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1. 0 0ne nenn 38 7 2 Energy Management anne 38 1 3 EMC earthing screen connection and potential u0022000222ne en 39 1 4 Control CAINS EEE ee ee ea 39 8 APPEND SER EEE EEE EEE NE 40 8 1 Support and Service uuassseesssnenensennnnnnnnnnnnennenennennnnnnnnnnonennensnnennnnnnnnnnennnnennnn 40 8 1 1 Beckhoff s branch offices and representatives ccccccccccceececeeeeeseeeeeeeeeeees 40 8 1 2 Beckhoff Headquarters 00222002240022000 00000 nnnnennnne anne nnnnnenenne nenne anne nennen 40 8 1 3 Beckhoff NL 40 8 1 4 Beckhoff Service 02222uussnsennnnnnnennenennennnnnnnnnnonnnnenennennnnnnnnnnnnennennnne nenn nennen 40 A Version 1 6 AX5000 BECKHOFF Drive Technology 1 Foreword 1 Foreword 1 1 Notes on the documentation This description is only intended for trained specialists in control automation and drive engineering who are familiar with the applicable national standards It is essential that the following notes and explanations are followed when installing and commissioning these components The responsible staff must ensure that the application or use of the products described satisfy all the requirements for safety including all the relevant laws regulations guidelines and standards The General safety instructions and Special safety instructions for AX5000 sections are also essential 1 2 Disclaimer The documentation has been prepared with care The
2. mains supply 400 480 V Max 890 V DC voltage at the DC link terminals Dangerous voltage may be present for 30 minutes after the device is switched off The device is safe once the voltage has fallen below 50 V 20 Version 1 6 AX5000 BECKHOFF Drive Technology 4 Product description 4 7 General overview AX5192 and AX5193 Item description INo Designation _ _ 1 X4x optional slot for expansion cards 2_ X3x optional slot for safety card 3 X11 feedback connection resolver X06 connection for digital inputs and outputs Navigation rocker _ 0 o Navigation rocker 6 Labeling field Labelingfield CS 7 X05 socket for EtherCAT output 8 X03 power supply 24 V DC input 16 X12 feedback connection encoder Max 890 V DC voltage at the 17 X01 mains supply 400 480 V DC link terminals Dangerous voltage may be present for 45 minutes after the device is switched off The device is safe once the voltage has fallen below 50 V AX5000 Version 1 6 21 No Designation 4 X14 sensor for motor temperature and brake 10 X07 External brake resistor DC link output 890 V DC voltage Motor connection U V W PE 13 X04 socket for EtherCAT input Labelingfield Labeling field 4 Product description BECKHOFF Drive Technolo 4 8 Overview of connectors terminal points 4 8 1 X01 voltage input 4 8 1 1 AX5160 and AX5172 L3 PE 4 8 1 3
3. rnnnarnannrvnnnvvnnnvnnnnennnnervnnnennnnennnnennnnsnvnnsnnnnnennnnennnnennnnsennene 22 EE GE GUD RE ee eee eee meee ene 22 4 8 1 2 AX5190 and AX5191 nenne dena en u 22 4 8 1 3 AX5192 and 1519 aaa a ie ee 22 AX5000 Version 1 6 3 1 Foreword BECKHOFF Drive Technology 4 8 2 X07 External brake resistor 00220022000en0 nen nennnenn nen nenn nennen nenn nnnnnen 22 4 8 2 1 ASTA 22 4 8 2 2 AX5190 and AI I ae 23 4 8 23 AX5192 and AI TB a ana bahn na 23 4 8 3 X13 Motor connection u222002200sennnnnnennnenennnnnnnnnnenennnnnnnnnnenenennnnnnnnenenenennn 23 4831 AX5100 and 2512 nn 23 4 8 3 2 NNN 23 4 8 3 3 AX5192 and AX5193 rrrrarnnrnnnrnnnrenrnnerrnnennnnnennnnenranennnnennnanennnsennnnennneennanennnsene 24 4 8 4 X02 DC link system currently not permissible rrrrrrnnrrrrrnnrrrrrnnrrenvnnnnen 24 4 8 4 1 AX5160 and AX5172 rrrannnrnnnrnnnnennanrnvannnnnnnnnnnnennansnnnnnnnnnnennnnennanennnnnennnnennnnen 24 4 8 4 2 AX5190 NN ae 24 4 8 4 3 AX5192 and AXS1 OS een 25 4 8 5 X03 24 Voc SUPPIY eeneeeennnuenssnennsnennsnnnnennennnnnnnnnnnnennnnnnnennnnennnnnnnnnnnnennenennennnnnn 25 4 8 6 X04 X05 EtherCAT connection uauennnsennanennnnnennnennnnnnnennnnennnnnnnnn nn nne nme nen 25 4 8 7 X06 Digital OS 42 anne en aaa 25 4 8 8 X11 feedback high resolution 00222002220002200enennennnnennnnnnnennenennenen 26 4 8 9 X12 resolver hall 2 eee 27 4 8 10 X1
4. Startup Servo Drive AX5000 60 A 170 A Please read this document carefully before installing and commissioning the servo drive Version 1 6 Date 2015 06 23 Language English BEG KM OFF Article no TDmIAX 5160 0000 0200 RJ 1 Foreword BECKHOFF Drive Technology Notes 2 Version 1 6 AX5000 BECKHOFF Drive Technology 1 Foreword Chapter Page Table of Contents AX5000 Startup 1 FOT Le NE ae ae ee ee aa ae Een ee 5 1 1 Notes on the documentation u02200224000nnnnne nenn anne nenn nenn nnnnennnenenn nennen 5 1 2 DEAN 5 1 3 MENN ver 5 1 4 POLEN FENG nenne een ne 5 1 5 Nr 5 1 6 Documentation issue Status uuessuensnensnennnnnnnnenenunennnnnnenenennnnnnnnenene nenn nnne nenn 6 1 7 Appropriate Use een eur iii 6 1 7 1 D al Use EUT 382 2010 nee een een 6 1 8 Documented servo drives uuesssesssuensnenenunnnnnnnnenenunnnnnnnnenenennnnnnnnenene nenn nnnnnenenn 7 2 ET iaaa 9 2 1 General safety instructions us0224400B44nne nennen nennen nenne nnennne nennen nenne nnennnnnnenn 9 2 1 1 Safely UES een 9 2 1 2 BIJ GIANG EE EN EN ee 9 2 1 3 Description of safety SYMDOIS cccccceeeceeseeeeeeeeeeeeseeeeeeseeeesaeeeeeseeeeesseeeeesaees 9 2 1 4 Personnel qualification arrrrnnnrrnanorrannornnnennnnrnnanrnrannnnnnnennnnennanennannennnnennnnene 10 2 2 Special safety instructions for AX5000 rrrrrnrrrvvnnrrenrnnrrrvnnnrernnnerennnnrrrnnnsrennnnn 10 3 Guideli
