Beckhoff AX2040 Assembly, Installation, Setup Download Page 1

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Assembly, Installation, Setup

Keep all product manuals as a product component

during the life span of the servo amplifier.

Pass all product manuals to future

users / owners of the servo amplifier.

Edition 06/2007

Digital Servo Amplifier

AX2040/2070

Summary of Contents for AX2040

Page 1: ...Setup Keep all product manuals as a product component during the life span of the servo amplifier Pass all product manuals to future users owners of the servo amplifier Edition 06 2007 Digital Servo...

Page 2: ...timing diagramm motor brake dispo sal acc to WEEE 2002 96 EG new structure SynqNet removed Quickstart integrated warnings updated WINDOWS is a registered trademark of Microsoft Corp HIPERFACE is a reg...

Page 3: ...2 Technical data 18 6 2 1 Recommended torques 19 6 2 2 Fusing 19 6 2 3 Ambient conditions ventilation mounting position 19 6 2 4 Conductor cross sections 20 6 3 LED display 20 6 4 Grounding system 20...

Page 4: ...2 1 Connection to a AX20 master 5 V signal level X5 57 8 12 2 Connection to incremental encoder master with 24 V signal level X3 57 8 12 3 Connection to a sine cosine encoder master X1 58 8 12 4 Conne...

Page 5: ...lements 81 9 3 4 Basic Setup 82 9 3 5 Motor synchronous 83 9 3 6 Feedback 84 9 3 7 Save Parameters and Restart 85 9 3 8 Jogging the Motor Speed Control 86 9 3 9 Status 87 9 3 10 Monitor 87 9 3 11 Addi...

Page 6: ...10 4 5 Modifying the station address 101 10 4 6 Modifying the baud rate and optical power 101 10 5 Expansion card DEVICENET 102 10 5 1 Front view 102 10 5 2 Connection technology 102 10 5 3 Connectio...

Page 7: ...ndling electrostatically sensitive components Unpacking only by electrically qualified personnel Installation only by electrically qualified personnel Setup only by personnel with extensive knowledge...

Page 8: ...0874 2 IEC International Electrotechnical Commission IGBT Insulated Gate Bipolar Transistor INC Incremental Interface ISO International Standardization Organization LED Light emitting diode MB Megabyt...

Page 9: ...analysis for the machine and take appropriate measures to ensure that unforeseen movements do not result in personal injury or material damage l Do not open or touch the equipment during operation Kee...

Page 10: ...ervo ampli fier may not exceed 1000V peak value Transient overvoltages 50 s between the outer conductors may not exceed 1000V Transient overvoltages 50 s between outer conductors and housing may not e...

Page 11: ...andards to be applied for conformance with the EC Low Voltage Directive 73 23 EEC EN 60204 1 Safety and Electrical Equipment in Machines EN 50178 Electronic Equipment in Power Installations EN 60439 1...

Page 12: ...178 is applied to ensure conformance with the Low Voltage Directive 3 4 2 UL and cUL Conformance This servo amplifier is listed under UL file number E195162 UL cUL certified servo amplifiers Underwrit...

Page 13: ...ble packaging l Max stacking height 3 cartons l Storage temperature 25 to 55 C max rate of change 20 C hour l Storage humidity 5 95 relative humidity no condensation l Storage duration Less than 1 yea...

Page 14: ...PC p 67 or Y adapter p 88 for parameter setting of up to 6 servo amplifiers from one PC power cable control cables fieldbus cables as lengths 5 2 Nameplate The nameplate depicted below is attached to...

Page 15: ...2007 Package Family AX20 AX2000 Voltage rating 0 230 480V Current rating 40 40A rms 70 70A rms electr option 1 AS Expansions 0000 no expansion B110 ETHERCAT B200 Lightbus B310 PROFIBUS B520 DeviceNet...

Page 16: ...mer p 46 l BB6 rectifier bridge off 3 phase earthed grounded supply integral inrush circuit l Fusing e g fusible cutout provided by the user l All shielding connections directly on the amplifier l Out...

Page 17: ...direction interface integrated for connection of a servomotor to a stepping motor control l Evaluation of the resolver signals and sine cosine signals of a high resolution encoder l Encoder simulation...

Page 18: ...Inputs Outputs Setpoint 1 2 resolution 14bit 12bit V 10 Common mode voltage max V 10 Input resistance to AGND kW 20 Digital inputs V low 0 7 high 12 36 mA 7 Digital outputs open collector V max 30 mA...

