Startup Servo Drive AX5000 (1.5 A – 40 A) Please read this document carefully before installing and commissioning the servo drive. Version : 4.5 Date: 2015-04-01 Language: English Article no.
BECKHOFF Drive Technology 1 Foreword Notes: 2 Version : 4.
BECKHOFF Drive Technology 1 Foreword Chapter Table of Contents - AX5000 Startup 1 Page Foreword............................................................................................................... 5 Notes on the documentation............................................................................... 5 Disclaimer........................................................................................................... 5 Trademarks ...........................................................
BECKHOFF Drive Technology 1 Foreword 4.7.1 4.7.2 4.7.3 4.7.4 4.7.5 4.7.6 4.7.7 4.7.8 4.7.9 4.7.10 4.7.11 4.7.12 4.8 X01 - wide voltage input ................................................................................... 23 X02 - DC link (AX5101 - AX5125 und AX520x)................................................ 23 X02 - DC link (Only AX5140)............................................................................ 23 X03 - 24 VDC supply .............................................................
BECKHOFF Drive Technology 1 Foreword 1 Foreword 1.1 Notes on the documentation This description is only intended for trained specialists in control, automation and drive engineering who are familiar with the applicable national standards. It is essential that the following notes and explanations are followed when installing and commissioning these components.
BECKHOFF Drive Technology 1 Foreword 1.5 Copyright © Beckhoff Automation GmbH & Co. KG 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. 1.6 Version 4.5 4.4 4.3 4.2 4.1 4.0 3.9 3.8 3.7 3.6 3.5 3.4 3.3 3.2 3.
BECKHOFF Drive Technology 3.0 Chapter-Update: 4.2.1; 4.4.2.2; 4.4.4; 4.8; 5.1.1.2; 5.2.1.1 New chapter: 1.8; 4.6; 4.7.9; 4.7.11; 7 Chapter-Update: 4.6.7; 6 Chapter-Update: 1.1; 1.2; 1.5; 4.5; 5.2 New chapter: 1.3; 1.4 Chapter-Update: 2.2; 5.2.3.1 New chapter: 6 Chapter-Update: 2.2; 3.1; 4.6.6; 4.6.8; 5.1.1; 5.2.1.5 Chapter-Update: 4.1; 4.6.6; 5.2.3 General revision on account of the UL-Listing of the AX5000. Chapter-Update: 1.1; 4.4.2.1; 4.4.2.2; 4.4.3.1; 4.4.3.2; 5.2.1; 5.2.1.
BECKHOFF Drive Technology 1 Foreword Council Regulation 428/2009 has been changed accordingly, Frequency inverters (listed in item position 3A225) with „operating frequency of 600 Hz or more“ are now export controlled items. As a consequence some modifications have to be noticed. Firmware versions without extension (Dual Use) can be used in consideration of Hardware Versions with following drives: • HW Version 1.0 (AX5xxx-0000-x0xx): Serial Number < 68.000 • HW Version 2.
BECKHOFF Drive Technology 2 Safety 2 Safety 2.1 General safety instructions 2.1.1 Safety rules Consider the following safety instructions and descriptions! Product specific safety instructions are to be found on the following pages or in the areas mounting, wiring, commissioning etc.. 2.1.2 Disclaimer All the components are supplied in particular hardware and software configurations appropriate for the application.
BECKHOFF Drive Technology 2 Safety 2.1.4 Personnel qualification This description is only intended for trained specialists in control, automation and drive engineering who are familiar with the applicable national standards. 2.2 Special safety instructions for AX5000 The safety instructions are designed to avert danger and must be followed during installation, commissioning, production, troubleshooting, maintenance and trial or test assemblies.
BECKHOFF Drive Technology 2 Safety Hazard to individuals! CAUTION • Carefully read this manual before using the servo drive 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 servo drive. • Only well trained, qualified electricians with sound knowledge of drive equipment may work on the device.
BECKHOFF Drive Technology 3 Guidelines and Standards 3 Guidelines and Standards 3.1 CE conformity The servo drives of the AX5000 series comply with the • EC Low-Voltage Directive, 2006/95/EC Applied harmonised standards: 61800-5-1 CAUTION 3.2 Hazard to individuals! Servo drives are not covered by the EC Machinery Directive.
