Beckhoff eXtended Transport System Operating Instructions Manual Download Page 71

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Mechanical installation

Version: 2.2

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XTS

7.2.3

System test

Before beginning with the assembly of the guide rails, check the
functionality of the modules. You can determine whether you have
assembled the modules properly and fully as well as identifying de-
fects.

Power supply

► Connect the entire system 1 to the power supply without guide

rails

► First switch the 24 V on, then the 48 V

► Make sure that the LEDs 2 light up

The following LEDs 1 must light up:

• Link / Act

• 48 V / 16 A

• 24 V / 4 A

If the LEDs do not light up:

► Check the power supply units and fuses for voltage

► Check whether the connector card has been inserted

► Contact the Support/Applications Department

TwinCAT

Beckhoff also recommends checking the modules using the Twin-
CAT software.

► Start a TwinCAT project

► Scan the modules

► Check the modules for functionality

Summary of Contents for eXtended Transport System

Page 1: ...XTS eXtended Trans port System Operating Instructions EN 4 20 2020 Version 2 2 ...

Page 2: ......

Page 3: ...on 32 Data for operation and environment 33 XTS Standard 34 Dimensional drawings 36 Scope of supply 57 Packaging 57 Transport and storage 58 Conditions 58 Long term storage 58 Mechanical installation 59 Preparation 59 Modules 63 Guide rails 72 Mover 79 Electrical installation 84 Connection technology 84 Pin assignment of the power cable 85 Earthing of the supply 86 Earthing of the machine beds 86 ...

Page 4: ...2 XTS 6 roller 50 mm mover 98 6 roller 70 mm mover 99 12 roller 50 mm mover 99 ESD brushes 100 Fault correction 101 Motor modules 101 TcIoXts object 104 SoftDrive object 108 Decommissioning 110 Disassembly 110 Disposal 111 Index 112 ...

Page 5: ...TwinCAT EtherCAT EtherCAT G EtherCAT 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...

Page 6: ...d nullify the liability of Beckhoff Automation GmbH Co KG The following is excluded from the liability Failure to observe these operating instructions 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 ex...

Page 7: ...cified in the current operating in structions are valid Further information given on the product pages of the Beckhoff homepage in emails or in other publications is not authoritative 1 3Scope of the documen tation In addition to this documentation the following documents are part of the complete documentation XTS Definition Original operating instructions this documentation Description of the mec...

Page 8: ...equirements including all appli cable laws regulations 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 pers...

Page 9: ...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 Customer service Customer service personnel and service personnel are verifiably trained and authorized by Beckhoff...

Page 10: ...ear 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 Pictograms and signal words in warning notices are used to identify important text passages DANGER Fai...

Page 11: ...ia 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 Appstore for Apple operating systems or the Google Playstore for Android operating systems If you cannot r...

Page 12: ...at the customer s premises Hotline 49 0 5246 963 5000 Fax 49 0 5246 963 95000 E mail training beckhoff com 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 49 0 5246 963 460 Fax 49 0 5246 963 479 E mail service beckhoff com Web www beckhoff de service 1 7 4Download area...

Page 13: ...ne manufacturer 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 par...

Page 14: ...pecial conditions need to be observed for the earthing of the XTS In every case read the chapter Earthing of the power supply Page 86 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 ...

Page 15: ...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 110 ...

Page 16: ...w 16 Version 2 2 XTS 3 1 2 3 4 5 6 7 8 9 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 ...

Page 17: ... 24V 4A Number Explanation 1 Link Act status LED 2 EtherCAT status LED 3 cURus approval 4 Product designation 5 Module length 6 DataMatrix code 7 Serial number 8 Module type 9 RoHS conformity 10 CE conformity 11 24 V 4 A power supply status LED 12 48 V 16 A power supply status LED 13 Firmware and hardware revision 14 XML sensor PCB revision number 15 XML motor PCB revision number 16 Date of manufa...

Page 18: ...support this fea ture you can download a free QR code reader app or barcode reader app for your smartphone Use the Appstore for Apple operat ing systems or the Google Playstore for Android operating systems Internet access is not required to use the app and to read out these DataMatrix codes Example scan on a straight module This example shows how to read the BTN number on a smart phone screen aft...

Page 19: ...0 45 0 curve 41 45 0 curve with supply 50 180 curve clothoid xxxx Product length Module length in mm 000x Execution 2 Black Line 3 Standard with supply UL certified 4 Black Line with supply UL certified The ordering detail is not extended with standard mod ules 3 2 2Mover AT 901 x 00x0 x 550 Explanation AT Product line AT drive technology 901 Product type 901 mover x Roller variants 1 mover 6 roll...