Page 19: ...sition Storage hints p 13 Transport hints p 13 Supply voltage tolerances Input power p 46 Aux power supply min 3x230V 10 AC max 3x 480V 10 50 Hz min 3x208V 10 AC max 3x 480V 10 60 Hz 24 VDC 0 15 check...

Page 20: ...voltage drop 24 V XGND max 2 5 mm 12 awg check voltage drop Regen resistor p 41 min 10 mm 6 awg shielded 1000V 105 C 221 F For multi axis systems please note the special operating conditions in your...

Page 21: ...internal ENABLE delay time of 100 ms DECDIS the speed setpoint of the servo ampli fier is internally driven down a 10 ms ramp to 0 The brake output is switched on when a speed of 5rpm is reached or af...

Page 22: ...power distribution several amplifiers even with different current ratings can be operated off a common DC bus link This is achieved by an auto matic adjustment of the regen thresholds which vary beca...

Page 23: ...for ins tance l Error message if the servo amplifier is to bring the drive to a standstill Error message F19 is output if an input phase is missing The servo amplifier is disabled and the BTB contact...

Page 24: ...ng the servo amplifier on and off Devices which are equipped with a selected Brake function use a special sequence for switching off the output stage p 21 The built in restart lock AS can be used to s...

Page 25: ...t of one or more electrical supply phases failing assuming that the standard parameter settings apply F16 F19 error messages Mains BTB input phase F05 error message Undervoltage Even if there is no in...

Page 26: ...rolled shut down whereby the energy supply to the drive machinery is maintained The parameters STOPMODE and ACTFAULT must be set to 1 in order to implement the stop categories If necessary change the...

Page 27: ...cal components may be used for the Category 0 Emergency Stop function It must not be triggered using switching logic hardware or software by transferring com mands via a communication network or via a...

Page 28: ...his type of disconnection A brake that is built into the motor must have an additional electromechanical control circuit as well as the control through the AX2040 2070 in order to meet Category 0 Usua...

Page 29: ...the speed VEL0 see sequence diagram in chapter 6 5 is undershot the holding brake is applied and the output stage is disabled As soon as two separate time periods set at the time relay have elapsed t...

Page 30: ...ndershot the holding brake is applied and the output stage is disabled In this case there is no interruption of the electrical supply If the electrical supply is switched off not only will the control...

Page 31: ...on 10mm must be used The following measures can be used to minimise leakage currents Reduce the length of the engine cable Use low capacity cables see p 41 6 9 2 Residual current circuit breakers FI I...

Page 32: ...shock hazard protection is sought the AX2040 2070 can also be operated via an isolating transformer A ground leakage monitor can be used to monitor for short circuits We would advise you to keep the l...

Page 33: ...iers and or shield the magnetic fields 7 2 Guide to mechanical installation The following notes should assist you to carry out the mechanical installation in a sensible sequence without overlooking an...

Page 34: ...mer service for information for pass through mounting Material 4 hexagon socket screws to DIN 912 M6 Tool required 5 mm Allen key A 4 038 4 12 34 AX2040 2070 Product Manual Mechanical Installation 06...

Page 35: ...7 4 Dimensions AX2040 2070 Product Manual 35 BECKHOFF 06 2007 Mechanical Installation...

Page 36: ...This page has been deliberately left blank 36 AX2040 2070 Product Manual Mechanical Installation 06 2007 BECKHOFF...

Page 37: ...on page 40 l Feedback lines may not be extended since thereby the shielding would be interrupted and the signal processing could be disturbed l The cable between servo amplifier and regen resistor mu...

Page 38: ...es are used Connect the analog setpoint if required Connect up the feedback unit resolver and or encoder Connect the encoder emulation if required Connect the expansion card see corresponding manual o...

Page 39: ...which you will find in all the wiring diagrams indicates that you must take care to provide an electrically conductive connection with the largest possible surface area between the unit indicated and...

Page 40: ...from the cores for the required length Secure the cores with a cable tie Remove the outer covering of the cable over a length of about 30mm without damaging the shielding braid Pull a cable tie throug...

Page 41: ...page 20 To operate the amplifier with the max permitted cable length you must use cable material which meets the requirements on the capacity given below Insulation material Sheathing PUR polyurethane...

Page 42: ...lectrical Installation 06 2007 BECKHOFF 24V power supply Fuses Drive contactor Terminals Motor PC Control PLC Mains choke Fuses Mains filter Regen resistor Cables drawn bold are shielded Electrical gr...

Page 43: ...8 5 Block diagram The block diagram below is just an overview AX2040 2070 Product Manual 43 BECKHOFF 06 2007 Electrical Installation...

