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AX8000 - system manual

Multi-axis servo system AX8000

1.02017-09-11

Version:Date:

Documented modules

AX8000 - system manual 3Version: 1.0

1 Documented modulesThis documentation describes the following modules of the AX8000 multi-axis servo system:

Supply modules:AX8620, AX8640

Axis modules:AX8108, AX8118, AX8206

Option modules:AX8810 (capacitor module)

Table of content

AX8000 - system manual4 Version: 1.0

Table of content1 Documented modules ............................................................................................................................... 3

2 Foreword .................................................................................................................................................... 72.1 Notes on the documentation........................................................................................................... 72.2 Documentation issue status............................................................................................................ 8

2.2.1 Scope of the documentation .............................................................................................. 82.3 Appropriate use .............................................................................................................................. 8

2.3.1 Dual Use (EU1382/2014) ................................................................................................... 9

3 Guidelines and Standards ...................................................................................................................... 103.1 EU Declaration of Conformity ....................................................................................................... 103.2 Electromagnetic compatibility (EMC)............................................................................................ 113.3 UL approval for the US and Canada............................................................................................. 11

3.3.1 UL-specific chapter .......................................................................................................... 123.3.2 UL-specific notes.............................................................................................................. 12

4 For your safety......................................................................................................................................... 134.1 Staff qualification .......................................................................................................................... 134.2 Description of symbols.................................................................................................................. 144.3 Notes on the AX8000 multi-axis servo system ............................................................................. 15

5 Handling ................................................................................................................................................... 175.1 Transport ...................................................................................................................................... 175.2 Storage ......................................................................................................................................... 175.3 Disposal ........................................................................................................................................ 18

6 Product overview..................................................................................................................................... 196.1 Scope of supply ............................................................................................................................ 196.2 Name plate and type key .............................................................................................................. 20

6.2.1 Supply modules ............................................................................................................... 206.2.2 Axis modules.................................................................................................................... 21

6.3 Drive-integrated safety technology ............................................................................................... 226.4 General description....................................................................................................................... 23

6.4.1 Supply module - AX8620 ................................................................................................. 236.4.2 Supply module - AX8640 ................................................................................................. 246.4.3 Axis modules – AX8108 and AX8118 .............................................................................. 256.4.4 Axis module - AX8206 ..................................................................................................... 26

6.5 Accessories .................................................................................................................................. 26

7 Technical description.............................................................................................................................. 277.1 Configuration of the servo system ................................................................................................ 27

7.1.1 System description........................................................................................................... 287.2 Technical data .............................................................................................................................. 29

7.2.1 Ambient and operating conditions.................................................................................... 297.2.2 Electrical data - supply modules 100 - 240 VAC.............................................................. 307.2.3 Electrical data - supply modules 400 - 480 VAC.............................................................. 327.2.4 Electrical data - axis modules 0 - 875 VDC ..................................................................... 327.2.5 Mechanical data............................................................................................................... 347.2.6 Dimensions ...................................................................................................................... 35

7.3 Display .......................................................................................................................................... 36

8 Mechanical Installation ........................................................................................................................... 38

Table of content


8.1 Installation conditions in the control cabinet ................................................................................. 398.2 Drilling pattern and installation example ....................................................................................... 40

9 Electrical installation............................................................................................................................... 419.1 Block diagram - AX8620 and AX8640 .......................................................................................... 429.2 Block diagram - AX81xx and AX82xx ........................................................................................... 439.3 Power supply ................................................................................................................................ 44

9.3.1 Standard connection to the mains supply (X01) .............................................................. 449.3.2 Further types of connection ............................................................................................. 469.3.3 24 VDC supply (X01) ....................................................................................................... 489.3.4 Fusing, CE-compliant....................................................................................................... 499.3.5 Fusing, UL - compliant ..................................................................................................... 499.3.6 Residual current circuit breaker ....................................................................................... 499.3.7 Safe system stop in the event of power failure ................................................................ 49

9.4 Terminal points - supply modules ................................................................................................. 509.4.1 DC link (external DC link-connection currently not permitted) ......................................... 509.4.2 External and internal brake resistor ................................................................................. 519.4.3 EtherCAT (X04 and X05) ................................................................................................. 52

9.5 Terminal points - axis modules ..................................................................................................... 539.5.1 Motor- feedback connection (X13 and X23) AX8108, AX8118 and AX8206 ................... 539.5.2 Digital inputs (X15 and X25) ............................................................................................ 53

9.6 Total motor cable length ............................................................................................................... 54

10 Option modules ....................................................................................................................................... 5510.1 Installation..................................................................................................................................... 5510.2 Option modules type key .............................................................................................................. 5510.3 AX8810 - capacitor module .......................................................................................................... 55

10.3.1 Technical data.................................................................................................................. 5510.3.2 Positioning within the system........................................................................................... 56

11 Project planning ...................................................................................................................................... 5711.1 Important information.................................................................................................................... 5711.2 Drive train design.......................................................................................................................... 5711.3 Energy management .................................................................................................................... 5711.4 EMC, earthing, screen connection and potential .......................................................................... 5711.5 Control cabinet.............................................................................................................................. 58

12 Accessories ............................................................................................................................................. 5912.1 Brake resistor - AX2090-BW80..................................................................................................... 59

12.1.1 Device description............................................................................................................ 5912.1.2 Intended use .................................................................................................................... 5912.1.3 Special safety notes on brake resistors ........................................................................... 6012.1.4 Product identification........................................................................................................ 6112.1.5 Mechanical installation..................................................................................................... 6112.1.6 Electrical installation......................................................................................................... 6212.1.7 Technical data.................................................................................................................. 66

13 Support and Service................................................................................................................................ 67

Table of content


Foreword


2 Foreword

2.1 Notes on the documentationThis description is only intended for the use of trained specialists in control and automation engineering whoare familiar with the applicable national standards.It is essential that the documentation and the following notes and explanations are followed when installingand commissioning the components. It is the duty of the technical personnel to use the documentation published at the respective time of eachinstallation and commissioning.

The responsible staff must ensure that the application or use of the products described satisfy all therequirements for safety, including all the relevant laws, regulations, guidelines and standards.

Disclaimer

The documentation has been prepared with care. The products described are, however, constantly underdevelopment.We reserve the right to revise and change the documentation at any time and without prior announcement.No claims for the modification of products that have already been supplied may be made on the basis of thedata, diagrams and descriptions in this documentation.

Trademarks

Beckhoff®, TwinCAT®, EtherCAT®, Safety over EtherCAT®, TwinSAFE®, XFC® and XTS® are registeredtrademarks of and licensed by Beckhoff Automation GmbH.Other designations used in this publication may be trademarks whose use by third parties for their ownpurposes could violate the rights of the owners.

Patent Pending

The EtherCAT Technology is covered, including but not limited to the following patent applications andpatents:EP1590927, EP1789857, DE102004044764, DE102007017835with corresponding applications or registrations in various other countries.

The TwinCAT Technology is covered, including but not limited to the following patent applications andpatents:EP0851348, US6167425 with corresponding applications or registrations in various other countries.

EtherCAT® is registered trademark and patented technology, licensed by Beckhoff Automation GmbH,Germany

Copyright

© Beckhoff Automation GmbH & Co. KG, Germany.The reproduction, distribution and utilization of this document as well as the communication of its contents toothers 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 apatent, utility model or design.

Foreword


2.2 Documentation issue statusVersion Comment1.0 First publication0.0.1 Internal version

2.2.1 Scope of the documentationThe overall documentation package for the AX8000 multi-axis servo system is comprised of the followingmanuals:

AX8000 - DefinitionSystem manual (this document) Description of the mechanical and electrical

parameters as well as all information necessary forthe use of the AX8000 multi-axis servo system.

Startup User manual for the installation and assembly of theAX8000 multi-axis servo system.

Commissioning under TwinCAT3 Commissioning tutorial under TwinCAT3 includinguser information on the TC DriveManager 2 and adescription of the safety function STO (Safe TorqueOff) over FSoE (Safety over EtherCAT).

CoE - object description Documentation of CAN over EtherCAT – objects withattribute tables.

Diagnostic messages Documentation of the error messages of the AX8000multi-axis servo system with attribute tables andproblem/solution descriptions.

AX2090-BW8x brake resistors Operating instructions for the use and installation ofthe AX2090-BW8x brake resistors as accessories forthe AX8000 multi-axis servo system.

2.3 Appropriate useThe AX8000 multi-axis servo system is exclusively designed for the operation of suitable synchronousmotors with torque, speed and position control. The max. permissible effective voltage of the motors must behigher than or at least equal to the effective mains voltage supplied to the servo system.

The supply, axis and capacitor modules of the AX8000 multi-axis servo system are installed exclusively ascomponents in electrical systems or machines. They may only be put into operation as integratedcomponents of the system.