Page 20: ...roduct type 0 without lock 1 with lock xx Rail variants 00 straight 20 22 5 outside curve 25 22 5 inside curve 40 45 curve 50 180 curve clothoid 42 360 full circle consisting of four elements with one lock xxxx Product length Rail length in mm 0070 When using a 70 mm mover AT9011 0070 0550 ap pend 0070 to the order details ...

Page 21: ...several rail systems and movers for every application Armature short circuit brake In the case of an emergency stop the movers can optionally be de celerated by means of an armature short circuit Integrated power electronics The entire power electronics is integrated in the modules To supply the modules you need a 24 V control voltage and a 48 V load volt age Software based control The XTS is cont...

Page 22: ...odules A system consists of individual motor modules that can be combined to form a complete drivetrain The straight and curved modules are each available in different versions 3 4 1 1Straight motor modules 3 4 1 1 Length mm Supply 250 without supply with supply with supply and UL with plug 249 with plug 233 without supply 3 4 1 2Curved motor modules 3 4 1 2 22 5 motor module This module is availa...

Page 23: ...view Version 2 2 23 XTS 45 motor module This module is available with a 45 curve with or without supply 180 clothoid This module is available as a 180 clothoid optionally with a mount ing plate for cooling systems ...

Page 24: ...t lock cover Available lengths 250 mm 1500 mm 500 mm 1750 mm 750 mm 2000 mm 1000 mm 2250 mm 1250 mm 2500 mm 3 4 2 2Curved guide rails 3 4 2 2 22 5 guide rail This guide rail is available in angles of 22 5 and 22 5 The assembly of this rail is possible in combination with a straight module and a 22 5 module Two 22 5 modules cannot be installed one behind the other 45 guide rail You can implement 45...

Page 25: ...angement of a straight module with two consecutive 45 modules 180 guide rail The 90 guide rail can be extended to 180 with this additional guide rail 180 clothoid The 180 clothoid enables a tight 180 curve It can be installed with the corresponding module of the 180 clothoid 360 guide rail You have the possibility to implement a 360 system with lock cover ...

Page 26: ... mounted on the guide rails and are available in the following variants 3 4 3 150 mm 3 4 3 1 The XTS mover with a width of 50 mm is available with 6 or 12 guide rollers 3 4 3 1 170 mm 3 4 3 1 1 The XTS mover with a width of 70 mm is available with 6 guide rollers ...

Page 27: ... Mover 1 functionality is used for the unambiguous identification of the individual movers 50 mm mover The XTS mover with the Mover 1 magnetic plate set is available as a 50 mm mover with 6 or 12 guide rollers 70 mm mover The XTS mover with the Mover 1 magnetic plate set is available as a 70 mm mover with 6 guide rollers Individual magnetic plate set The Mover 1 magnetic plate set is individually ...

Page 28: ...mmended for exter nal movers 1 6 mm encoder flag standard The 1 6 mm encoder flag can be ordered with the following order number AT9001 0550 1640 1 6 mm encoder flag Mover 1 The Mover 1 magnetic plate set with pre mounted 1 6 mm encoder flag is available under the following order number AT9001 1550 1640 ...

Page 29: ...config ured in the shape of an L U O or Z by combining curved modules with different radii and straight modules with different lengths In this way the travel path of the movers can be adapted more flexibly to the existing system The following figures show the possible module arrangements The positions of the 233 mm modules are marked in red 3 6 1L shape 3 6 1 3 6 2U shape 3 6 2 ...

Page 30: ...Product overview 30 Version 2 2 XTS 3 6 3O shape 3 6 3 3 6 4Z shape 3 6 4 ...

Page 31: ...utomation software Read the entire drive system documentation This translation of the original instructions Translation of the original instructions for the control computer Complete machine documentation provided by the machine manufacturer 3 7 1Improper use Any use exceeding the permissible values specified in the Technical data is considered improper and therefore prohibited The Standard XTS is...

Page 32: ...e set position from different directions multi directional The absolute accuracy is valid within a module and is defined as the difference between the set position and the actual position of the positioning system Standstill repeatability mm Specification of how accurately the system positions when ap proaching a position from the same direction unidirectional The standstill repeatability is to be...

Page 33: ... to our Applications Department in case of de viating environmental conditions and operating states of your ma chine or plant Environmental requirements Climate category 2K3 according to EN 60721 Ambient temperature operation 5 to 40 C Ambient temperature transport and storage 25 to 85 C Permissible air humidity operation 15 to 95 relative humidity no condensation non condensing Contamination leve...