5. 4 9 Dimensions The specified measurements relate to the actual device without connectors and cables The fitting dimensions for control cabinet installation can be found in section Mechanical installation gt Installation examples AX5160 AX5172 AX5190 AX5191 AX5192 AX5193 ee I OG CoCo MIC I OG I Co I OG LoCo I Co I C4 co OG I Co Co Co Co Co I OG CoCo I C4 LI C4 LI Co I OG I OG CI EI I C4 CoCo I Co I Co DO I OG CoCo I Co I Co Co Co CoCo I OG Co Co C1 H1 H2 Fastening mm mm EIN NE EIGE mm mm mm mm screw 380 Sire iss 1190 san je 65 45 908 165 250 Tax 5190 200 280 582 10 9 540 603 10 254 4xM8 5191 200 280 582 10 9 1540 603 10 254 4xM8 5192 200 280 575 10 9 1540 600 20 335 4xM8 5193 200 280 575 10 9 1540 600 20 1335 4xM8 28 Version 1 6 AX5000 BECKHOFF Drive Technolo 5 Installation 5 Installation Caution Risk of injury A e The servo drives may only be installed by trained qualified personnel WARNING The qualified personnel must know and comply with the national accident prevention regulations e Safety boots must be worn Caution Risk of injury through electric shock De energise all electrical components servo drive control cabinet etc before commencing the installation or deinstallation Destruction of the servo drive e Always install the servo drive vertically e Pro
6. The power section motor connection DC link connection and mains connection and the control unit are doubly insulated against each other so that safe protection against accidental contact is ensured at all terminals of the control unit without additional measures The air and creepage distances also meet the requirements of the above standard 14 Version 1 6 AX5000 BECKHOFF Drive Technolo 4 Product description 4 Product description The servo drives of the AX5000 series are available as single or multi channel versions and are optimised in terms of function and cost effectiveness In conjunction with EtherCAT the real time Ethernet system the integrated control technology offers minimum cycle times and supports fast highly dynamic positioning tasks 4 1 Type code AXSXYZ abe d Product line Version Servo Drives 0 Standard 1 Customer specific Series 5000 Hardware features 00 Standard Numb fch Is M nn 0 01 Cold Plate 1 single channel Se two channel 02 Auxiliary fan Rated current per channel Single channel units 01 03 06 12 18 25 40 60 72 90 or 91 110 A 92 143 A 93 170A Two channel units 01 03 06 4 2 Scope of supply The scope of delivery may vary depending on the ordered configuration Before installing the device please ensure that all ordered components were delivered and that they are undam
7. Voc a BEER EEE Input 7 or output configurable Up 24 Voc Output voltage GND Eee Pin EnDAT BiSS Hiperface Sin Cos1Vpp TIL rv ov sv osv 2 GNDSV GND9V GND SV GNDSV 3 008 1008 1008 Inc gt 4 JUS SV new 1Us SV lUSSV 5 DX Data DX Data Inc 84 6 pme ls 9V ne moe no ne fREFZ REFZ _ 5 ok Geek Ine fne Jar 9 REFSIN REFSIN REFSIN Inc 10 GND Sense Inc GND Sense GND Sense 13 DX Data DX Data nc B The max output current per channel is 0 25 A 26 Version 1 6 AX5000 BECKHOFF Drive Technolo 4 Product description 4 8 9 X12 resolver hall Feedback system Analog Hall sensor Temperature only PTC Klixon or bimetall Switchpoint 1300 Q 3 C n c n c C SIN 1Vpp 120 oder 90 1Vpp Us 9 V supply n c C C C REFSIN 1 Vpp n c REF 120 oder 90 1Vpp The angle must be configured 12 PIER I i gt gt hi 4 Age EN 5 5 5 gt gt 210 Jo o o o o O I N TI AI OO DO ODIN m 0O 4 8 10 X14 motor brake and thermal contact Temp SS T gt JTemp 1 PE Signalpairseren 4 BJ BrakeGND 1 S Switch KTY 83 1xx or KTY 84 1xx Output current The specified output current is the maximum value The actual value depends on your current configuration AX5000 Version 1 6 27 4 Product description BECKHOFF Drive Technolo
8. duct F ZA Z Z m m D m ZAZ 77 5160 and 5172 2180 20 gt 20 5190 and 5191 5192 and 5193 AX5000 Version 1 6 31 5 Installation BECKHOFF Drive Technology 5 1 3 Installation of the shroud optional 1 Remove the screws 1 Don t use again 2 Position the shroud at the ground of the servo drive 3 Mount the shroud with the SCrews 2 Take the new delivered screws A Connect the lines at the terminals 5 Connect the shield of the lines at the connecting links 3 32 Version 1 6 AX5000 BECKHOFF Drive Technolo 5 Installation 5 2 Electrical installation A DANGER Attention AX5000 UL Listing It is essential to observe chapter 3 3 if you wish to operate an AX5000 in an economic area that requires a UL Listing Serious risk of injury through electric shock Due to the DC link capacitors dangerous voltage may persist at the DC link contacts ZK and ZK and RB and RB after the servo drive has been disconnected from the mains supply After disconnecting the servo drive wait at AX5160 AX5172 15 minutes at AX5190 AX5191 30 minutes and at AX5192 AX5193 45 minutes and measure the voltage at the DC link contacts ZK and ZK The device is safe once the voltage has fallen below 50 V Caution Risk of injury through electric shock e Before installation wiring and commissioning it is essential to read the section on Safety e Before installing uninstal
9. product hardware For products with option x21x shipment as single part may be subject to export control regulations 1 8 Documented servo drives This documentation describes the following servo drives in the AX5000 range AX5160 AX5172 AX5190 AX5191 AX5192 AX5193 AX5000 Version 1 6 7 1 Foreword BECKHOFF Drive Technology Notes 8 Version 1 6 AX5000 BECKHOFF Drive Technology 2 Safety 2 Safety 2 1 General safety instructions 2 1 1 Safety rules Consider the following safety instructions and descriptions Product specific safety instructions are to be found on the following pages or in the areas mounting wiring commissioning etc 2 1 2 Disclaimer All the components are supplied in particular hardware and software configurations appropriate for the application Modifications to hardware or software configurations other than those described in the documentation are not permitted and nullify the liability of Beckhoff Automation GmbH amp Co KG 2 1 3 Description of safety symbols The following safety symbols with a adjoining safety advise are used in this manual You have to read the adjoining safety advice carefully and adhere it strictly Acute risk of injury If you do not adhere the safety advise adjoining this symbol there is immediate danger to life and health of individuals Risk of injury If you do not adhere the safety advise adjoining this symbol there is danger to life and health of in
