System Manual Servo Drives AX5000 Ftp://ftp.beckhoff.com//motion/ax5000_system_manual_hw2_en Hw2 En

User Manual: Pdf ftp://ftp.beckhoff.com//motion/ax5000_system_manual_hw2_en manual pdf

Open the PDF directly: View PDF .
Page Count: 266

Download
Open PDF In Browser	View PDF

System manual

Servo Drives AX5000

Version:
Date:

2.4
2017-09-14

Documented servo drives

This documentation describes the following servo drives in the AX5000 range:
AX5101
AX5103
AX5106
AX5112
AX5118
AX5125
AX5140
AX5201
AX5203
AX5206

Servo Drives AX5000

AX5160
AX5172
AX5190
AX5191
AX5192
AX5193

Version: 2.4

Table of contents

Table of contents
1 Documented servo drives......................................................................................................................... 3
2 Foreword .................................................................................................................................................... 9
2.1

Notes on the documentation........................................................................................................... 9

2.2

Documentation issue status.......................................................................................................... 10
2.2.1 Scope of the documentation ............................................................................................ 10

2.3

Appropriate use ............................................................................................................................ 11
2.3.1 Dual Use (EU 1382/2014) ................................................................................................ 12

3 Guidelines and Standards ...................................................................................................................... 13
3.1

EC declaration of conformity......................................................................................................... 13

3.2

UL approval for devices up to 40 A for the US and Canada.........................................................
3.2.1 UL-specific chapter changes............................................................................................
3.2.2 UL-specific chapter ..........................................................................................................
3.2.3 UL-specific notes..............................................................................................................

14
14
15
16

3.3

UL approval for devices above 60A for the US and Canada ........................................................
3.3.1 UL-specific chapter changes............................................................................................
3.3.2 UL-specific chapter ..........................................................................................................
3.3.3 UL-specific notes..............................................................................................................

16
16
17
17

3.4

Electrical isolation according to EN 50178 / VDE 0160 ................................................................ 17

4 Safety........................................................................................................................................................ 18
4.1

Safety instructions ........................................................................................................................ 18

4.2

Special safety notes for servo drives ............................................................................................ 19

5 Handling ................................................................................................................................................... 21
5.1

Transport and storage .................................................................................................................. 21

5.2

Maintenance ................................................................................................................................. 21

5.3

Cleaning........................................................................................................................................ 22

5.4

Disposal ........................................................................................................................................ 22

6 Product overview..................................................................................................................................... 23
6.1

Scope of supply ............................................................................................................................ 23

6.2

Name plate ................................................................................................................................... 23

6.3

Type key ....................................................................................................................................... 25

6.4

Image showing AX5101 - AX5112 and AX520x ........................................................................... 26

6.5

Image showing AX5118, AX5125 and AX5140 ............................................................................ 27

6.6

Image showing AX5160 - AX5172................................................................................................ 28

6.7

Image showing AX5190 - AX5191................................................................................................ 29

6.8

Image showing AX5192 - AX5193................................................................................................ 30

7 Technical description.............................................................................................................................. 31

7.1

Configuration of the servo drives .................................................................................................. 31

7.2

General technical data..................................................................................................................
7.2.1 Permissible ambient and operating conditions ................................................................
7.2.2 Electrical data - servo drive (AX5101 - AX5140) .............................................................
7.2.3 Electrical data - servo drive (AX52xx) ..............................................................................
7.2.4 Electrical data - servo drive (AX5160 - AX5193) .............................................................
7.2.5 Mechanical data - servo drive (AX5101-AX5140) ............................................................
7.2.6 Mechanical data - servo drive (AX52xx) ..........................................................................
7.2.7 Mechanical data - servo drive (AX5160 - AX5193) ..........................................................

Version: 2.4

32
32
33
34
35
36
36
36

Servo Drives AX5000

Table of contents
7.3

Dimensions ................................................................................................................................... 37
7.3.1 AX5000 as single device (1.5 A - 40 A) ........................................................................... 37
7.3.2 AX5000 as single device (60 A - 170 A) .......................................................................... 38

7.4

Properties ..................................................................................................................................... 39

7.5

Wide voltage range....................................................................................................................... 39

7.6

Variable motor interface................................................................................................................ 40

7.7

Multi-feedback interface................................................................................................................ 40

8 Mechanical installation ........................................................................................................................... 41
8.1

Installation examples (1.5 A - 40 A devices)................................................................................. 41

8.2

Installation examples (60 A - 170 A devices)................................................................................ 43

9 Electrical installation............................................................................................................................... 46
9.1

Connection of several servo drives to form a drive system ..........................................................
9.1.1 Connection example - module AX5901 and AX5911 (AX Bridge) ...................................
9.1.2 Connection example - wiring in series without AX bridge ................................................
9.1.3 Connection example – DC link group (60 A to 170 A devices) ........................................
9.1.4 UL drive system - configuration example .........................................................................

9.2

Connection example AX5101 - AX5112 and AX520x................................................................... 55

9.3

Connection example AX5118 - AX5125 and AX5140 .................................................................. 56

9.4

Connection example AX5160 - AX5172 ....................................................................................... 57

9.5

Connection example AX5190 - AX5191 ....................................................................................... 58

9.6

Connection example AX5192 - AX5193 ....................................................................................... 59

9.7

Power supply (1.5 A - 40 A devices).............................................................................................
9.7.1 X01: Main supply connection ...........................................................................................
9.7.2 Fuse protection ................................................................................................................
9.7.3 X02: DC Link (AX5101 - AX5125 und AX520x) ...............................................................
9.7.4 X02: DC Link (only AX5140) ............................................................................................
9.7.5 X03: 24 VDC supply.........................................................................................................
9.7.6 Safe system stop in the event of power failure ................................................................

60
60
63
65
65
66
66

9.8

Power supply (60 A - 170 A devices)............................................................................................
9.8.1 X01 - Voltage input ..........................................................................................................
9.8.2 Fusing ..............................................................................................................................
9.8.3 X02: DC link .....................................................................................................................
9.8.4 X03: 24 VDC supply.........................................................................................................
9.8.5 Safe system stop in the event of power failure ................................................................

67
67
68
69
70
70

9.9

Leakage currents .......................................................................................................................... 71

9.10

EtherCAT ...................................................................................................................................... 74
9.10.1 X04, X05: EtherCAT connection ...................................................................................... 74

9.11

Digital I/Os ....................................................................................................................................
9.11.1 X06: Digital I/Os ...............................................................................................................
9.11.2 Technical data..................................................................................................................
9.11.3 Ordering information for I/O plug connectors ...................................................................
9.11.4 Connection of digital sensors/actuators ...........................................................................

75
75
76
76
77

9.12

Feedback ......................................................................................................................................
9.12.1 Rotational encoders .........................................................................................................
9.12.2 Linear encoders ...............................................................................................................
9.12.3 X11 and X21: Feedback, high-resolution .........................................................................
9.12.4 Resolver ...........................................................................................................................
9.12.5 X12 and X22: Feedback, resolver / Hall ..........................................................................
9.12.6 X14 and X24: Feedback, OCT (1.5 A - 40 A devices) .....................................................

78
79
81
82
82
83
83

9.13

Motors........................................................................................................................................... 84
9.13.1 Concept............................................................................................................................ 84

Servo Drives AX5000

Version: 2.4

47
48
49
50
54

Table of contents
9.13.2
9.13.3
9.13.4
9.13.5
9.13.6

Motor data set .................................................................................................................. 84
TwinCAT Drive Manager.................................................................................................. 85
Motor types ...................................................................................................................... 86
Motor connections (1.5 A - 40 A devices) ...................................................................... 100
Motor connections (60 A - 170 A devices) ..................................................................... 102

9.14

External brake resistor................................................................................................................
9.14.1 X02 - AX5101-AX5125 and AX520x ..............................................................................
9.14.2 X07 - AX5140.................................................................................................................
9.14.3 AX5160 and AX5172 .....................................................................................................
9.14.4 AX5190 and AX5191 .....................................................................................................
9.14.5 AX5192 and AX5193 .....................................................................................................

103
103
103
104
104
104

9.15

Motors and cables for servo drives ............................................................................................ 105

10 Advanced system characteristics........................................................................................................ 106
10.1

Commissioning ...........................................................................................................................
10.1.1 Important information for commissioning .......................................................................
10.1.2 Software requirements ..................................................................................................
10.1.3 Rotary motors.................................................................................................................
10.1.4 Linear motors .................................................................................................................
10.1.5 Third-party motors..........................................................................................................
10.1.6 Homing...........................................................................................................................
10.1.7 Error messages during commissioning ..........................................................................

106
106
106
109
148
167
171
179

10.2

EtherCAT .................................................................................................................................... 185
10.2.1 Parameter handling........................................................................................................ 185
10.2.2 EtherCAT synchronization ............................................................................................. 186

10.3

Operation modes ........................................................................................................................ 192
10.3.1 Mode parameterisation according to SoE ...................................................................... 192

10.4

Display and navigation rocker..................................................................................................... 194
10.4.1 Navigation rocker ........................................................................................................... 194
10.4.2 Display ........................................................................................................................... 194

10.5

Motor brake management........................................................................................................... 200
10.5.1 IDNs involved ................................................................................................................. 200
10.5.2 Functioning..................................................................................................................... 200

10.6

Commutation methods................................................................................................................
10.6.1 Rotary servomotors........................................................................................................
10.6.2 Linear motors .................................................................................................................
10.6.3 Commutation error "F2A0" .............................................................................................
10.6.4 Commutation error during regular operation (very rare) ................................................

10.7

OCT ............................................................................................................................................ 211
10.7.1 Precondition for operation .............................................................................................. 211

10.8

Decommissioning ....................................................................................................................... 213

10.9

Integrated safety .........................................................................................................................
10.9.1 Safety-Card AX5801 ......................................................................................................
10.9.2 Intended use ..................................................................................................................
10.9.3 Scope of supply .............................................................................................................
10.9.4 Safety regulations ..........................................................................................................
10.9.5 Personnel qualification ...................................................................................................
10.9.6 Product description ........................................................................................................
10.9.7 Technical data................................................................................................................
10.9.8 Installation of the AX5801 Safety Card ..........................................................................
10.9.9 Application example (emergency stop – stop category 1) .............................................
10.9.10 Application example with several AX5000 .....................................................................