WARNING

Caution - Risk of injury!Basically, electronic devices are not fail-safe. The machine manufacturer is responsible forensuring that the connected motors and the machine are brought into a safe state in theevent of a fault in the drive system.

The components and modules listed above may only be operated in a closed control cabinet, taking intoconsideration the environmental and operating conditions [ 29] described in the section: "Technical Data".

Improper use

The AX8000 multi-axis servo system is not suitable for use in the following areas:

• in ATEX zones without a suitable housing• in areas with aggressive environments (e.g. aggressive gases or chemicals)

Foreword


The relevant standards and directives for EMC interference emissions must be complied with in residentialareas. The servo drives may only be installed in housings and control cabinets with appropriate shieldingattenuation.

2.3.1 Dual Use (EU1382/2014)According to the EU directive 1382/2014 published on 30/12/2014, commercially available frequencyconverters – that also means the Beckhoff product series: AX8000 multi-axis servo systems are now newlyclassified as dual-use goods.

The goods list, Annex I of the Dual Use directive 428/2009 has been amended accordingly:• Frequency converters (listed in goods list position 3A225) ≥ 600 Hz are subject to export control.• Frequency converters (AX8000 multi-axis servo system) with a rotary field frequency of 599 Hz are not

subject to export control.

Guidelines and Standards


3 Guidelines and Standards

CAUTION

Personal injuries!Servo drives are not products within the meaning of the EC Machinery Directive. Operationof the servo drives in machines or systems is only permitted once the machine or systemmanufacturers has provided evidence of CE conformity of the complete machine or system.

3.1 EU Declaration of ConformityWe,

Beckhoff Automation GmbH & Co. KGHülshorstweg 2033415 VerlGermany

hereby declare, under our sole responsibility, that the product range

Digital Compact AX8000 servo drive(Types AX8620, AX8640, AX8108, AX8118, AX8206, AX8810).

The modules named here have been developed, designed and manufactured in accordance with the LowVoltage Directives 2006/95/EC (until 19/04/2016) and 2014/35/EC (from 20/04/2016) as well as the EMCDirectives 2004/108/EC (until 19/04/2016) and 2015/30/EC (from 20/04/2016). They meet the requirementsof RoHS Directive 2011/65/EU.

The following standards were applied:• Generic standard: EN 6100-6-2:2005

(Interference immunity for the industrial area)• Generic standard: EN 61000-6-4:2007+A1:2011

(Interference emission for the industrial area)• Product standard: EN 61800-3:2004+A1:2012

(Adjustable speed electrical drives - EMC requirements and specific test methods).• Product standard: EN 61800-5-1:2007

(Adjustable speed electrical power drive systems - Safety requirements)• RoHS: EN50581:2012

(Technical documentation for the assessment of electrical and electronic products with respect to therestriction of hazardous substances)

Attachment of the CE marking:2016

Issued by:ManagementH. BeckhoffVerl, 17/07/2017



3.2 Electromagnetic compatibility (EMC)Beckhoff Automation GmbH & Co. KG guarantees the conformity of the AX8000 multi-axis servo system tothe EMC Directive 2004/108/EC.

Applied harmonized standards:• IEC / EN 61800-5-3

Installation of electrical systems and components

In order to be able to establish an effective protective earth conductor system, in addition to the protectiveconductors and all electronic components all conductive components of a machine must be included in theprotective earth conductor system through equipotential bonding.

Attention

Attachment of the protective earth conductor!When installing electrical systems and components, the protective earth conductors shouldalways be connected first and removed last. The specifications for the protective earth con-ductor connections depend on the level of leakage currents:

• The minimum requirement for the protective earth conductor is a KU value1) of 4.5• The minimum requirement for leakage currents is IL < 10 mA or KU = 6 for IL > 10 mA.

1) The KU-value is a variable for the classification of safety-related types of failure for protection againstdangerous shock current and excessive heating. A value of KU = 4.5 in relation to interruption is attained:

• with a permanently attached protective conductor ≥ 1.5 mm²• for protective earth conductor connections ≥ 2.5 mm² with plug connectors for industrial systems (IEC

60309−2).

KU = 6 in relation to interruption is attained with permanently connected conductors ≥ 10 mm², wherein thetype of connection and routing must comply with the standards applicable to PE conductors.

3.3 UL approval for the US and CanadaThe German translation of this section is purely informative!All statements made in the English version (AX8000 – System Manual Version 1.0) of thissection are binding!

The following components of the AX8000 multi-axis servo system are cULus-certified:

Modules from the AX8000 series with UL certificationAX8620, AX8640, AX8108, AX8118, AX8206, AX8810

The above components are permitted to bear the certification logo on the type plate. If you wish to operate aservo drive from the AX8000 series in the USA or Canadian economic areas, please check whether thecULus sign appears on the type plate.

Below is a list of the relevant chapters that are amended with respect to the cULus approval. Furthermore,UL-specific remarks are listed.



3.3.1 UL-specific chapterThe integrated protection against short circuit is no substitute for the external mains protection. The mainsprotection must comply with the manufacturer's specification and the national and international regulationsand laws.

Components of the AX8000 multi-axis servo system must be operated on mains supplies that can supply amaximum current carrying capacity of 5 kA at 480 VAC. UL circuit breakers of class "J" are to be used for protection.

• AX8620 supply modules must be protected by 25 A.• AX8640 supply modules must be protected by 50 A.

With regard to alternatives to the UL circuit breakers of the class "J", be sure to refer to the UL standard "UL508 A, section SB4.2.3, exception no. 1".

Fuse holders with UL approvalPossible configuration examples are described in the further course of this document. Be-fore implementing a UL configuration, please contact your UL certification body and discussfurther necessary boundary conditions. Furthermore, when using fuse holders, care mustbe taken that they have also been tested and manufactured in accordance with the applica-ble standards of the UL certification body.

Also see about this2 Fusing, UL - compliant [ 49]

3.3.2 UL-specific notesWhat's important:

• Components from the AX8000 multi-axis servo system may be used in an environment with non-conductive dirt. This corresponds to the degree of soiling 2. Note that occasionally, depending on theenvironmental conditions, temporary conductivity can be expected due to condensation.

• The wiring must be done using copper conductors with a thermal conductivity of at least 60 °C - 75 °C.• The AX8000 multi-axis servo system does not offer an overheating sensor for the connected motor.• Various sizes of motor can be operated. The level of the internal motor overload protection switch is

adjustable.

Canadian economic area!In Canada the devices are only approved with a transient suppressor on the input side.Technical requirements for the device for transient suppression:

• Rated voltage: 480 V (Ph / GND), 480 V (PH / PH)• Overload category: 3• Protection against a rated surge voltage peak: 4 kV

For your safety


4 For your safetyRead the section on safety and heed the notices to protect yourself against personal injury and materialdamages.

Liability limitations

All the components of the AX8000 multi-axis servo system are supplied in certain hardware and softwareconfigurations appropriate for the conditions of the application. Unauthorized modifications to the hardwareand/or software configurations other than those described in the documentation are not permitted, and nullifythe liability of Beckhoff Automation GmbH & Co. KG.

In addition, the following actions are excluded from the liability of Beckhoff Automation GmbH & Co.KG:

• Failure to comply with this documentation

• Improper use [ 8]• Untrained personnel• Use of unauthorized spare parts

4.1 Staff qualificationOnly technical personnel with knowledge of control and automation technology may carry out any of theillustrated work steps on the Beckhoff software and hardware, in particular on the AX8000 multi-axis servosystem.

The technical personnel must have knowledge of drive technology and electrical systems and must alsoknow how to work safely on electrical equipment and machines.

This also includes:• work preparation and• securing of the working environment (e.g. securing the control cabinet against being switched on

again).

The technical personnel must be familiar with the current and necessary standards and directives for theautomation and drive environment.

For your safety


4.2 Description of symbolsIn this documentation the following symbols are used with an accompanying safety instruction or note. Thesafety instructions must be read carefully and followed without fail!

Symbols that warn of personal injury:

DANGER

Serious risk of injury!This is an extremely dangerous situation. Disregarding the safety notice will lead to seriouspermanent injuries or even death.

WARNING

Risk of injury!This is a dangerous situation. Disregarding the safety notice may lead to serious injuries.

CAUTION

Personal injuries!This is a dangerous situation. Disregarding the safety notice may lead to minor injuries.

Symbols that warn of damage to property or equipment:

Attention

Warning of damage to property or the environment!This notice indicates disturbances in the operational procedure that could damage theproduct or the environment.

Symbols indicating further information or tips:

Note

Tip or pointer!This notice provides important information that will be of assistance in dealing with theproduct or software. There is no immediate danger to product, people or environment.

UL note!This symbol indicates important information regarding UL certification.

For your safety


4.3 Notes on the AX8000 multi-axis servo systemThe notes are intended to avert danger and facilitate the handling of the AX800 multi-axis servo system.They must be followed during installation, commissioning, production, troubleshooting, maintenance and trialor test assemblies.