10. 4 motor brake and thermal contact 2220024002000 nenn nnn nenn nenn nnnnnen 27 4 9 UMEN ION ee ee 28 5 ITS 3 Eg EN 29 5 1 Mechanical installation ccccccscccsecccececeeeceeeecueeceeeceueeccecseeseueeeueeseeessueeaes 29 5 1 1 Installation in the control cabinet rrrnrrrnnrrnnnrrranernnrrnrrnnnnnnnennnnnnnnnnnennsnnnnnne 30 5 1 2 Installation example cccccscccsecceeccececeeeceeeeceeceeceueeseecseessueeseeeseeesaeeseeess 31 Da Installation of the Shroud optional rrrrrnronrrrrrnnrrrrnnnrrrrnnrrnrrnnrennnnrrennnnrennnnn 32 9 2 EISEIICAl INSTANALOMN u 33 5 2 1 Mains supply connection XD01 uu024440002ennnennenne nennen nennen nnnnne nennen 34 5 2 1 1 External protection for individual devices CE compliant 34 5 2 1 2 External protection for individual devices UL compliant 34 522 24 Voc supply network connection X03 rrrrrnrnnrrrnrnnrrnnnnrrenrnnnrrrnnrennnnsnen 35 5 0 Motors and CaDlES EE een 36 6 Important information for commissioning eurrsnuenennnnnnnnnnnnnnnnnnnnnnn nen 37 7 Project planning important information enrennnnnennnnnnnnnnnnnnnn nen 38 7 1 Drive train design PARPRPRENENEEEERSEPRREEENEEEEERELENFURENEEEEHEREEREFEUESERESHERECREREREORELFENEECRERUENERDE 38 7 1 1 Control quality mass inertia ratio and load connection
11. 4 3 Mechanical data Mechanical data EE AX5190 AX5191 AX5192 AX5193 Breite Width Height without plugs accessories 18 Version 1 6 AX5000 BECKHOFF Drive Technolo 4 Product description 4 5 General overview AX5160 and AX5172 The servo drive illustrated below is an AX5172 the AX5160 is structurally similar HUNN _ j SSeS Set 9 G _ nz m u Lact 8 re ge d w OO Item description INo Designation _ No Designation 9 X01 mains supply400 480V_ 4 X06 connection for digital inputs and outputs Navigation rocker Labeling field 14 X14 sensor for motor temperature and brake X05 socket for EtherCAT output 15 Connection for external brake resistor X03 power supply 24 V DC input DC link output 890 V DC voltage Max 890 V DC voltage at the Motor connection U V W PE DC link terminals Dangerous voltage may be present for 15 minutes after the device is switched off The device is safe once the voltage has fallen below 50 V AX5000 Version 1 6 19 4 Product description BECKHOFF Drive Technology 4 6 General overview AX5190 and AX5191 Item description No Designation INolDesignation dl and brake Connection for external brake resistor 6 Labelingfield __ 7 X05 socket for EtherCAT output 115 X12 feedback connection encoder 8 X03 power supply 24 V DC input 16 X01
12. AX5192 and AX5193 4 8 2 X07 External brake resistor Hazard to devices Connect the PE connection of the external brake resistor at the central Atenton grounding bar Serious risk of injury through high electrical voltage 890 V DC voltage at the RB and RB terminals Dangerous voltage may be present at AX5160 AX5172 for 15 minutes at AX5190 AX5191 for 30 minutes and at AX5192 AX5193 for 45 minutes after the device is switched off Check voltage 4 8 2 1 AX5160 and AX5172 n u Cr Terminal Connection point External brake resistor RB External brake resistor 22 Version 1 6 AX5000 BECKHOFF Drive Technolo 4 Product description 4 8 2 2 AX5190 and AX5191 Terminal Connection point External brake resistor RB External brake resistor 4 8 2 3 AX5192 and AX5193 Terminal Connection point External brake resistor RB External brake resistor 4 8 3 X13 Motor connection 4 8 3 1 AX5160 and AX5172 point 4 8 3 2 AX5190 and AX5191 Terminal Connection point JE fe Moto connection V Motor connection W Protective conductor AX5000 Version 1 6 23 4 Product description BECKHOFF Drive Technolo 4 8 3 3 AX5192 and AX5193 4 8 4 X02 DC link system currently not permissible Destruction of the AX5000 The DC link connection is currently not permissible Attention Serious risk of injury through high electrical voltage 890 V DC voltag
13. Mail service beckhoff com 40 Version 1 6 AX5000
14. V maximum When protected by RK5 class fuses rated 100 A maximum AX5190 AX5193 Suitable for use on a circuit capable of delivering not more than 10000 rms symmetrical amperes 480 V maximum When protected by RK5 class fuses rated 225 A maximum Fusing OO AC supply max 4 V supply max Brake resistor electronic Mains fuses according to type RK5 min 480 V must be used 3 3 3 UL specific notes Use in a Pollution Degree 2 environment Use 75 C Copper Conductors min Control Board rating 24 V AX5000 Version 1 6 13 3 Guidelines and Standards BECKHOFF Drive Technolo Drive intended for use over a range of motor sizes Internal motor overload protection level is adjustable The internal motor protection is parameterised via the IDN P 0 0062 Thermal motor model based on the value of the IDN S 0 0111 Motor continuous stall current The IDN P 0 0062 Time constant is specified by the motor manufacturer and must be entered here The IDN P 0 0062 Warning limit Default is responsible for deciding when a warning is to be generated The IDN P 0 0062 Error limit Default is responsible for deciding when the motor is to be switched off The default values take into account the specific characteristics of the servomotors Canada In Canada use only in combination with unit AX2090 TS50 manufactured by Beckhoff Automation 3 4 Electrical isolation according to EN 50178 VDE 160