BECKHOFF Drive Technology 3.3 3 Guidelines and Standards UL-Listing in USA and Canada The following servo drives from the AX5000 series have a UL-Listing and must bear the CUS symbol AX5000 with UL-Listing AX5101, AX5103, AX5106, AX5112, AX5118, AX5125, AX5140, AX5201, AX5203 und AX5206 on the name plate. If you wish to operate an AX5000 in USA or Canada , please check that there is a CUS symbol on the name plate. Below is a list of the relevant chapters that are amended with respect to the UL-Listing.
BECKHOFF Drive Technology 3 Guidelines and Standards When protected by RK5 class fuses: AX5112 Rated 20 A, min. 480 V AX5118 Rated 35 A, min. 480 V AX5125 Rated 45 A, min. 480 V AX5140 Rated 80 A, min. 480 V 3.3.3 UL-specific notes Use in a Pollution Degree 2 environment Use 75 °C Copper Conductors min. Control Board rating = 24 V Drive intended for use over a range of motor sizes.
BECKHOFF Drive Technology 4 4 Product description Product description The servo drives of the AX5000 series are available as single- or multi-channel versions and are optimised in terms of function and cost-effectiveness. In conjunction with EtherCAT, the real-time Ethernet system, the integrated control technology offers minimum cycle times and supports fast, highly dynamic positioning tasks. 4.
BECKHOFF Drive Technology 4 Product description 4.2.2 Accessories A comprehensive list of accessories can be found in the complete Beckhoff catalogue or on our website at www.beckhoff.com. Accessories with UL-Listing! If you wish to operate an AX5000 in USA or Canada , please make sure that the accessories also have a UL-Listing. 4.3 Name plate The servo drive features two name plates. A comprehensive name plate can be found on the right-hand side.
BECKHOFF Drive Technology 4.4 4 Product description Technical data UL-Listing! It is essential to observe chapter 3.3 if you wish to operate an AX5000 in USA or Canada. 4.4.
BECKHOFF Drive Technology 4 Product description Electrical data S1 mode (selection) 120 V 230 V (2) Power dissipation Max. continuous braking power (with internal brake resistor) Max. braking power (with internal brake resistor) Min. brake resistor (external brake resistor) Max. braking power (with external brake resistor) AX5101 AX5103 AX5106 0.3 kVA 0.6 kVA 35 W 0.6 kVA 1.2 kVA 50 W 1.2 kVA 2.4 kVA 85 W 50 W 50 W 150 W 14 kW 47 Ω 15 kW (1) Ieff for max.
BECKHOFF Drive Technology 4 Product description 4.4.3 Electrical data - two-channel servo drive (AX52xx) 4.4.3.1 Single-phase connection Electrical data AX5201 AX5203 AX5206 Rated output current / channel 1.5 A 3A 6A Minimum channel current at full current 0.35 A 1A 1A resolution Maximum rated channel current 3A 4.5 A 9A Total rated output current 3A 4.5 A 9A (1) Max. output current /channel 5A 10 A 13 A (1) Max.
BECKHOFF Drive Technology 4 Product description Electrical data 230 V 400 V 480 V (2) Power dissipation Max. continuous braking power (with internal brake resistor) Max. braking power (with internal brake resistor) Min. brake resistor (external brake resistor) Max. braking power (with external brake resistor) (1) (2) AX5201 1.2 kVA 2.1 kVA 2.5 kVA 55 W AX5203 2.4 kVA 4.2 kVA 5.0 kVA 85 W 50 W 150 W AX5206 4.8 kVA 8.3 kVA 10.0 kVA 160 W 90 W 14 kW 47 Ω 15 kW Ieff for max.
BECKHOFF Drive Technology 4.5 4 Product description General overview (AX5101 – AX5112 and AX520x) The servo drive shown below is a two-channel device. Components that are only available for the second channel are identified in the item description.
BECKHOFF Drive Technology 4 Product description 4.6 General overview (AX5118, AX5125 und AX5140) The servo drive illustrated below is an AX5140; the devices with 18 A or 25 A are structurally similar apart from pos. 11 "X07" (external brake resistor).