Page 34: ... Weight without magnetic plate set g 278 463 328 Weight with magnetic plate set AT9001 0550 g 410 595 460 Weight magnetic plate set AT9001 0550 g 132 132 132 Distance between the feedback flag and the module mm 0 5 to 1 4 0 5 to 1 4 0 5 to 1 4 Modules AT20xx 00 02 50 01 02 50 50 05 00 40 02 50 41 02 50 20 02 50 21 02 50 25 02 50 26 02 50 Height mm 96 96 194 5 114 4 114 4 106 8 106 8 107 8 107 8 De...

Page 35: ... at standstill N Dependent on the air gap between stator and drive magnet 100 Synchronization accuracy at 1 5 m s within a straight module mm Dependent on the mechanical rigidity and applied load on the mover 0 15 Absolute accuracy within a straight module mm Can be exceeded in the case of high thermal warming of the module or lack of parallelism orthogonality of the encoder flag to the module 0 2...

Page 36: ...dimensional drawings and 3D models of the individual components from the Beckhoff website www beckhoff de download Direct link to the download 4 4 1Dimensional drawings modules AT2000 0250 Motor straight All figures in millimeters 17 1 0 1 13 5 96 39 1 35 0 1 90 0 2 180 0 2 80 0 1 90 0 1 5 M 3x 13 3x 5 F6 2x 8 2x 250 0 3 0 1 15 A A 1 2 ...

Page 37: ...a Version 2 2 37 XTS AT2001 0250 Motor straight with supply All figures in millimeters 96 39 1 35 0 1 90 0 2 180 0 2 80 0 1 90 0 1 13 3x 5 F6 2x 8 2x 250 0 3 0 1 15 17 1 0 1 5 M 3x 39 9 49 9 10 2 5 5 8 05 6 A A 1 2 ...

Page 38: ...Technical data 38 Version 2 2 XTS AT2001 0250 0003 Motor straight with supply and UL All figures in millimeters ...

Page 39: ...Technical data Version 2 2 39 XTS AT2000 0233 Motor straight 233 mm All figures in millimeters ...

Page 40: ...Technical data 40 Version 2 2 XTS AT2002 0249 Motor straight 249 mm with plug All figures in millimeters ...

Page 41: ...Technical data Version 2 2 41 XTS AT2002 0250 Motor straight 250 mm with plug All figures in millimeters ...

Page 42: ...Technical data 42 Version 2 2 XTS AT2020 0250 Motor 22 5 curved All figures in millimeters A 1 2 A 1 3 3 x 5 M 3x 5 F6 2x 8 2x 25 0 1 120 0 1 22 5 R 65 6 6 2 98 9 13 5 15 256 2 17 1 0 1 39 1 96 40 1 0 1 ...

Page 43: ...ion 2 2 43 XTS AT2021 0250 Motor 22 5 curved with supply All figures in millimeters B 17 6 29 6 6 8 0 5 5 5 10 2 A A B 1 3 3 x 5 M 3x 5 F6 2x 8 2x 25 0 1 120 0 1 22 5 R 6 56 6 2 98 9 15 256 2 17 1 0 1 39 1 96 40 1 0 1 1 2 ...

Page 44: ...Technical data 44 Version 2 2 XTS AT2025 0250 Motor 22 5 curved All figures in millimeters A 1 2 A 22 5 R6 16 62 1 3 3 x 5 M 3x 25 0 1 5 F6 2x 47 0 1 8 2 x 96 13 5 15 17 1 0 1 278 05 39 1 96 70 1 0 1 ...

Page 45: ...Technical data Version 2 2 45 XTS AT2026 0250 Motor 22 5 curved with power supply All figures in millimeters ...

Page 46: ...Technical data 46 Version 2 2 XTS AT2040 0250 Motor 45 curved All figures in millimeters A 1 2 A 45 R 3 3 8 3 1 106 75 5 M 3x 5 F6 2x 110 0 1 130 0 2 20 1 0 1 13 3x 8 2x 13 5 15 17 1 0 1 258 93 96 39 1 ...

Page 47: ...data Version 2 2 47 XTS AT2041 0250 Motor 45 curved with supply All figures in millimeters A 1 2 A 106 75 15 45 R 3 3 8 3 1 13 3x 8 2x 5 F6 2x 110 0 1 5 M 3x 130 0 2 11 21 6 8 05 10 2 5 5 17 1 0 1 258 93 96 39 1 ...

Page 48: ...cal data 48 Version 2 2 XTS AT2050 0500 Motor clothoid 180 curved All figures in millimeters 114 7 0 2 0 0 96 96 13 5 194 5 9 7 0 1 0 0 17 1 0 1 39 1 5 5 3x 9 8 3x 5 M 3x 20 8 3x 60 0 2 306 7 96 8 0 2 M 6x16 ...