15. X5000 BECKHOFF Drive Technolo 3 Guidelines and Standards 3 3 UL Listing in USA and Canada The following servo drives from the AX5000 series have a UL Listing and must bear the CUS symbol G AX5000 with UL Listing c US LISTED noe AX5160 AX5172 AX5190 AX5191 AX5192 und AX5193 on the name plate If you wish to operate an AX5000 in USA or Canada please check that there is a CUS symbol on the name plate Below is a list of the relevant chapters that are amended with respect to the UL Listing Furthermore UL specific remarks are listed It is essential to observe these specifications 3 3 1 UL specific chapter changes 9 2 1 Mains supply connection X01 AX5000 shall be connected only to a grounded wye source where the maximum voltage does not exceed 277 V to ground 9 2 3 Connection of several servo drives to form a drive system Drive system with UL Listing Please consult our Application Department with respect to the requirements for a drive system with UL Listing 3 3 2 UL specific chapter 5 2 1 3 External protection UL compliant Integral solid state short circuit protection does not provide branch circuit protection Branch circuit protection must be provided in accordance with the Manufacture Instructions National Electrical Code and any additional local codes AX5160 and AX5172 Suitable for use on a circuit capable of delivering not more than 5000 rms symmetrical amperes 480
16. aged In the event of any damage please contact the carrier immediately and document the damage 4 2 1 Standard scope of supply AX5000 in the performance class according to the order Connectors for X03 DC power supply 24 V X06 Digital inputs and outputs X14 Motor temperature sensor and brake Startup this manual Complete documentation on CD AX5000 Version 1 6 15 4 Product description BECKHOFF Drive Technolo 4 2 2 Accessories A comprehensive list of accessories can be found in the complete Beckhoff catalogue or on our website at www beckhoff com Accessories with UL Listing If you wish to operate an AX5000 in an economic area that requires a UL Listing please make sure that the accessories also have a UL Listing 4 3 Name plate The servo drive features two name plates A comprehensive name plate can be found on the right hand side An extract showing the main data can be found at the top of the servo drive H lshorstweg 20 I FOSS BECKHOFF ao A A cat no Ax5160 0000 i 40 sera 000000018 Customized 0000 11 u Small Input rated voltage C name 3 phase 400 480 VAC ate Output rated current Input frequency 7 u 1x60A 50 60 Hz 5 p Huelshorstweg 20 Phone 49 52 46 9 63 0 BECKHOFF D 83415 ver Fax 4952 46 963 198 L German www beckhoff com info beckhoff com L 1 Cat No AX5160 0000 0200 Seri
17. al 000000018 10 u 2 max amb temp 40 C Customized 0000 11 LJ Large 3 Input rated voltage 3 phases 400 480 VAC H g 4 Input rated current 3 phases 64 53 A name 5 Input frequency 50 60 Hz F plate 6 Output rated voltage 3 phases OV mains voltage 7 Output rated current 1x60A I 42 8 Output frequency range 0 599 Hz ER COOCOO o MI Ip20 Vr us LISTED C I nce Made in Germany N N 14 13 Catalog number 6 Output rated voltage Customer specific Max ambient temperature 7 Output rated current Input rated voltage 8 Output frequency range CE Conform Input rated current 9 Protection class 14 cULus Listed Input frequency 10 Serialnumber S 16 Version 1 6 AX5000 BECKHOFF Drive Technolo 4 Product description 4 4 Technical data UL Listing It is essential to observe chapter 3 3 if you wish to operate an AX5000 in an economic area that requires a UL Listing 4 4 1 Permissible ambient and operating conditions Ambient operating conditions Permissible values Ambient temperature during operation O C up to 40 C Up to 55 C with reduced power 2 C Ambient temperature during transport Ambient temperature during storage Pollution degree Corrosion protection Normally not required Under extreme operating conditions separate measures must be agreed with the manufacturer Operating altitude up to 1000 m abov
18. binet The AX5000 incl periphery control cabinet machine bed and motors must be at the same potential as the AX5000 control quality will suffer under differing potentials and operational malfunction may result Using the screen connection for potential equalisation is not permitted If you are unable to provide a uniform reference potential you need to lay potential equalisation cables of adequate dimensions Smooth operation is only guaranteed by faultless screen connections of the cables The screens must be applied generously at both ends and must on no account be disconnected Use Beckhoff motor and feedback cables as these are optimally adapted to the drive system and reduce interference to a minimum Ensure that the connectors and cables are properly connected 7 4 Control cabinet The dimensions of the control cabinet must be sufficient to accommodate all components with the specified distances Remember that high temperatures may necessitate forced cooling Position the control cabinet as close as possible to the machine so that the motor cables can be as short as possible In addition the control cabinet should have an earthed metal rear panel to which the AX5000 incl periphery are attached so that safe earthing can be guaranteed If you are unable to guarantee these conditions you need to earth the AX5000 and the relevant components using an approved cable of adequate size AX5000 Version 1 6 39 8 Appendix BECKHOFF Drive Technolo
19. dividuals Hazard to individuals If you do not adhere the safety advise adjoining this symbol there is obvious hazard to individuals Hazard to devices and environment If you do not adhere the notice adjoining this symbol there is obvious hazard to materials and environment Note or pointer This symbol indicates information that contributes to better understanding UL pointer C Up US This symbol indicates important information about the UL compliant AX5000 Version 1 6 9 2 Safety BECKHOFF Drive Technology 2 1 4 Personnel qualification This description is only intended for trained specialists in control automation and drive engineering who are familiar with the applicable national standards 2 2 Special safety instructions for AX5000 The safety instructions are designed to avert danger and must be followed during installation commissioning production troubleshooting maintenance and trial or test assemblies The servo drives of the AX5000 series are not designed for stand alone operation and must always be installed in a machine or system After installation the additional documentation and safety instructions provided by the machine manufacturer must be read and followed N Serious risk of injury through high electrical voltage Never open the servo drive when it is live Wait until the DC link capacitors are discharged The voltage measured between the ZK and ZK and RB and RB terminals must ha