200
200
209
210
211

214
214
214
214
214
215
215
215
216
217
219

11 Project planning .................................................................................................................................... 220

Version: 2.4

Servo Drives AX5000

Table of contents
11.1

Important information for project planning .................................................................................. 220

11.2

Drive train design........................................................................................................................ 220

11.3

Energy management .................................................................................................................. 220

11.4

EMC, earthing, shield connection and potential ......................................................................... 220

11.5

Control cabinet............................................................................................................................ 220

12 Accessories ........................................................................................................................................... 221
12.1

AX-Bridge - quick connection system .........................................................................................
12.1.1 Supply module for multi-axis system..............................................................................
12.1.2 AX-Bridge connection module (AX5x01 - AX5112) .......................................................
12.1.3 AX-Bridge connection module (AX5118 and AX5125) ..................................................

222
222
222
222

12.2

Brake module - AX5021-0000 ....................................................................................................
12.2.1 Electrical data.................................................................................................................
12.2.2 Mechanical data .............................................................................................................
12.2.3 General overview ...........................................................................................................
12.2.4 Pin strip assignment of X51 and X52 .............................................................................
12.2.5 Electrical connection (example) .....................................................................................
12.2.6 Integration into TwinCAT ...............................................................................................
12.2.7 DC link (only for 60A-170A devices) ..............................................................................
12.2.8 Operation modes of the AX5021....................................................................................
12.2.9 Braking power diagnosis ................................................................................................

223
223
224
224
225
225
226
227
227
227

12.3

Optional encoder card - AX5701 / AX5702.................................................................................
12.3.1 Intended use ..................................................................................................................
12.3.2 Safety regulations ..........................................................................................................
12.3.3 Product identification......................................................................................................
12.3.4 Installation of the optional encoder card ........................................................................
12.3.5 Sample: Renishaw RGH 22Z30D00 ..............................................................................

228
228
228
229
231
231

12.4

Optional encoder card - AX5721 / AX5722.................................................................................
12.4.1 Intended use ..................................................................................................................
12.4.2 Safety regulations ..........................................................................................................
12.4.3 Product identification......................................................................................................
12.4.4 Installation of the optional encoder card ........................................................................
12.4.5 Error messages..............................................................................................................

232
232
232
233
234
234

12.5

External Brake Resistor AX2090-BW5x .....................................................................................
12.5.1 Appropriate use..............................................................................................................
12.5.2 Safety rules ....................................................................................................................
12.5.3 Product identification......................................................................................................
12.5.4 Mechanical installation ...................................................................................................
12.5.5 Electrical installation.......................................................................................................
12.5.6 Technical data................................................................................................................

235
235
235
236
237
237
242

12.6

Cables.........................................................................................................................................
12.6.1 General specification .....................................................................................................
12.6.2 Order key for motor and feedback cables ......................................................................
12.6.3 SEW motors from the “DFS / CFM” range with stopping brake .....................................
12.6.4 Special motor connections .............................................................................................

243
243
244
244
245

12.7

Motor chokes AX2090-MD50......................................................................................................
12.7.1 Electrical connection ......................................................................................................
12.7.2 Technical data................................................................................................................
12.7.3 Installation of the motor choke AX2090-MD50-0012 .....................................................
12.7.4 Dimensions ....................................................................................................................

246
246
246
248
250

12.8

Mains choke AX2090-ND50 ....................................................................................................... 252
12.8.1 Technical data................................................................................................................ 252
12.8.2 Installing the mains chokes ............................................................................................ 252

12.9

Mains filter - AX2090-NF50 ........................................................................................................ 254

Servo Drives AX5000

Version: 2.4

Table of contents
12.9.1 Technical data................................................................................................................ 254
12.9.2 Installing the mains filter ................................................................................................ 254
12.10 Transient voltage suppressor - AX2090-TS50............................................................................
12.10.1 Guidelines and Standards..............................................................................................
12.10.2 Technical data................................................................................................................
12.10.3 Installation of the transient box ......................................................................................

257
257
258
259

13 Appendix ................................................................................................................................................ 261
13.1

Error management......................................................................................................................
13.1.1 General ..........................................................................................................................
13.1.2 Requirement...................................................................................................................
13.1.3 Parameterization ............................................................................................................
13.1.4 SyncUnit diagnostics......................................................................................................
13.1.5 Reinitialization, troubleshooting and reset .....................................................................

261
261
261
261
262
263

13.2

Firmware Update ........................................................................................................................ 263
13.2.1 Firmware version on the AX5000................................................................................... 263
13.2.2 Update to a new firmware version ................................................................................. 264

14 Support and Service.............................................................................................................................. 266

Version: 2.4

Servo Drives AX5000

Foreword

2.1

Notes on the documentation

This description is only intended for the use of trained specialists in control and automation engineering who
are familiar with the applicable national standards.
It is essential that the documentation and the following notes and explanations are followed when installing
and commissioning the components.
It is the duty of the technical personnel to use the documentation published at the respective time of each
installation and commissioning.
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.
Disclaimer
The documentation has been prepared with care. The products described are, however, constantly under
development.
We reserve the right to revise and change the documentation at any time and without prior announcement.
No claims for the modification of products that have already been supplied may be made on the basis of the
data, diagrams and descriptions in this documentation.
Trademarks
Beckhoff®, TwinCAT®, EtherCAT®, Safety over EtherCAT®, TwinSAFE®, XFC® and XTS® 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.
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.

EtherCAT® is registered trademark and patented technology, licensed by Beckhoff Automation GmbH,
Germany
Copyright
© Beckhoff Automation GmbH & Co. KG, Germany.
The reproduction, distribution and utilization of this document as well as the communication of its contents 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.

Servo Drives AX5000

Version: 2.4

Foreword

2.2

Documentation issue status

This documentation specifically refers to AX5000 hardware version 2
Version
2.4

Comment
Chapter update:
Disposal 5.2
New chapter:
EU Declaration of Conformity 3.1

2.3

2.2

Delete chapter:
EU Conformity 3.1 (see: „New Chapter“); Electromagnetic compatibility 3.2; Asynchronous
motors – Special functions 10.8
Chapter update:
Name plate 6.2; Permissible ambient and operating conditions 7.2.1; Rotational encoders
9.12.1; OCT 10.7.1; Rotational encoders 9.12.1; External brake resistor 12.5.3; Motor chokes
12.7.1 and 12.7.2
Chapter update:
1.0; 3.0; 6.4 – 6.8; 7.2.2; 7.2.3; 7.2.4; 9.1.3; 9.1.4; 9.3 – 9.7; 9.8.4; 9.11.1; 9.12; 9.14.1;
10.1.6.3; 11.4
New Chapter:
Third party motors 10.1.5

2.1

2.0
1.1

1.0

2.2.1

General update:
Accessoires 12.0; Appendix 13.0
Chapter update:
2.3.1; 7.2.4; 8.2; 9.1.3; 9.1.4; 9.3; 9.12.1; 10.4.1; 10.4.2; 10.5; 12.2.1.1; 12.3.5.3
Delete Chapter:
10.7.2
General update
Chapter update:
9.7.5; 9.8.1; 9.8.4; 14.2.1.1; 14.2.1.2
New chapter:
9.8.2
First published

Scope of the documentation

The overall documentation package for the AX5000 is comprised of the following manuals:
• This system manual
• Function manual
• Description of the drive parameters (S-IDN and P-IDN)
• Description of diagnostic messages
• Description of the TCDriveManager
• Description of the accessories

Version: 2.4

Servo Drives AX5000

Foreword

2.3

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 components.

Caution - Risk of injury!

WARNING

Electronic equipment is not fail-safe. The machine manufacturer is responsible for ensuring
that the connected motors and the machine are brought into a safe 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" chapter.

Servo Drives AX5000

Version: 2.4

Foreword

2.3.1

Dual Use (EU 1382/2014)

According to EU Regulation 1382/2014 (published on 30.12.2014), standard frequency converters, including
the Beckhoff AX5000 product range, are now classified as dual-use products. The list of goods in Annex I of
Dual-Use Regulation 428/2009 was amended accordingly; frequency converters (listed under item 3A225)
with an "operating frequency greater than or equal to 600 Hz" are now subject to export control. Note the
following changes.
Firmware versions without the supplement (Dual Use compliant) can only be operated on the following
devices, taking into account the hardware versions:
• HW Version 1.0 (AX5xxx-0000-00xx): serial number < 68.000
• HW Version 1.0 (AX5xxx-0000-001x)
• HW Version 2.0 (AX5xxx-0000-02xx): serial number < 140.000
• HW Version 2.0 (AX5xxx-0000-021x)
Firmware versions with the supplement (Dual Use compliant) can continue to be operated on all devices,
irrespective of the hardware versions. These versions support both rotary field frequency ranges (< 600 Hz,
>= 600 Hz), depending on the device.
Devices with optional ID “001x” and "021x": shipping as individual part may require official approval.

Version: 2.4

Servo Drives AX5000

Guidelines and Standards

3.1

EC declaration of conformity

We,
Beckhoff Automation GmbH & Co. KG
Hülshorstweg 20
33415 Verl
Germany
hereby declare, under our sole responsibility, that the product range
Digital Compact AX5000 servo drive
(Types AX510x, AX511x, AX5125, AX5140; AX520x, AX5160, AX5172, AX519x).
The modules named here have been developed, designed and manufactured in accordance with the Low
Voltage Directives 2006/95/EC (until 19/04/2016) and 2014/35/EC (from 20/04/2016) as well as the EMC
Directives 2004/108/EC (until 19/04/2016) and 2015/30/EC (from 20/04/2016). They meet the requirements
of RoHS Directive 2011/65/EU.
The following standards were applied:
• Generic standard: EN 6100-6-2:2005
(Interference immunity for the industrial area)
• Generic standard: EN 61000-6-4:2007+A1:2011
(Interference emission for the industrial area)
• Product standard: EN 61800-3:2004+A1:2012
(Adjustable speed electrical drives - EMC requirements and specific test methods).
• Product standard: EN 61800-5-1:2007
(Adjustable speed electrical power drive systems - Safety requirements)
• RoHS: EN50581:2012
(Technical documentation for the assessment of electrical and electronic products with respect to the
restriction of hazardous substances)
Attachment of the CE marking:
2016
Issued by:
Management
H. Beckhoff
Verl, 17/07/2017

Servo Drives AX5000

Version: 2.4

Guidelines and Standards

3.2

UL approval for devices up to 40 A for the US and
Canada
The German translation of this section is intended for information only!
The English version of this section is binding.

The following servo drives from the AX5000 series have a UL-Listing and must bear the CUS symbol
AX5000 with UL approval
AX5101, AX5103, AX5106, AX5112, AX5118, AX5125, AX5140, AX5201, AX5203 and
AX5206.
on the name plate. If you intend to operate an AX5000 in the US or Canada, please check whether the name
plate shows the CUS label.
Below is a list of the relevant chapters that are amended with respect to the UL-Listing. Furthermore, ULspecific remarks are listed.