Page 49: ...d 180 curved with mounting plate for cooling sys tem All figures in millimeters Z 1 2 Z 114 7 0 2 0 96 96 13 5 9 7 0 1 0 17 1 0 1 39 1 5 5 3x 9 8 3x 5 M 3x 20 8 3x 60 0 2 306 7 96 8 0 2 M 6x16 104 8 0 2 70 0 2 131 6 0 2 M4x10 8x 48 6 0 2 50 7 0 2 104 8 0 2 8 2 52 1 ...

Page 50: ...Technical data 50 Version 2 2 XTS 4 4 2Dimensional drawings mover AT9011 0050 0550 Mover with a length of 50 mm and 6 guide rollers All figures in millimeters ...

Page 51: ...Technical data Version 2 2 51 XTS AT9011 0050 1550 Mover 1 with a length of 50 mm and 6 guide rollers All figures in millimeters ...

Page 52: ...Technical data 52 Version 2 2 XTS AT9011 0070 0550 Mover with a length of 70 mm and 6 guide rollers All figures in millimeters ...

Page 53: ...Technical data Version 2 2 53 XTS AT9011 0070 1550 Mover 1 with a length of 70 mm and 6 guide rollers All figures in millimeters 1 ...

Page 54: ...Technical data 54 Version 2 2 XTS AT9012 0050 0550 Mover with a length of 50 mm and 12 guide rollers All figures in millimeters ...

Page 55: ...Technical data Version 2 2 55 XTS AT9012 0050 1550 Mover 1 with a length of 50 mm and 12 guide rollers All figures in millimeters ...

Page 56: ...l data 56 Version 2 2 XTS 4 4 3Dimensional drawings mag netic plate sets AT9001 0550 Standard magnetic plate set All figures in millimeters AT9001 1550 Mover 1 magnetic plate set All figures in millimeters 1 2 ...

Page 57: ...ymbol Explanation This is the correct position for the packaging Protect the packaging against wetness The contents are fragile Label Symbol Explanation The carton contains electrostatically sensitive compo nents 5 1 1ESD conductivity ESD conductive packaging is necessary for the safe delivery of some components The table below provides information on the foam inserts in which the components are d...

Page 58: ...EN 60721 Temperature 25 C to 85 C maximum fluctuation 20 K hour Use of the vendor s original packaging 6 2Long term storage Perform recurring inspections Check the XTS every six months to ensure it is in good condition Damage to the XTS or failure to carry out maintenance can shorten the service life of the installed components and parts Prevent the formation of condensation Keep the ambient tempe...

Page 59: ... assemble the XTS Observe the order of assembly Assemble the XTS from the inside outwards Insert straight mod ules first Then insert curved modules and close the system This will help you to avoid complications with the positioning and assem bly of individual modules at the end of the mechanical installation 7 1Preparation The following illustration provides you with an initial overview of the com...

Page 60: ...nding on the application 10 M5 x 20 bolts and washers for modules with a Beckhoff machine bed 11 Short locating pins for modules 12 Long locating pins for modules 13 Rubber seal 14 Connector card for modules 15 M4 x 40 screws for guide rails 16 Locating pins for guide rails 17 M3 x 12 screws washers and M3 nuts for connecting the guide rails together 7 1 1Technical aids You need the following aids...

Page 61: ...s are connected with the locating pins 1 and all individual modules with locating pins 2 The aim of this maintenance concept is to generate individual exchange able supply segments between power supply modules 4 with mod ules without supply 3 so that each supply segment can be removed individually from the overall system Without locating pins BECKHOFF insert this side first 1 2 4 3 You have the op...

Page 62: ...rail 2 and a module without supply 3 with a power supply mod ule 4 You can lift the module segment vertically out of the XTS sys tem The guide rails are connected to one another at the connectors and the modules are fixed to the machine bed Detailed information on the assembly of a complete XTS system can be found in the follow ing chapters of the mechanical installation ...

Page 63: ...ng pins 2 in the slots in the ma chine bed 5 Make sure that the cables 3 are positioned in the cut outs in the machine bed 5 Screw the screw and washer 4 hand tight into the center of the module 1 Make sure that the contact surface on the washer is free of paint residues and glue Make sure that the module 1 is slightly movable in the slots 1 2 4 5 3 Insert short locating pins 1 and 2 on the top of...

Page 64: ...ector card or in the module may be damaged BECKHOFF insert this side first 1 2 3 The lettering 1 insert this side first must be inserted into the mod ule at the position of the seal The marking 2 then lines up with the outer edge of the module The lettering 3 is for orientation 1 Insert the seal 1 Insert connector card 2 at the position of the seal 1 1 2 3 Position module 1 in the slots on the mac...

Page 65: ...align the modules at the specified dis tance between the locating pins The distance from the center of the first locating pin to the center of the first locating pin in the attached module is 250 mm 1 2 Place the alignment gauge 1 on top of two adjacent modules 2 1 2 3 Make sure that the marking 1 is placed in the center between two modules Important If the alignment gauge is placed the wrong way ...