20. e at the DC link terminals Dangerous voltage may be present at AX5160 AX5172 for 15 minutes at AX5190 AX5191 for 30 minutes and at AX5192 AX5193 for 45 minutes after the device is switched off Check voltage point Currently not permissible 4 8 4 2 AX5190 and AX5191 Terminal Connection point Currently not permissible 24 Version 1 6 AX5000 BECKHOFF Drive Technolo 4 Product description 4 8 4 3 AX5192 and AX5193 Terminal Connection point Currently not permissible hr md mA D 4 8 5 X03 24 Voc supply Terminal Connection Current consumption point p U 24 Voc 0 25 periphery Depending on the connected e g separate braking consumers see X06 and voltage X14 X24 24 Vpc 25 System supply 60 A 72 A 3A 90 A 170 A 10 A GND pp 4 8 6 X04 X05 EtherCAT connection m EtherCAT inang Terminal point X04 IN incoming EtherCAT line LE na X05 OUT outgoing EtherCAT line X05 X04 a 4 8 7 X06 Digital I Os Destruction of the AX5000 A This connector is not designed for external power supply It is supplied via CAUTION the 24 V supply Up of connector X03 Output current The specified output currents are maximum values The actual values depend on your current configuration AX5000 Version 1 6 25 4 Product description BECKHOFF Drive Technolo Terminal point Output current 24 Output voltage Up 24
21. e sea level without reduced power Between 1000 m and max 2000 m with reduced power 1 per 100 m Installation position Ventilation Built in temperature controlled fan Protection class IP 20 except the terminals IP00 EMC Category C3 standard Category C2 C1 auxiliary filter required AX5000 Version 1 6 17 4 Product description BECKHOFF Drive Technolo 4 4 2 Electrical data Electrical Data AX5160 AX5172 AX5190 AX5191 AX5192 AX5193 110A 143A Minimum rated motor current 25 A 40 A 50 A 60 A 70 A 80 A at full current resolution Peak output current Rated supply voltage 3x 400 10 480 10 Vac Max DC link voltage 890 Voc Max DC link voltage 89ND SSS Rated apparent power S1 mode selection 400 V 42 KVA 50 KVA 62 KVA 76 KVA 99 KVA 118 KVA 480 V 45 KVA 54 KVA 67 KVA 82 KVA 107 KVA 127 KVA brake resistor 130 139 109 100 650 650 ver braking power Maing choke AX2090 ND50 0090 0110 0143 0170 Mains filter AX2090 NF50 integrated integrated 0100 0150 0150 0180 The rated current must be reduced by 10 when connecting rated voltage of 480V The specified values are valid for output rotary frequency gt 5Hz lerr for max 3 s at max 70 preload of rated current 9 1 mode incl power supply unit without brake chopper i Required according to EN61800 3 EMC product standard C3 industrial environment with motor cable length max 25 m N 4
22. e state in the event of a fault in the drive system The servo drives may only be operated in enclosed control cabinets and in accordance with the conditions described in the Technical data section 1 7 1 Dual Use EU 1382 2014 As published on December 30 2014 by EU Commission Delegated Regulation 1382 2014 standard frequency inverters and with that also Beckhoff products AX5000 become newly classified Dual Use items the item list Annex of the Dual Use Council Regulation 428 2009 has been changed accordingly Frequency inverters listed in item position 3A225 with a rotation field frequency of 600 Hz or more are now 6 Version 1 6 AX5000 BECKHOFF Drive Technology 1 Foreword export controlled items As a consequence some modifications have to be noticed Firmware versions without extension Dual Use conform can be used in consideration of Hardware Versions with following drives only e HW Version 1 0 AX5xxx 0000 x0xx Serial Number lt 68 000 e HW Version 2 0 AX5xxx 0000 x20x Serial Number lt 140 000 e HW Version 2 0 AX5xxx 0000 x21x This firmware versions allow operation gt 600 Hz rot field frequency shipment as single part may be subject to export control regulations Firmware versions with extension Dual Use conform can be used in consideration of Hardware Versions with all drives These versions support both rotational field frequency bands lt 600 Hz gt 600 Hz depending on
23. gy 8 Appendix 8 1 Support and Service Beckhoff and their partners around the world offer comprehensive support and service making available fast and competent assistance with all questions related to Beckhoff products and system solutions 8 1 1 Beckhoff s branch offices and representatives Please contact your Beckhoff branch office or representative for local support and service on Beckhoff products The addresses of Beckhoff s branch offices and representatives round the world can be found on her internet pages hitp www beckhoff com You will also find further documentation for Beckhoff components there 8 1 2 Beckhoff Headquarters Beckhoff Automation GmbH amp Co KG Hulshorstweg 20 33415 Verl Germany Phone 49 0 5246 963 0 Fax 49 0 5246 963 198 E Mail info beckhoff com 8 1 3 Beckhoff Support Support offers you comprehensive technical assistance helping you no only with the application of individual Beckhoff products but also with other wide ranging services e Support e Design programming and commissioning of complex automation systems e Extensive training program for Beckhoff system components Hotline 49 0 5246 963 157 Fax 49 0 5246 963 9157 E Mail support beckhoff com 8 1 4 Beckhoff Service The Beckhoff Service Center supports you in all matters of after sales service e On site service e Repair service e Spare parts service Hotline 49 0 5246 963 460 Fax 49 0 5246 963 479 E