3.2.1

UL-specific chapter changes

“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.

“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.

Version: 2.4

Servo Drives AX5000

Guidelines and Standards

3.2.2

UL-specific chapter

AC-supply (max.) *)
24 V-supply (max.)
Brake resistor

AX5101
6A

AX5103
12 A

AX5106 AX5201
20 A
12 A
3A
electronic

AX5203
20 A

AX5206
20 A

AX5101
6A

AX5103
12 A

AX5106 AX5112
20 A
20 A
3 AT
electronic

AX5118
35 A

AX5125
45 A

AX5140
80 A

AX5201
12 A

AX5203 AX5206
20 A
20 A
3 AT
electronic

*) Mains fuses according to type “RK5” must be used.
Three-phase:

AC-supply (max.) *)
24 V-supply (max.)
Brake resistor

*) Mains fuses according to type “RK5” must be used.

When protected by RK5 class fuses:
AX5112:
Rated 20 A, min. 480 V
AX5118:
Rated 35 A, min. 480 V
AX5125:
Rated 45 A, min. 480 V
AX5140:
Rated 80 A, min. 480 V

Servo Drives AX5000

Version: 2.4

Guidelines and Standards

3.2.3

UL-specific notes

Use in a Pollution Degree 2 environment
Use 75 °C Copper Conductors min.
Control Board rating = 24 V
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-TS50-3000, manufactured by Beckhoff Automation.

3.3

UL approval for devices above 60A for the US and
Canada
The German translation of this section is intended for information only!
The English version of this section is binding.

The following servo drives from the AX5000 series have a UL-Listing and must bear the CUS symbol
AX5000 with UL approval
AX5160, AX5172, AX5190, AX5191, AX5192 and AX5193.
on the name plate. If you intend to operate an AX5000 in the US or Canada, please check whether the name
plate shows the CUS label.
Below is a list of the relevant chapters that are amended with respect to the UL-Listing. Furthermore, ULspecific remarks are listed.

3.3.1

UL-specific chapter changes

“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.

“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.

Version: 2.4

Servo Drives AX5000

Guidelines and Standards

3.3.2

UL-specific chapter

“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 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.
AX5160
AC-supply (max.) *)
24 V-supply (max.)
Brake resistor

AX5172

AX5190

AX5191

4 AT

AX5192

AX5193

10 AT
electronic

*) Mains fuses according to type “RK5” min. 480 V must be used.

3.3.3

UL-specific notes

Canada!
In Canada use only in combination with unit AX2090-TS50-3000, manufactured by Beckhoff Automation.

3.4

Electrical isolation according to EN 50178 / VDE 0160

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.

Servo Drives AX5000

Version: 2.4

Safety

4.1

Safety instructions

Safety regulations
Please note the following safety instructions and explanations!
Product-specific safety instructions can be found on following pages or in the areas mounting, wiring,
commissioning etc.
Exclusion of liability
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 & Co. KG.
Personnel qualification
This description is only intended for trained specialists in control, automation and drive engineering who are
familiar with the applicable national standards.
Description of symbols
In this documentation the following symbols are used with an accompanying safety instruction or note. The
safety instructions must be read carefully and followed without fail!

Serious risk of injury!
Failure to follow the safety instructions associated with this symbol directly endangers the
life and health of persons.
DANGER

Risk of injury!
Failure to follow the safety instructions associated with this symbol endangers the life and
health of persons.
WARNING

Personal injuries!
Failure to follow the safety instructions associated with this symbol can lead to injuries to
persons.
CAUTION

Damage to the environment or devices
Failure to follow the instructions associated with this symbol can lead to damage to the environment or equipment.
Attention

Tip or pointer
This symbol indicates information that contributes to better understanding.
Note

UL pointer
This symbol indicates important information about the UL-compliant.

Version: 2.4

Servo Drives AX5000

Safety

4.2

Special safety notes for servo drives

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.

Serious risk of injury through high electrical voltage!

WARNING

• Never open the servo drive when it is live. Wait until the DC link capacitors are discharged. The measured voltage between the terminals "DC+ and DC-" and "RB+ and
RB-" must have dropped below 50 V. Opening the device (with the exception of expansion card slots) invalidates all warranty and liability claims against Beckhoff Automation
GmbH & Co. KG.
• 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 > 50 V.
• Due to the DC link capacitors, the DC link terminal points "ZK+ and ZK- (DC+ and
DC-)" and "RB+ and RB-" may be subject to dangerous voltages exceeding 875 VDC,
even after the servo drive was disconnected from the mains supply. Wait 5 minutes for
the AX5101 - AX5125 and AX520x; 15 minutes for the AX5140/AX5160/AX5172; 30
minutes for the AX5190/AX5191; 45 minutes for the AX5192/AX5193 after disconnecting, and measure the voltage at the DC link terminal points "ZK+ and ZK- (DC+ and
DC-)". The device is safe once the voltage has fallen below 50 V.

Serious risk of injury through hot surfaces!
• The surface temperature may exceed 50 °C, resulting in a risk of burns.
WARNING

• Avoid touching the housing during or shortly after operation.
• Leave the servo drive to cool down for at least 15 minutes after it is switched off.
• Use a thermometer to check whether the surface has cooled down sufficiently.

High risk of injury through uncontrolled movements!
• Read and take note of chapter "Important information for commissioning" each time before commissioning the AX5000
WARNING

Personal injuries

CAUTION

• Carefully read this manual before using the servo drive thoroughly, 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 harmonized standards and regulations required for
implementation of this Directive in national legislation.

Servo Drives AX5000

Version: 2.4

Safety

Damage to the environment or devices

Attention

• 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 contaminated 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:
ð Please ensure you are electrostatically discharged before touching the servo drive
directly.
ð Avoid contact with highly insulating materials (synthetic fibers, plastic film etc.).
ð Place the servo drive on a conductive surface.
ð Do not touch the motor connector while the AX5000 is in operation.

Version: 2.4

Servo Drives AX5000

Handling

5.1

Transport and storage

Transport
• Only by qualified personnel
• Only in recyclable original manufacturer's packaging
• Avoid sharp impacts
• Temperature: -40...+70°C, varying no faster than 20K / hour
• Air humidity: relative humidity max. 95%, non-condensing
• 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 fibers, plastic film etc.).
- Place the servo drive on a conductive surface.
• If the packaging is damaged, check the uprighter and any included accessories for visible damage.
Inform the transport company and, if necessary, the manufacturer.
Storage
• The AX5000 and its accessories must not be stored outdoors. The storage space must be adequately
ventilated and dry.
• The devices must be stored in the recyclable original manufacturer's packaging.
• 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 fibers, plastic film etc.).
- Place the servo drive on a conductive surface.
• Max. stack height 8 cartons
• Storage temperature: - 40...+ 55° C, varying no faster than 20 K / hour
• Air humidity: relative humidity max. 95%, non-condensing
• Storage time:
< 5 years: without limitation

Destruction of the equipment

Attention

On no account must the device be connected to 400 V if the DC link capacitors have lost
their forming.
The capacitors must be reformed (see below).

> 5 years: The dielectric (an oxidation layer with a thickness of approx. 1 µ) in the DC link capacitors
degrades over time, and the capacitors lose their forming.
Prior to commissioning of the servo drive the capacitors must be reformed. Release all electrical
connections and feed the servo drive for about 30 minutes with 230 VAC (single-phase) at terminals L1/L2 or
L2/L3.
Packaging
• Recyclable carton with inserts
• Dimensions:
(H x W x D) 348 x 324 x 175 mm
Identification: Device name plate on the outside of the carton

5.2

Maintenance

• The devices are maintenance-free
Servo Drives AX5000

Version: 2.4

Handling
• Opening the devices invalidates the warranty

5.3

Cleaning

• Soiled housing: Clean with isopropanol or similar
Do not immerse or spray!
• Contamination inside the device: Cleaning by the manufacturer
• Soiled fan guard: Clean with (dry) brush

5.4

Disposal

• Screw connections enable the servo drives to be dismantled into main components (aluminum heat
sink, steel cases, PCBs)
• The device should be disposed of by a certified disposal company. You can obtain addresses from us.
Housing components (polycarbonate, polyamide (PA6.6)) are suitable for plastic recycling.
• Metal parts can be sent for metal recycling.
• Electronic parts such as circuit boards and terminals must be disposed of in accordance with national
electronics scrap regulations.
In accordance with the WEEE 2012/96/EG Directives we take old devices and accessories back for
professional disposal, provided the transport costs are taken over by the sender.
Send the devices with the note “For disposal” to:
Beckhoff Automation GmbH & Co. KG
Huelshorstweg 20
D-33415 Verl

Version: 2.4

Servo Drives AX5000

Product overview

6.1

Scope of supply

The AX5000 is supplied as follows:
• AX5000 in the performance class according to the order
• Connector
X01: for mains input
X02: for DC link (not for AX5140)
X03: for DC power supply (24 V)
X06: for digital inputs and outputs
X07: external brake resistor (only AX5140)
• Quick reference guide (Startup)
• Documentation on CD-ROM

Connector

Note

6.2

The D-SUB connectors X11, X12, X21, X22 (for feedback cable and resolver/Hall) and the
motor and sensor connectors X13, X14, X23, X24 are not part of the scope of delivery of
the servo drive. However, they are included with pre-assembled motor and feedback cables.

Name plate

The servo drive features two name plates.
• Large name plate:
• Small name plate:

Servo Drives AX5000

The large name plate attached at the side of the servo drive and includes
the following information:
The second name plate is attached to the upper mounting flange
mounted and is designed to show the main, even if several AX5000 are
installed directly side by side. The small name plate contains the
following information.

