Digitaler Servoverstärker AX2500: Assembly, Installation, Setup
Digitaler Servoverstärker AX2500: Assembly, Installation, Setup
Digitaler Servoverstärker AX2500: Assembly, Installation, Setup
AX2500
Edition Comments
07/03 First edition
SSI emulation updated (Multiturn), UL/cUL information updated,
07/05
typographical changes, chapter 1 new sorted, several corrections
02/06 Chapter feedback updated, label updated, several small corrections
Technical changes to improve the performance of the equipment may be made without notice !
Printed in the Federal Republic of Germany
All rights reserved. No part of this work may be reproduced in any form (by printing, photocopying, microfilm
or any other method) or processed, copied or distributed by electronic means without the written permission
of Beckhoff.
Beckhoff 02/06 Contents
page
1 General
1.1 About this manual . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5
1.2 Symbols used in this Manual . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5
1.3 Abbreviations used in this Manual . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6
2 Technical description
2.1 Safety Instructions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7
2.2 Use as directed . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8
2.3 European Directives and Standards. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9
2.4 CE Conformity . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9
2.5 UL and cUL- Conformance. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10
2.6 Nameplate . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11
2.7 Equipment description . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11
2.7.1 Package as supplied . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11
2.7.2 Digital servo amplifiers in the series AX2500 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12
2.8 Components of a servo system . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14
2.9 Technical data . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15
2.9.1 Rated data . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15
2.9.2 Connections . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16
2.9.3 Recommended tightening torques . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16
2.9.4 Fusing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16
2.9.4.1 Internal fusing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16
2.9.4.2 External fusing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16
2.9.5 Permissible ambient conditions, ventilation, mounting position . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17
2.9.6 Conductor cross-sections. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17
2.10 Motor holding brake control . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 18
2.11 Regen circuit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 19
2.11.1 LED display . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 19
2.12 Grounding system . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 19
2.13 Switch-on/-off behaviour. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20
2.13.1 Stop function as per EN 60204 (VDE 0113). . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20
2.13.2 Emergency stop methods . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 21
3 Installation
3.1 Important notes . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 23
3.2 Guide to installation / wiring . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 24
3.3 Mounting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 25
3.3.1 Dimensions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 26
3.4 Wiring. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 27
3.4.1 Connection diagram AX250x and AX251x . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 28
3.4.2 Connection diagram AX252x . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 29
3.4.3 Example of connections for multi-axis system . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30
3.4.4 Connector assignments . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 31
3.4.5 Connection techniques. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 32
3.4.5.1 Shield connection on the front panel . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 32
3.4.5.2 Requirements to cables. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 33
3.5 Setup software . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 34
3.5.1 General . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 34
3.5.1.1 Use as directed . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 34
3.5.1.2 Software description . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 34
3.5.1.3 Hardware requirements. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 35
3.5.1.4 Operating systems . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 35
3.5.2 Installation under WINDOWS 98 / 2000 / ME / NT / XP. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 35
4 Interfaces
4.1 Block diagram . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 37
4.2 Power supply, master only . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 38
4.2.1 Mains supply connection (X0) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 38
4.2.1.1 Three-phase supplies . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 38
4.2.1.2 Single-phase supplies . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 38
4.2.2 24V auxiliary voltage (X0) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 38
4.3 DC Bus link/DC-bus (X0) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 39
4.4 Motor connection with brake (X6). . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 39
4.5 External regen resistor (X0), master only. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 39
4.6 Feedback . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40
4.6.1 Resolver (X5) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40
4.6.2 ComCoder (X2) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 41
4.6.3 Incremental or sine encoder with hall sensors (X2) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 42
4.6.4 Sine Encoder with EnDat or HIPERFACE (X2) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 43
4.6.5 Sine Encoder without data channel (X2) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 44
4.6.6 Incremental Encoder (X4) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 45
4.7 Digital and analog inputs and outputs . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 46
4.7.1 Analog input (X3) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 46
4.7.2 Digital inputs (X3). . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 47
4.7.3 Digital outputs (X3) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 48
4.7.4 Digital I/O on the Master (X1). . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 49
4.8 Encoder emulations . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 50
4.8.1 Incremental encoder output - A quad B (X4) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 50
4.8.2 SSI output (X4) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 51
4.9 Master-slave operation, encoder master control . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 52
4.9.1 Connection to a AX2500 master, 5V signal level (X4). . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 52
4.9.2 Connection to incremental encoder master with 24V signal level (X3) . . . . . . . . . . . . . . . . . . . . . . . . . 53
4.9.3 Connection to a sine-cosine encoder master (X2) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 53
4.10 Interface for stepper motor controllers (pulse/direction) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 54
4.10.1 Connection to a stepper motor controller with 5V signal level (X4) . . . . . . . . . . . . . . . . . . . . . . . . . . . . 55
4.10.2 Connection to a stepper motor controller with 24V signal level (X3) . . . . . . . . . . . . . . . . . . . . . . . . . . . 55
4.11 RS232 interface, PC connection (X8), master only . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 56
4.12 Fieldbus connection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 57
4.12.1 CANopen interface (X7). . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 57
4.12.2 PROFIBUS interface (X7), option . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 58
4.12.3 SERCOS interface (X7), option . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 59
4.12.3.1 Light emitting diodes (LEDs) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 59
4.12.3.2 Connection diagram . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 59
5 Setup
5.1 Important notes . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 61
5.2 Guide to setup . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 62
5.3 Parameterization . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 63
5.3.1 Multi-axis systems . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 63
5.3.2 Key pad controls and status displays. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 64
5.3.2.1 Operating . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 64
5.3.2.2 Status display on the axis module. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 64
5.3.2.3 Status display on the master . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 65
5.4 Error messages . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 66
5.5 Warning messages . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 67
6 Accessories
6.1 External PSU 24V DC / 5A. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 69
6.2 External PSU 24V DC / 20A. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 70
6.3 External regen resistor BAR(U) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 71
6.4 Add-on fan . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 72
7 Appendix
7.1 Transport, storage, maintenace, disposal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 73
7.2 Fault-finding . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 74
7.3 Glossary. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 77
7.4 Index . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 79
1 General
l General Chapter 1
l Technical description Chapter 2
l Assembly / installation Chapter 3
l Interfaces Chapter 4
l Commissioning Chapter 5
l Accessories Chapter 6
l Transport, storage, maintenance, disposal Chapter 7
A more detailed description of the field bus interfaces and the digital connection to auto-
mation systems can be found on the accompanying CD-ROM in PDF format (system
requirements: WINDOWS, Internet browser, Acrobat Reader) in several language ver-
sions.