Page 66: ...bly without alignment gauge If you don t use an alignment gauge Beckhoff recommends that you use a vernier caliper for the assembly of the straight modules If a vernier caliper is used the distance from the outer edge of the first locating pin to the outer edge of the first locating pin in the at tached module is 255 mm Fix module 1 hand tight with a screw and washer 2 Checking the distance betwee...

Page 67: ...caliper It should be 255 mm 1 2 4 5 3 Insert short locating pins 1 and 2 on the top of the module Insert long locating pin 3 at the side Insert short locating pins 4 and 5 underneath the module 1 Then rotate module 1 by 180 degrees 2 1 3 4 Position module 3 with the locating pins 2 in the slots in the ma chine bed 4 Fix module 3 hand tight in the center with a screw and washer 1 Make sure that the...

Page 68: ... modules in line and fix them hand tight in the center to the machine bed with screws and washers 1 and 2 Maintain distance 3 by using the alignment gauge or a vernier caliper during the installation Make sure that the modules are slightly movable in the slots ...

Page 69: ...ently be inserted without removing the curved modules 1 2 3 Insert long locating pin 1 seal 2 and connector card 3 1 2 3 Insert short locating pins 1 2 and 3 Avoid damaging the cables Make sure when assembling the curved modules that you insert and fasten the screws behind the cables on the machine bed If you insert the screws in front of the cables the cables could be crushed and damaged when fas...

Page 70: ...ind the cables 5 Tighten the screw and washer 4 immediately by hand 1 2 No connector card exists on the power supply modules No connector card is inserted on the cable side of power supply modules At this point there is only sealing compound 1 Make sure that the connector card 2 is present ...

Page 71: ... the power supply without guide rails First switch the 24 V on then the 48 V Make sure that the LEDs 2 light up 1 The following LEDs 1 must light up Link Act 48 V 16 A 24 V 4 A If the LEDs do not light up Check the power supply units and fuses for voltage Check whether the connector card has been inserted Contact the Support Applications Department TwinCAT Beckhoff also recommends checking the mod...

Page 72: ...must be replaced by a rail on support during the assembly Further information is given in the course of the mechanical instal lation in the chapter Mover Page 79 1 2 3 The screws 1 with the lock 2 and the locating pins 3 are pre mounted on the guide rail 1 2 Observe the alignment of the guide rail 1 The name plate 2 serves as an orientation aid with regard to the side of the complete system from w...

Page 73: ...Mechanical installation Version 2 2 73 XTS 1 3 1 2 Place the guide rail 1 with lock 2 straight down onto the locating pins 3 of the XTS ...

Page 74: ...er components of the XTS Subsequent movement Beckhoff recommends initially fixing all guide rails hand tight with a screw in the center This allows you to compensate unequal distances later on 2 1 3 Use threadlocker 1 for fixing the screws in the guide rails Insert screw 2 into the center of the guide rail 3 and screw it in hand tight 1 2 3 Insert locating pins 1 and 2 into the guide rail 3 1 2 Se...

Page 75: ...guide rails 1 and 2 to each other The guide rails on the lower side of the XTS are now mounted horizontally and vertically mirrored 2 1 Fix the opposite guide rail 1 with screw 2 and threadlocker hand tight again 1 2 3 Insert locating pins 1 and 2 into the opposite guide rail 3 ...

Page 76: ...nner running surfaces of the curved rails before assembly Straight guide rails and curved rails will be easier to fit together as a result A suitable substance for greasing is for example Vaseline 1 2 3 4 Grease connecting surfaces 1 and 4 as well as inner running surfaces 2 and 3 2 1 3 Push curved rail 2 onto the guide rails 1 and 3 Mount the curved rail on the opposite side of the XTS and close ...

Page 77: ...fixing You have the option to use hole 3 for dismantling Completion of the assembly 2 2 1 Tighten the screws 1 in the curved rails Tighten the screws 2 Observe tightening torques Components Tightening torque Nm Screws M4 x 40 4 1 Insert all screws with washers into the remaining curved mod ules on the machine bed 1 and screw tight Observe tightening torques Components Tightening torque Nm Screws M...

Page 78: ... to the cables 1 3 2 Insert all screws with washers 1 and 2 into the remaining straight modules on the machine bed and screw tight Use smaller washer 3 for the screw at the cut out for the cables in the machine bed Observe tightening torques Components Tightening torque Nm Screws M5 x 20 6 1 Link all guide rails at the connectors 1 1 2 3 4 5 Connect the connectors of the guide rails 1 with screw 5...