Version: 2.4

Product overview

1
2
3

Order number
Max. ambient temperature
Rated input voltage

7
8
9

Rated output current
Output frequency range
Barcode

13
14
15

4
5
6

Rated input current
Input frequency
Rated output voltage

10
11
12

Protection class
EAC compliant
cULus approval

16
17

Version: 2.4

EtherCAT compliant
CE compliant
Standard mains supply with
earthed center
Customer-specific
Serial number

Servo Drives AX5000

Product overview

6.3

Type key

Servo Drives AX5000

Version: 2.4

Product overview

6.4

Image showing AX5101 - AX5112 and AX520x

The servo drive shown below is a two-channel device designed for a maximum current of 12 A. Components
that are only available for the second channel are identified in the item description.
Item descriptions:
No.
1
2
3
4
5
6
7
8
9
10
11
12
13
14
15
16

18
19
20
21
22

Name
X11 - feedback connection, encoder
X12 - feedback connection, resolver
X21 - feedback connection, encoder
channel B (only for two-channel unit)
X22 - feedback connection, resolver
channel B (only for two-channel unit)
X3x - optional slot for safety card
X4x - optional slot for expansion cards
Navigation rocker
Status LED for EtherCAT output
Labelling field
X05 - socket for EtherCAT output
X03 - power supply 24 V DC input
X14 – sensor for motor temperature, brake and OCT
X24 – sensor for motor temperature, brake and OCT
channel B (only for two-channel unit)
X23 - motor connection (U, V, W, PE)
channel B (only for two-channel unit)
X13 - motor connection (U, V, W, PE)
X01 - mains supply 100 - 480 V
X02 - DC link output
(max. voltage 875 V DC)
Connection for the external brake resistor
Max. voltage 875 V DC at the DC link
terminal points (X02). Once the device
has been switched off dangerous
voltage will still be present for a
further 5 minutes. The device is safe
DANGER
once the voltage has fallen below 50
V.
X04 - socket for EtherCAT input
Labelling field
Status LED for EtherCAT input
Display
X06 - connection for digital inputs and outputs

Version: 2.4

Servo Drives AX5000

Product overview

6.5

Image showing AX5118, AX5125 and AX5140

The servo drive illustrated below is an AX5140; the devices with 18 A or 25 A are structurally similar apart
from pos. 11 "X07" (external brake resistor).

Pos.
1
2
3
4

5
6
7
8
9

Name
X11 - feedback connection, encoder
X12 - feedback connection, resolver
X3x - optional slot for safety card
X4x - optional slot for expansion cards
Navigation rocker

Pos.
11
12
13

Name
X07 - external brake resistor (only AX5140)
X13 - motor connection (U, V, W, PE)
X01 - mains supply 100 - 480 V

Status LED for EtherCAT output
Labelling field
X05 - socket for EtherCAT output
X03 - power supply 24 V DC input
Max. voltage 875 V DC at
the DC link terminals
(X02). Dangerous voltage
continues to be present for
around 5 minutes after the
DANGER
device has been switched
off (AX5140 = 15 min.).
The device is safe once the
voltage has fallen below 50
V.
X14 – sensor for motor temperature, brake
and OCT

15
16
17
18
19

X02 – DC link output (max. voltage 875 V DC),
connection for external brake resistor (only
AX5118 and AX5125)
X04 - socket for EtherCAT input
Labelling field
Status LED for EtherCAT input
Display
X06 - connection for digital inputs and outputs

Servo Drives AX5000

Version: 2.4

Product overview

6.6

Image showing AX5160 - AX5172

The servo drive shown below is a AX5172; the AX5160 is identical.

Item descriptions:
No.
1
2
3
4
5
6
7
8

Name
X4x - optional slot for expansion cards
X3x - optional slot for safety card
X12 - feedback connection, encoder
X06 - connection for digital inputs and
outputs
Navigation rocker
Labelling field
X05 - socket for EtherCAT output
X03 - power supply 24 V DC input

No.
9
10
11
12

Name
X01 – mains supply 400 V – 480 V
X11 - feedback connection, resolver
Display
Labelling field

13
14
15

X04 - socket for EtherCAT input
X14 - sensor for motor temperature and brake
Connection for the external brake resistor DC link
output (875 V DC voltage). Motor connection (U, V, W,
PE)

Serious risk of injury through high electrical voltage!

DANGER

Due to the DC link capacitors, the DC link terminal points "DC+ and DC-" and "RB+ and
RB-" may be subject to dangerous voltages exceeding 875 VDC, even after the servo drive
was disconnected from the mains supply.
After disconnection, wait for 15 minutes (AX5160/AX5172), 30 minutes (AX5190/AX5191)
or 45 minutes (AX5192/AX5193) and measure the voltage at the DC link-terminal points
DC+ and DC-. The device is safe once the voltage has fallen below 50 V.

Version: 2.4

Servo Drives AX5000

Product overview

6.7

Image showing AX5190 - AX5191

The servo drive shown below is a AX5190; the AX5191 is identical.

Item descriptions:
No. Name
1
X4x - optional slot for expansion cards
2
X3x - optional slot for safety card
3
4
5
6
7
8

X12 - feedback connection, encoder
X06 - connection for digital inputs and outputs
Navigation rocker
Labelling field
X05 - socket for EtherCAT output
X03 - power supply 24 V DC input

No. Name
9 X14 - sensor for motor temperature and brake
10 DC link output (875 V DC voltage), connection for
the external brake resistor
11 Motor connection (U, V, W, PE)
12 X04 - socket for EtherCAT input
13 Labelling field
14 Display
15 X11 - feedback connection, resolver
16 X01 - mains supply

Serious risk of injury through high electrical voltage!

DANGER

Servo Drives AX5000

Version: 2.4

Product overview

6.8

Image showing AX5192 - AX5193

The servo drive shown below is a AX5192; the AX5193 is identical.

Item descriptions:
No.
1
2
3
4
5
6
7
8

Name
X4x - optional slot for expansion cards
X3x - optional slot for safety card
X12 - feedback connection, encoder
X06 - connection for digital inputs and outputs
Navigation rocker
Labelling field
X05 - socket for EtherCAT output
X03 - power supply 24 V DC input

No.
9
10
11
12
13
14
15
16
17

Name
X14 - sensor for motor temperature and brake
X07 – external brake resistor
DC link output (875 V DC voltage).
Motor connection (U, V, W, PE)
X04 - socket for EtherCAT input
Labelling field
Display
X11 - feedback connection, resolver
X01 – mains supply 400 V – 480 V

Serious risk of injury through high electrical voltage!

DANGER

Version: 2.4

Servo Drives AX5000

Technical description

7.1

Configuration of the servo drives

The servo drives of the AX5000 series are available as single- or multi-channel versions and are optimized in
terms of function and cost-effectiveness. Integrated control technology supports fast and highly dynamic
positioning tasks. EtherCAT as a high-performance system communication enables ideal interfacing with PCbased control technology.
The single-channel AX51xx servo drives are designed for rated motor currents up to 170 A.
The AX52xx two-channel servo drive enables operation of two motors with identical or even with different
capacity, up to a total current of 12 A. The multi-axis drives with variable motor output allocation optimize
packaging density and the cost per drive channel.
The AX5000 system enables simple and fast connection of several AX5000 devices to form a multi-axis
system through the AX-Bridge quick connection system. The pluggable supply and connection module
combines power supply, DC link, and control (24 VDC) and braking voltage.
A wide range of motor types can be connected to the AX5000. Motors of different size and type can be
connected without additional measures. Examples include synchronous, linear, torque and asynchronous
motors. The multi-feedback interface supports all common feedback standards.
such as: OCT, BiSS, EnDat, 1 Vss, Resolver.
The AX5000 was developed specifically for the EtherCAT real-time Ethernet system. The outstanding
features of EtherCAT are particularly beneficial for drive technology. They include short cycle time,
synchronicity and simultaneity. EtherCAT enables very short cycle times, even in networks containing a large
number of devices.

Servo Drives AX5000

Version: 2.4

Technical description

7.2

General technical data
UL approval
If you intend to operate an AX5000 in a region that requires UL approval, please refer to
the chapter "Guidelines and Standards".

7.2.1

Permissible ambient and operating conditions

Technical data
Ambient temperature during operation

Ambient temperature during transport
Ambient temperature during storage
Air humidity
Level of contamination
Corrosion protection

Operating altitude

Permissible installation position
Ventilation
Protection class
Vibration test (EN 60068-2-6)

Shock test (EN 60068-2-27)

EMC
Approvals
Special operating conditions

AX5000
0 °C to +50 °C (1.5 A – 40 A devices)
0 °C to +40 °C (60 A – 170 A devices), up to 55 °C with power
derating (2% / °C)
-25 °C to +70 °C
-25 °C to +70 °C (1.5 A – 40 A devices)
-25 °C to +55 °C (60 A – 170 A devices)
5% to 95%, non-condensing (1.5 A – 40 A units)
5% to 85 %, non-condensing (60 A – 170 A units)
Contamination level 2 according to EN 60204 / EN 50178
Normally not required.
Under extreme operating conditions, special measures must be
agreed with the manufacturer, and implemented by the user.
up to 1000 m above sea level without restrictions
60 A to 170 A devices – from 1000 m up to 3000 m above sea
level with power derating (1.5% per 100 m)
vertical
Total rated device current ≤3 A: free convection,
Total rated device current >3 A: built-in temperature-controlled fan
IP20
Frequency range: 10 - 500 Hz
Amplitude: 10 - 58 Hz = 0.075mm pk-pk
59 - 500 Hz = 1 g
Half sine wave amplitude: 5 g
Duration: 30 ms
Number of shocks: 3 per axis and direction (total 18)
Half sine wave amplitude: 5 g
Duration: 30 ms
Number of shocks: 1000 per axis and direction (total 6000)
Category C3 - standard
Category C1, C2 - auxiliary filter required
CE
The usability of Beckhoff servo drives from the AX5000 series
under harsh operating conditions or other unfavorable conditions
must be ascertained individually in consultation between the
manufacturer and the user.