24. ling or connecting the servo drive and the motors please note the following Remove all relevant mains fuses Switch off the main system switch and secure it with a lock Put up a warning sign e The control and power connections for the motors may be live even if the motor is prevented from rotating by the internal brake Destruction of the equipment e Check the rated voltage and current of the servo drive and the connected motors e When the AX5000 is disconnected from the mains supply emergency stop mains contactor etc query the status of the IDN P 0 0205 see documentation of the IDN Description before starting Version 1 6 33 5 Installation BECKHOFF Drive Technolo 5 2 1 Mains supply connection X01 The servo drives of the AX5000 series are equipped with a wide voltage input X01 and can be connected to voltage systems three phase 400 Vac 10 480 Vac 10 Connection to the standard mains supply TT TN with earthed centre is described below Connections to other supply systems are not permissible Three phase 400 10 480 10 Vac 5 2 1 1 External protection for individual devices CE compliant Fire hazard through short circuit The recommended fuses are designed for line protection The servo drives CAUTION feature integrated self protection Fusing AX5160 AX5172 AX5190 AX5191 AX5192 AX5193 125 AT 160 AT Application class gG mains fuses according to IEC 60269 o
25. nes and Standards nxrrnnnurnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnennnnnennnnnnnnnnnnnnnennnnunnnnr 12 3 1 EN rd 12 3 2 Electromagnetic compatibility rarrnrnnrnnnnnrnnnrernnrrnrnnrennnnennnrrnnnnrrnnerennnnennnnen 12 3 3 UL Listing in USA and Canada rrnnonnnonnnnnnnnnnnnnnnnnnnennnnsnrnnnnnnnnnnsnennnnsnennnnsnen 13 3 3 1 UL specific chapter changes u uen een 13 3 3 2 UL Speciliechapler en Ben 13 3 3 3 AS DSC NCO Sea Se a ee ee ee 13 3 4 Electrical isolation according to EN 50178 VDE 160 u 224uu0sne nennen 14 4 Product dESCHIPHON 5c amianaeae aan ea ea aa aan Te Eee 15 4 1 DEE 15 4 2 Scope ASU NS e ke eis 15 4 2 1 Standard scope of supply arameiske 15 4 2 2 Fe be 8 gt ee EE ee re ee 16 4 3 Name pal ssai ne SN SN NE 16 4 4 TEEN 17 4 4 1 Permissible ambient and operating conditions rrrrnnnrrrnnrrnrnnrernnrerrnrrnnnrennne 17 4 4 2 EISCHICA Aae 18 4 4 3 Mechanical data ccccccccccccceecceeeeeeeseeeseeeeseeeseeeeaeeeseeeseeeeseeeseeseeeseeeseeesaees 18 4 5 General overview AX5160 and AX5172 rrnnnnnnnnnnennnnnnnvnnnnennnnrennnnrrenrnsrennnnn 19 4 6 General overview AX5190 and AX5191 rnrrnnnnnnnnnnnnnnnnnnnnennnnnrennnnrrennnsnennnnn 20 4 7 General overview AX5192 and AX5193 rrrrnnnnnnrrnnnnnrnrnnnrennnnrrenrnnnrenrnsnennnnn 21 4 8 Overview of connectors terminal POINKS cccccsecceseececeececeeeeeeeeeeaeeeeeeeeeaes 22 4 8 1 X01 voltage INpUt
26. ntaminated ambient air the cooling Openings must be checked regularly for blockage These checks should be carried out several times per day The servo drives contain components at risk from electrostatic discharge caused by improper handling Please ensure you are electrostatically discharged before touching the servo drive directly Avoid contact with highly insulating materials synthetic fibres plastic film etc Place the servo drive on a conductive surface Attention AX5000 Version 1 6 11 3 Guidelines and Standards BECKHOFF Drive Technology 3 Guidelines and Standards 3 1 CE conformity The servo drives AX5160 AX5172 AX5190 AX5191 AX5192 and AX5193 comply with the e EC Low Voltage Directive 2006 95 EC Applied harmonised standards 61800 5 1 Hazard to individuals A Servo drives are not covered by the EC Machinery Directive Operation of the servo drives in machines or systems is only permitted once the machine or system manufacturers has provided evidence of CE conformity of the complete machine or system CAUTION 3 2 Electromagnetic compatibility The servo drives AX5160 AX5172 AX5190 AX5191 AX5192 and AX5193 comply with the e 2004 108 EC EMC Directive Applied harmonised standards IEC EN 61000 4 2 IEC EN 61000 4 3 IEC EN 61000 4 4 IEC EN 61000 4 5 IEC EN 61000 4 6 IEC EN 61000 6 1 IEC EN 61000 6 2 IEC EN 61000 6 3 IEC EN 61000 6 4 IEC EN 61800 3 12 Version 1 6 A
27. products described are however constantly under development For this reason the documentation may not always be have been fully checked for consistency with the performance data standards or other characteristics described In the event that it contains technical or editorial errors we retain the right to make alterations at any time and without warning No claims for the modification of products that have already been supplied may be made on the basis of the data diagrams and descriptions in this documentation 1 3 Trademarks Beckhoff TwinCAT EtherCAT Safety over EtherCAT TwinSAFE and XFC are registered trademarks of and licensed by Beckhoff Automation GmbH Other designations used in this publication may be trademarks whose use by third parties for their own purposes could violate the rights of the owners 1 4 Patent Pending The EtherCAT Technology is covered including but not limited to the following patent applications and patents EP1590927 EP1789857 DE102004044764 DE102007017835 with corresponding applications or registrations in various other countries The TwinCAT Technology is covered including but not limited to the following patent applications and patents EP0851348 US6167425 with corresponding applications or registrations in various other countries 1 5 Copyright O Beckhoff Automation GmbH amp Co KG The reproduction distribution and utilization of this document as well as the communica