Page 44: ...8 6 Pin assignments 44 AX2040 2070 Product Manual Electrical Installation 06 2007 BECKHOFF...

Page 45: ...duct Manual 45 BECKHOFF 06 2007 Electrical Installation AX2040 2070 Reference Safety Instructions p 9 and Use As Directed p 10 p 67 p 68 p 47 p 47 p 48 p 69 p 48 p 50 p 63 p 64 p 65 p 66 p 61 p 62 p 5...

Page 46: ...g transformer is always required for 400 480V mains networks without earth ground and for networks with asymmetrical earth ground 46 AX2040 2070 Product Manual Electrical Installation 06 2007 BECKHOFF...

Page 47: ...to patented circuit to distribute the regen power among all the amplifiers connected to the same DC bus link circuit Connection example p 89 Only servo amplifiers with mains supply from the same main...

Page 48: ...ake X0 X4 Cable cross section see motor documentation 8 10 External regen resistor X0 Fusing and regen resistor provided by the user 48 AX2040 2070 Product Manual Electrical Installation 06 2007 BECKH...

Page 49: ...ARMODE X For a detailed description of the ASCII parameters please refer to the online help of the setup soft ware The table below provides an overview of the supported feedback types their correspond...

Page 50: ...he thermostat contact in the motor is connected via the resolver cable to the AX20 and evaluated there If cable lengths of more than 100 m are planned please contact our customer service FBTYPE 0 3 50...

Page 51: ...e uploaded after that phase only the sine cosine signals are used The thermostat contact in the motor is connected via the encoder cable to X1 and evaluated there All signals are connected using our p...

Page 52: ...he resolver cable to the AX20 and evaluated there All signals are connected using our pre assembled encoder connection cable If cable lengths of more than 50 m are planned please consult our customer...

Page 53: ...out of the amplifier s EEPROM The thermostat contact in the motor is connected via the encoder cable to X1 and evaluated there If lead lengths of more than 50 m are planned please consult our custome...

Page 54: ...be used as complete feedback system combined with an additional Hall encoder All signals are connected to X1 If cable lengths of more than 25 m are planned please consult our customer service Frequen...

Page 55: ...ier s EEPROM The thermostat contact in the motor is connected to X1 see p 52 or X2 see p 50 If lead lengths of more than 50 m are planned and for questions concerning the power supply of the encoder p...

Page 56: ...SI Encoder X5 p 59 7 17 Pulse and Direction 5V X5 p 60 4 14 Pulse and Direction 24V X3 p 60 1 11 adjustable via terminal screen of the setup software The follwing table shows the allowed feedback comb...

Page 57: ...ctor X3 must be joined together 8 12 2 Connection to incremental encoder master with 24 V signal level X3 This interface can be used to operate the AX2040 2070 as a slave mastered by an encoder with 2...

Page 58: ...ne cosine encoder master slave operation The connector X1 must be used If cable lengths of more than 25 m are planned please consult our customer service Frequency limit 250 kHz AGND and DGND connecto...

Page 59: ...pper motor controllers step and direction This interface can be used to connect the servo amplifier to a third party stepper motor controller The parameters for the servo amplifier are set up with the...

Page 60: ...ector X3 must be joined together 8 12 5 2 Step Direction with 24 V signal level X3 This interface can be used to connect the servo amplifier to a stepper motor controller with 24 V signal level The di...

Page 61: ...ter Encoder function ENCMODE Feedback system Resolution Zero position ROD 1 Resolver 256 4096 one per revolution only if A B 1 Encoder 256 524288 28 219 one per revolution only if A B 1 ROD interpolat...

Page 62: ...n and for 6 pole resolvers it is within a third of a turn Exception If an encoder with a commutation track is used as the feedback unit then the upper 12 bits are set to 1 data invalid until a homing...

Page 63: ...speed setpoint Input Analog In2 terminals X3 6 7 Differential input voltage max 10 V resolution 12 bit scalable Standard setting torque setpoint Application examples for setpoint input Analog In2 adju...

Page 64: ...etting Analog Out 1 Tachometer voltage nact speed The output delivers 10 V at the preset limit speed Analog Out 2 Current actual value Iact torque The output delivers 10 V at the preset peak current e...

Page 65: ...input is freshly assigned to a pre programmed function then the data set must be stored in the EEPROM of the servo amplifier and the 24 V auxiliary supply of the servo amplifier must be swit ched off...

Page 66: ...digital outputs DIGITAL OUT 1 2 You can use the digital outputs DIGITAL OUT1 terminal X3 16 and DIGITAL OUT2 terminal X3 17 to outputs messages from pre programmed functions that are stored in the ser...