Version: 2.4

Servo Drives AX5000

Technical description

7.2.2

Electrical data - servo drive (AX5101 - AX5140)

Single-phase connection
Technical data
Rated output current
Minimum rated channel current at full current resolution
Peak output current 1)
Rated supply voltage
Max. DC link voltage
Rated apparent power S1 operation (selection)
120 V
230 V
Power loss 2)
Continuous braking power (internal brake resistor)
Max. braking power (internal brake resistor)
Min. brake resistance (external brake resistor)
Max. braking power (external brake resistor)
DC link capacity
1)
2)

AX5101
AX5103
AX5106
1.5 A
3A
4.5 A
0.35 A
1A
1A
4.5 A
7.5 A
13 A
1 x 100-10% - 240+10% VAC
875 VDC
0.3 kVA
0.6 kVA
35 W
50 W

0.6 kVA
1.2 kVA
50 W
50 W
14 kW
47 Ω
15 kW
235 µF

1.2 kVA
2.4 kVA
85 W
150 W

Ieff for max. 7 s, by switching frequency of 8 kHz (IDN P-0-0001)
S1 mode, including power supply unit, without brake chopper

Three-phase connection
Electrical data
Rated output current
Minimum rated channel current at
full current resolution
Peak output current 3)
Rated supply voltage
Max. DC link voltage
Rated apparent power S1 operation
(selection)
120 V
230 V
400 V
480 V
Power loss 5)
Max. continuous braking power
(internal brake resistor)
Braking power (internal brake
resistor)
Min. brake resistance (external
brake resistor)
Max. braking power (external
brake resistor)
DC link capacity

AX5101
1.5 A
0.35 A

AX5103 AX5106 AX5112 AX5118
3A
6A
12 A
18 A
1A
1A
6A
12 A

4.5 A

7.5 A

0.3 kVA
0.6 kVA
1.0 kVA
1.2 kVA
35 W
50 W

0.6 kVA
1.2 kVA
2.1 kVA
2.5 kVA
50 W
50 W

13 A
26 A
36 A
3 x 100-10% - 480+10% VAC2)
875 VDC

1.2 kVA
2.4 kVA
4.2 kVA
5.0 kVA
85 W
150 W

2.5 kVA
4.8 kVA
8.3 kVA
10 kVA
160 W
90 W

14 kW

AX5125
25 A1)
12 A

AX5140
40 A
18 A

50 A

80 A 4)

3.4 kVA 4.8 kVA
7.2 kVA 10 kVA
12.5kVA 17.3 kVA
15 kVA 20.8 kVA
255 W
340 W
200 W
200 W

8.3 kVA
16 kVA
28 kVA
33 kVA
510 W
150 W

26 kW

47 Ω

30 Ω

22 Ω

22 Ω 6)

15 kW

23.5 kW

32 kW

235 µF

470 µF

1175 µF 1485 µF

cULus = 24 A
cULus = AX5118 and AX5125 = 3 x 480 VAC ± 10%
3)
Ieff for max. 7 s, by switching frequency of 8 kHz (IDN P-0-0001)
4)
Ieff for max. 7 s, if rotary field frequency > 3 Hz at max. 40 °C
5)
S1 mode, including power supply unit, without brake chopper
6)
Brake resistor < 22 Ω –> Please consult our support

Servo Drives AX5000

Version: 2.4

Technical description

7.2.3

Electrical data - servo drive (AX52xx)

Single-phase connection
Electrical data
Rated output current / channel
Minimum rated channel current at full current resolution
Maximum rated channel current at full current resolution
Total rated current with full current resolution
Max. peak output current 1)/channel
Peak output current 1) total device current
Rated supply voltage
Max. DC link voltage
Rated apparent power S1 operation (selection)
120 V
230 V
Power loss 2)
Max. continuous braking power (internal brake resistor)
Max. braking power (internal brake resistor)
Min. brake resistance (external brake resistor)
Max. braking power (external brake resistor)
DC link capacity
1)
2)

AX5201
AX5203
AX5206
1.5 A
3A
6A
0.35 A
1A
1A
3A
4.5 A
9A
3A
4.5 A
9A
5A
10 A
13 A
10 A
20 A
26 A
1 x 100-10% - 240+10% VAC
875 VDC
0.6 kVA
1.2 kVA
55 W
50 W

1.2 kVA
2.4 kVA
85 W
150 W
14 kW
47 Ω
15 kW
235 µF

2.5 kVA
4.8 kVA
160 W
90 W

470 µF

Ieff for max. 7 s, by switching frequency of 8 kHz (IDN P-0-0001)
S1 mode, including power supply unit, without brake chopper

Three-phase connection
Electrical data
Rated output current / channel
Minimum rated channel current at full current resolution
Maximum rated channel current at full current resolution
Total rated current with full current resolution
Max. peak output current (1)/channel
Peak output current (1) total device current
Rated supply voltage
Max. DC link voltage
Rated apparent power S1 operation (selection)
120 V
230 V
400 V
480 V
Power loss (2)
Max. continuous braking power (internal brake resistor)
Max. braking power (internal brake resistor)
Min. brake resistance (external brake resistor)
Max. braking power (external brake resistor)
DC link capacity
1)
2)

AX5201
AX5203
AX5206
1.5 A
3A
6A
0.35 A
1A
1A
3A
6A
9A
3A
6A
12 A
5A
10 A
13 A
10 A
20 A
26 A
3 x 100-10% - 480+10% VAC
875 VDC
0.6 kVA
1.2 kVA
2.1 kVA
2.5 kVA
55 W
50 W

1.2 kVA
2.4 kVA
4.2 kVA
5.0 kVA
85 W
150 W
14 kW
47 Ω
15 kW
235 µF

2.5 kVA
4.8 kVA
8.3 kVA
10.0 kVA
160 W
90 W

470 µF

Ieff for max. 7 s, by switching frequency of 8 kHz (IDN P-0-0001)
S1 mode, including power supply unit, without brake chopper

Version: 2.4

Servo Drives AX5000

Technical description

7.2.4

Electrical data - servo drive (AX5160 - AX5193)

Electrical data
Rated output current1)
Minimum rated motor current at
full current resolution
Peak output current2)
Rated supply voltage
Max. DC link voltage
Rated apparent power S1 operation
(selection)
400 V
480 V
Power loss3)
Min. brake resistor
(external brake resistor)
Max. braking power
(external brake resistor)
Continuous braking power5)
Mains chokes4) AX2090-ND50
Mains filters4) AX2090-NF50
DC link capacity
1)

AX5160
60 A
25 A

AX5172
72 A
40 A

1202) A

1442) A

42 kVA
45 kVA
830 W
13 Ω

50 kVA
54 kVA
1010 W
13 Ω

62 kVA
67 kVA
1300 W
10 Ω

76 kVA
82 kVA
1600 W
10 Ω

99 kVA
107 kVA
2100 W
6.5 Ω

118 kVA
127 kVA
2500 W
6.5 Ω

52 kW

67 kW

103 kW

56 kW
0090
0100
1060 µF

65 kW
0110
0150
2120 µF

65 kW
0143
0150
3180 µF

65 kW
0170
0180
4240 µF

37 kW
52 kW
----integrated integrated
900 µF

AX5190
90 A
50 A

AX5191
110 A
60 A

AX5192
143 A
70 A

AX5193
170 A
80 A

1802) A
1802) A
2152) A
3x 400-10% – 480+10% VAC
875 VDC

2212) A

With a rated supply voltage of 480 V, the rated current must be reduced by 10%.

The specified values apply for an initial rotational frequency > 3 Hz
2)

Ieff for max. 3 s with a preload of max. 70% of the rated output current, a mains voltage of 400 VAC and a
switching frequency by 8 kHz (P-0-0001).
3)
S1 mode, including power supply unit, without brake chopper
4)
Required for compliance with EN 61800-3 (EMC product standard) C3 (industrial environment) with max. 25
m motor cable length.
5)
Based on a mains voltage of 3 x 400 Veff and a frequency of 8 kHz.

Derating and switching frequency of the servo drive!

Note

For further information of the Derating and the switching frequency from the servo drive
AX5000, please look at the english version of the IDN-Description (P-0-0001 Switching frequency of the IGBT module).

Servo Drives AX5000

Version: 2.4

Technical description

7.2.5

Mechanical data - servo drive (AX5101-AX5140)

Mechanical data
Weight
Width
Height without plugs
Depth without connectors /
accessories

7.2.6

AX5101 AX5103 AX5106 AX5112 AX5118
AX5125
AX5140
approx. 4 approx. approx. approx. approx. 11 approx. 11 approx. 13
kg
4 kg
5 kg
5 kg
kg
kg
kg
92 mm
185 mm
185 mm
185 mm
274 mm
232 mm

Mechanical data - servo drive (AX52xx)

Mechanical data
Weight
Width
Height without plugs
Depth without connectors / accessories

7.2.7

AX5203
approx. 6 kg
92 mm
274 mm
232 mm

AX5206
approx. 6 kg

Mechanical data - servo drive (AX5160 - AX5193)

Mechanical data
Weight
Width
Height without plugs
Depth without connectors /
accessories

AX5201
approx. 5 kg

AX5160
AX5172
AX5190
AX5191
AX5192
AX5193
approx. 14 approx. 14 approx. 31 approx. 31 approx. 38 approx. 38
kg
kg
kg
kg
kg
kg
190 mm
283 mm
283 mm
345 mm
540 mm
259 mm
253 mm
334 mm

Version: 2.4

Servo Drives AX5000

Technical description

7.3

Dimensions

7.3.1

AX5000 as single device (1.5 A - 40 A)

All dimensions in millimeters.
AX5118 / AX5125 / AX5140

AX5101-AX5112 / AX5201-AX5206
5
6.

Servo Drives AX5000

153
185

299.2
8

317.2

299
8,2

317.2

6.5

Version: 2.4

60
92

Technical description

7.3.2

AX5000 as single device (60 A - 170 A)

The specified measurements relate to the actual device, without connectors and cables.
AX5160, AX5172, AX5190, AX5191, AX5192, AX5193

AX
5160
5172
5190
5191
5192
5193

A
B
C
[mm] [mm] [mm]
158
190
380
158
190
380
200
280
582
200
280
582
200
280
575
200
280
575

C1
[mm]
8
8
10
10
10
10

D [mm]
6.5
6.5
9
9
9
9

H
[mm]
345
345
540
540
540
540

H1
[mm]
398
398
603
603
600
600

Version: 2.4

H2
[mm]
16.5
16.5
10
10
20
20

T
[mm]
259
259
254
254
335
335

Fastening screws
4 x M5
4 x M5
4 x M8
4 x M8
4 x M8
4 x M8

Servo Drives AX5000

Technical description

7.4

Properties

• High-speed EtherCAT system communication
• Wide voltage range: 1 x 100-10% VAC - 1 x 240+10% VAC … 3 x 100-10%VAC - 3 x 480+10% VAC
• Multi-feedback interface
• flexible motor type selection
• scalable wide range motor current measurement
• High-speed capture inputs
• Diagnostic and parameter display
• integrated mains filter
• Optional safety functions: restart lock, intelligent TwinSAFE safety functions
• compact design for simple control cabinet installation
• AX-Bridge - the quick connection system for power supply, DC link and control voltage
The integrated, fast AX5000 control technology with a current control cycle of up to 62.5 µs supports fast and
highly dynamic positioning tasks. The drives are designed as single- or two-channel servo drives:
• AX51xx: single-channel servo drive
rated motor current: 1 A, 3 A, 6 A, 12 A, 18 A, 25 A, 40 A, 60 A, 72 A, 90 A, 110 A, 143 A, 170 A
• AX52xx: two-channel servo drive
rated motor current: 2 x 1 A, 2 x 3 A, 2 x 6 A (with flexible allocation of total device current on both
axes)
The 2-channel servo drives with variable motor output allocation enable operation of two motors with
identical or even with different capacity on a single servo drive. For example, an asynchronous motor with a
rated current of 1 A and a linear motor with a rated current of 9 A can be operated with a servo drive with two
6 A channels. The total current is relevant for the device utilization.
The AX Bridge (only up to AX5140) enables convenient and fast connection of several servo drives of the
AX5000 series to form a drive system. This pluggable supply and connection module combines power
supply, DC link and control voltage (24 VDC) and enables fast installation and commissioning.
The AX5000 offers flexible and universal connection options. It supports
• almost all feedback systems, including robust resolvers via OCT, sine/cosine encoders with EnDat,
Hiperface or BiSS.
• a wide range of motor types such as asynchronous, synchronous, torque or linear motors.