You can print out this documentation on any standard printer. A printed copy of the docu-
mentation is available from us at extra cost.
Danger to personnel
Danger to maschinery, Important
from electricity and its
general warning notes
effects effects
Abbrev. Meaning
AGND Analog ground
BTB/RTO Ready to operate
CAN Fieldbus (CANopen)
CE Communité Europeenne (=EC)
CLK Clock signal
COM Serial interface for a PC-AT
DGND Digital ground
DIN Deutsches Institut für Normung
Disk Magnetic storage (diskette, hard disk)
EEPROM Electrically erasable memory
EMC Electromagnetic compatibility
EMI Elektromagnetic interference
EN European standard
ESD Electrostatic discharge
F-SMA Fiber Optic Cable connector according to IEC 60874-2
IEC International Electrotechnical Commission
IGBT Insulated gate bipolar transistor
ISO International Standardization Organization
LED Light-emitting diode
MB Megabyte
NI Zero pulse
NSTOP Limit-switch input, rot. dir. CCW (left)
PC Personal Computer
PELV Protected low voltage
PLC Programmable logic controller
PSTOP Limit-switch input, rot. dir. CW (right)
PSU Power supply unit
PWM Pulse-width modulation
RAM Volatile memory
RBext External regen resistor
RBint Internal regen resistor
RES Resolver
ROD 426 A quad B Encoder
SRAM Static RAM
SSI Synchronous serial interface
UL Underwriter Laboratory
V AC AC voltage
V DC DC voltage
VDE Verein deutscher Elektrotechniker
2 Technical description
l The manufacturer of the machine must produce a hazard analysis for the ma-
chine and take appropriate measures to ensure that unforeseen movements do
not result in personal injury or material damage.
l Do not open or touch the equipment during operation. Keep all covers and ca-
binet doors closed during operation. Touching the equipment is allowed du-
ring installation and commissioning for properly qualified persons only. Other-
wise, there are deadly hazards, with the possibility of death, severe injury or
material damage.
— During operation, servo amplifiers may have uncovered live
components, depending on their level of enclosure protection.
— Control and power connections may be live, even though the
motor is not rotating.
— Servo amplifiers may have hot surfaces during operation.
Surface can reach temperatures above 80°C.
l Never undo any electrical connections to the servo amplifier while it is live.
There is a danger of electrical arcing with damage to contacts and personal in-
jury.
Wait at least five minutes after disconnecting the servo amplifier from the main
supply power before touching potentially live sections of the equipment (e.g.
contacts) or undoing any connections. Capacitors can still have dangerous
voltages present up to five minutes after switching off the supply power. To be
sure, measure the voltage in the DC Bus link and wait until it has fallen below
40V.
The manufacturer of the machine must produce a hazard analysis for the machine
and take appropriate measures to ensure that unforeseen movements do not result
in personal injury or material damage.
The servo amplifier should only be used with power supplies with a maximum
symmetrical rated current of 5000A and a voltage of 115/230V AC (AX250x) or 400V
AC (AX251x).
If the servo amplifiers are used in residential areas, or in business or commercial premi-
ses, then additional filter measures must be implemented by the user.
The AX2500 family of servo amplifiers is only intended to drive specific brushless syn-
chronous servomotors with closed-loop control of torque, speed and/or position. The
rated voltage of the motors must be at least as high as the DC Bus link voltage of the
servo amplifier.
The servo amplifiers may only be operated in a closed control cabinet, taking into
account the ambient conditions defined on page 17. Ventilation or cooling measures may
be required to keep the temperature below 45°C.
Use only copper-cored cables for wiring. The conductor cross-sections can be taken from
the European standard EN 60204 (or Table 310-16 of NEC for 60°C or 75°C in the
column for AWG cross-sections).
We can only guarantee that the system will conform to the standards cited on page 9 if
the components used are exclusively those supplied by us (servo amplifier, motor, cables
etc.).
The manufacturer of the machine must produce a hazard analysis for the machine
and take appropriate measures to ensure that unforeseen movements do not result
in personal injury or material damage.
To fulfill the Low Voltage Directive 73/23/EEC, the following standards have to be applied:
EN 60204-1 (Safety and electrical equipment of machines)
EN 50178 (Equipment of high voltage plant with electronic devices)
EN 60439-1 (Low-voltage switchgear and controlgear assemblies)
To fulfill the EC EMC regulations 89/336/EEC, the following standards have to be applied:
EN 61000-6-1 or EN 61000-6-2 (noise immunity in the domestic range/industrial range)
EN 61000-6-3 or EN 61000-6-4 (noise emission in the domestic range/industrial range)
The manufacturer of the machine or plant is responsible for ensuring that they meet the
limits required by the EMC regulations. Advice on the correct installation for EMC – such
as shielding, grounding, arrangement of connectors and cable routing – can be found in
this documentation.