28. r C type automatic circuit breakers must be used 5 2 1 2 External protection for individual devices UL compliant Fire hazard through short circuit A The recommended fuses are designed for line protection The servo drives CAUTION feature integrated self protection Fusing 1 AX5160 AX5172 AX5190 AX5191 AX5192 AX5193 AC supply max EE EE GE 4 V supply max 10 AT Brake resistor electronic Mains fuses according to type RK5 min 480 V must be used 34 Version 1 6 AX5000 BECKHOFF Drive Technolo 5 Installation 5 2 2 24 Voc supply network connection X03 The 24 Vpc connection X03 is used for supplying control electronics and periphery with DC voltage The control electronics and the periphery can be supplied separately with two different voltage sources If one transformer is used for the 24 Vpc power supply the connections Us and Up must be bridged in order to ensure that both the control electronics and the periphery are supplied Supply via two transformers AX5000 Version 1 6 35 5 Installation BECKHOFF Drive Technolo 5 3 Motors and cables With longer motor cables the resulting commutation currents can affect the control quality and lead to EMC faults Use the tables below to check whether motor chokes or mains filters have to be used in your application When selecting the control cabinet ensure that there is adequate space for motor chokes mains filters etc Lay
29. ry due to uncontrolled movements Read and take note of chapter 6 Important information for commissioning each time before commissioning the AX5000 10 Version 1 6 AX5000 BECKHOFF Drive Technolo 2 Safet Hazard to individuals A Carefully read this manual before using the servo drive thoroughly CAUTION paying particular attention to the safety instructions In the event of any uncertainties please notify your sales office immediately and refrain from working on the servo drive Only well trained qualified electricians with sound knowledge of drive equipment may work on the device During the electrical installation it is essential to ensure that the correct fuses protective circuit breakers are used between the mains supply and the servo drive Further information can be found in the Electrical installation section If a servo drive is installed in a machine it must not be commissioned until proof of compliance of the machine with the latest version of the EC Machinery Directive has been provided This includes all relevant harmonised standards and regulations required for implementation of this Directive in national legislation Hazard to devices and environment e 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 Technical data and Mechanical installation sections If the servo drive is operated in co
30. ry good load connection Likewise however a good Control quality dynamic due to a favourable mass moment of inertia can be reduced through a poor load connection 7 2 Energy management If the quality of the mains supply is impaired due to wide fluctuations in voltage then both the servo drive specification and the speed range of the motor will need to be considered With a positive tolerance for voltage fluctuation the upper limit value of the wide voltage input of the AX5000 needs to be taken into account With a negative tolerance of the voltage fluctuation it must be checked whether the decrease in speed caused by the low voltage is permissible With these motors what is known as field weakening operation check availability of the servo drive may provide a solution 38 Version 1 6 AX5000 BECKHOFF Drive Technology 7 Project planning important information 7 3 EMC earthing screen connection and potential The AX5000 corresponds to EMC category C3 industrial sector in terms of conducted interference emissions If you wish to use components which comply with a higher category you can limit the AX5000 conducted interference emissions with the aid of additional filters to such a degree that this complies with the EMC category C2 residential and industrial environment or C1 residential environments Ensure that there is adequate earthing large area low impedance connection of all relevant components incl control ca
31. s of uncontrolled movements The diagnostic system of the AX5000 is equipped with complex plausibility checks which constantly monitor installation operation parameterisation and operation and if necessary interrupt them with a diagnostic message The points listed below are naturally also monitored as standard but it is not possible to include all eventualities therefore with respect to the following points you must always consider whether the driven axes can only perform permissible movements Incorrect commutation results e g during wake amp shake It is essential to observe chapter AX5000 User manual gt commissioning gt commutation methods gt commutation error F2A0 on our Homepage Specific caution with synchronous motors of third parties always execute the command P 0 0166 without load when changing the motor or feedback or when changing the SysMan file TSM and evaluate the result Correct the commutation offset if applicable as described in chapter AX5000 User manual gt Commissioning gt Commutation methods Input of invalid parameters Measuring transducer and or signal transducer defective or incorrectly adjusted Cables defective or not adequately screened Incorrectly attached sensors When commissioning vertical axes the risk consideration described above is to be carried out with particular care An uncontrolled movement can mean the sudden falling down of a load in this case Increased atten
32. the power and signal cables in separate metal cable ducts or if both types of cable use the same metal cable duct make sure there is an earthed metal dividing wall between the cables Motor chokes For the series AX5160 up to AX5193 motor chokes are not required AX2090 ND50 0060 ND50 0072 ND50 0090 ND50 0110 ND50 0143 AX2090 ND50 0170 For compliance with EN 61800 3 only with mains filter AX2090 NF50 0100 For compliance with EN 61800 3 only with mains filter AX2090 NF50 0150 For compliance with EN 61800 3 only with mains filter AX2090 NF50 0180 Aa OQ Without line choke up to max 10m gt Without line choke up to max 25m 36 Version 1 6 AX5000 BECKHOFF Drive Technolo 6 Important information for commissionin 6 Important information for commissioning Caution Risk of injury A Electronic equipment is not fail safe The machine manufacturer is responsible for ensuring that the connected motors and the machine are WARNING brought into a safe state in the event of a fault in the drive system Please be aware each time before commissioning the AX5000 that connected motors can make uncontrolled movements which cannot always be prevented even by the AX5000 s integrated diagnostic system or may permit uncontrolled movements until the diagnostic system responds Analyse your system and take suitable precautions to prevent damage being caused by these uncontrolled movements Potential cause