7.5

Wide voltage range

In order to facilitate worldwide application with different voltage systems, the AX5000 features a wide voltage
range. Virtually any voltage system can be connected with one and the same device, from 1 x 100 VAC - 1 x
240 VAC to 3 x 100 VAC - 3 x 480 VAC. This reduces stock-keeping and prevents destruction through
unsuitable mains voltage. Examples for different mains systems:
• 1 x 100 VAC, 3 x 200 VAC for Asia
• 1 x 115 VAC, 3 x 230 VAC, 3 x 480 VAC for North America
• 1 x 220 VAC, 3 x 380 VAC for China
• 1 x 230 VAC, 3 x 400 VAC for Europe

Servo Drives AX5000

Version: 2.4

Technical description

7.6

Variable motor interface

The AX5000 supports the connection of different motor types, ranging from standard asynchronous motors
to ironless linear motors:
Motor type
Brushless synchronous motors
Torque motors

Operation mode and limits
• Servo mode with feedback
• Multipole servomotors with high torque and
relatively low speed
• Servo mode with feedback
• Servo mode with feedback
• Frequency converter mode without feedback

Linear motors (iron core)
Linear motors (ironless)
Asynchronous motor

• High-frequency spindle up to 60,000 rpm
(only for devices of the AX5xxx-0000-x21x
series "Dual Use [} 12]")
• Servo mode with feedback

7.7

Multi-feedback interface

AX5000 offers interfaces for all common feedback systems. No additional interface cards are required.
Connection options:
• OCT One cable feedback system
• Sine / cosine 1 Vpp
• EnDAT, single- and multi-turn
• Hiperface, single- and multi-turn
• BiSS, single- and multi-turn
• Resolver, 2-pin - 8-pin
• Support for electronic motor name plates

Version: 2.4

Servo Drives AX5000

Mechanical installation

Mechanical installation
Caution - Risk of injury!
• The servo drives may only be installed by trained, qualified personnel. The qualified
personnel must know and comply with the national accident prevention regulations.

WARNING

• Safety boots must be worn.

Caution - Risk of injury through electric shock!
De-energize all electrical components (servo drive, control cabinet, etc.) before commencing the installation or deinstallation.
WARNING

Destruction of the servo drive!
• Always install the servo drive vertically.
• Provide adequate ventilation for the servo drive. The permissible ambient conditions
are specified in the chapter "Technical data".

Attention

• It is essential to adhere to the required distances (see diagrams below).

Installation examples (1.5 A - 40 A devices)

299.2
8

60
92
Cable duct

Servo Drives AX5000

Cable duct
93

5
6.

317.2
Min.100

299.2
8

317.2

Min. 100

Cable duct
93

Min. 100

AX5000 with AX-Bridge

AX5000 without AX-Bridge

Min.100

8.1

60
92
Cable duct

Version: 2.4

Mechanical installation
AX5118 / AX5125 / AX5140 without AX-Bridge

AX5118 / AX5125 / AX5140 with AX-Bridge
186

6,5

Min.100

153
185

Cable duct

Min.200 (AX5140)

317.2

6,5

Min.200 (AX5140)

Min.100

153
185

299

6,5

60
6.5

299
8,2

317.2

6,5

Cable duct
186

8,2

Min. 100

60
6.5

Min. 100

Cable duct

Caution - Risk of injury through electric shock!
The mounting plate must be earthed according to the statutory regulations.
WARNING

Earthing!
Non-compliant earthing of the AX5000 can cause EMC problems.
Attention

Version: 2.4

Servo Drives AX5000

Mechanical installation

8.2

Installation examples (60 A - 170 A devices)

AX
5160 and 5172
5190 and 5191
5192 and 5193

Servo Drives AX5000

F [mm]
≥ 180
≥ 180
≥ 180

E [mm]
20
40
40

Version: 2.4

Mechanical installation
Installation in the control cabinet

G [mm]

M [mm]

H3 [mm]

5160 and 5172

≥ 300

4 x M5

445

5190 and 5191

≥ 300

4 x M8

640

5192 and 5193

≥ 500

4 x M8

640

Caution - Risk of injury through electric shock!
The mounting plate must be earthed according to the statutory regulations. Non-compliant
earthing of the AX5000 can cause EMC problems.
WARNING
Installation of the shield (optional)
AX5160 and AX5172
Preparing for installation

Shroud mounting
1.) The threaded holes (1) for
mounting of the shroud, are in
the delivery state of the servo
drive AX5160 / AX5172, not fitted with screws.
Check before mounting the
shroud, if the threaded holes are
free of Dirt.

2.) Position the shroud.
3.) Mounted the shroud with the
screws (2). Use for mounting
only the screws of the shroud
set. The screws are included in
the shroud set.
4.) Connect the wires to the terminals provided. Attach the
shield by the tabs.

Shroud set for AX5160 and AX5172 consisting of shroud and mounting screws (2 x M4 x 10).

Version: 2.4

Servo Drives AX5000

Mechanical installation
AX5190 and AX5191
Preparing for installation

Shroud mounting
1.) Remove the 2 pre-mounted
screws.

Shroud set for AX5190 and AX5191 consisting of shroud and mounting screws (2 x M4 x 10).

AX5192 and AX5193
Preparing for installation

Shroud mounting
1.) Remove the 2 pre-mounted
screws.

Shroud set for AX5192 and AX5193 consisting of shroud and mounting screws (2 x M4 x 10).

Servo Drives AX5000

Version: 2.4

Electrical installation

Electrical installation
UL approval
If you intend to operate an AX5000 in a region that requires UL approval, please refer to
the chapter "Guidelines and Standards".

Caution - Risk of injury!
• The servo drives may only be installed by trained, qualified personnel. The qualified
personnel must know and comply with the national accident prevention regulations.
WARNING

• Safety boots must be worn.

Caution – Risk of injury through electric shock!
De-energize all electrical components (servo drive, control cabinet, etc.) before commencing the installation or deinstallation.
WARNING

Serious risk of injury through electric shock!

DANGER

Caution – Risk of injury through electric shock!
• Before installation, wiring and commissioning it is essential to read the section on
"Safety".
WARNING

• Before installing, uninstalling 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.
• 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 AX5000!
• Check the rated voltage and current of the servo drive and the connected motors.
CAUTION

• Once the AX5000 has been disconnected from the mains supply, (emergency off,
mains contactor etc.), wait at least 3 minutes before switching it on again or query the
status of IDN "P-0-0205" (see "IDN description" in the documentation).

Version: 2.4

Servo Drives AX5000

Electrical installation

9.1

Connection of several servo drives to form a drive
system
Destruction of the equipment!

Attention

• The connection sequence of the devices is not arbitrary. The total rated current of the
device must decrease from the power supply. AX5112-AX5106-AX5203-AX5201 = OK
AX5201-AX5112-AX5203 ≠ OK
• All devices in a drive system are always to be disconnected from and reconnected to
the mains supply together (emergency stop, mains contactor etc.).

Danger for persons and equipment
Note the total rated current of the connected devices. According to CE, the current carrying
capacity of the power busbars of the AX Bridge is limited to 85 A.
CAUTION

Destruction of the external brake resistor!
An external brake resistor may not be connected to the X02 terminal point (DC link) in a
drive system. Use an external brake module AX5021 for this.
Attention

Servo Drives AX5000

Version: 2.4

Electrical installation

9.1.1

Connection example - module AX5901 and AX5911 (AX Bridge)

This connection option enables a safe system to be set up very quickly. The modules are attached to plug
contacts X01, X02 and X03, the relevant slides are pushed to the left and screwed tight. According to CE,
the current carrying capacity of the power busbars of the AX Bridge is limited to 85 A.

Risk of injury due to electric shock!
Move all busbar sliders to the left limit stop in order to ensure full current carrying capacity.
Then tighten all screws with a torque of 2.2 Nm.
CAUTION

Personal injuries!

CAUTION

Please ensure that the connection line for the AX5901 supply module is adequately dimensioned. The dimensioning depends on the total rated current and must comply with
EN60204-1. A 3-phase connection must be used if the total rated current exceeds 9 A.

AX52xx

AX51xx

AX52xx

AX5901

AX5911

UP
Us
GND

L1
L2
L3/N
PE

AX5901 (AX520x and AX5101 - AX5125)
Terminal points

Conductor design

L1-L3, PE

solid wire
stranded wire with ferrule
stranded- / multi-wire

Max. conductor crosssection
10 mm2, AWG 7
16 mm2, AWG 5
25 mm2, AWG 3

Tightening torque

Max. conductor crosssection
16 mm2, AWG 5
16 mm2, AWG 5
25 mm2, AWG 3

Tightening torque

2.2 Nm
2.2 Nm
2.2 Nm

AX5902 (AX5140)
Terminal points

Conductor design

L1-L3, PE

solid wire
stranded wire with ferrule
stranded- / multi-wire

Version: 2.4

3.2 ± 0.8 Nm
3.2 ± 0.8 Nm
3.2 ± 0.8 Nm

Servo Drives AX5000

Electrical installation

9.1.2

Connection example - wiring in series without AX bridge

Wire the relevant connections using individual cables.

Damage to persons and devices!

CAUTION

• Please ensure that the final supply network connection cable is adequately dimensioned. The dimensioning depends on the total current and must comply with
EN60204-1.
• To establish a DC link system wire the X02 connections with a suitable cable. Voltages
up to 890 V may be present.
• The connectors are designed for a maximum current of 41 A and a maximum conductor
cross-section of 6 mm².
• Avoid phase reversal between the devices!

AX52xx

AX51xx

AX52xx

UP
US
GND
DC+
DC -

L1
L2
L3/N
PE

No UL drive system!

Note

The following figure shows an AX wiring in series configuration without AX Bridge. To configure a UL drive system, please refer to the information in chapter 9.1.3 "UL drive system –
configuration example".

Servo Drives AX5000

Version: 2.4

Electrical installation

9.1.3

Connection example – DC link group (60 A to 170 A devices)

This connection technique enables you to establish a DC link group for servo drives from the series AX5160
to AX5193
The following illustration shows a possible configuration example.