The machine / plant manufacturer must examine whether with its machine / plant
still further or other standards or EEC guidelines are to be used.
2.4 CE Conformity
Conformity with the EC Directive on EMC 89/336/EEC and the Low Voltage Directive
73/23/EEC is mandatory for servoamplifiers supplied within the European Union.
To fulfill the EMC directive, the standard EN 61800-3 is applied.
In the reference to noise immunity the servoamplifier fulfills the requirement to the cate-
gory second environment (industrial environment). For noise emission the amplifier meets
the requirement to a product of the category C2 (motor cable £ 25m).
Warning!
This product can cause high-frequency interferences in non industrial
environments which can require measures for interference suppression.
The servo amplifiers have been tested by an authorized testing laboratory in a defined
configuration with the system components which are described in this documentation.
Any divergence from the configuration and installation described in this documentation
means that you will be responsible for carrying out new measurements to ensure that the
regulatory requirements are fulfilled.
To fulfill the Low Voltage Directive, the standard EN 50178 has to be applied.
2.6 Nameplate
The nameplate depicted below is attached to the side of the servo amplifier.
Umgebungstemp.
Ambient temp.
008102106842 5.76
If you order a AX2500 series amplifier from us, you will receive:
— AX250x or AX251x (Master)
— Mating connectors for X0, X1, X3, X6
— Protective cover for the axis-side (required only once per system)
— Assembly and Installation Instructions
— Setup software DRIVE.EXE and online documentation on CD-ROM
alternatively
— AX252x (axis module)
— Mating connector for X3, X6
— Short-form instructions
The mating SubD connectors are not part of the package supplied!
Minimum complexity
l up to 8 axes in a single system
l only one power supply feed and one auxiliary voltage supply per system
l shield connection directly on the servo amplifier
l all axes in a system can be parameterized through a single interface
l strongly reduced wiring expenditure by modular structure
l simple mechanical structure on DIN rails
Standard version
l 2 supply voltage versions: AX250x up to 3x230VAC and
AX251x up to 3x400VAC
l one size for the master and axis modules each, see page 26
l analog input
l fieldbus interface is integrated (standard: CANopen)
l RS232 is integrated
l pulse-direction interface is integrated
Supply power
l directly off electrical supply input (master only, B6 rectifier bridge,
integral power input filter and inrush circuit):
1 x 115V AC (AX250x only, unearthed operation is permitted)
3 x 115V AC (AX250x only, unearthed operation is permitted)
1 x 230V AC (AX250x only, unearthed operation is permissible)
3 x 230V AC (all types, unearthed operation is permissible)
3 x 400V AC (AX251x only, TN-system or TT-system with
earthed neutral point)
l fusing (e.g. fusible cutout) provided by the user
l integrated interference suppression filter for the supply input (for category 2)
l integrated interference suppression filter for the 24V auxiliary supply (for category 2)
l all shielding connections directly on the amplifier
l output stage IGBT module with isolated current measurement
Clock frequency can be switched from 8 to 16 kHz with
ASCII command (with power reduction, please contact
our customer support)
l regen circuit internal regen resistor as standard,
external regen resistor if required
l DC Bus link voltage 160...310V DC for AX250x
310...560V DC for AX251x
160...560V DC for AX252x
Integrated safety
l safe electrical separation to EN 50178 between the power input / motor connections
and the signal electronics, provided by appropriate creepage distances and complete
electrical isolation
l Soft-start, overvoltage detection, short-circuit protection, phase-failure monitoring
l temperature monitoring of servo amplifier and motor (when using our motors with our
pre-assembled cables)
Comfort functions
l 4 programmable digital inputs
(two are normally defined as limit-switch inputs)
l 2 programmable digital outputs
l freely programmable combinations of all digital signals
Options
l PROFIBUS DP interface instead of CANopen, see page 58
l SERCOS interface instead of CANopen, see page 59
PC
Control / PLC
24V supply
AX2500
fuses
drive contactor
terminals
motor
2.9.2 Connections
2.9.4 Fusing
Function
Auxiliary supply 24V 20 AM
Regen resistor electronical
auxiliary supply
w/o brake and w/o fan 20 VDC ... 30 VDC
with brake or with fan 24 VDC (-0% +15%), check voltage drop
0...+45oC at rated conditions
Ambient temperature in operation
+45...+55°C with power derating 2.5% / K
Humidity in operation rel. humidity 85%, no condensation
up to 1000m amsl without restrictions
Site altitude
1000...2500m amsl with derating 1.5% / 100m
Pollution level Pollution level 2 as per EN 60204 / EN 50178
Enclosure rating IP 20
Mounting position normally vertical ð p.25
AX25x3: free convection
Ventilation
AX25x6: add-on fan (ð p.72)
Check voltage drop, measure the voltage at brake input and check brake function
(brake and no brake).
This function does not ensure personnel safety!
The brake function must be enabled through the BRAKE parameter (on the screen page
for Motor): the setting is WITH.
In the diagram below you can see the timing and functional relationships between the
ENABLE signal, speed setpoint, speed and braking force.
During the internal enable delay time of 100ms the speed setpoint of the servo amplifier is
internally driven down a 10ms ramp to 0V. The brake output is switched on when 3% of
the final speed is reached, at the latest after 1 second.
The rise (fbrH) and fall (fbrL) times of the holding brakes that are built into the motors vary
for the different types of motor (see motor manual).
A description of the interface can be found on page 39.
Personnel-safe operation of the holding brake requires an additional “make” contact in
the brake circuit and a spark suppressor device (e.g. a varistor) in the recommended
brake circuit:
AX25
A 3-digit LED display indicates the amplifier status after switching on the 24V supply
(ð p.65).