Page 67: ...hrough an optocoupler and is at the same potential as the CANopen interface The interface is selected and set up in the setup software Further notes can be found on page 76 With the optional expansion...

Page 68: ...D connector X3 must be joined together CAN bus cable To meet ISO 11898 you should use a bus cable with a characteristic impedance of 120 W The maximum usable cable length for reliable communication de...

Page 69: ...n approved by the Trade Liability Association Moving single axis groups in setting up operation In setting up operation people will frequently be within the danger zone of the machinery Axes will norm...

Page 70: ...contacts KSO1 2 for all servo amplifiers are wired into the control signal loop The AS restart lock may only be controlled by a CNC if the control of the internal safety relay is arranged for redunda...

Page 71: ...d the servo amplifier is ready for operation If the drive is electronically braked the servo amplifier is disabled and the motor holding brake is on then the safety relay is energized manually or by t...

Page 72: ...suspended loads 2 Activate the restart lock AS 3 Open protective screens but do not enter hazardous area 4 Pull off the X10 connector from an amplifier the mains contactor must drop out 5 Reconnect X1...

Page 73: ...8 17 8 Application example category 1 according to EN 954 1 8 17 8 1 Control circuit 8 17 8 2 Mains supply circuit AX2040 2070 Product Manual 73 BECKHOFF 06 2007 Electrical Installation...

Page 74: ...8 17 9 Application example category 3 according to EN 954 1 Please contact our customer service 74 AX2040 2070 Product Manual Electrical Installation 06 2007 BECKHOFF...

Page 75: ...apacitors can still have residual charges with dangerous levels up to 300 seconds after switching off the supply power Heat sinks of the amplifier can reach a temperature of up to 80 C 176 F in operat...

Page 76: ...the assistance of the setup software The PC is connected to the servo amplifier by a null modem cable p 67 The setup software provides the communication between AX2040 2070 and the PC You will find t...

Page 77: ...r WINDOWS 95a and 95b WINDOWS FOR WORKGROUPS 3 xx DOS OS2 DRIVE EXE is not executable under WINDOWS 3 xx DOS and OS2 In emergency operation is possible through an ASCII terminal emulation without user...

Page 78: ...ter 9 2 9 3 1 2 Documents You need access to these documents located on the product CD ROM you can download the latest editions from our website l Product Manual this manual l CANopen Communication Pr...

Page 79: ...fety or functionality of your application it just shows the required wiring for drive testing without load AX2040 2070 Product Manual 79 BECKHOFF 06 2007 Setup Motor Feedback Motor Power Motor Power O...

Page 80: ...ption on page 92ff If there is fault fix the problem Double Click the DRIVE EXE icon on your Windows desktop to start the software You can work offline or online with Work ONLINE now Select the interf...

Page 81: ...tion to all parameters the servo amplifier can work with Key F1 Starts Online Help for the actual screen page Menu Bar or Online HTML Help Starts Online Help with table of contents Tool Bar Save to EE...

Page 82: ...mains AC voltage Mains Phase Missing You can select either warning n05 or error F19 in case of phase loss The setting F19 disables the output stage n05 is just a message Units Acceleration Velocity P...

Page 83: ...ged Click OK If your motor has a built in brake click Yes otherwise No If Software Enable is active a warning appe ars You can proceed but after the amplifier is restarted you must check whether the h...

Page 84: ...nfiguration change cannot be performed Click OK on the warnings press F12 SW disab le and start the Feedback procedure again If everything was ok the same procedure para meter upload that has been des...

Page 85: ...plifier s EEPROM automatically and a reset command restarts the amplifier takes a few seconds For example this happens after motor or feedback selection Other parameters changed No warning appears Par...

Page 86: ...ows an E and the current rating e g for Enable 40 amps l Click the icon Oscilloscope l Select Service Mode Speed F6 then click Parameter button l Enter a safe speed The sign defines the direction of m...

Page 87: ...ual error messages A description of errors war nings can be found on page 92 Now you have setup and tested the basic functions of the drive successfully 9 3 10 Monitor Click the icon Monitor The Monit...

Page 88: ...station addresses for the individual amplifiers and the baud rate for communication by means of the keypad on the front panel p 91 9 4 2 Baud rate for CAN bus After changing the station address and b...

Page 89: ...9 4 3 Example of connections for a multi axis system AX2040 2070 Product Manual 89 BECKHOFF 06 2007 Setup AX2040 2070 AX2040 2070 Reference Safety Instructions p 9 and Use As Directed p 10...

