Beckhoff AX2500 Series 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 02/06

Digitaler Servoverstärker

AX2500

Summary of Contents for AX2500 Series

Page 1: ...on 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 02 06 Digitaler Serv...

Page 2: ...Microsoft Corp HIPERFACE is a registered trademark of Max Stegmann GmbH EnDat is a registered trademark of Dr Johannes Heidenhain GmbH Technical changes to improve the performance of the equipment may...

Page 3: ...ctions 17 2 10 Motor holding brake control 18 2 11 Regen circuit 19 2 11 1 LED display 19 2 12 Grounding system 19 2 13 Switch on off behaviour 20 2 13 1 Stop function as per EN 60204 VDE 0113 20 2 13...

Page 4: ...der master with 24V signal level X3 53 4 9 3 Connection to a sine cosine encoder master X2 53 4 10 Interface for stepper motor controllers pulse direction 54 4 10 1 Connection to a stepper motor contr...

Page 5: ...WS Internet browser Acrobat Reader in several language ver sions You can print out this documentation on any standard printer A printed copy of the docu mentation is available from us at extra cost Th...

Page 6: ...ctor according to IEC 60874 2 IEC International Electrotechnical Commission IGBT Insulated gate bipolar transistor ISO International Standardization Organization LED Light emitting diode MB Megabyte N...

Page 7: ...machine must produce a hazard analysis for the ma chine and take appropriate measures to ensure that unforeseen movements do not result in personal injury or material damage l Do not open or touch th...

Page 8: ...f the servo amplifiers are used in residential areas or in business or commercial premi ses then additional filter measures must be implemented by the user The AX2500 family of servo amplifiers is onl...

Page 9: ...manufacturer of the machine or plant is responsible for ensuring that they meet the limits required by the EMC regulations Advice on the correct installation for EMC such as shielding grounding arrang...

Page 10: ...e which can be trigge red by electrically operated devices The technical conformance with the U S and Cana dian standard is determined by an independent UL cUL inspector through the type testing and r...

Page 11: ...s required for AX25x6 Synchronous servomotor linear or rotary Motor lead pre assembled or motor cable as cut off length loose connectors motor and amplifier side Feedback cable pre assembled or both f...

Page 12: ...cuit 1 x 115V AC AX250x only unearthed operation is permitted 3 x 115V AC AX250x only unearthed operation is permitted 1 x 230V AC AX250x only unearthed operation is permissible 3 x 230V AC all types...

Page 13: ...play on the master l fully programmable via RS232 interface Completely digital control l digital current controller space vector pulse width modulation 62 5 s l freely programmable digital speed contr...

Page 14: ...2 8 Components of a servo system 14 AX2500 Installation Manual Technical description 02 06 Beckhoff 24V supply fuses drive contactor terminals motor AX2500 PC Control PLC...

Page 15: ...al voltage drop at rated current V 5 5 Quiescent dissipation output stage disabled W 12 15 12 15 12 15 12 15 Dissipation at rated current without regen dissipation W 35 60 30 40 35 60 30 40 Inputs out...

Page 16: ...pol plug 2 9 3 Recommended tightening torques Connector Tightening torque X1 X3 X6 0 3 Nm X0 1 3 Nm Earthing bolts 3 5 Nm lower mounting bolt 3 5 Nm 2 9 4 Fusing 2 9 4 1 Internal fusing Function Auxil...

Page 17: ...lution level 2 as per EN 60204 EN 50178 Enclosure rating IP 20 Mounting position normally vertical p 25 Ventilation AX25x3 free convection AX25x6 add on fan p 72 Make sure that there is adequate force...

Page 18: ...braking force During the internal enable delay time of 100ms the speed setpoint of the servo amplifier is internally driven down a 10ms ramp to 0V The brake output is switched on when 3 of the final s...

Page 19: ...off with the error message overvoltage p 66 The BTB RTO contact terminals X1 1 2 will be opened simultaneously p 49 Technical data Supply voltage Rated data DIM Value 3 x 230 V Upper switch on thresho...