BECKHOFF Drive Technology 4 Product description 4.7 Overview of connectors/terminal points 4.7.1 X01 - wide voltage input Connection 3-phase 1-phase Phase L1 Phase L1 Phase L2 not used Phase L3 Neutral conductor Protective conductor Terminal point L1 L2 L3/ N PE 4.7.2 0,5 -0,6 Nm X02 - DC link (AX5101 - AX5125 und AX520x) Terminal point Connection DC+ DC – 4.7.
BECKHOFF Drive Technology 4 Product description 4.7.5 X04, X05 - EtherCAT connection Terminal point X04 (IN) X05 (OUT) 4.7.6 Connection incoming EtherCAT line outgoing EtherCAT line X06 – Digital I/Os Destruction of the AX5000! CAUTION This connector is not designed for external power supply. It is supplied via the 24 V supply (Up) of connector X03. Output current Note The specified output currents are maximum values. The actual values depend on your current configuration.
BECKHOFF Drive Technology 4.7.7 4 Product description X11 (channel A) , X21 (channel B) - feedback, high-resolution Pin EnDAT / BiSS Hiperface Sin / Cos 1Vpp 1 SIN + SIN + SIN + 2 GND_5 V GND_9 V GND_5 V 3 COS + COS + COS + *) *) 4 US_5 V n.c. US_5 V 5 DX + (Data) DX + (Data) n.c. *) 6 n.c. US_9 V n.c. 7 n.c. n.c. REF Z 8 CLK + (Clock) n.c. n.c. 9 REFSIN REFSIN REFSIN 10 GND_Sense n.c. GND_Sense 11 REF COS REF COS REF COS 12 US_5 V Sense n.c. US_5 V Sense 13 DX - (Data) DX - (Data) n.c. 14 n.c. n.c.
BECKHOFF Drive Technology 4 Product description 4.7.9 X13 (channel A) , X23 (channel B) - motor connection (power) (AX5101 - AX5125 und AX520x) Terminal point U V+ W PE Shroud 4.7.10 Connection Motor connection U Motor connection V Motor connection W Protective conductor Screen X13 - motor connection (power - only AX5140) Terminal point U V+ W PE Shroud Connection Motor connection U Motor connection V Motor connection W Protective conductor Screen Grounding shield! Attention 4.7.
BECKHOFF Drive Technology 4 Product description AX5000-xxxx-0200 (Hardware 2) Terminal point Connection TOCT – and temperature T+ OCT + and temperature PE Signal pair screen BBrake GND B+ Brake (Up) + Output current 2.2 A max. Output current Note 4.7.12 The specified output current is the maximum value. The actual value depends on your current configuration.
BECKHOFF Drive Technology 4 Product description 4.8 Dimensions The specified measurements relate to the actual device, without connectors and cables. The fitting dimensions for control cabinet installation can be found in section "Mechanical installation Installation examples". AX5118, AX5125 and AX5140 AX5101-AX5112 / AX5201-AX5206 All dimensions are in mm 28 Version : 4.
BECKHOFF Drive Technology 4 Product description AX5000 without AX bridge AX5000 with AX bridge All dimensions are in mm AX5000 Version : 4.
BECKHOFF Drive Technology 5 Installation 5 Installation Caution – Risk of injury! WARNING • The servo drives may only be installed by trained, qualified personnel. The qualified personnel must know and comply with the national accident prevention regulations. • Safety boots must be worn. Caution - Risk of injury through electric shock! WARNING 5.1 De-energise all electrical components (servo drive, control cabinet, etc.) before commencing the installation or deinstallation.
BECKHOFF Drive Technology 5 Installation 5.1.1.1 Installation example - AX5101-AX5112 and AX5201-AX5206 5.1.1.2 Installation example - AX5118, AX5125 and AX5140 AX5000 Version : 4.
BECKHOFF Drive Technology 5 Installation 5.2 Electrical installation UL-Listing! It is essential to observe chapter 3.3 if you wish to operate an AX5000 in USA or Canada. Serious risk of injury through electric shock! DANGER Due to the DC link capacitors dangerous voltage may persist at the DC link contacts "X02" after the servo drive has been disconnected from the mains supply. After disconnecting the servo drive wait 5 minutes and measure the voltage at the DC link contacts DC+ and DC-.