If a fault occurs (ð p.66), the output stage of the servo amplifier is switched off and the
BTB/RTO contact is opened. In addition, a global error signal can be given out at one of
the digital outputs (terminals X3/8 and X3/9) (see the Online help in the setup software).
These signals can be used by the higher-level control to terminate the current PLC cycle
or to shut down the drive (through an additional brake or similar means).
Instruments with a selected Brake function use a special sequence for switching off the
output stage (ð p.18). The Stop functions are defined in EN 60204 (VDE 0113), Paras.
9.2.2 and 9.2.5.3.
Categories of Stop functions
Category 0: Shut down by immediate switch-off of the supply of energy to the
drive machinery (i.e. an uncontrolled shut-down)
Category 1: A controlled shut-down, during which the supply of energy to the
drive machinery is maintained to perform the shut-down, and where
the supply is only interrupted when standstill has been reached
Category 2: A controlled shut-down, where the supply of energy to the drive
machinery is maintained
Every machine must be equipped with a Stop function to Category 0.
Categories 1 and/or 2 must be provided if the safety or functional requirements of the
machine make this necessary.
Implementation of the Stop function :
You can find wiring recommendations in our application note
“Stop and Emergency Stop functions"
The Emergency Stop function is defined in EN 60204 (VDE 0113), Para. 9.2.5.4.
In addition to the requirements for Stop, the Emergency Stop must fulfill the following
requirements:
l it must have priority over all other functions and controls in all operating situations
l the energy supply to any drive machinery that could cause dangerous situations
must be switched off as fast as possible, without causing any further hazards (e.g. by
using
mechanical latching devices that do not require an external supply of energy, by
counter-current braking in Stop Category 1)
l the reset must not initiate a restart
If necessary, provision must be made for the additional connection of emergency stop
devices (see EN 60204 Requirements for emergency stop devices).
The Emergency Stop must be effective as a stop of either Category 0 or Category 1.
The Emergency Stop Category must be determined by a risk evaluation of the machine.
Category 0
Only hard-wired electromechanical components may be used for an Emergency Stop
function to Category 0. The action must not depend on switching logic (hardware or soft-
ware) or on the transmission of commands through a communications network or a data
connection.
In multi-axis systems using a coupled DC Bus link the motor cable must also be discon-
nected by a changeover switch (a contactor, such as Siemens type 3RT1516-1BB40) and
short-circuited by resistors wired in a star configuration.
Category 1
For Emergency Stop Category 1 the final disconnection of the energy supply to the drive
machinery must be ensured by electromechanical components. Supplementary Emer-
gency Stop devices may be plugged in.
3 Installation
Caution
Never disconnect the electrical connections to the servo amplifier while it is live.
Residual charges in the capacitors can have dangerous levels up to 300 seconds
after switching off the mains supply voltage. Measure the voltage in the DC Bus
link (+RBext/-DC) and wait until the voltage has fallen below 40V.
Control and power connections can still be live, even when the motor is not
rotating.
Make a final check of the wiring carried out against the wiring
Check
diagrams that have been used
3.3 Mounting
Material: 2 mounting rails to EN60715, min. length = system width + 40mm,
make sure there is a conductive connection to the mounting plate
Mount the protective cover (7mm) on the left side of the system.
Tools required: Screwdriver with approx. 5 mm blade width
AX2500
3.3.1 Dimensions
AX252x
3.4 Wiring
Only professional staff who are qualified in electrical engineering are allowed to
install the servo amplifier.
The installation procedure is described as an example. A different procedure may be
appropriate or necessary, depending on the application of the equipment.
We provide further know-how through training courses (on request).
Caution !
Only install and wire up the equipment when it is not live, i.e. when neither the
mains power supply nor the 24 V auxiliary voltage nor the operating voltages of
any other connected equipment is switched on.
Take care that the cabinet is safely disconnected (lock-out, warning signs etc.).
The individual voltages will be switched on for the first time during commissioning.
The ground symbol X , which you will find in all the wiring diagrams, indicates
that you must take care to provide an electrically conductive connection with the
largest possible area between the unit indicated and the mounting plate in the
control cabinet. This connection is for the effective grounding of HF interference,
and must not be confused with the PE symbol W (protective earth to EN 60204).
ð p.43
ð p.46
ð p.46
ð p.40
ð p.48
ð p.39
ð p.49
ð p.52 ð p.38
ð p.39
ð p.57
ð p.38
ð p.56
ð p.43
ð p.46
ð p.46
ð p.40
ð p.48
ð p.39
ð p.52
ð p.57
M
AX250x/AX251x
M
AX252x
AX252x
00
X25
A
Tighten up the cable ties so that the
shielding ferrule and the sheathing
of the cable is pressed down tightly
against the shielding strip.
00
25
AX
Insulation material
Sheathing PUR (polyurethane, code 11Y)
Core insulation PETP (polyesteraphthalate, code 12Y)
Capacitance
Motor cable less than 150 pF/m
RES/encoder cable less than 120 pF/m
Technical data
— The brackets in the cable designation indicate the shielding.
— All cables are suitable for use as trailing cables.
— The technical data refer to the use as moveable cables.
— Operating life : 1 million bending cycles
Operation-
max. Outside Bending
Cores used for Temperature
length diameter radius
range
[mm²] [m] [°C] [mm] [mm]
(4x1,0) 25 Motor / power -30 / +80 10 100
(4x1.0+(2x0.75)) 25 Motor incl. brake -30 / +80 10.5 105
(4x2x0,25) 100 Resolver -30 / +80 7,7 70
(7x2x0,25) 50 Encoder -30 / +80 9,9 90
3.5.1 General
This chapter describes the installation of the setup software DRIVE.EXE for the AX2500
digital servo amplifiers.