The multi-axis servo system from the AX8000 series is not capable of running alone. It must always beinstalled in a machine or system. After installation the additional documentation and safety instructionsprovided by the machine manufacturer must be read and followed.

DANGER

Danger to life due to high voltage on the DC link capacitors!The DC link capacitors RB+ and RB- and the test contacts DC+ and DC- on the supply, axis and option modules can carry life-threatening voltages of ≥ 875 VDC.Take the following measures to avert danger:

• After disconnecting the servo drive from the mains supply, wait until the voltage hasfallen below 50 VDC. Only then is it safe to work.

• Measure the voltage on the test contacts properly.• Secure the work area properly and wear the PPE.

CAUTION

Proper connection of the protective earth conductor!Protective earth systems must be connected when installing electrical systems and compo-nents.Please observe the following notes when installing the protective earth conductor:

• Read section 3.2: "Electromagnetic compatibility (EMC)", in particular the parts regard-ing the attachment of a protective earth conductor.

• Make sure that the protective earth conductor has been firmly connected.• Disconnect the servo drive from the mains supply. Secure the control cabinet and the

device against being switched on again.• Wear PPE.

WARNING

Serious burns due to hot surfaces on the devices!The surface temperature of the devices can reach ≥ 50 °C during operation of the system.There is an acute risk of sustaining burns to parts of the body and limbs.Take the following measures to avert danger:

• Do not touch any components (housing, etc.) shortly after or during operation.• Wait until all components have cooled sufficiently. At least 15 minutes.• Check the surface temperature with a thermometer.• DO NOT wear work gloves with a rubber coating. These can fuse with the skin on ac-

count of the high temperature and cause serious injuries.

Note

Notes on operation of the AX8000 multi-axis servo system:• Read this manual completely and carefully before using the servo drive. Notify the re-

sponsible sales office immediately if any passages are not understandable. Refrainfrom working on the servo drive.

• When carrying out the electrical installation, ensure that the correct fuses/circuit break-ers are selected between the mains supply and the supply module. Further informationcan be found in the "Electrical installation [ 41]" section.

For your safety


Attention

Damage to the environment or devices• During installation it is essential to ensure that the specified ventilation clearances and

climatic conditions are adhered to. Further information can be found in the "Technicaldata [ 29]" and "Mechanical installation [ 38]" sections.

• If the servo drive is operated in contaminated ambient air, the cooling openings must bechecked regularly for blockage.

• The servo drives contain components at risk from electrostatic discharge caused by im-proper handling:

ð Please ensure you are electrostatically discharged before touching the servo drivedirectly.

ð Avoid contact with highly insulating materials (synthetic fibers, plastic film etc.).

ð Place the servo drive on a conductive surface.

ð Do not touch the motor connector while the AX8000 is in operation.

Handling


5 Handling

5.1 Transport

Attention

Short circuit due to moistureCondensation may form when transporting in cold weather or in the case of extreme tem-perature differences:

• make sure that no moisture (condensation) forms inside the servo drive. Equalize theroom temperature slowly. Do not switch the device on until it is completely dry.

Despite the robust design of the unit, the components are sensitive to strong vibrations and impacts.

During transport, protect the product against:• high mechanical stress• large temperature fluctuations (max. 20 K/hour)• excessively high humidity (max. relative humidity 95%, non-condensing)

Use the manufacturer's original packaging for dispatch.

Since servo drives contain electrostatically sensitive components that can be damaged by improperhandling:

• Avoid electrostatic charging before you touch the device or components directly.• Avoid contact with highly insulating materials (synthetic fibers, plastic film etc.).• Place the servo drive on a conductive surface.• If the packaging is damaged, inspect the device and any accessories for visible damage. Inform the

transport company and, if necessary, the manufacturer.

Packaging and dimensions

AX8108, AX8206 and AX8620 AX8118 and AX8640Dimensions (H x W x D) 370 x 275 x 130 (specified in mm) 395 x 275 x 170 (specified in mm)Packaging Recyclable cardboard box with inserts

5.2 Storage• The servo drive and accessories may not be stored outdoors. The storage space must be adequately

ventilated and dry.• The devices may only be stored in the manufacturer's original packaging.• Max. stack height 8 cartons• Storage temperature: - 40...+ 55° C, varying no faster than 20 K / hour• Air humidity: relative humidity max. 95%, non-condensing• Storage time: < 5 years: without limitation

Attention

Destruction of the equipment!On no account must the device be connected to 400 V if the DC link capacitors have losttheir forming. The capacitors must be reformed (see below).

Forming:

Capacitors must be reformed before putting the servo drive into operation. Release all electrical connectionsand feed the servo drive for about 30 minutes with 230 VAC (single-phase) at terminals L1/L2 or L2/L3.

Handling


5.3 DisposalThe device should be disposed of by a certified disposal company. You can obtain addresses from us.Housing components (polycarbonate, polyamide (PA6.6)) are suitable for plastic recycling.

Metal parts can be sent for metal recycling.

Electronic parts such as circuit boards and terminals must be disposed of in accordance with nationalelectronics scrap regulations.

In accordance with the WEEE 2012/96/EG Directives we take old devices and accessories back forprofessional disposal, provided the transport costs are taken over by the sender.

Send the devices with the note “For disposal” to:

Beckhoff Automation GmbH & Co. KGHuelshorstweg 20D-33415 Verl

Product overview


6 Product overviewThe servo drives from the AX8000 series have a modular design and offer the optimum in function andeconomy. The supply modules support several axis modules, which can be used in various ways. Inconjunction with EtherCAT, the real-time Ethernet system, the integrated control technology offers minimumcycle times and supports fast, highly dynamic positioning tasks.

6.1 Scope of supplyThe scope of delivery may vary depending on the ordered configuration. Before installing the device pleaseensure that all ordered components were delivered and that they are undamaged. In the event of anydamage please contact the carrier immediately and document the damage.

The scope of supply of an AX8000 multi-axis servo system can be made up of the followingcomponents:

AX8000 multi-axis servo system components Connectors for:Supply module AX8620 X01: Mains supply, DC link, 24 V supply and external

brake resistorSupply module AX8640 X01: Mains supply

X02: DC link, 24 V supply and external brake resistorAxis modules AX8108 and AX8118 X15: Digital inputs and outputsAxis module AX8206 X15: Digital inputs and outputs

X25: Digital inputs and outputsCapacitor module Not yet available

*the components of the AX8000 multi-axis servo system are delivered exclusively in the performance classordered by the customer.

The scope of supply always includes:• Quick reference guide (Startup)• Documentation on CD-ROM

Product overview


6.2 Name plate and type key

6.2.1 Supply modules

Name plate

No. Position No. Position No. Position1 Order number 7 Rated output voltage 13 CE conformity2 Serial number 8 Rated output current 14 EAC approval3 Rated input voltage 9 Date of manufacture 15 Serial number sticker4 Rated input current 10 QR code 16 Attachment of the type plate5 Input frequency 11 EtherCAT conformity6 Max. ambient temperature 12 cULus certification

Type key

Product overview


6.2.2 Axis modules

Name plate

No. Position No. Position No. Position1 Order number 6 Rated output current 11 cULus certification2 Serial number 7 Output frequency range 12 EAC approval3 Rated input voltage 8 Date of manufacture 13 CE conformity4 Max. ambient temperature 9 QR code 14 Serial number sticker5 Rated output voltage 10 EtherCAT conformity 15 Attachment of the type plate

Type key

Product overview


6.3 Drive-integrated safety technologyThe AX8000 axis modules are also optionally available with integrated safety functions. These correspond toIEC 61800-5-2 and meet the safety standards EN ISO 13849-1:2008 (up to Cat 4, PL e) and IEC 61508:2010 (SIL 3).

Communication takes place via the Safety-over-EtherCAT (FSoE) protocol according to IEC 61784-3-12.The safety function STO can optionally also be activated via two safely integrated digital inputs [ 53].

Order designation Safety functionsAX8xxx-x1xx • STO (Safe Torque Off)

• SS1 (Safe Stop 1)

Optionally via safe digital inputs [ 53] or via FSoEAX8xxx-x2xx • TwinSAFE (in preparation)

Attention

Safety-related documentation!Axis modules with the order designation AX8xx-x1xx support the safety functions STO (Safe Torque Off) and SS1 (Safe Stop 1).Before putting the axis module into operation, read the documentation for:

• AX8911 - TwinSAFE Drive option for AX8000 series servo drives.

Product overview


6.4 General description

6.4.1 Supply module - AX8620No. Name1 Display2 Quick coupling – 24 VDC

3 Quick coupling – DC link, FE4 X01 – 10-pin input terminal: DC, 24 V, mains

supply, PE and external brake resistor5 Earthing bolt6

DANGER

875 VDC voltage at the DC link (3)and test contacts (DC+ and DC-).After switching off, measure thevoltage at the test contacts DC+and DC-. Safe working is onlypossible once the voltage hasdropped below 50 VDC.