Key to picture:
F0-n
=
FDC1-DCn =
K0
L0
Z1-n

=
=
=

Mains fuses = UL fuse (480 VAC)
DC link fuses (DC fuses) = UL fuse (700 VAC / 800 VDC)
e.g. ferrule FWP from Cooper-Bussmann
Common mains contactor
Mains choke
Mains filter (optional)

Drive system with UL approval!
Before implementation a DC link group, please contact your UL approval body and discuss
further necessary boundary conditions.
Dimensioning of the UL fuses FDC1-FDCn
The dimensioning of the fusesFDC1 to FDCn in the DC link is application-dependent. The motor and the load
profile are incorporated directly into the calculation. Please consider this when dimensioning.

Fuse holders with UL approval
Note when using UL fuses that the necessary fuse holders also have to carry UL approval.

Version: 2.4

Servo Drives AX5000

Electrical installation
Mains choke
To ensure balancing of all servo drives, a common mains choke (Lo) must be provided. The rated current of
the mains choke must be ≥ the rated current of the common mains fuse (F0) of the drive system (see section
"Mains fuse"). The short-circuit voltage Uk of the mains choke must be 2%
Dimensioning the mains fuse
The following section describes the dimensioning of the mains fuse to be used for individual devices and the
use of mains fuses in the DC link group.
Series AX5160 to AX5193 (60 A to 170 A):
Individual device:
• The main fuse must be dimensioned such that it corresponds to the rated current of the servo drive
multiplied by the correction factor 1.1. The value determined is rounded up to the next larger standard
step (see section Electrical Data [} 35]). If the size of the current (in your application) on the mains side
is known, the mains fuse can also be dimensioned smaller in accordance.
• The cross-section of the mains supply cable must be dimensioned such that the permissible current
load of the cable is ≥ the rated current of the selected mains fuse (see section Motors and Cables
[} 105]).
DC link group:
• The common main fuse (F0) must be dimensioned such that it corresponds to the sum of all the rated
currents of the servo drives multiplied by the correction factor 1.1. The value determined is rounded up
to the next larger standard step (see section dimensioning example). If the size of the current (in your
application) on the mains side is known, the mains fuse (F0) can also be dimensioned smaller in
accordance.
• The cross-section of the mains supply cable must be dimensioned such that the permissible current
load of the cable is ≥ the rated current of the selected mains fuse.
• The cross-section of the mains supply cable and the mains fuses (F1 to Fn) of the individual servo
drives in the DC link group are to be selected analogously to the operation of the individual servo
drives (see section "Individual devices").
The local regulations and the local conditions (ambient temperature, cable routing, etc.) must be referred to
when determining the permissible current load of the cables (selection of the necessary cross-section – see
section Motors and Cables [} 105]).
Dimensioning example:
1 x AX5172
72 A

+
+

2 x AX5192
286 A

Servo Drives AX5000

+
+

1 x AX5193
170 A

= 528 A x 1.1 = 581 A

Version: 2.4

630 A selected

Electrical installation
Mains switch-on conditions:
The mains must be switched through to all servo drives simultaneously. Therefore, use a common mains
contactor (K0) for all servo drives. The phase error detection (grid monitoring) of the servo drives must be
active. Observe the relevant parameterization for this (P-0-0204 Disable Umain monitoring and Umain phase
error detection).
Parameterization P-0-0204:
The default values of the parameter P-0-0204 (Power management control word) are set to:
• Disable Umain monitoring = 0 and
• Umain phase error detection = 1.
In the DC link group the default values of the parameter P-0-0204 are to be checked before commissioning
and set to the above values if discrepancies are found.
Parameterization P-0-0214:
To parameterize an AX5160 to AX5193 DC link group, the following settings must be made in parameter
P-0-0214 (DC link connection mode):
• The value 0x000A sets the servo drives AX5160 to AX5193 to stand-alone mode
• The value 0x000B sets the servo drives AX5160 to AX5193 to DC link group mode
The external brake resistor is activated in both cases.
Mains filter:
If mains filters are used, a separate mains filter must be used for each servo drive. The mains filter must be
positioned as close to the servo drive as possible. Use short cables without loops.
A suitable shield connection is ensured by adhering to the following points:
• The mounting plate must not be painted. The shield is automatically connected via the mounting plate.
• If the mounting plate is painted, the shield must be connected via the underside of the servo drive
(earthing bolt).
Max. cable sizes accepted by the connecting terminals:
The maximum cable cross-sections are dictated by the maximum cable sizes that can be accepted by the
connecting terminals on the servo drive (see table below):
Device type

Mains terminal

Motor terminal

DC link terminal

Rb terminal

min.
max.
min.
max.
min.
max.
min.
max.
[mm² / AWG] [mm² / AWG] [mm² / AWG] [mm² / AWG] [mm² / AWG] [mm² / AWG] [mm² / AWG] [mm² / AWG]
AX5160

4 / 12)

35 / 2

4 / 12

35 / 2

4 / 12

35 / 2

4 / 12

AX5172

4 / 12

35 / 2

4 / 12

35 / 2

4 / 12

35 / 2

4 / 12

35 / 2

AX5190

25 / 4

95 / 2/0

35 / 2

95 / 3/0

25 / 6

50 / 2/0

25 / 6

50 / 2/0

AX5191

25 / 4

95 / 2/0

35 / 2

95 / 3/0

25 / 6

50 / 2/0

25 / 6

50 / 2/0

AX5192

25 / 4

95 / 2/0

150 / 300

25 / 6

50 / 2/0

AX5193

25 / 4

95 / 2/0

150 / 300

25 / 6

50 / 2/0

Version: 2.4

35 / 2

Servo Drives AX5000

Electrical installation
Dimensioning of the brake resistors for operation in the DC link group:
In individual braking situations the energy balance in the DC link group can be generative. Servo drives from
the series AX5160 to AX5193 have no internal brake resistor. External brake resistors must be used to
dissipate the energy generated. The brake resistor must always be connected to the connector provided on
the servo drive.
Under the following conditions it is possible to dispense with one or more brake resistors:
• the remaining brake resistors must be able to handle the continuous power
• the remaining brake resistors must be able to handle the short-term power
• the ohmic value of the brake resistor for each servo drive must not be lower than the minimum
permissible value.
Part of the brake energy is also stored in the DC link, independent of the brake resistor. The more servo
drives there are in the DC link group, the larger the storage capacity. It is therefore possible to store more
energy.
The following must be considered when dimensioning the brake resistors:
• The external brake resistor must have an ohmic value that is at least as large as the minimum value
permitted by the servo drive.
Servo Drives
Min. brake resistor
(external brake resistor)

AX5160
13 Ω

AX5172
13 Ω

AX5190
10 Ω

AX5191
10 Ω

AX5192
6.5 Ω

AX5193
6.5 Ω

• The peak braking power of the DC link group is given by the sum of the peak braking powers of all the
brake resistors in the DC link group:

• The continuous braking power is derived from the calculation of the effective braking power:

where:
Ppeak_Br_DC
Peff_Br_DC

is the peak braking power of the entire DC link group and
is the effective braking power of the entire group

DC link group with other AX5000 servo drives:

No DC link group permissible with devices for 1.5 A to 40 A!

Note

Servo drives from the series AX5101 to AX5140 are excluded from the DC link group with
servo drives from the series AX5160 to AX5193 and may NOT be connected to one another! The DC link group described here is permissible only for AX5160 to AX5193 servo
drives!

Servo Drives AX5000

Version: 2.4

Electrical installation

9.1.4

UL drive system - configuration example
Drive system with UL approval!
The following illustration shows a possible configuration example. Before implementation,
please contact your UL approval body and discuss further necessary boundary conditions.

Legend:
1 = UL fuse (480 VAC)
2 = UL fuse (700 VAC / 800 VDC) e.g. Ferrule FWP from Cooper-Bussmann

Fuse holders with UL approval
Note when using UL fuses that the necessary fuse holders also have to carry UL approval.

Version: 2.4

Servo Drives AX5000

Electrical installation

9.2

Connection example AX5101 - AX5112 and AX520x
AX5101 - AX5112 - AX520x
Optional: Slot for safety card
Optional: Slot for expansion
cards

Eiserstr. 5
BECKHOFFD-33415
Verl
Automation GmbH

Phone: +49 5246 / 963-0

Type:

AX5203-0000

Serial #:

000000018

Customized #:

0000

Power Supply:

1x100 - 3x480 VAC 50/60 Hz

Nominal Current: 2 x 3 A

X3x
X4x

Rated con. load: 5 kVA
www.beckhoff.com

info@beckhoff.com

Sin/Cos
Encoder
X22

X21

X12

X11

Sin/Cos
Encoder

Resolver

Resolver
X06

Incoming EtherCAT line

X04

X05

Outgoing EtherCAT line

Output voltage (Up 24 VDC+)
Output voltage GND (-)

Optional: Second power supply

FB1

DC+

FB2

DC-

Up+
Us+
GND

X02

Break
resistor
(optional)

X03

Input 7 or output (Up 24 VDC +)

+
Power supply
+24V DC
X01

EMC-Filter (C2)
(optional)

Main chokes
(optional)
U
V
W
PE
L1 L2 L3 PE

FN1 FN2 FN3

X13
X23

Motor
Channel
A
U
V
W
Motor choke PE
(optional)

X14
X24

T- / OCT
T+ / OCT
PE
BB+

Motor
Channel
B

FH1 FH2 FH3 PE

T- / OCT
T+ / OCT
PE
BB+

PE
L3
L2
L1

Servo Drives AX5000

Version: 2.4

Electrical installation

9.3

Connection example AX5118 - AX5125 and AX5140

Version: 2.4

Servo Drives AX5000

Electrical installation

9.4

Connection example AX5160 - AX5172

Servo Drives AX5000

Version: 2.4

Electrical installation

9.5

Connection example AX5190 - AX5191

Version: 2.4

Servo Drives AX5000

Electrical installation

9.6

Connection example AX5192 - AX5193

Servo Drives AX5000

Version: 2.4

Electrical installation

9.7

Power supply (1.5 A - 40 A devices)
Caution - Risk of injury!

WARNING

The electrical installation must be carried out by a qualified electrician. Before installing and
commissioning AX5000 servo drives please read the safety notes in the foreword of this
documentation.

Destruction of the AX5000!
The connection sequence of the devices is not arbitrary. The total rated current of the device must decrease from the power supply. The order "AX5112-AX5106-AX5201-AX5103"
is correct; the order "AX5201-AX5112-AX5203" is wrong.

Attention

Personal injuries!
Note the total current of the connected devices. According to CE the current carrying capacity of power busbars is limited to 85 A.
CAUTION

Personal injuries!

