacts DC+ und DC-. Do not work
on the linear motor until the voltage has dropped below 50 V DC.
Never loosen electrical connections when live. Disconnect all com-
ponents from the mains and secure them against being switched on
again.
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.
For your safety
16 ─── Version: 1.0AL8200
Avoid overheating
Activate and monitor the temperature contact of the motor. Provide
for sufficient cooling. Switch off the motor immediately if the temper-
ature 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.
2.1.3 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".
Product overview
Version: 1.0 ─── 17AL8200
3 Product overview
12
3
4
Item number Explanation
1 Cable
2 Thread for mounting on the machine carriage
3 Mounting plate
4 Holes for locating pins
Product overview
18 ─── Version: 1.0AL8200
3.1 Name plate
Item number Explanation
1 Article name
2 Article description
3 Order number
4 BTN = Beckhoff-Traceability-Number
5 CE conformity
6 WEEE conformity
7 UKCA conformity
8 Data matrix code; BIC = Beckhoff Identification Code
3.2 Type key
AL8200-000z-0000 Ordering option
AL8200 Product area
Magnetic encoder system for linear motors
000z Connection technology
0 = without connector plug and 3m cable
1 = with connector plug and 0.5m cable
-0000 not used
Product overview
Version: 1.0 ─── 19AL8200
3.3 Ordering options
Ordering options are defined via the type key. The listed compo-
nents cannot be retrofitted.
3.3.1 Connection cable
You have the option of ordering the AL8200 MES with a pre-assem-
bled connection cable with open ferrules or with a plug.
3.3.1.1 Ferrules
If you do not require a plug, you can order the
connection cable with ferrules.
3.3.1.2 Connector
The following connector variant is used:
• EMC encoder coupling M23
Product overview
20 ─── Version: 1.0AL8200
3.4 Product characteristics
Magnetic encoder system
AL8200 is used as feedback system for AL8000 linear motors. The
installed Hall sensors measure the magnetic field of the magnetic
track, so that no additional measuring element needs to be mounted
parallel to the magnetic track.
Part-absolute positioning
The alternating magnetic field of the magnetic track generates a
sine-cosine waveform. Part-absolute positioning is thus possible
within one signal period. This means that a commutation determina-
tion only has to be carried out once during initial commissioning.
The encoder signals can be used for commutation, speed and posi-
tion control.
Absolute positioning is not possible with the AL8200.
Analog output signal
The position is forwarded by the AL8200 as an analog SinCos signal
to the servo drive. The servo drive must be suitable for reading ana-
log linear feedback systems, such as AX5000.
Accessories for AL8000
AL8200 can only be used as an accessory for the AL8000 linear
motors. The installed Hall sensors are adapted to the pole pair dis-
tance (24mm) of the AL8000.
Dust-protected IP64 housing
The MES is fully potted and IP64 protected, making the product
dustproof and suitable for temporary submersion.
Table of contents
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