7 Test contact -DC (DC link)8 Test contact +DC (DC link)9 Test contact GND10 Test contact + 24 VDC

11 X05 - socket for EtherCAT output12 X04 - socket for EtherCAT input

Product overview


6.4.2 Supply module - AX8640No. Name1 Display2 Quick coupling – 24 VDC

3 Quick coupling – DC link, FE4 X02 – 7-pin input terminal: DC, 24 V and external

brake resistor5 X01 – 4-pin input terminal: mains supply, PE6 Earthing bolt7

DANGER

875 VDC voltage at the DC link(3) and test contacts (DC+ andDC-). After switching off, measurethe voltage at the test contactsDC+ and DC-. Safe working isonly possible once the voltagehas dropped below 50 VDC.

8 Test contact -DC (DC link)9 Test contact +DC (DC link)10 Test contact GND11 Test contact + 24 VDC

12 X05 - socket for EtherCAT output13 X04 - socket for EtherCAT input

Product overview


6.4.3 Axis modules – AX8108 and AX8118The diagram below shows the AX8118 module. The AX8108 module only differs in the width; otherwise it isidentical to the AX8118.

No. Name1 Display2 X15 – digital inputs3 Quick coupling – 24 VDC

4 Quick coupling – DC link and FE5 X13 – 8-pin motor connector: U, V, W, PE,

T+ (OCT+), T- (OCT-), B+ and B-6 Earthing bolt7 AX-Bridge: DC link and FE8

DANGER

875 VDC voltage at the DC linkrails (4 and 7). After disconnectingmeasure the voltage at the DClink rails. Safe working is onlypossible once the voltage hasdropped below 50 VDC.

9 AX-Bridge: EtherCAT10 AX-Bridge: 24 VDC

Product overview


6.4.4 Axis module - AX8206No. Name1 Display – channel B2 X25 – digital inputs (channel B)3 Quick coupling – 24 VDC

4 Quick coupling – DC link and FE5 X23 – 8-pin motor plug (channel B): U, V, W, PE,

T+ (OCT+), T- (OCT-), B+ and B-6 X13 – 8-pin motor plug (channel A): U, V, W, PE,

T+ (OCT+), T- (OCT-), B+ and B-7 Earthing bolt8 AX-Bridge: DC link and FE9

DANGER

875 VDC voltage at the DC linkrails (4 and 8). After disconnectingmeasure the voltage at the DClink rails. Safe working is onlypossible once the voltage hasdropped below 50 VDC.

10 AX-Bridge: EtherCAT11 AX-Bridge: 24 VDC

12 X15 – digital inputs (channel A)13 Display – channel A

6.5 AccessoriesInformation about our comprehensive range of accessories can be found in the main Beckhoff main catalogor online under http://www.beckhoff.de.

Accessories with UL certification!If you want to operate an AX8000 in the US or Canada, please note that any accessoriesalso require UL certification.

Technical description


7 Technical description

7.1 Configuration of the servo system

With a supply module and several axis modules, the servo drives of the AX8000 series offer optimumfunctionality and cost-effectiveness. Integrated control technology supports fast and highly dynamicpositioning tasks. EtherCAT as a high-performance system communication enables ideal interfacing with PC-based control technology.

The AX8000 system enables convenient and fast connection of the DC link of the supply module and severalaxis modules via an AX Bridge. The connection can be established without tools through spring-loadedterminals for DC link, control circuit and EtherCAT.

The AX8000 was developed specifically for the EtherCAT real-time Ethernet system. The outstandingfeatures of EtherCAT are particularly beneficial for drive technology. They include short cycle time,synchronicity and simultaneity. EtherCAT enables very short cycle times, even in bus systems containing alarge number of devices.

The axis modules enable operation of motors with different ratings, thanks to scalable motor currentmeasurement. At an 8 A module the rated motor current can be set between 1 A and 8 A, without affectingthe quality of the resolution.

At a two-channel axis module two identical or two different motor versions can be connected. The total ratedcurrent of the two motors is relevant for the choice of axis module. Note that the maximum current that canbe supplied at any one time is the rated current of the axis module.



7.1.1 System descriptionFunction / characteristic Supply module Axis moduleMains supply with mains and phase monitor

x -

Temperature monitoring:DeviceHeat sink

x x

Brake chopper x -DC link connectionintegrated (AX Bridge)per line

x-

x-

Connector including x (X01, X02) x (X15, X25)Digital inputs / channel - 4Motors (incl. holding brake control)Synchronous servo motors - xFeedback systemOCT - xOperation modesTorque control Speed control Position control

---

xxx

Special features of the multi-axis servo system:• High-speed EtherCAT system communication• flexible motor type selection• scalable wide range motor current measurement• High-speed capture inputs• Diagnostic and parameter display• integrated mains filter• compact design for simple control cabinet installation• Integrated quick connection system for DC link, control circuit and EtherCAT

The integrated fast control technology of the AX8000 multi-axis servo system with a current control cycle ofup to 16 µs supports fast and highly dynamic positioning tasks.

7.1.1.1 Wide voltage range

In order to simplify use on the most diverse voltage systems, the supply modules of the AX8000 multi-axisservo system are equipped with a wide voltage range.

This covers the following different mains supplies:• 1-phase mains supplies: 1 x 100-10% VAC - 1 x 240+10% VAC

• 3-phase mains supplies: 3 x 200-10% VAC - 3 x 240+10% VAC or 3 x 400-10% VAC - 3 x 480+10% VAC

Country-specific examples of different mains systems:

Country 1-phase mains supplies: 3-phase mains supplies:Japan 1 x 100 VAC 3 x 200 VAC

North America 1 x 115 VAC 3 x 480 VAC

Europe 1 x 230 VAC 3 x 400 VAC



7.2 Technical data

7.2.1 Ambient and operating conditionsUL-listed!If you wish to operate a component from the AX8000 multi-axis servo system in a US orCanadian economic area that requires cULus approval, be sure to read section 3.3: "UL ap-proval in the USA and Canada [ 11]".

Ambient / operating conditions Permissible valuesAmbient temperature during operation 0 °C to +40 °C

up to +55 °C with power derating of 2.5 % / KAmbient temperature during transport -25 °C to +70 °CAmbient temperature during storage -25 °C to +55 °CAir humidity 15% to 85%, non-condensingLevel of contamination 2 according to EN 60204/EN 50178Corrosion protection Normally not required.

Under extreme operating conditions separatemeasures must be agreed with the manufacturer.

Operating altitude Up to 1000 m above sea level without powerderating.From 1000 m up to 2000 m with power derating →1.5 % / 100 m.

Installation position VerticalVentilation built-in temperature-controlled fanProtection class IP 20 except the terminals (IP00)



7.2.2 Electrical data - supply modules 100 - 240 VAC

1-phase connection

Electrical data AX8620-1000Rated input current 10 AAC

Max. input current 1) 20 AAC

Rated supply voltage 1 x 100-10% / 240+10% VAC

Rated output current 7 ADC

Peak output current1) 14 ADC

Rated output power 2) 2 kWMax. DC link voltage 425 VDC

DC link capacity 1020 µF24 V system and peripheral voltage 24 V ± 10%24 V current consumption 120 mAPower dissipation (without chopper) 8 W + 6 W / kWContinuous braking power(internal brake resistor)

100 W

Max. braking power(internal brake resistor)

5.4 kW

Min. brake resistor(external brake resistor)

18 Ω

Continuous braking power(external brake resistor)

1 kW

Max. braking power(external brake resistor)

9.8 kW

Mains filter Integrated (category "C3")SCCR value 5 kA

1)for max. 5 s2) at 240 V mains voltage



3-phase connection

Electrical data AX8620-1000 AX8640-1000Rated input current 17.5 AAC 35 AAC

Max. input current 1) 35 AAC 70 AAC

Rated supply voltage 3 x 200-10% / 240+10% VAC

Rated output current 20 ADC 40 ADC

Peak output current1) 40 ADC 80 ADC

Rated output power 2) 6.4 kW 12.8 kWMax. DC link voltage 425 VDC

DC link capacity 1020 µF 1240 µF24 V system and peripheral voltage 24 V ± 10%24 V current consumption 120 mAPower dissipation (without chopper) 8 W + 6 W / kWContinuous braking power(internal brake resistor)

100 W 200 W


5.4 kW 10.8 kW


18 Ω 8 Ω


1 kW 2 kW


9.8 kW 22 kW

Mains filter Integrated (category "C3")