Page 79: ...of the entire system before mounting the movers and commis sioning the XTS A suitable substance for greasing is for example Vaseline 1 Grease the running surface on the guide rails on both sides in the entire system 1 with Vaseline 1 2 3 Loosen and remove screws 1 and 2 Remove lock 3 1 2 3 Insert the rail on support 3 and secure it with screws 1 and 2 ...

Page 80: ...other and are damaged 1 2 3 4 Position mover 1 with encoder flag 2 over the rail on support 3 Observe the name plate 4 and encoder flag 2 for orientation In the view the encoder flag is located on the opposite side of the XTS when mounting the movers 1 2 Make sure when mounting the movers that the guide rollers 1 of the movers do not press against the edges 2 of the rail on sup port 1 2 1 2 Carefu...

Page 81: ...maining movers have been mounted Check that the air gap between all modules is approximately 0 85 mm Check that the air gap between the encoder flags of the movers and the modules is approximately 0 90 mm and that the encoder flags are positioned parallel to the modules 1 2 3 Loosen and remove screws 1 and 2 Remove rail on support 3 Fit the lock again Observe tightening torques Components Tighteni...

Page 82: ...der flag 2 centrally over the rail on support 3 and tilted slightly forward Observe the name plate 4 and encoder flag 2 for orientation In the view the encoder flag is located on the opposite side of the XTS when mounting the movers 1 2 Make sure when mounting the movers that the guide rollers 1 of the movers do not press against the edges 2 of the rail on sup port 1 2 Carefully insert mover 1 wit...

Page 83: ...maining movers have been mounted Check that the air gap between all modules is approximately 0 85 mm Check that the air gap between the encoder flags of the movers and the modules is approximately 0 90 mm and that the encoder flags are positioned parallel to the modules 1 2 3 Loosen and remove screws 1 and 2 Remove rail on support 3 Fit the lock again Observe tightening torques Components Tighteni...

Page 84: ...n accordance with applicable regulations and standards Use the pre assembled and shielded Beckhoff cables for power and EtherCAT connections Laying The following cables are integrated in the supply modules 5 m orange power cable Lapp cable 3 x 2 5 mm2 2 x 0 75 mm2 5 m green EtherCAT cable ZK1091 9191 050 Lay the cables so that they are protected against external damage Make sure that the cables li...

Page 85: ... 4 4 4 3 3 1 1 1 2 2 2 24V 48V 48V GND 24V EtherCAT wire 3 4 1 2 4 1 2 1 2 2 3 3 4 4 1 1 2 2 2 ZB8110 10Ω 100W EL9576 Brake chopper teminal with ZB8110 Brake resistor Power Supply Control cabinet earth Power Supply 48V 24V 24V GND 48V GND C4A B 16A 2 x B 4A B 4A The following table shows the XTS cable configuration for the power cable Identification Signal Wire cross section Core 1 48 V 2 5 mm2 Co...

Page 86: ...48 V I 48V I 48V I 24V I 24V I compensation 0 A U 48 V U 24 V 0 75 mm2 0 75 mm2 2 5 mm2 2 5 mm2 Modules Supply line 3 x 2 5 mm 2 x 0 75 mm2 2 2 5 mm2 Power supplies 8 3 2Load current circuit Beckhoff recommends not to earth the 48 V power supply unit on the secondary side The 24 VDC return line 0 75 mm2 could be overloaded If the 48 V power supply unit is earthed the currents will be distrib uted ...

Page 87: ...e of wide connections with large contact surfaces Wide earth straps are suitable for this The table below illustrates typical suit able connectors 1 2 3 Number Connector 1 Copper rail 2 Earth strap with cable lugs 3 Cable with cable lugs Make sure that an optimally conductive connection is available at the connection point for the protective conductor To ensure this carefully remove paint dirt cor...

Page 88: ...ng washer 1 washer 2 nut 3 and bolt 4 8 5Fuse protection Ensure adequate fuse protection is provided for the power supply units If power supply units other than those recommended in this chapter are used this should be reflected in the fuse dimensioning Note that the selected fuse can be triggered at a higher current than 16 A with the power supply unit used Follow the documentation of the power s...

Page 89: ...41 QS40 481 QT40 481 Primary fusing See documentation on Puls website See documentation on Puls website Secondary fusing 2 pin 4 A circuit breaker 5SL4204 6 Outlet to module with supply 16 A B circuit breaker Siemens 5SY6116 6 Outlet to brake chopper terminal 4 A C circuit breaker Siemens 5SY6104 7 Single channel contactor switch off Siemens 3RT2526 2BB40 3RT2926 1BB00 Self locking of the movers b...