We offer training and familiarization courses on request.
The operator software is intended to be used for altering and storing the operating para-
meters for the AX2500 series of servo amplifiers. The attached servo amplifier is commis-
sioned with the assistance of the software - during this process the drive can be control-
led directly by the service functions.
Only professional personnel who have the relevant expertise described on page 5
are permitted to carry out online parameter setting for a drive which is running.
Sets of data which are stored on data media are not safe against unintended
alteration by other persons. After loading a set of data you must therefore check all
parameters thoroughly before enabling the servo amplifier.
The servo amplifiers must be adapted to the requirements of your installation. Usually you
will not have to carry out this parameter setting yourself on the amplifier, but on a PC,
with the assistance of the operator software. The PC is connected to the servo amplifier
by a null-modem (serial, ð p.56) cable. The setup software provides the communication
between the PC and AX2500.
You will find the setup software on the accompanying CD-ROM and in the download sec-
tion of our website.
With very little effort you can alter parameters and immediately observe the effect on the
drive, since there is a continuous (online) connection to the amplifier. At the same time,
important actual values are read out from the amplifier and displayed on the PC monitor
(oscilloscope function).
Any interface modules which may be built into the amplifier are automatically recognized,
and the additional parameters which are required for position control or motion-block defi-
nition are made available.
Sets of data can be stored on data media (archived) and loaded again. You can also print
out the data sets.
We provide you with motor-specific default sets of data for all the reasonable combina-
tions of servo amplifier and motor. In most applications you will be able to use these
default values to get your drive running without any problems.
The PC interface (X6, RS232) of the master is connected to a serial interface on the PC
by a null-modem cable (not a null-modem link cable !) (ð p.56).
Connect / disconnect the interface cable only when the supply is switched off for
both the PC and the servo amplifier.
The interface in the servo amplifier is electrically isolated by an optocoupler, and is at the
same potential as the CANopen interface.
Minimum requirements for the PC:
Processor : Pentium I or higher
Operating system : WINDOWS 98 / 2000 / ME / NT4.0 / XP
Graphica adapter : Windows compatible, color
Drives : Hard disk (10 MB free space)
CD-ROM drive
Main memory : at least 8MB
Interface : one free serial interface (COM1:, 2:, 3: or 4:)
WINDOWS 98 / 2000 / ME / NT / XP
DRIVE.EXE can work under WINDOWS 98 / 2000 / ME / XP or WINDOWS NT 4.0.
Emergency operation is possible with an ASCII terminal-emulation.
Interface setting: 9600 bps, databit 8, stopbit 1,no parity, no handshake
Unix, Linux
DRIVE.EXE does not work under Unix and Linux.
The CD-ROM includes an installation program called SETUP.EXE that makes it easier to
install the setup software on your PC.
Connection to the serial interface of the PC
Connect the interface cable to a serial interface on your PC and the PC interfaces (X8) of
the AX2500 (ð p.56).
Installation
Insert the CD-ROM into a free drive.
Autostart activated:
The start screen of the CD-ROM pops up. Click on the link to the Setup Software and
follow the instructions.
Autostart deactivated:
Click on START (task bar), then on Run. Enter the program call x:\start.exe (where x= is
the drive letter for the CD drive). Click on OK and follow the instructions.
4 Interfaces
This chapter presents all the important interfaces, divided between master and axis
module. The precise location of the connectors and terminals can be seen on page 31.
Directly to earthed supply, filter is integrated, fusing (e.g. fusible cut-outs) to be provided
by the user (ð p.16).
AX2500
for AX250x
for AX251x
Directly to supply, filter is integrated, fusing (e.g. fusible cut-outs) to be provided by the
user (ð p.16).
AX2500
for AX250x
— Electrically isolated supply from an external 24V DC PSU, e.g. with isolating
transformer
— Required current rating (ð p.15)
— Integrated EMC filter for the 24V auxiliary supply
AX2500
Only servo amplifiers with mains supply from the same mains (identical mains
supply voltage) may be connected by the DC bus link.
AX2500
AX2500
4.6 Feedback
As an option our motors can be equipped with a ComCoder as feedback unit. For the
commutation hall sensors are used and for the resolution an incremental encoder.
The thermostat contact in the motor is connected via the ComCoder cable to X2 and
evaluated there.
If cable lengths of more than 25m are planned, please consult our customer service.
Frequency limit (A,B): 350 kHz
AX2500 SubD15
As an option, the motors can be fitted with a single-turn or multiturn sine-cosine encoder.
Preferred types are the ECN1313 and EQN1325 encoders.
The encoder is used by the AX2500 as a feedback device for drive tasks that require
highly precise positioning or extremely smooth running.
The thermostat contact in the motor is connected via the encoder cable to the AX2500
and evaluated there.
If lead lengths of more than 25m are planned, please consult our customer support.
Frequency limit (A, B): 350 kHz
A sine-cosine encoder without data channel can be used as standard motor feedback.
Select feedback type 7 "SinCos 5V with W&S". Drive executes wake&shake to calculate
the necessary start-up information for the position controller every time the 24V auxiliary
voltage is switched on.
If lead lengths of more than 50m are planned, please consult our customer service.
The thermostat contact in the motor is connected via the encoder cable to X2 and evalua-
ted there.
Frequency limit: 350 kHz
Don't use this feedback type with vertical load (hanging load).
AX2500 SubD 15
Don't use this feedback type with vertical load (hanging load).
AX2500 SubD 9
AX2500
AX2500
You can use the digital inputs PSTOP / NSTOP / DIGITAL-IN1 and DIGITAL-IN2 to
initiate pre-programmed functions that are stored in the servo amplifier.