1) for up to 5 s2) at 240 V mains voltage



7.2.3 Electrical data - supply modules 400 - 480 VAC

3-phase connection

Electrical data AX8620-0000 AX8640-0000Rated input current 17.5 AAC 35 AAC

Max. input current 1) 35 AAC 70 AAC

Rated supply voltage 3 x 400 / 480+10% VAC

Rated output current 20 ADC 40 ADC

Peak output current1) 40 ADC 80 ADC

Rated output power 2) 10.7 kW 21.4 kWMax. DC link voltage 875 VDC

DC link capacity 405 µF 625 µF24 V system and peripheral voltage 24 V ± 10%24 V current consumption 120 mAPower dissipation (without chopper) 8 W + 6 W / kWContinuous braking power(internal brake resistor)

100 W 200 W


21.8 kW 43.6 kW


33 Ω 18 Ω


1.6 kW 3.2 kW


21.8 kW 40.1 kW

Mains filter Integrated (category "C3")

1) for up to 5 s2) at 400 V mains voltage

7.2.4 Electrical data - axis modules 0 - 875 VDC

Single-channel

Electrical data AX8108-0000 AX8118-0000Rated output current 8 A 18 AMax. DC link voltage 875 VDC

DC link capacity 135 µF 405 µFCurrent consumption 24 V (without holdingbrake)

500 mA 530 mA

Power dissipation (without holding brake) 12 W+ 9 W / A at 240 V AC 2)

+ 11 W / A at 400 V AC 2)

+ 12.5 W / A at 480 V AC 2)

12 W+ 8 W / A at 240 V AC 2)

+ 10 W / A at 400 V AC 2)

+ 11 W / A at 480 V AC 2)

Minimum rated channel current at full currentresolution

1 A 5 A

Peak output current 1) 400 V / 480 V 2) 20 A / 18 A 40 A / 36 A

1) Ieff for max. 5 s2) Mains voltage



Two-channel

Electrical data AX8206-0000Rated output current / channel 6 AMax. DC link voltage 875 VDC

DC link capacity 135 µFCurrent consumption 24 V (without holding brake) 570 mAPower dissipation (without holding brake) 12 W

+ 9 W / A at 240 V AC 2)

+ 11 W / A at 400 V AC 2)

+ 12.5 W / A at 480 V AC 2)

Minimum rated channel current at full current resolution 1 AMaximum rated channel current / left channel (A) 6 AMaximum rated channel current / right channel (B) 8 ATotal rated output current 12 APeak output current 1) / left channel (A), 400 V / 480 V 2) 14 A / 14 APeak output current 1) / right channel (B), 400 V / 480 V 2) 20 A / 18 APeak output current 1)as total device current 28 A

1) Ieff for max. 5 s2) Mains voltage



7.2.5 Mechanical data

Supply modules

Mechanical data AX8620 AX8640Width 60 mm 90 mmHeight without plugs 230 mm 230 mmDepth without connectors / accessories 192 mm 192 mmWeight 2.5 kg 3.5 kg

Axis modules

Mechanical data AX8108AX8206

AX8118

Width 60 mm 90 mmHeight without plugs 230 mm 230 mmDepth without connectors / accessories 192 mm 192 mmWeight 2.0 kg 2.5 kg

Option modules

Mechanical data AX8810Width 60 mmHeight without plugs 230 mmDepth without connectors / accessories 192 mmWeight 1,9 kg



7.2.6 DimensionsThe AX8000 multi-axis servo system features only modules with two different dimensions – there are narrowmodules and wide modules. The specified measurements refer to the actual devices, without plugconnectors and cables. The fitting dimensions for control cabinet installation can be found in section"Mechanical installation [ 38]".

AX8620, AX8108, AX8206, AX8810 AX8640, AX8118

R2,75

R2,7530

230

60

15

217

6,5

230

217

9030 R2,75

15 60

30

R2,75

6,5

The diagrams are schematic diagrams.



7.3 Display

General

The display of the AX8000 multi-axis servo system provides a quick overview of the states of the individualmodules. Different symbols are used for the individual modules.

Display DescriptionDisplay black:

• The module is switched off.

Supply module

“E” – EtherCAT

Display Description

E

EtherCAT symbol lights up green:• The EtherCAT master is active.

E

EtherCAT symbol flashes green:• The EtherCAT master is active, the configuration is inactive.

E

EtherCAT symbol flashes red:• EtherCAT error.

“P” – power supply module

Display Description

PPower symbol lights up green:

• The mains voltage is connected, and the DC link is charged.

PPower symbol flashes green:

• The DC link is charged / discharged:Fast blinking: DC link voltage > 48 VSlow flashing: DC link voltage ≤ 48 V

PPower symbol lights up red:

• Error.

PPower symbol flashes red:

• Error, but the DC link is charged / discharged:Fast blinking: DC link voltage > 48 VSlow flashing: DC link voltage ≤ 48 V

PE

EtherCAT and power symbol light up green:• The supply module is in normal operating state.



Axis module

This documentation describes the display of a single-channel module (AX81xx). The display for a two-channel module is split vertically. The left column shows the symbols for channel “B”, the right column showsthe symbols for channel “A”. The EtherCAT symbol is shown in the center.

“E” – EtherCAT

The description corresponds to the description of the supply module, see above.

“A” – axis module

Display Description

AAxis symbol lights up green:

• The axis is enabled and error-free.

AAxis symbol flashes green:

• Fast blinking: The axis is disabled and is being initialized.Slow flashing: The axis is disabled and error-free.

AAxis symbol flashes green-red:

• The error reaction of the axis is active.

AAxis symbol flashes red:

• Error.

Axis symbol lights up red:• The module is in EtherCAT INIT state.

“S” – safety, only for safety axis modules

Display Description

SSafety symbol lights up green:

• No safety error.

SSafety symbol lights up red:

• The axis is in state “STO”.

The display for the situation when the two-channel safety axis module has reached its operating state isshown below.

Display Description

SAA S E

EtherCAT, axis and safety symbols light up green:• The safety axis module is in normal operating state.

Mechanical Installation


8 Mechanical Installation

WARNING

Danger of injury through electrocution!Injuries can be sustained through electrocution during the mounting and commissioning ofthe AX8000 multi-axis servo system.The installation may only be carried out by trained and qualified technical personnel whoare well-versed in electrical and automation technology. Furthermore, the national accidentprevention regulations must be adhered to.Take the following measures to avert danger:

• Wear personal protective equipment (PPE).

• Before starting work, read the section For your safety [ 13] carefully.• Place the electrical environment (servo drive, control cabinet, etc.) in a safe, voltage-

free state.

ð Remove all relevant mains fuses.

ð Turn off the main switch and secure it against being turned on again.

ð Put up a warning sign.• The control and power connections for the motors may be live, even if the motor is pre-

vented from rotating by the internal brake.

Attention

Destruction of the servo drive!Observe the following notes to avoid damage to or destruction of the components duringthe mechanical installation of the AX8000 multi-axis servo system:

• Always install the servo drive vertically.• Provide adequate ventilation for the servo drive. The permissible environmental condi-

tions can be found in the section "Environmental and operating conditions [ 29]".• It is essential to adhere to the required distances (see diagrams below).



8.1 Installation conditions in the control cabinetWhen dimensioning the control cabinet, consider that you may have to install input filters, mains chokes andbrake resistors for your application. Appropriate space should be provided for these components, so thatadequate ventilation is ensured.

Risk of injury through electric shock!The mounting plate must be earthed according to thestatutory regulations.

120

min

. 50

min

. 90

6,5 R2,75R2,75

R2,75R2,753030

230

6060

3015

217

Cable duct

Cable duct



8.2 Drilling pattern and installation exampleBefore you start with the installation, make the threaded holes in the mounting plate according to theuniversal drilling pattern for screwing on the AX8000 multi-axis servo system.

Generic drilling template

30

3015 1530 30 30 30 30 30 30

30 30 30 30 30 30 30 30

M5 M5 M5 M5 M5 M5 M5 M5 M5

M5 M5 M5 M5 M5 M5 M5 M5

217

If you equip the mounting plate with the universaldrilling pattern, you can change the configuration ofthe multi-axis system at any time without having toredrill all of the holes.

+DC

GND

+24V DC

X05

X04

-DC

AX8620 AX8108AX8206

4

5

3

7 77 7

7 7

7 77 7

73

1

2

6

Procedure:• Loosely screw in the three flat-head screws (M5 x 5) (1 and 2).• Hang the AX8620 supply module on the flat-head screw (2) and gently push it against the mounting

plate. The upper screw heads should slip through the rectangular openings into the mounting holes.• Tighten the three flat-head screws (1 and 2) with a torque of 3 Nm.

Mounting further modules:• For all relevant modules, push the AX bridge (3) into the right end position.• Loosely screw in the three flat-head screws (M5x5) (4 and 5).• Hang the AX8206 axis module on the flat-head screw (5) and gently push it against the mounting plate.

The upper screw heads should slip through the rectangular openings into the mounting holes.• The detail (6) shows the integrated mounting aid. Ensure that the bar is flush with the cutout and the

rear panels do not overlap.• Tighten the three flat-head screws (4 and 5) with a torque of 3 Nm.• Now open the quick release couplings (7) and push the AX Bridge (3) to the left end position for all

relevant modules. Close the quick release couplings (7) again.