33. tion of its contents to others without express authorization are prohibited Offenders will be held liable for the payment of damages All rights reserved in the event of the grant of a patent utility model or design AX5000 Version 1 6 5 1 Foreword BECKHOFF Drive Technolo Documentation issue status Chapter Update 4 4 2 Chapter Update 4 5 4 6 4 7 4 8 2 New Chapter 5 2 1 2 Chapter Update 3 3 4 3 4 4 2 5 2 1 1 New Chapter 1 7 1 Chapter Update 1 5 2 1 2 4 3 4 4 2 8 2 100 Chapter Update 4 4 2 4 5 4 6 4 7 4 8 4 5 1 1 5 1 3 5 2 1 5 3 New Chapter 4 7 5 1 3 5 3 Chapter Update 1 8 2 2 3 1 3 2 4 5 4 6 4 8 4 9 5 1 1 5 2 1 1 1 1 1 1 1 1 First edition 6 6 5 A 2 2 1 0 1 7 Appropriate use The servo drives of the AX5000 series are exclusively designed for torque speed and position control of suitable asynchronous and synchronous three phase current motors The maximum permissible effective motor voltage must be at least equal the effective mains voltage fed into the servo drive The servo drives from the AX5000 series are designed for installation as components in electrical systems or machines and may be operated only as integrated system or machine components Caution Risk of injury A Electronic equipment is not fail safe The machine manufacturer is WARNING responsible for ensuring that the connected motors and the machine are brought into a saf
34. tion in the case of vertical axes CAUTION AX5000 Version 1 6 37 7 Project planning important information BECKHOFF Drive Technology 7 Project planning important information The more thoroughly a machine or plant project is thought through in advance the less risk there is of having to carry out expensive modifications during or after commissioning This applies to both the mechanical and electrical design This section can only give a rough overview of electrical design Further information can be found in the publication Project planning aid under Downloads on our website at www beckhoff com 7 1 Drive train design Application servo drive motors and gear mechanism must be adapted to each other so that there is an adequate safety margin for all components as a degree of sluggishness appears over time due to high temperatures or wear Make sure that the components in the working area of the system have adequate reserves so that the working life is not impaired and the necessary control quality can be maintained 7 1 1 Control quality mass inertia ratio and load connection Control quality is dependent on the parameters mass inertia ratio and load connection Control quality Dynamics up to 3 1 up to 5 1 up to 10 1 The Control quality dynamics is primarily affected by the mass moment of inertia a poor Control quality dynamic due to an unfavourable mass moment of inertia cannot be improved even with a ve
35. ve fallen below 50 V Opening the device with the exception of expansion card slots invalidates all warranty and liability claims against Beckhoff Automation Negligent improper handling of the servo drive and bypassing of the safety devices can lead to personal injury or death through electric shock Ensure that the protective conductor is connected properly Disconnect the servo drive from the mains supply and secure it against reconnection before connecting or disconnecting the pluggable terminals Disconnect the servo drive from the mains supply and secure it against reconnection before working on electrical parts with a voltage gt 50 V Due to the DC link capacitors dangerous voltage may persist at the DC link contacts ZK and ZK and RB and RB after the servo drive has been disconnected from the mains supply After disconnecting the servo drive wait at AX5160 AX5172 15 minutes at AX5190 AX5191 30 minutes and at AX5192 AX5193 45 minutes and measure the voltage at the DC link contacts ZK and ZK The device is safe once the voltage has fallen below 50 V WARNING Serious risk of injury through hot surfaces e The surface temperature may exceed 50 C resulting in a risk of burns e Avoid touching the case during or shortly after operation e Leave the servo drive to cool down for at least 15 minutes after it is switched off e Use a thermometer to check whether the surface has cooled down sufficiently Danger of inju
36. vide adequate ventilation for the servo drive The permissible ambient conditions are specified in the Technical data section e It is essential to adhere to the required distances see diagrams below Attention AX5000 Version 1 6 29 5 Installation BECKHOFF Drive Technology 5 1 1 Installation in the control cabinet 225 mm N Control cabinet door Mounting plate Ne contuctible zinced N q N N IN N St N m o 1 N IE N N N i jije N N N So N ES cn T N N N N CoCo N oo N oO N L FR N L mn N Shroud 1 optional N ae 5160 and 5172 AxM5 445 5190 and 5191 5192 and 5193 Caution Risk of injury through electric shock The mounting plate must be earthed according to the statutory regulations Grounding If the ground connection of the AX5000 is not done as specified it is possible to get trouble with some EMC issues Attention 30 Version 1 6 AX5000 BECKHOFF Drive Technology 5 Installation 5 1 2 Installation example Cabke duct Y d SCHI RR AG MD ER AEG TE AE AG ME MG AT MERE MR 3 D AER ME MF ME ME AE MG MER 4 LLV EEE EEG ET EHER EZ ER LULL le Cable

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