You will find a list of the pre-programmed functions in the Online Help.
If an input has to be re-assigned to a pre-programmed function, then the data set must be
stored in the EEPROM of the servo amplifier, and the 24V auxiliary supply for the servo
amplifier must be switched off and then on again (to reset the amplifier software).
Limit-switches PSTOP / NSTOP
Terminals X3/6 and X3/7 are used to connect limit switches. They are deactivated upon
delivery. If these inputs are not needed for the connection of limit switches, then they can
be used for other input functions.
Limit-switch positive/negative (PSTOP / NSTOP, terminals X3/6 and X3/7), high level in
normal operation (fail-safe for cable break). A low signal (open) inhibits the corresponding
direction of rotation.
DIGITAL-IN 1 / DIGITAL-IN 2
You can link the digital inputs at terminals X3/4 (DIGITAL-IN 1) and X3/5 (DIGITAL-IN2)
with a pre-programmed function.
Technical characteristics
— Ground reference is Digital-GND (DGND, terminal X1/4,5 on the master)
— Alle digital outputs are floating
— DIGITAL-OUT1 and 2 : Open-collector, max. 30V DC, 10mA
— Update rate: 250 µs
AX2500
Technical characteristics
— Ground reference is Digital-GND (DGND, terminal X1/4,5)
— The logic is dimensioned for +24V / 7mA (PLC-compatible)
— H-level from +12...36V / 7mA, L-level from 0...7V / 0 mA
BTB/RTO: Relay output, max. 30V DC or 42V AC, 0.5A
AX2500
ENABLE input
The output stage of the servo amplifier is activated by the enable signal
(terminal X1/3, input 24V, active-high).
In the inhibited state (low signal) the motor which is attached does not have any torque.
Ready-to-operate contact BTB/RTO
Operational readiness (terminals X1/1 and X1/2 ) is signalled via a floating relay contact.
The contact is closed when all servo amplifiers in the system are ready for operation.
This signal is not influenced by the enable signal, the I²t- limit, or the regen threshold.
All faults cause the BTB/RTO contact to open and the switch-off of the output
stage (if the BTB contact is open, the output stage is disabled -> no power). A list
of the error messages can be found on page 66.
The incremental-encoder interface is part of the package supplied. Select the encoder
function ROD (screen page “Encoder”, funktion ENCMODE). In the servo amplifier, the
position of the motor shaft is calculated from the cyclic-absolute signals of the resolver or
encoder.
Incremental-encoder compatible pulses are generated from this information. Pulses are
output as two signals, A and B, with 90° phase difference and a zero pulse. The resolu-
tion (lines before quadrature) can be changed with the RESOLUTION parameter:
PGND must always be connected to the control ground. The max. admissible cable
length is 10 m.
AX2500
The SSI interface (synchronous serial absolute-encoder emulation) is part of the package
supplied. Select encoder function ROD (“Encoder” screen page).
The servo amplifier calculates the motor shaft position from the cyclic-absolute signals of
the resolver or encoder. From this information a SSI date (after Stegmann patent specifi-
cation DE 3445617C2) is provided.
28 bits are transferred. The 12 leading data bits contains the number of revolutions. The
following max. 16 bits contain the resolution and are not variable.
The following table shows the allocation of the SSI date:
Revolution Resolution
11 10 9 8 7 6 5 4 3 2 1 0 15 14 13 12 11 10 9 8 7 6 5 4 3 2 1 0
The signal sequence can be output in Gray code or in Binary (standard) code (parameter
SSI-CODE). The servo amplifier can be adjusted to the clock frequency of your SSI-eva-
luation through the SSI-TIMEOUT parameter (cycle time 1.3 µs or 10 µs).
The ground reference for the interface is PGND.
AGND (terminal X3/1) must be connected to the ground of the control system!
Observe the limit frequency!
Please contact our customer support for information on connecting external SSI enco-
ders.
Signal diagram (for encoders with RS422 or 24V outputs)
This interface can be used to link several AX2500 amplifiers in master-slave operation.
Up to 16 slave amplifiers can be controller by the master via the encoder output. The
SubD connector X4 is used for this purpose.
AGND (terminal X3/1) must be connected to the ground of the control system!
AX2500 AX2500
4.9.2 Connection to incremental encoder master with 24V signal level (X3)
You can use this interface to set up the AX2500 as a slave following an encoder with a
24V signal level (master-slave operation). This application uses the digital inputs DIGI-
TAL-IN 1 and 2 on connector X3.
AGND (terminal X3/1) must be connected to the ground of the control system!
AX2500
You can use this interface to set up the AX2500 as a slave following a sine/ cosine enco-
der (master-slave operation). This application uses the SubD connector X2.
Limit frequency: 350 kHz
AGND (terminal X3/1) must be connected to the ground of the control system!
AX2500
AGND (terminal X3/1) must be connected to the ground of the control system!
Observe the limit frequency!
Note:
Connecting an A quad B encoder offers more EMI supression.
You can use this interface to connect the servo amplifier to a stepper motor control with a
5V signal level. The SubD connector X4 is used for this purpose.
Limit frequency: 1 MHz
AGND (terminal X3/1) must be connected to the ground of the control system!
AX2500
4.10.2 Connection to a stepper motor controller with 24V signal level (X3)
You can use this interface to connect the servo amplifier to a stepper motor control with a
24V signal level. The digital inputs DIGITAL-IN 1 and 2 on connector X3 are used for this
purpose.
Limit frequency: 100 kHz
AGND (terminal X3/1) must be connected to the ground of the control system!
AX2500
AX2500
Interface cable between the PC and servo amplifiers of the AX2500 series:
(View: front view of the built-in SubD connectors, this corresponds to looking at the solder
side of the SubD connector on the cable.)