Electrical installation


9 Electrical installation

DANGER




WARNING




free state.





Note

Max. DC link capacitance of the AX8000 multi-axis servo system:Each module has a specified DC link capacity. When the mains are first connected, thesupply module loads the whole DC link.For planning the drive system note the max. DC link capacity:Drive system up to 240 VAC supply: 16725 µFDrive system up to 480 VAC supply: 4,226 µF

Example at 400 VAC:1 x AX8640-0000 = 675 µF10 x AX8206-0000 = 1350 µF1 x AX8810-0000 = 1755 µFTotal capacity = 3780 µF = OK

WARNING

Connection of the protective earth conductor (PE) to the AX8000 multi-axisservo system!Potential equalization of the entire system must be carried out in order to avoid interference(EMC) and personal injuries.Each servo drive must be connected via the earthing bolts on the device according to IEC60364-4-41:2005 and DIN VDE 0100-410:2007-06.Special features in a drive system:In a drive system, the individual components of the AX8000 multi-axis servo system mustbe connected via the earthing bolts. In addition, a standard-compliant PE connection mustbe installed on the start and end modules of the system.



9.1 Block diagram - AX8620 and AX8640

Item no. Explanation1 Connection socket for incoming EtherCAT cable2 Connection socket for outgoing EtherCAT cable3 Measuring and test contacts on the devices4 Fast connection of the AX8000 multi-axis servo system (AX bridge)5 Optional brake resistor

Attention: When using the optional brake resistors with the AX8000 servo system, the bridge ofthe 10-pin supply plug "X01" (between RB- and RBint) must be removed.

6 Schematic contacts on the 10-pin supply plug "X01"7 Power supply unit with 24 VDC supply voltage



9.2 Block diagram - AX81xx and AX82xx

Item no. Explanation1 Fast connection of the AX8000 multi-axis servo system (AX bridge)2 Motor cable: ZK4800-80xx-xxxx (including OCT)



9.3 Power supply

Attention

Connection sequence of the AX8000 multi-axis servo system!The connection sequence of the devices is not arbitrary. The total rated current of the de-vice must decrease from the supply module onwards.The following combinations are permissible or impermissible respectively.

• The sequence "AX8640-AX8118-AX8206-AX8108" is permissible.• The sequence "AX8640-AX8206-AX8108-AX8118" is impermissible.

CAUTION

DC link group of the supply modules!To manufacture a DC link group of the supply modules, pay attention to the total rated cur-rent of the connected components.Various aspects need to be considered here.

• The plug connectors for the AX8620 / AX8640 have a current carrying capacity of 38A / 70 A.

• The bus bar system has a current carrying capacity of 50 A.

CAUTION

Dimensioning of the connection cable for the supply module!The dimensioning depends on the total rated current of the devices and must conform toEN 60204-1. The connection plugs for the AX8620 are designed for a max. conductorcross-section of 6 mm2, those for the AX8640 for a max. conductor cross-section of 16mm2.

9.3.1 Standard connection to the mains supply (X01)The supply modules of the AX8000 series are equipped with a wide voltage input X01 and can be connectedto 1-phase voltage systems between 100 VAC and 240 VAC or 3-phase systems between 200 VAC and 240 VACor 3-phase systems between 400 VAC to 480 VAC.

Note

Mains supplyConnection to the standard mains supply (TT/TN) with earthed center is described below.Connection to other mains types, e.g. “IT”, are possible.

Connection to the standard mains supply (TT / TN) with earthed center

1-phase 100 -10% .- 240 +10% VAC, 50/60 Hz 3-phase 100 -10% .- 480 +10% VAC, 50/60 Hz



X01 – input terminal AX8620

Note

CommissioningCommissioning of the AX8000 is only possible if the terminal points “Rbin´+” and “RB -” arebridged (delivery state) or an external brake resistor is connected to the terminal points “RB+” and “RB -”. Without this measure the AX8000 is stopped with an error message.

Input terminal Terminalpoint

Connection Max. wire cross-section

Tightening torque

PE Protective conductor6 mm2 (AWG 8) 0.5 – 0.6 Nm

(4.4 – 5.3 lbf in)L3 / N Phase L3 / N (for 1-

phase power supply)L2 Phase L2L1 Phase L1



Connection Max. wire cross-section

Tightening torque

L3 / N Phase L3

16 mm2 (AWG 6) 1.2 – 1.5 Nm(10.6 – 13.3 lbf in)

L2 Phase L2L1 Phase L1PE Protective

conductor



9.3.2 Further types of connection

Connection to an IT network (100 - 240 V) without an isolating transformer

Attention

EMC law in Europe!In Europe, the AX8000 multi-axis servo system may be operated on an IT network only withan isolating transformer on account of the electromagnetic emission.

Connection to other types of network (100 - 240 V) without isolating transformer



Connection to other mains types (100 - 480 V) with isolating transformer

Attention

Destruction of the AX8000 multi-axis servo system!The use of an isolating transformer is necessary in every case for asymmetric earthed ornon-earthed 100 – 480 V networks.

100 – 480 V isolating transformer 240 – 480 V isolating transformer



9.3.3 24 VDC supply (X01)The supply connection X01 is used for supplying the supply modules of the AX8000 with 24 VDC systemvoltage.

CAUTION

Safe operationWhen connecting motors with holding brake it is essential to observe the voltage toler-ances.


Input terminal Terminal point Connection Max. wire cross-section

Tightening torque

24 VDC 24 VDC ±10%System andperipheral voltage 6 mm2 (AWG 8) 0.5 – 0.6 Nm

(4.4 – 5.3 lbf in)GND GND



Tightening torque

24 VDC 24 VDC ±10%System andperipheral voltage 16 mm2 (AWG 6) 1.2 – 1.5 Nm

(10.6 – 13.3 lbf in)GND GND

Note

CommissioningCommissioning of the AX8000 is only possible if the terminal points “Rbin´+” and “RB -” arebridged (delivery state) or an external brake resistor is connected to the terminal points “RB+” and “RB -”. Without this measure the AX8000 is stopped with an error message.



9.3.4 Fusing, CE-compliant

CAUTION

Fire hazard through cable overload!The recommended fuses are designed for line protection. The servo drives feature inte-grated self-protection.

External protection

AX8620-1000 AX8620-0000 AX8640AC supply (max.) *) 25 A 25 A 50 A24 V supply (max.) 20 A

*) Application class "gG(A)" mains fuses according to IEC 60269 or "C" type automatic circuit-breakers mustbe used.

Internal protection

Circuit Fuse24 V system / peripheral voltage electronicBrake resistor (internal) electronic

9.3.5 Fusing, UL - compliant

CAUTION

Fire hazard through cable overload!The recommended fuses are designed for line protection. The servo drives feature inte-grated self-protection.

External protection

AX8620-1000 AX8620-0000 AX8640AC supply (max.) *) 25 A 25 A 50 A24 V supply (max.) 20 A

*) Application class "J" UL mains must be used.

Internal protection

Circuit Fuse24 V system / peripheral voltage electronicBrake resistor (internal) electronic

9.3.6 Residual current circuit breakerServo drives with built-in mains filters generate a small leakage current (fault current) due to the capacitors inthe filter. This fault current is responsible for malfunctions in standard residual current circuit breakers. Forthis reason so-called AC/DC sensitive residual current circuit breakers must be used, which also take intoaccount DC currents.

9.3.7 Safe system stop in the event of power failureA power failure can lead to the uncontrolled run-out of the drive axes: linear axis or lifting axes would hit thelimit stop unbraked. The supply voltage for the control electronics can be buffered by the UPS of theIndustrial PC until all axes have been safely stopped.



9.4 Terminal points - supply modules

Note

Terminal points for the power supplyThe terminal points for the mains supply can be found here [ 44].The terminal points for the 24 VDC supply can be found here [ 48].

9.4.1 DC link (external DC link-connection currently not permitted)

Attention

Destruction of the equipmentAn “external” DC link connection (e.g. AX5000 with AX8000) is currently not permitted.

DANGER




X01 – DC link terminal AX8620


Connection Max. wire cross-sec-tion

Tightening torque

n.c. not used

6 mm2 (AWG 8) 0.5 – 0.6 Nm(4.4 – 5.3 lbf in)

RB+ Brake resistor +(DC link voltage DC+)



X02 – DC link terminal AX8640


Tightening torque

DC - DC link -16 mm2 (AWG 6) 1.2 – 1.5 Nm

(10.6 – 13.3 lbf in)RB+ DC link +

9.4.2 External and internal brake resistor

DANGER




Note

Connection instructionsBefore you can connect the external brake resistor, you have to remove the bridge betweenthe contacts "RB – "and "RBINT +".Connect the PE connection of the brake resistor with the central earthing bar of the controlcabinet.