Page 90: ...itching on the 24V supply 9 5 1 Key operation The two keys can be used to perform the following functions Key symbol Functions press once go up one menu item increase number by one press twice in rapi...

Page 91: ...Extended menu structure Keep the right key pressed while switching on the 24V supply AX2040 2070 Product Manual 91 BECKHOFF 06 2007 Setup see p 88 the entry will be stored automatically when you exit...

Page 92: ...ceeded F16 Supply BTB RTO 2 or 3 phases missing in the mains supply feed F17 A D converter Error in the analog digital conversion normally caused by ex treme electromagnetic interferences F18 Regen Re...

Page 93: ...es loaded n13 Slot warning 24V supply of the I O expansion board is missing n14 SinCos feedback SinCos commutation wake shake not completed will be canceled when amplifier is enabled and wake shake ca...

Page 94: ...uence check brake control check mechanism set no of motor poles set up feedback correctly motor oscillates gain too high speed controller shielding in feedback cable broken AGND not wired up reduce Kp...

Page 95: ...n option slot l Push the expansion card carefully into the provided guide rails of the main slot without twisting it l Press the expansion card firmly into the slot until the front cover touches the f...

Page 96: ...ical data Control inputs 24V 7mA PLC compatible Signal outputs 24V max 500mA PLC compatible Supply inputs to IEC 1131 24V 18 36V 100mA plus total current of the outputs depends on the input wiring of...

Page 97: ...MT_Restart Continues the motion task that was previously interrupted The motion task can also be continued by an appropriately configured digital input on the basic unit 2 In Start_MT I O Start of the...

Page 98: ...10 2 6 Connection diagram AGND and DGND connector X3 must be joined together 98 AX2040 2070 Product Manual Expansion Cards 06 2007 BECKHOFF AX2040 2070 I O 14 08...

Page 99: ...in parallel The supply voltage for the expansion card is provided by the servo ampli fier 10 3 1 Front view 10 3 2 Connection technology Cable selection cable routing shielding bus connector bus term...

Page 100: ...rference If this LED is very bright then communication is suffering strong interference or is non existent Check the SERCOS transmission speed for the controls and the servo amplifier BAUDRATE and the...

Page 101: ...munication is not possible The SBAUD parameter can be used to set the baud rate where is the baud rate If the optical power is not set correctly errors occur in telegram transmission and the red LED o...

Page 102: ...et Communication Profile 10 5 1 Front view 10 5 2 Connection technology Cable selection cable routing shielding bus connector bus termination and transmission times are all described in the DeviceNet...

Page 103: ...t the front of the expansion card to a value higher than 63 Now you can set up the station address by using the ASCII commands DNMACID x SAVE COLD START whereby x stands for the station address l Set...

Page 104: ...le Shunt R 20KW Absolute max voltage range 25 V to 18 V CAN_H CAN_L The voltages for CAN_H and CAN_L refer to the ground pin of the transceiver The voltage is higher than that on the V terminal by the...

Page 105: ...d Configuration single flash Unsolicited State Change double flash Watchdog Timeout off No Error RUN on Device is in state OPERATIONAL blinking Device is in state PRE OPERATIONAL single flash Device i...

Page 106: ...us 10 7 1 Installation The modul must be placed onto the option slot after levering off the cover of the option slot l Screw the distance pieces into the fixing lugs of the option slot l Place the exp...

Page 107: ...ments RS232 CAN1 CAN2 X6A Pin Signal X6B X6C Pin Signal 1 Vcc 1 2 RxD 2 CAN Low 3 TxD 3 CAN GND 4 4 5 GND 5 6 6 7 7 CAN High 8 8 9 9 10 7 5 Connection diagram AX2040 2070 Product Manual 107 BECKHOFF 0...

Page 108: ...This page has been deliberately left blank 108 AX2040 2070 Product Manual Expansion Cards 06 2007 BECKHOFF...

Page 109: ...mbers H Holding brake Brake in the motor which can only be used when the motor is at stillstand I I t threshold Monitoring of the actually required r m s current Input drift Temperature and age depend...

Page 110: ...odic change of direction Ring core Ferrite rings for interference suppression ROD Interface Incremental position output S Servo amplifier Control device for regulating the position of a servomotor Set...

Page 111: ...current 31 Limit Switch Inputs 65 M Mains supply connection interface 47 Mains supply networks 46 Maintenance 13 Master Slave 56 Motor holding brake 21 Motor interface 48 Mounting position 19 Multi ax...

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