The interface for connection to the CAN bus (default: 500 kbps). The master is fitted with
a CAN input. All axis modules in the system are connected to this through the internal
bus. The last axis module has a CAN output, where the CAN bus either continues to
other bus participants or is terminated by a termination resistor.
The integrated profile is based on the communication profile CANopen DS301 and the
drive profile DS402. The following functions are available in connection with the integra-
ted position controller: Jogging with variable speed, homing, start motion task, start direct
task, digital setpoint provision, data transmission functions and many others.
Detailed information can be found in the CANopen manual.
The interface is at the same potential as the internal logic, and uses AGND as the ground
reference.
AGND must be connected to the control system ground for potential equalization!
AX2500
To meet ISO 11898 you should use a bus cable with a 120 W characteristic impedance.
The maximum usable cable length for reliable communication decreases with increasing
transmission speed. As a guide, you can use the following values which we have measu-
red, but they must not be assumed to be limits:
Cable data: Characteristic impedance 100-120 W
Cable capacitance max. 60 nF/km
Conductor loop resistance 159.8 W/km
Cable length, depending on the transmission rate
Transmission rate / kbps max. cable length / m
1000 20
500 70
250 115
Lower cable capacitance (max. 30 nF/km) and lower lead resistance (loop: 115 W/km)
make it possible to transmit over longer distances.
(Characteristic impedance 150 ± 5W Þ terminating resistance 150 ± 5W).
For EMC reasons, the SubD connector housing must fulfill the following conditions:
— metal or metallized housing
— provision for connecting the cable shielding within the housing,
large-area connections
AX2500
This section describes the SERCOS interface of the AX2500. Information on the range of
functions and the software protocol can be found in the manual “IDN Reference Guide
SERCOS”.
For the fiber optic cable connection, only use SERCOS components to the SERCOS
Standard IEC 61491.
RT: indicates whether SERCOS telegrams are being correctly received. In the final
Communication Phase 4 this LED should flicker, since cyclical telegrams are being
received.
TT: indicates that SERCOS telegrams are being transmitted. In the final Communi-c
ation Phase 4 this LED should flicker, since cyclical telegrams are being trans-
mitted. Check the stations addresses for the controls and the servo amplifier if:
- the LED never lights up in SERCOS Phase 1 or
- the axis cannot be operated, although the RT LED is lighting up cyclically.
Err: indicates that SERCOS communication is faulty or suffering from interference.
If this LED is very bright, then communication is suffering strong interference, or is
non-existent. Check the SERCOS transmission speed for the controls and the
servo amplifier (BAUDRATE) and the fibre-optic connection. If this LED flickers,
this indicates a low level of interference for SERCOS communication, or the optical
transmitting power is not correctly adjusted to suit the length of cable.
Check the transmitting power of the (physically) previous SERCOS station.
The transmitting power of the servo amplifier can be adjusted in the setup software
DRIVE.EXE on the SERCOS screen page, by altering the parameter
for the cable length.
Layout of the SERCOS bus system in ring topology, with optical fibre cables (schematic).
5 Setup
Before setting up, the manufacturer of the machine must produce a hazard
analysis for the machine and take appropriate measures to ensure that unforeseen
movements do not result in personal injury or material damage.
Check that all connection components that are live in operation are safely
protected against bodily contact. The equipment produces potentially lethal
voltages up to 800V.
Never undo the electrical connections to the servo amplifier while it is live.
Capacitors can still have dangerous residual charges up to 300 seconds after
switching off the supply voltage.
The heat sink and front panel of the amplifier can reach temperatures up to 80°C in
operation. Check the heat sink temperature. Wait until the heat sink has cooled
down to 40°C before touching it
If the servo amplifier has been stored for longer than 1 year, then the DC Bus link
capacitors will have to be re-formed.
To do this, disconnect all the electrical connections.
Supply the servo amplifier for about 30 min. from single-phase 230V AC to the
terminals L1 / L2. This will re-form the capacitors.
5.3 Parameterization
A default parameter set is loaded into your servo amplifier at the factory. This contains
valid and safe parameters for the current and speed controllers.
A database for motor parameters is stored in the servo amplifier. During commissioning
you must select the data set for the motor that is connected and store it in the servo
amplifier. For most applications these settings will already provide good to very good con-
trol loop characteristics.
An exact description of all parameters and the options for optimizing the control loop cha-
racteristics can be found in the online help of the setup software.
All the axes in a system can be parameterized through the RS232 interface in the master.
To do this, there is an internal connection between the master and the axis modules. The
PC cable only has to be connected to the master.
The internal address assignment is carried out automatically, so that it is only necessary
to set up the basic station address for the master.
PC
Axismodule 1
Axismodule 2
Axismodule 3
Master
COMx
X8 / PC RS232
After changing the station address it is necessary to turn off the 24V auxiliary
supply, and then turn it on again.
Starting at the master, descending addresses are assigned automatically to the axis
modules. The following table shows an example with one master and three axis modules:
The highest permitted master address is 128. When choosing the master address,
please consider that at least address 1 will be assigned to the last (leftmost) axis
module.
In CAN and PROFIBUS field bus systems the automatically assigned addresses
must not match the address of other nodes.
Two keys are fitted in the operating panel of the master. Here you can enter the basic
address for the system and call up status information on all the axes that are connected.
5.3.2.1 Operating
Each axis module is fitted with 2 LEDs that provide a quick indication of the instrument
status.
LED
red green Interpretation
lit off axis is not ready for operation (fault)
blinking off a warning has been generated
off lit axis is ready for operation, and enabled
off blinking axis is ready for operation, but not enabled
blinking blinking axis is selected for editing by the master
A detailed display of the warnings and faults can be called up in the display on the master
( ð p.65).