X01 – brake resistor terminal AX8620


Tightening torque

RB - Ext. brake resistor -

6 mm2 (AWG 8) 0.5 – 0.6 Nm(4.4 – 5.3 lbf in)RB + Ext. brake

resistor +



X02 – brake resistor terminal AX8640


Tightening torque

RB - Ext. brake resistor -

16 mm2 (AWG 6) 1.2 – 1.5 Nm(10.6 – 13.3 lbf in)

RB + Ext. brake resistor +

9.4.3 EtherCAT (X04 and X05)

Terminal Terminal point Connection

X04 (IN) incoming EtherCAT line

X05 (OUT) outgoing EtherCAT line



9.5 Terminal points - axis modules

9.5.1 Motor- feedback connection (X13 and X23) AX8108, AX8118and AX8206

For two-channel axis modules this hybrid motor connector is required for both channel “A” and channel “B”; itis part of pre-assembled Beckhoff motor cables.

View Terminal point Connection Max. wirecross-section

Tighteningtorque

PE Protective conductor

6 mm2(AWG 8) push in

U Motor connection UV Motor connection VW Motor connection WT - OCT – and temp. - *)

T + OCT + and temp. +*)

B - Motor brake GNDB + Motor brake +

*) Digital: KTY 83-1xx or KTY 84-1xx

Note

Brake currentThe max. output current for the motor brake (B– and B+) is:1 A for AX8108 and AX82062 A for AX8118

9.5.2 Digital inputs (X15 and X25)For two-channel axis modules this plug connector is required both for channel “A” and for channel “B”.

View Terminalpoint

ConnectionAX8xxx-x0xx

Max. wire cross-sec-tion

ConnectionAX8xxx-x1xx

Max. wire cross-sec-tion

Tighten-ing torque

1 Dig. input 1(20 µs)

with wire endsleeveaccording to DIN46 228/1max. 1.5 mm²(AWG 16)

Dig. safety input 1(20 µs)

with wire endsleeve and collaraccording to DIN46 228/4max. 1 mm2

(AWG 17)

push in


Dig. safety input 2(20 µs)


Dig. input 3(8 µs)


Dig. input 4(8 µs)

Attention

Safety-related documentation!Axis modules with the order designation AX8xx-x1xx support the safety functions STO (Safe Torque Off) and SS1 (Safe Stop 1).Before putting the axis module into operation, read the documentation for:

• AX8911 - TwinSAFE Drive option for AX8000 series servo drives.



9.6 Total motor cable length

Total motor cable length in compliance with EMC Category C3 (industrial area)

Motor cable length per mo-tor

Total motor cable length perdrive system

Number of axes per drive system

without mainschoke

max. 25 m max. 300 m • limited by the max. chargeable DC linkcapacitance (see section 7: "Electricalinstallation [ 41]") and

• limited by the 24 VDC supply (max. 50ADC).

The requirement is determined through themodule and motor braking current.

with mains choke AX2090-ND80-xxxx

max. 50 m max. 500 m

*always in relation to the connection to a common AX86x0 supply module

Total motor cable length in compliance with EMC Category C2 (mixed area / residential area)

Practical example:

Existing drive system comprising:• Motors from the AM8031-0D21 series (4 units)

Cable lengths (in m): 4, 10, 15 and 22 m• Motors from the AM8051-0G21 series (4 units)

Cable lengths (in m): 16, 18, 21, 25 m• AX8206 axis modules (4 units) and AX8620 supply module

Total standstill current (I0) of all motors:

4 x 1.95 A (AM8031) + 4 x 4.75 A (AM8051) = 26.8 A

Total standstill current (I0) x estimated simultaneity factor:

26.8 A x 0.7 = 18.76 A (the AX8620 supply module was selected on the basis of this calculation).

24 V DC current consumption of all components:

0.12 A (AX8620) + 4 x 0.57 A (AX8206) + 4 x 0.33 A (brake) + 4 x 0.54 A (brake) = 5.88 ADC

Result:

The max. single cable length is ≤ 25 m √ Requirement fulfilled

The total cable length is 131 m (≤ 300 m) √ Requirement fulfilled

The max. DC link capacitance is: 945 µF* (≤ 4226 µF) √ Requirement fulfilled

The 24 V DC current consumption of all components is: 5.88 ADC (≤ 50 ADC) √ Requirement fulfilled

Therefore no mains choke is required.*for the different capacitances, refer to section 7: "Electrical installation [ 41]".

Option modules


10 Option modules

10.1 InstallationThe option modules are installed in the same way as described in section Mechanical Installation [ 38]. Theelectrical installation mainly consists of connecting the AX Bridge via slider and interlock. If further steps arerequired, the instructions can be found in a separate section under the description of the individual optionmodules.

DANGER




10.2 Option modules type keyAX y z 8 8 - a b c d - 0000

Reserved0 = Standard

Product lineServo drives

SeriesAX8000

Power supply0 = 0 - 875 VDC

1 = 0 - 425 VDC



Modules8 = Option modules

Option modules10 = Capacitor module

10.3 AX8810 - capacitor moduleThe capacitor module extends the DC link capacity and is particularly suitable in combination with the 1-phase supply of the AX8620-1000 for supporting the DC link. Voltage peaks during motor braking areabsorbed and stored. This largely avoids the need for connecting the external brake resistor and reduced thepower dissipation.

10.3.1 Technical dataData AX8810-1000 AX8810-0000Capacity 4420 µF 1755 µFMax. DC link voltage 425 VDC 875 VDC

Height 230 mm 230 mmWidth 60 mm 60 mmDepth 192 mm 192 mmWeight 1.9 kg 1.9 kg

Option modules


10.3.2 Positioning within the system

Supply voltage: 100 VAC – 240 VAC

With this supply voltage the capacitor module AX8810-1000 must be positioned directly next to the supplymodule. Due to the significantly higher capacitance compared with the AX8810-0000, it is the preferredmodule for this supply voltage.

+DC

GND

+24V DC

X05

X04

-DC

AX8620-1000

+DC

GND

+24V DC

X05

X04

-DC

AX8620-1000

AX8810-1000

AX8810-1000

AX8206

AX8206

AX8108

AX8108

Supply voltage: 400 VAC – 480 VAC

With this supply voltage the capacitor module AX8810-0000 can be positioned anywhere within the system.

Project planning


11 Project planning

11.1 Important informationThe more thoroughly a machine or plant project is thought through in advance, the less risk there is of havingto carry out expensive modifications during or after commissioning. This applies to both the mechanical andelectrical design. This section can only give a rough overview of electrical design.

11.2 Drive train designApplication, servo drive, motors and gear mechanism must be adapted to each other so that there is anadequate safety margin for all components as a degree of sluggishness appears over time due to hightemperatures or wear. Make sure that the components in the working area of the system have adequatereserves so that the working life is not impaired and the necessary control quality can be maintained.The Beckhoff software “TCMotionDesigner” is available for configuration of the drivetrain and selection ofsuitable components.

11.3 Energy managementIf the quality of the mains supply is impaired due to wide fluctuations in voltage, then both the servo drivespecification and the speed range of the motor will need to be considered. With a positive tolerance forvoltage fluctuation the upper limit value of the wide voltage input of the AX8000 needs to be taken intoaccount. With a negative tolerance of the voltage fluctuation it must be checked whether the decrease inspeed caused by the low voltage is permissible. With these motors what is known as field weakeningoperation (check availability) of the servo drive may provide a solution. If the mains supply does not meet thespecifications for operation of the AX8000, then isolating transformers, mains chokes, mains filters or othermeasures may be required. An energy efficient drive system operates in a drive system with a shared DClink and shared internal and possibly also external brake resistors. If you are already using similar drivesystems, the AX8000 offers a convenient diagnostic system for determining the load on the brake resistorsand for transferring the values. Previous experience with drive systems shows that in such a system muchsmaller or even no external brake resistors need to be used.The Beckhoff software “TCMotionDesigner” is available for energy management purposes.

11.4 EMC, earthing, screen connection and potentialThe AX8000 corresponds to EMC category "C3" (industrial sector) in terms of conducted interferenceemissions. If you wish to use components which comply with a higher category you can limit the AX8000conducted interference emissions with the aid of additional filters to such a degree that this complies with theEMC category "C2" (residential and industrial environment) or "C1" (residential environments). Ensure thatthere is adequate earthing (large-area low-impedance connection) of all relevant components (incl. controlcabinet). The AX8000 incl. periphery, control cabinet, machine bed and motors must be at the samepotential, as the AX8000 control quality will suffer under differing potentials and operational malfunction mayresult. Using the screen connection for potential equalisation is not permitted. If you are unable to provide auniform reference potential you need to lay potential equalisation cables of adequate dimensions. Smoothoperation is only guaranteed by faultless screen connections of the cables. The screens must be appliedgenerously at both ends and must on no account be disconnected. Use pre-assembled Beckhoff motor andfeedback cables as these are optimally adapted to the drive system and reduce interference to a minimum.Ensure that the connectors are properly connected.