Page 90: ...fusing See documentation on Puls website See documentation on Puls website Secondary fusing 2 pin 4 A circuit breaker 5SL4204 6 Outlet to module with supply 16 A B circuit breaker Siemens 5SY6116 6 Outlet to brake chopper terminal 4 A C circuit breaker Siemens 5SY6104 7 Single channel contactor switch off Siemens 3RT2526 2BB40 3RT2926 1CB00 Self locking of the movers according to the arma ture sho...

Page 91: ... Brake chopper teminal with ZB8110 Brake resistor B 32A C 4A B 4A B 32A B 32A B 32A 2 x B 4A B 32A 11 31 12 32 2 x B 4A 2 x B 4A 2 x B 4A A1 1 R1 R3 3 A2 2 R2 R4 4 A1 1 R1 R3 3 A2 2 R2 R4 4 A1 1 R1 R3 3 A2 2 R2 R4 4 A1 1 R1 R3 3 A2 2 R2 R4 4 B 16A B 16A B 16A B 16A 48 VDC power supply unit Puls power supply unit QS40 481 QT40 481 Primary fusing See documentation on Puls website Secondary fusing 32...

Page 92: ...T20 241 QS40 481 QT40 481 Primary fusing See documentation on Puls website See documentation on Puls website Secondary fusing 2 pin 4 A circuit breaker 5SL4204 6 Outlet to module with supply 16 A B circuit breaker Siemens 5SY6116 6 Two channel contactor switch off Siemens 3RT2526 2BB40 3RT2926 1BB00 Self locking of the movers according to the armature short circuit principle Modules have no Safe T...

Page 93: ... wiring connection and proper earthing If using Mover 1 Check whether precisely one mover is equipped with the Mover 1 magnetic plate set 9 2During commissioning Make sure that all fittings were checked for function and adjust ment Observe information for environment and operation Check protective measures against moving and live parts Configuration Beckhoff recommends the use of the latest TwinCA...

Page 94: ...sture or dust Check temperature development Observe recommended maintenance intervals Check function of safety devices 9 4After operation WARNING Ensure safe condition of the machine system Make sure that all movers come completely to a standstill If the controller enable is canceled or the 48 V power supply is switched off movers on a vertical section can move uncontrol lably and cause serious in...

Page 95: ...TS components only with a cleaning agent and a cloth Cleaning by immersion can lead to damage to the XTS compo nents and surfaces as well as to leak tightness problems due to im permissible solutions Beckhoff recommends regular maintenance in order to prevent per manent damage to the system Contamination dust or chips can have a negative effect on the function of the components In the worst case c...

Page 96: ...val Maintenance Coil cores 6 months Visual inspection of the coil cores for abrasion Feedback Sensor Sys tem 6 months Visual inspection of the sensor surfaces for abrasion Machine bed 6 months Check the fastening of the modules to the machine bed 10 2 2Mover Components Interval Maintenance Guide rollers 3 months or when the expected ser vice life is reached Check the guide rollers for wear and bre...

Page 97: ...s 6 months Check all connections for tightness and wear Every month Clean the running surfaces Recommended cleaner Isopropanol As required Lubricate the running surfaces Recommended lubricant Vaseline 6 months Check the fastening of the curved rails to the modules Mover lock 6 months Check the mover lock for wear and break outs Every month Clean the running surfaces Recommended cleaner Isopropanol...

Page 98: ...tandard movers are mounted on the guide rails using the rail on support 11 36 roller 50 mm mover 11 3 The roller set is available to replace worn or damaged guide rollers in the 50 mm long movers with 6 guide rollers AT9011 0050 0550 AT9011 0050 1550 Scope 4 x cylindrical guide rollers with short shoulder bolts 2 x cylindrical guide rollers with long shoulder bolts ...

Page 99: ...11 5 The roller set is available to replace worn or damaged guide rollers in the 50 mm long movers with 12 guide rollers AT9012 0050 0550 AT9012 0050 1550 Scope Packaging with foam insert for the guide rollers Installation instructions on the label on the inside of the lid 4 cylindrical guide rollers 4 conical guide rollers 2 cylindrical guide rollers lower 2 conical guide rollers lower With the l...

Page 100: ...Accessories 100 Version 2 2 XTS 11 6ESD brushes 11 6 The ESD brushes are available to replace worn ESD brushes in 50 mm movers and 70 mm movers ZX9016 0000 Scope 30 x ESD brushes for standard movers ...

Page 101: ...fter firmware version 14 0x840B Peak module overall current threshold exceeded Peak overall current threshold ex ceeded 12 1 1Warning 12 1 1 ID Message Error Number of the cause 0x4101 Module overtemperature Motor module temperature exceeds 65 C see COE 9000 19 9000 1C 1 0x4103 Undervoltage control voltage 24 V control voltage lower than 20 4 V 2 3 0x4411 Undervoltage DC Link 48 V power supply is ...