BECKHOFF Drive Technology 5.2.1 5 Installation Mains supply connection (X01) The servo drives of the AX5000 series are equipped with a wide voltage input "X01" and can be connected to voltage systems between single-phase 100 VAC -10% - 240 VAC +10%and three-phase 100 VAC -10% - 480 VAC +10%. Connection to the standard mains supply (TT/TN) with earthed centre is described below. Details for connections to other supply systems (e.g. ITmains supply, isolating transformer etc.
BECKHOFF Drive Technology 5 Installation 5.2.1.3 External protection, UL-compliant Integral solid state short circuit protection does not provide branch circuit protection. Branch circuit protection must be provided in accordance with the Manufacture Instructions, National Electrical Code and any additional local codes. Suitable for use on a circuit capable of delivering not more than 18000 rms symmetrical amperes, 480 V maximum, when protected by RK5 class fuses.
BECKHOFF Drive Technology 5.2.1.5 External drive system protection Rule of thumb: Example: 5 Installation Determine the total device rated current, multiply by correction factor and round it up to the next higher standard level. 1 x AX5103 + 2 x AX5201 + 2 x AX5203 + 12 A = 21 x 1,1 = 23,1 A selected 25 A 3A + 6A Special requirements for a drive system Please consult our Application Department with respect to the special requirements for a drive system with UL-Listing. AX5000 Version : 4.
BECKHOFF Drive Technology 5 Installation 5.2.2 24 VDC - supply network connection (X03) The 24 VDC connection "X03" is used for supplying control electronics and periphery with DC voltage. The control electronics and the periphery can be supplied separately with two different voltage sources. If one transformer is used for the 24 VDC power supply, the connections US and UP must be bridged, in order to ensure that both the control electronics and the periphery are supplied.
BECKHOFF Drive Technology 5.2.3.1 5 Installation Connection example - module AX5901 and AX5911 (AX Bridge) This connection option enables a safe system to be set up very quickly. The modules are attached to plug contacts X01, X02 and X03, the relevant slides are pushed to the left and screwed tight. According to CE the current carrying capacity of power busbars of the AX Bridge is limited to 85 A.
BECKHOFF Drive Technology 5 Installation 5.2.3.2 Connection example - wiring in series without AX Bridge Wire the relevant connections using individual cables. Hazard to inviduals and equipment CAUTION • Please ensure that the final supply network connection cable is adequately dimensioned. The dimensioning depends on the total rated current and must comply with EN60204-1. • To establish a DC link system wire the X02 connections with a suitable cable. Voltages up to 890 V may be present.
BECKHOFF Drive Technology 5.2.4 AX5000 5 Installation Configuration example, general Version : 4.
BECKHOFF Drive Technology 5 Installation 5.2.5 40 Connection diagram AX5101 – AX5112 and AX520x Version : 4.
BECKHOFF Drive Technology 5.2.6 AX5000 5 Installation Connection diagram AX5118, AX5125 and AX5140 Version : 4.
BECKHOFF Drive Technology 5 Installation 5.3 Motors and cables With longer motor cables the resulting commutation currents can affect the control quality and lead to EMC faults. Use the tables below to check whether motor chokes or mains filters have to be used in your application. When selecting the control cabinet ensure that there is adequate space for motor chokes, mains filters, etc.
BECKHOFF Drive Technology 6 6 Important information for commissioning Important information for commissioning Caution – Risk of injury! WARNING Electronic equipment is not fail-safe. The machine manufacturer is responsible for ensuring that the connected motors and the machine are brought into a safe state in the event of a fault in the drive system.
7 Project planning – important information 7 BECKHOFF Drive Technology Project planning – important information The more thoroughly a machine or plant project is thought through in advance, the less risk there is of having to carry out expensive modifications during or after commissioning. This applies to both the mechanical and electrical design. This section can only give a rough overview of electrical design.
BECKHOFF Drive Technology 7.3 7 Project planning – important information EMC, earthing, screen connection and potential The AX5000 corresponds to EMC category "C3" (industrial sector) in terms of conducted interference emissions.
BECKHOFF Drive Technology 8 Appendix 8 Appendix 8.1 Support and Service Beckhoff and their partners around the world offer comprehensive support and service, making available fast and competent assistance with all questions related to Beckhoff products and system solutions. 8.1.