Project planning


11.5 Control cabinetThe dimensions of the control cabinet must be sufficient to accommodate all components with the specifieddistances. Remember that high temperatures may necessitate forced cooling. Position the control cabinet asclose as possible to the machine so that the motor cables can be as short as possible. In addition, thecontrol cabinet should have an earthed metal rear panel to which the AX8000 incl. periphery are attached sothat safe earthing can be guaranteed. If you are unable to guarantee these conditions you need to earth theAX8000 and the relevant components using an approved cable of adequate size.

Accessories


12 Accessories

12.1 Brake resistor - AX2090-BW80

12.1.1 Device descriptionInfographic Article no. Description

AX2090-BW80 The external brake resistors of the AX2090-BW80series are able to convert the dynamic energygenerated during braking of a servomotor into heat. Allbrake resistors of the AX2090-BW80 series are cULand CSA approved.

Attention

Absorption of the arising braking energy!The AX8000 multi-axis servo system offers the option of destroying arising braking energythrough internal brake resistors. If the built-in resistors do not suffice, an external brake re-sistor can be connected to the AX86xx supply module (terminal X01)

12.1.2 Intended useThe brake resistors from the AX2090-BW80-xxxx series are intended exclusively for use directly on a supplymodule from the AX86xx series (terminal X01). They are installed together with the AX86xx supply moduleon a multi-axis servo system as components in control cabinets of electrical systems and machinery andmay only be operated there.

WARNING

Nature and source of the dangerBasically, electronic devices are not fail-safe. The machine manufacturer is responsible forensuring that the connected motors and the machine are brought into a safe state in theevent of a fault in the drive system.

Improper use

The AX2090-BW80-xxxx brake resistors are not suitable for use in the following areas:

• in ATEX zones without a suitable housing• in areas with aggressive environments (e.g. aggressive gases or chemicals)

The relevant standards and directives for EMC interference emissions must be complied with in residentialareas. The brake resistors may only be installed in housings and control cabinets with appropriate shieldingattenuation.

Accessories


12.1.3 Special safety notes on brake resistorsThe responsible staff must ensure that the application or use of the products described satisfy all therequirements for safety, including all the relevant laws, regulations and guidelines.

DANGER




WARNING

Caution - Risk of injury through hot surfaces!The temperature of the brake resistor housing surface may reach over 200 °C. Please en-sure that the housing has cooled down below 40 °C before touching it.

UL- recognized componentThe brake resistors from the AX2090-BW80 series are certified according to applicable ULand CSA safety requirements. They may therefore be used in products, plants or systemsbearing the UL-Listing test mark.

Accessories


12.1.4 Product identification

Type key

Infographic Item no. Description1 Drive Technology Accessories2 BR = brake resistor3 Servo drives from the AX8000 series4 1000 = AX8620-1000 and AX8640-0000, 1 kW,

18 Ω 1)

1600 = AX8620-0000, 1.6 kW, 33 Ω 1)

2000 = AX8640-1000, 2.0 kW, 18 Ω 2)

3200 = AX8640-0000, 3.2 kW, 18 Ω 2)

1) recommended connecting cable: ZK4000-2101-2xxx (1.5 mm²)2) recommended connecting cable: ZK4000-2102-2xxx (2.5 mm²)

12.1.5 Mechanical installation

12.1.5.1 Mounting positions and distances

(A) = vertical installation is only permitted according to the diagram (terminal box facing downwards).(B) = horizontal installation

For all mounting positions the following minimum distances must be adhered to:

200 mm to adjacent components, walls, etc. and 300 mm to components, ceilings, etc. located above. In thecase of vertical mounting (A), a distance of 200 mm must be maintained to components located underneathto ensure that air can flow without hindrance to the brake resistor.

Accessories


12.1.6 Electrical installation

12.1.6.1 Important notes

WARNING




free state.





12.1.6.2 Connection the brake resistor

Remove the two screws (1) and remove the cover (2) in direction of the arrow. Connect an adequatelydimensioned cable (see chapter: Cables [ 63]) to the connections (3) of the resistor and the earthing stud(5) and take it out of the terminal box through the strain-relief assembly (9). Ensure adequate strain reliefwith the two screws (8). Connect the other end of the cable to terminal X01 on the AX86xx supply module.Connect the earthing cable to the earthing conductor of the control cabinet.

Install the cover (2) in reverse order.

Accessories


12.1.6.3 Cables

Beckhoff Automation GmbH & Co. KG offers preassembled cables for safe, faster and flawless installation ofthe motors. Beckhoff cables have been tested with regard to the materials, shielding and connectors used.They ensure proper functioning and compliance with statutory regulations such as EMC, UL etc. The use ofother cables may lead to unexpected interference and invalidate the warranty.

WARNING

Caution - Fire hazard!The brake resistors can reach temperatures of almost 200 °C. Therefore, ensure adequatethermostability of the cables! Cables with inadequate thermostability can cause a cable fire!

Attention

EMC safetyUse only shielded cables.

Type Brake resistor Temperature switch[mm2] [AWG] [mm2] [AWG]

AX2090-BW80-1000 1.5 16 0.75 18AX2090-BW80-1600 1.5 16 0.75 18AX2090-BW80-2000 2.5 12 0.75 18AX2090-BW80-3200 2.5 12 0.75 18

We recommend wire end sleeves.

Accessories


12.1.6.4 Short-term capacity

Brake resistors are usually not operated continuously, but only exposed to short-time duty. In the followingsection the permitted short-term capacity is calculated based on the continuous power, overload factor andduty cycle.

12.1.6.4.1 Duty cycle

The duty cycle is a relative value that depends on the switch-on time (ton) and the cycle time. Cycle times upto 120 sec. are used directly in the calculation. Should the cycle time exceed 120 sec., the maximumrelevant cycle time of 120 sec. is used in the calculation.

Example 1Ton = 60 sCycle time = 280 sDuty cycle = 50%

Example 2Ton = 40 sCycle time = 100 sDuty cycle = 40%

Accessories


12.1.6.5 Overtemperature and continuous power at 100% duty cycle

If your application requires a higher continuous power than the specified nominal capacity, you can acceptthis state if a higher brake resistor temperature is permitted. The following diagram shows theovertemperature v. the continuous power.

Normal operating range,max. 130%

Permitted operating range,max. 160%

Inadmissible operating range,more than 160%

This operating range is recommended formaximum service life and error-free opera-tion.

This operating range is still permitted, al-though it results in shorter service life withhigher failure probability

In this operating range there is a risk of de-struction of the brake resistor through over-heating. Due to the high temperatures theadjacent components are also at risk.

Attention

Destruction of the brake resistor and adjacent components!Always ensure adequate ventilation of the brake resistor, since the temperatures of thehousing surface may exceed 200 °C.

Accessories


12.1.7 Technical data

Dimensions

Type Type rating [W] * at 40 °C

Resistance[Ω]

O[mm]

R [mm]

H[mm]

M[mm]

U [mm]

Weight[kg]

AX86xx

AX2090-BW80-1000 1000 18 749 92 120 630 80 4 AX8620-1000AX8640-0000

AX2090-BW80-1600 1600 33 649 185 120 530 150 5.8 AX8620-0000AX2090-BW80-2000 2000 18 749 185 120 630 150 6.7 AX8640-1000AX2090-BW80-3200 3200 18 649 185 210 530 150 10.3 AX8640-0000

*) 4% output reduction per 10 K temperature difference

Dimensional drawings

Support and Service


13 Support and ServiceBeckhoff and their partners around the world offer comprehensive support and service, making available fastand competent assistance with all questions related to Beckhoff products and system solutions.

Beckhoff's branch offices and representatives

Please contact your Beckhoff branch office or representative for local support and service on Beckhoffproducts!

The addresses of Beckhoff's branch offices and representatives round the world can be found on her internetpages:http://www.beckhoff.com

You will also find further documentation for Beckhoff components there.

Beckhoff Headquarters

Beckhoff Automation GmbH & Co. KG

Huelshorstweg 2033415 VerlGermany

Phone: +49(0)5246/963-0Fax: +49(0)5246/963-198e-mail: [email protected]

Beckhoff Support

Support offers you comprehensive technical assistance, helping you not only with the application ofindividual Beckhoff products, but also with other, wide-ranging services:

• support• design, programming and commissioning of complex automation systems• and extensive training program for Beckhoff system components

Hotline: +49(0)5246/963-157Fax: +49(0)5246/963-9157e-mail: [email protected]

Beckhoff Service

The Beckhoff Service Center supports you in all matters of after-sales service:

• on-site service• repair service• spare parts service• hotline service

Hotline: +49(0)5246/963-460Fax: +49(0)5246/963-479e-mail: [email protected]

http://www.beckhoff.de/english/support/default.htm

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