6 Accessories
Technical data
Input voltage 120 / 230V
Input current 0.9 / 0.6A
Frequency 50/60Hz
Primary fusing 3.15AT
Output voltage 24V ± 1%
Max. output current 5A
Residual ripple <150mVss
Switching peaks <240mVss
Output fusing short-circuit proof
Temperature range 0 to +60°C
DIN-rail, vertical mounting
Mounting method
50mm free space required above and below the instrument
Weight 0.75kg
Mounting plate
Mounting plate
Technical data
Input voltage 3 x 400V AC ± 10%
Input current approx. 1.1A
Frequency 50/60Hz
Primary fusing none
Output voltage 24V ± 1%
Max. output current 20A
Residual ripple <0.1%
Output fusing short-circuit proof
Test voltage to VDE 0550
Temperature range -20 to +60°C
on mounting plate
Mounting method (supplied)
Keep space free
Weight 3.5kg
Caution:
Surface temperature may exceed 200°C.
Observe the requested free space.
Do not mount to combustible surface.
To mount the fan, just hook it in the designated slots at the bottom of the AX25 and screw
the fixing bolt into the thread in the housing. The electrical connection takes place auto-
matically when mounting the fan.
Please consider that a mounted fan increases the required space underneath the
amplifier! (Þ p. 25)
The drawing below shows, how the fan should be mounted. With an odd number of axes
(master included), the fan must also cover the power supply unit at the master.
Single master Master with 1 Axis module Master with 2 Axis modules
7 Appendix
7.2 Fault-finding
The table below should be regarded as a “First-aid” box. Depending on the conditions in
your installation, there may be a wide variety of reasons for the fault. In multi-axis sys-
tems there may be further hidden causes of a fault. Our customer support can give you
further assistance with problems.
7.3 Glossary
C clock Clock signal
common-mode voltage The maximum amplitude of a disturbance (on both
inputs) which a differential input can eliminate
continuous power of regen circuit Mean power which can be dissipated in the
regen circuit
counts Internal count pulses, 1 pulse = 1/220 turn-1
current controller Regulates the difference between the current
setpoint and the actual value to 0
Output : power output voltage
D DC Bus link Rectified and smoothed power voltage
disable Removal of the enable signal (0V or open)
E earth short electrical connection between a phase and
the protective earth (PE)
enable Enable signal for the servo amplifier (+24V)
F fieldbus interface CANopen, PROFIBUS, SERCOS
free convection Free movement of air for cooling
G GRAY-code Special format for representing binary numbers
H holding brake Brake in the motor, which should only be used
when the motor is at standstill
I I²t threshold Monitoring of the r.m.s. current that is actually
required
incremental encoder interface Position signalling by 2 signals with 90° phase
difference, not an absolute position output
input drift Temperature and age-dependent alteration of an
analog input
Ipeak, peak current The effective value of the peak current
Irms, effective current The r.m.s. value of the continuous current
K Kp, P-gain Proportional gain of a control loop
L limit speed Maximum value for speed normalization at ±10V
limit-switch Switch limiting the traverse path of the machine;
implemented as n.c. (break) contact
M machine The complete assembly of all connected parts or
devices, of which at least one is movable
motion-block Set of all the position control parameters
which are required for a motion task
multi-axis system Machine with several driven axes
N natural convection Free movement of air for cooling
O optocoupler Optical connection between two electrically
independent systems
7.4 Index
S safety instructions . . . . . . . . . . . . . 7
SERCOS interface . . . . . . . . . . . . 59
setpoint input . . . . . . . . . . . . . . . 46
setup software . . . . . . . . . . . . . . 34
SETUP.EXE . . . . . . . . . . . . . . . 35
shield connection. . . . . . . . . . . . . 32
shielding
installation . . . . . . . . . . . . . . 24
wiring diagram . . . . . . . . . . . . 28
sine-cosine encoder, interface . . . . . . 44
site altitude . . . . . . . . . . . . . . . . 17
SSI, interface. . . . . . . . . . . . . . . 51
stacking height . . . . . . . . . . . . . . 73
standards . . . . . . . . . . . . . . . . . 9
status display. . . . . . . . . . . . . . . 64
stop function . . . . . . . . . . . . . . . 20
storage . . . . . . . . . . . . . . . . . . 73
storage duration . . . . . . . . . . . . . 73
storage temperature . . . . . . . . . . . 73
supply connection, interface . . . . . . . 38
supply voltage . . . . . . . . . . . . . . 17
switch on/off behaviour. . . . . . . . . . 20
symbols . . . . . . . . . . . . . . . . . . 5
system components, summary. . . . . . 14
T technical data . . . . . . . . . . . . . . 15
ambient conditions . . . . . . . . . . 17
cables . . . . . . . . . . . . . . . . 33
conductor cross sections . . . . . . . 17
connections. . . . . . . . . . . . . . 16
fusing . . . . . . . . . . . . . . . . . 16
rated data . . . . . . . . . . . . . . 15
tightening torques . . . . . . . . . . 16
tightening torques, connectors . . . . . . 16
transport . . . . . . . . . . . . . . . . . 73
transport temperature . . . . . . . . . . 17
U use as directed
servo amplifier . . . . . . . . . . . . . 8
setup software . . . . . . . . . . . . 34
V ventilation
installation . . . . . . . . . . . . . . 24
techn. data . . . . . . . . . . . . . . 17
W warning messages . . . . . . . . . . . . 67
wiring. . . . . . . . . . . . . . . . . . . 24
wiring diagram
axis module. . . . . . . . . . . . . . 29
master . . . . . . . . . . . . . . . . 28