Page 20: ...The Stop functions are defined in EN 60204 VDE 0113 Paras 9 2 2 and 9 2 5 3 Categories of Stop functions Category 0 Shut down by immediate switch off of the supply of energy to the drive machinery i...

Page 21: ...er Category 0 or Category 1 The Emergency Stop Category must be determined by a risk evaluation of the machine Category 0 Only hard wired electromechanical components may be used for an Emergency Stop...

Page 22: ...This page has been deliberately left blank 22 AX2500 Installation Manual Technical description 02 06 Beckhoff...

Page 23: ...If a motor power cable is used which includes cores for brake control the brake control cores must be separately shielded Earth the shielding at both ends p 28 l Install all heavy current cables with...

Page 24: ...ate motor housing and CNC GND of the controls Notes on connection techniques are on page 32 Wiring Route power leads separately from control cables Wire the BTB RTO contact in series into the safety l...

Page 25: ...stem width 40mm make sure there is a conductive connection to the mounting plate Mount the protective cover 7mm on the left side of the system Tools required Screwdriver with approx 5 mm blade width A...

Page 26: ...3 3 1 Dimensions 26 AX2500 Installation Manual Installation 02 06 Beckhoff AX250x and AX251x AX252x...

Page 27: ...diagrams indicates that you must take care to provide an electrically conductive connection with the largest possible area between the unit indicated and the mounting plate in the control cabinet This...

Page 28: ...ram AX250x and AX251x 28 AX2500 Installation Manual Installation 02 06 Beckhoff p 38 p 57 p 56 p 52 p 39 p 43 p 40 p 46 p 46 p 48 p 49 p 38 p 39 AX250x AX251x Follow the safety instructions p 7 and th...

Page 29: ...3 4 2 Connection diagram AX252x AX2500 Installation Manual 29 Beckhoff 02 06 Installation p 57 p 52 p 39 p 43 p 40 p 46 p 46 p 48 AX252x Follow the safety instructions p 7 and the use as directed p 8...

Page 30: ...3 Example of connections for multi axis system 30 AX2500 Installation Manual Installation 02 06 Beckhoff AX252x AX252x AX250x AX251x M M M Follow the safety instructions p 7 and the use as directed p...

Page 31: ...3 4 4 Connector assignments AX2500 Installation Manual 31 Beckhoff 02 06 Installation...

Page 32: ...00 are provided with an over all metal ferrule at the amplifier end that is electrically connected to the shielding Thread a cable tie through each slot in the shielding strip front panel of the servo...

Page 33: ...ulation PETP polyesteraphthalate code 12Y Capacitance Motor cable less than 150 pF m RES encoder cable less than 120 pF m Technical data The brackets in the cable designation indicate the shielding Al...

Page 34: ...ut this parameter setting yourself on the amplifier but on a PC with the assistance of the operator software The PC is connected to the servo amplifier by a null modem serial p 56 cable The setup soft...

Page 35: ...WINDOWS 98 2000 ME XP or WINDOWS NT 4 0 Emergency operation is possible with an ASCII terminal emulation Interface setting 9600 bps databit 8 stopbit 1 no parity no handshake Unix Linux DRIVE EXE doe...

Page 36: ...This page has been deliberately left blank 36 AX2500 Installation Manual Installation 02 06 Beckhoff...

Page 37: ...presents all the important interfaces divided between master and axis module The precise location of the connectors and terminals can be seen on page 31 4 1 Block diagram AX2500 Installation Manual 37...

Page 38: ...supplies Directly to supply filter is integrated fusing e g fusible cut outs to be provided by the user p 16 4 2 2 24V auxiliary voltage X0 Electrically isolated supply from an external 24V DC PSU e...

Page 39: ...ly from the same mains identical mains supply voltage may be connected by the DC bus link 4 4 Motor connection with brake X6 Max admisible length of the motor cable is 25 m 4 5 External regen resistor...