Page 102: ... Coil x Current on coil x too high 11 12 0x8406 Undervoltage DC Link 48 V power supply lower than 20 V 2 3 4 0x8407 Overvoltage DC Link 48 V power supply higher than 56 V 2 5 0x8409 I2T Motor module overload Overload of the motor module at 105 I2T utilization rate 105 I2T utilization rate not reached If 100 I2T utilization rate is reached Current limited to nominal current 6 0x840A Overall current...

Page 103: ...pause times Reduce the mover dynamics 7 XTS task overflow Add further XTS task distribute movers and motor modules to both tasks Incorrect Distributed Clock settings Adjust the Distributed Clocks settings No optimum real time settings Distribute processor cores and adjust task priorities EtherCAT frame disturbed by external influences Check EtherCAT cable for damage and connect shield properly Che...

Page 104: ...6 Abnormal behavior is de tected All values of XTS module x are negative All values on the sensor side of the XTS motor module are negative 5 5007 Abnormal behavior is de tected All values of XTS module x are positive All values are positive on the sensor side of the XTS motor module 5 5008 Abnormal behavior is de tected Some values of XTS module x are not in the ex pected range 400 400 Offset val...

Page 105: ...id The stored teaching file does not match the XTS system Teaching file originates from a differ ent system 16 9007 Teaching data file y is cor rupt The teaching file in the directory C TwinCAT 3 1 Target Config TcIoXts is corrupt or missing 4 9008 Teaching file of XTS module x is invalid Damaged or missing teaching file in the directory C TwinCAT 3 1 Target Config TcIoXts Or motor module x not co...

Page 106: ...that there is only one mover with Mover 1 magnet plate set on the System More than one mover with Mover 1 magnetic plate set on the system 20 9016 The Axis x gets an enable command before Mover1 has been detected If there s no Mover1 on the XTS set MoverIdDetectionMode to Standard Controller enable for a mover before mover 1 was found 21 9017 MoverIdDetection was inter rupted by changing the Mover...

Page 107: ...onfigure the path with the manager of the TcIoXtsDrv object 9 After starting the Mover 1 detection wait until a TRUE is displayed in the parameters online for IsMoverIdDetectionValid or HasMoverIdDetectionError 10 At the start of the MoverID detection wait until the following results are achieved in the parameters online AreAllMoverPositionsValid TRUE ExpectedMoverCount DetectedMoverCount 11 Start...

Page 108: ... 3 10001 Emergency ramp takes too long Emergency ramp triggered by TcSoft Drive requires more time than the time of 0 5 sec configured in the parameter EmergencyRamp 4 5 10002 Velocity following error check setpoint generation commutation actual velocity command velocity Different sign to the setpoint velocity and actual velocity deviation from one another by more than the velocity of 1000 mm s se...

Page 109: ...er mover 8 Check whether the mover was correctly detected when starting up and that no metallic components are affecting the sensor sig nal 9 Increase parameter CommutationErrorVelocity or switch it off with the value 0 10 Check HW module for errors Check the error ID in the DiagHistory of the motor module For the solution on the basis of the error ID see Motor modules table in this chapter 11 Che...

Page 110: ...mbling the magnetic plate sets Make sure that the magnetic plate sets do not magnetically attract one another with your hands in between If you don t take care during the disassembly opposite magnetic plate sets may attract each other without warning and injure your hands Do not remove components from the products Only Beckhoff Automation GmbH Co KG is permitted to remove components Contact Beckho...

Page 111: ...ies and rechargeable batteries Batteries and rechargeable batteries may also be marked with the crossed out trash can symbol You must separate these compo nents from the waste and are legally obliged to return used batteries and rechargeable batteries within the EU Observe the relevant pro visions outside the area of validity of the EU Directive 2006 66 EC 13 2 1Returning to the vendor In accordan...

Page 112: ...tended use 31 L Lock 72 M Maintenance 95 Intervals 96 Module segment 62 Modules Activation 90 Curved 22 Generating supply segments 61 Mounting 63 Straight 22 Switching 89 Mover 50 mm 26 70 mm 26 Mounting 79 N Name plate 17 O Operating Conditions 33 Ordering options 27 Mover 1 magnetic plate set 27 P Pictograms 10 Power derating 33 Power supply Activation 92 Switching 91 R Rail on support Mounting ...

Page 113: ...rsion 2 2 113 XTS Tightening torques Curved modules 77 78 Curved rails 77 Straight guide rails 78 Transport 58 X XTS Dismantling 110 Electrical installation 84 Mechanical installation 59 Storage 58 Transport 58 ...

Page 114: ...Beckhoff Automation GmbH Co KG Hülshorstweg 20 D 33415 Verl www beckhoff com info beckhoff com More Information www beckhoff com xts ...

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