Page 40: ...l X1 p 44 Sine Cosine Zero Incremental encoder A quad B X5 p 45 A B Zero 4 6 1 Resolver X5 Our rotary servomotors have 2 pole hollow shaft resolvers built in as a standard It is possible to connect 2...

Page 41: ...nd for the resolution an incremental encoder The thermostat contact in the motor is connected via the ComCoder cable to X2 and evaluated there If cable lengths of more than 25m are planned please cons...

Page 42: ...ute informa tion for commutation can be used as complete feedback system combined with an addi tional Hall encoder All signals are connected to X2 If cable lengths of more than 25m are planned please...

Page 43: ...the AX2500 as a feedback device for drive tasks that require highly precise positioning or extremely smooth running The thermostat contact in the motor is connected via the encoder cable to the AX2500...

Page 44: ...information for the position controller every time the 24V auxiliary voltage is switched on If lead lengths of more than 50m are planned please consult our customer service The thermostat contact in...

Page 45: ...r every time the 24V auxiliary vol tage is switched on If lead lengths of more than 50m are planned and for questions concerning the power supply of the encoder please consult our customer service The...

Page 46: ...e voltage range for both inputs 10 V supplementary Update rate 62 5 s Input Analog IN terminals X3 2 3 Input voltage max 10 V 14 bit resolution scalable Standard setting Speed Setpoint Fixing the dire...

Page 47: ...t must be stored in the EEPROM of the servo amplifier and the 24V auxiliary supply for the servo amplifier must be switched off and then on again to reset the amplifier software Limit switches PSTOP N...

Page 48: ...minal X3 8 and DIGITAL OUT2 terminal X3 9 to output messages from pre programmed functions that are stored in the servo amplifier A list of the pre programmed functions can be found in the Online Help...

Page 49: ...l the motor which is attached does not have any torque Ready to operate contact BTB RTO Operational readiness terminals X1 1 and X1 2 is signalled via a floating relay contact The contact is closed wh...

Page 50: ...Feedback system Resolution Zero position ROD 1 Resolver 16 1024 one per revolution only if A B 1 EnDat HIPERFACE 16 4096 and 8192 524288 2n one per revolution only if A B 1 ROD interpolation 3 Increme...

Page 51: ...and are not variable The following table shows the allocation of the SSI date Revolution Resolution 11 10 9 8 7 6 5 4 3 2 1 0 15 14 13 12 11 10 9 8 7 6 5 4 3 2 1 0 The signal sequence can be output i...

Page 52: ...t frequency Please contact our customer support for information on connecting external SSI enco ders Signal diagram for encoders with RS422 or 24V outputs 4 9 1 Connection to a AX2500 master 5V signal...

Page 53: ...cy 100 kHz transition speed tv 0 1 sec AGND terminal X3 1 must be connected to the ground of the control system 4 9 3 Connection to a sine cosine encoder master X2 You can use this interface to set up...

Page 54: ...The number of steps can be adjusted so that the servo ampli fier can be adjusted to the pulse direction signals of any stepper motor controller Various monitoring signals can be output The analog inpu...

Page 55: ...connected to the ground of the control system 4 10 2 Connection to a stepper motor controller with 24V signal level X3 You can use this interface to connect the servo amplifier to a stepper motor con...

Page 56: ...o a serial interface on the PC do not use a null modem link cable The interface has the same potential as the internal logic and uses AGND as the ground reference The interface is selected and set up...

Page 57: ...AGND must be connected to the control system ground for potential equalization CAN bus cable To meet ISO 11898 you should use a bus cable with a 120 W characteristic impedance The maximum usable cable...

Page 58: ...oftware protocol can be found in the manual Communication profile PROFIBUS DP The selection of cables cable routing shielding bus connectors bus termination and propagation times are described in the...

Page 59: ...in SERCOS Phase 1 or the axis cannot be operated although the RT LED is lighting up cyclically Err indicates that SERCOS communication is faulty or suffering from interference If this LED is very bri...

Page 60: ...This page has been deliberately left blank 60 AX2500 Installation Manual Interfaces 02 06 Beckhoff...

Page 61: ...to the servo amplifier while it is live Capacitors can still have dangerous residual charges up to 300 seconds after switching off the supply voltage The heat sink and front panel of the amplifier ca...

Page 62: ...minal voltage of the amplifier Motor pole no must match the feedback unit in the motor IRMS maximum is the motor standstill current I0 nameplate IPEAK maximum is 4 x motor standstill current I0 Limit...

Page 63: ...odules The PC cable only has to be connected to the master The internal address assignment is carried out automatically so that it is only necessary to set up the basic station address for the master...

Page 64: ...n rapid succession decrease number by ten press and hold right key then press left key as well enters a number return function 5 3 2 2 Status display on the axis module Each axis module is fitted with...

Page 65: ...5 3 2 3 Status display on the master AX2500 Installation Manual 65 Beckhoff 02 06 Setup...

Page 66: ...hecksum error F11 brake cable break short circuit short to ground F12 motor phase motor phase missing cable break or similar F13 internal temperature internal temperature too high F14 output stage fau...

Page 67: ...switch 2 passed software limit switch 2 n08 motion task error a faulty motion task was started n09 no reference point no reference point set at start of motion task n10 PSTOP PSTOP limit switch activ...

Page 68: ...This page has been deliberately left blank 68 AX2500 Installation Manual Setup 02 06 Beckhoff...

Page 69: ...ng 3 15AT Output voltage 24V 1 Max output current 5A Residual ripple 150mVss Switching peaks 240mVss Output fusing short circuit proof Temperature range 0 to 60 C Mounting method DIN rail vertical mou...

Page 70: ...none Output voltage 24V 1 Max output current 20A Residual ripple 0 1 Output fusing short circuit proof Test voltage to VDE 0550 Temperature range 20 to 60 C Mounting method on mounting plate supplied...

Page 71: ...3 External regen resistor BAR U Caution Surface temperature may exceed 200 C Observe the requested free space Do not mount to combustible surface AX2500 Installation Manual 71 Beckhoff 02 06 Accessori...

Page 72: ...the housing The electrical connection takes place auto matically when mounting the fan Please consider that a mounted fan increases the required space underneath the amplifier p 25 The drawing below s...

Page 73: ...scharge yourself before touching the servo amplifier Avoid contact with highly insulating materials artificial fabrics plastic films etc Place the servo amplifier on a conductive surface max stacking...

Page 74: ...unit feedback connector not inser ted feedback cable is damaged check connector check cable F05 message undervoltage supply voltage not present or too low when servo amplifier is enabled only enable t...

Page 75: ...etpoint cable motor phases swapped brake not released drive is mechanically blocked no of motor poles set incor rectly feedback set up incorrectly apply enable signal check setpoint cable correct moto...

Page 76: ...nalog I O join AGND and CNC GND n12 message Motor default values loaded Motor number stored in sine encoders EEPROM different than what drive is configured for If n12 is displayed default valu es for...

Page 77: ...ed when the motor is at standstill I I t threshold Monitoring of the r m s current that is actually required incremental encoder interface Position signalling by 2 signals with 90 phase difference not...

Page 78: ...eration with a periodic change of direction ROD interface Incremental position output S servo amplifier Control device for regulating the speed torque and position of a servomotor setpoint ramps Limit...

Page 79: ...llation wiring 24 setup 62 H Hall interface 42 hardware requirements 35 humidity 73 I incremental encoder interface 45 inputs ANALOG IN 46 DIGI IN 1 2 47 enable 49 encoder 43 encoder for master slave...

Page 80: ...rage 73 storage duration 73 storage temperature 73 supply connection interface 38 supply voltage 17 switch on off behaviour 20 symbols 5 system components summary 14 T technical data 15 ambient condit...

Page 81: ...This page has been deliberately left blank AX2500 Installation Manual 81 Beckhoff 02 06 Appendix...

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