CAUTION

Please ensure that the connection line for the AX5901 supply module is adequately dimensioned. The dimensioning depends on the total rated current and must comply with EN
60204-1. The connector plugs are designed for a maximum conductor cross-section of 25
mm2. A 3-phase connection must be used if the total rated current exceeds 9 A.

Personal injuries!

CAUTION

9.7.1

To set up a drive system without AX5901 supply module and AX bridge please note the following: The connector plugs of the wide voltage input are designed for a maximum current
of 41 A and a maximum conductor cross-section of 6 mm2. The cable configuration must
comply with the requirements specified in DIN VDE 0298 Part 4 / 2003-08 and EN 60204-1.
Avoid phase reversal between the devices!

X01: Main supply connection
UL Listing
It is essential to observe chapter "Guidelines and Standards" if you wish to operate an
AX5000 in an economic area that requires a UL-Listing.

Voltage systems ranging from single-phase 100 VAC to three-phase 480 VAC can be connected to the wide
voltage input of the AX5000 . In single-phase systems the mains phase is connected to terminal point L1 and
the neutral conductor to terminal point L3/N.
Terminal point
L1

3-phase
Phase L1

Phase L2

Connection
1-phase
Phase L1

Tightening torque

not used
0,5 - 0,6 Nm

L3/ N

Phase L3

Protective conductor Protective conductor

Version: 2.4

Neutral conductor

Servo Drives AX5000

Electrical installation
Connection to the standard mains supply (TT / TN) with earthed centre
Single phase 100 -10% .- 240 +10% VAC, 50/60 Hz

Three phase 100 -10% .- 480 +10% VAC, 50/60 Hz

Connection to a IT-mains supply (100 - 240 V) without isolating transformer

EMC Act in europe!
Due to electromagnetic emission, in Europe the AX5000 must be operated in conjunction
with an isolating transformer
Attention

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

Servo Drives AX5000

Version: 2.4

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

Destruction of the AX5000!
For asymmetrically earthed or non-earthed 100...480 V mains an isolating transformer must
be used.
Attention
100 - 480 V Isolating transformer

240 - 480 V Isolating transformer

Version: 2.4

Servo Drives AX5000

Electrical installation

9.7.2

Fuse protection

External protection, CE-compliant

Fire hazard due to overload of the connection cable!
• The following data refer to stand-alone devices. Please note the total current of all connected devices in a multi-axis system.
WARNING

• The recommended fuses are designed for line protection. The servo drives feature integrated self-protection.

Single-phase:
AX5101
10 AT

AC supply *)
24 V supply
Brake resistor

AX5103
10 AT

AX5106
16 AT

AX5201
10 AT

AX5203
16 AT

AX5206
20 AT

5 AT
electronic

*) Application class "gG" mains fuses according to IEC 60269 or "C" type automatic circuit-breakers must be
used.
Three-phase:
AC supply *)

AX5101

AX5103

AX5106

AX5112

AX5118

AX5125

AX5140

AX5201

AX5203

AX5206

6 AT

10 AT

20 AT

35 AT

50 AT

10 AT

20 AT

24 V supply
Brake resistor

5 AT
electronic

*) Application class "gG / gL" mains fuses according to IEC 60269 or "C" type automatic circuit-breakers
must be used.
Internal protection, CE-compliant
Circuit
24 V system voltage
24 V peripheral voltage
Brake resistor

Servo Drives AX5000

Fuse
3.4 AF
electronic
electronic

Version: 2.4

Electrical installation
External protection, UL-compliant
The integrated protection against short circuit is no substitute for the external mains protection. The mains
protection must comply with the manufacturer's specification and the national and international regulations
and laws.
Can be used in power supply systems with a maximum current carrying capacity of 18000 A at 480 V.
Single-phase:

AC supply (max.) *)
24 V supply (max.)
Brake resistor

AX5101
6A

AX5103
12 A

AX5106
20 A

AX5201
12 A

AX5203
20 A

AX5206
20 A

3A
electronic

*) UL-approved mains fuses of class "RK5" must be used.
Three-phase:
AC supply (max.) *)

AX5101

AX5103

AX5106

AX5112

AX5201

AX5203

AX5206

12 A

20 A

12 A

20 A

24 V supply (max.)

Brake resistor

electronic

*) UL-approved mains fuses of class "RK5" must be used.

AX5112!
Protection through UL-approved fuses of class "RK5" with a rated current of 20 A and 480
V min.
Internal protection, UL-compliant
Circuit
24 V system voltage
24 V peripheral voltage
Brake resistor

Fuse
3.4 AF
electronic
electronic

External drive system protection
Rule of thumb:
Sample:

Determine the total rated device currents, multiply with the correction factor
and round up to the next higher standard level.
1 x AX5103 + 2 x AX5201 + 2 x AX5203
3 A + 6 A + 12 A = 21 x 1.1 = 23.1 A --> selected 25 A

Special requirements for a drive system
Please consult our Application Department with respect to the special requirements for a
drive system with UL approval.
Residual current circuit breaker
Servo drives with built-in mains filters generate a small leakage current (fault current) due to the capacitors in
the filter. This fault current is responsible for malfunctions in standard residual current circuit breakers. For
this reason so-called AC/DC sensitive residual current circuit breakers must be used, which also take into
account DC currents.

Version: 2.4

Servo Drives AX5000

Electrical installation

9.7.3

X02: DC Link (AX5101 - AX5125 und AX520x)

DC link coupling or external brake resistor is possible via terminal X2.

9.7.4

Terminal point
DC+

Connection
DC link +

DC-

DC link -

Tightening torque

External brake
resistor

0,5 - 0,6 Nm

X02: DC Link (only AX5140)

Via terminal X2 a DC link coupling can be configured. Don´t connect a brake resistor under circumstances!
Terminal point
DC+

Connection
DC link +

DC-

DC link -

Serious risk of injury through high electrical voltage!

WARNING

890 V DC voltage at the DC link terminals X02. Once the device has been switched off
dangerous voltage will still be present for a further 5 minutes. Only remove the connector if
you wish to configure a drive system with the AX bridge. Only remove the white hexagonal
plug if the terminal points are to be rewired.

Servo Drives AX5000

Version: 2.4

Electrical installation

9.7.5

X03: 24 VDC supply

System and peripheral voltage for the servo drive is supplied via connector X3. The supply is based on two
channels in order to offer an option to separate between motor stopping brakes and control electronics.

Safe operation!
The voltage tolerances must be taken into account when connecting motors with stopping
brake.
CAUTION
Terminal
point
Up

GND

Connection

Current consump- Tightening torque
tion
24 VDC ±10% (depending on the Depending on the
connected
motor holding brake) peripheral voltage
consumers (see X06
0.5 – 0.6 Nm
(e.g. separate brake and X14, X24)
supply)
24 VDC-15% + 20% -12 A = 0.4 A – 0.8 A
system supply
18 A - 25 A = 1.1 A
voltage
40 A = 1.6 A
GND

Connection to the standard mains supply 24 VDC (X03)
The 24 VDC connection "X03" is used for supplying the control electronics and periphery with DC voltage.
The control electronics and the periphery can be supplied separately with two different voltage sources.
If one power supply unit is used for the 24 VDC power supply, the connections US and UP
must be bridged, in order to ensure that both the control electronics and the periphery are
supplied.
Note
Supply via one or two power supply units

9.7.6

Safe system stop in the event of power failure

A power failure can lead to uncontrolled idling of the drive axes: linear axis or lifting axes would hit the limit
stop unbraked. The 24 VDC supply of the AX5000 has two channels, so that separate power supplies can be
used for the control electronics and the brake control. This enables the supply voltage for the control
electronics to be buffered via the UPS of the Industrial PCs until all axes were stopped safely.

Version: 2.4

Servo Drives AX5000

Electrical installation

9.8

Power supply (60 A - 170 A devices)
Caution - Risk of injury!

WARNING

The electrical installation must be carried out by a qualified electrician. Before installing and
commissioning AX5000 servo drives please read the safety notes in the foreword of this
documentation.

Destruction of the AX5000!

Attention

9.8.1

The connection sequence of the devices is not arbitrary. The total rated current of the device must decrease from the power supply. The order "AX5112-AX5106-AX5201-AX5103"
is correct; the order "AX5201-AX5112-AX5203" is wrong.

X01 - Voltage input

AX5160 and AX5172
Figure

Terminal point
L1
L2
L3
PE

Connection
Phase L1
Phase L2
Phase L3
Protective conductor

Terminal points
L1
L2
L3
PE

Connection
Phase L1
Phase L2
Phase L3
Protective conductor

Terminal points
L1
L2
L3
PE

Connection
Phase L1
Phase L2
Phase L3
Protective conductor

AX5190 and AX5191
Figure

AX5192 and AX5193
Figure

Servo Drives AX5000

Version: 2.4

Electrical installation
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-phases 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.
Note
Three-phase 400-10% - 480+10% VAC

9.8.2

Fusing

External protection for individual devices, CE-compliant

Fire hazard through short circuit!
The recommended fuses are designed for line protection. The servo drives feature integrated self-protection.
CAUTION
Fusing
AX5160
*)
AC supply
80 AT
24 V supply
Brake resistor

AX5172
100 AT
4 AT

AX5190
125 AT

AX5191
160 AT

AX5192
200 AT
10 AT

AX5193
224 AT

electronic

Application class „gG“ mains fuses according to IEC 60269 or „C“ type automatic circuit breakers must be
used.
External protection for individual devices, UL-compliant

AX5172

AX5190

AX5191

4 AT

AX5192

AX5193

10 AT
electronic

Mains fuses according to type “RK5” min. 480 V must be used.

Version: 2.4

Servo Drives AX5000

Electrical installation

9.8.3

X02: DC link
DC link AX5000 (60 A -170 A devices)!

Note

When establishing a DC link connection (only for 60 A – 170 A devices!), it is essential to
follow the chapter:
"Connection example – DC link group (60 A - 170 A devices)". [} 50]

Serious risk of injury through high electrical voltage!

DANGER

AX5160 - AX5172
Figure

Terminal point
DC +
DC -

Connection
DC link +
DC link -

Figure

Terminal point
DC +
DC -

Connection
DC link +
DC link -

Figure

Terminal point
DC +
DC -

Connection
DC link +
DC link -

AX5190 – AX5191

AX5192 – AX5193

Servo Drives AX5000

Version: 2.4

Electrical installation

9.8.4

X03: 24 VDC supply

Safe operation!
The voltage tolerances must be taken into account when connecting motors with stopping
brake.
CAUTION
Terminal point Connection
Up
24 VDC ±10% (depending on the motor holding
brake) - peripheral voltage (e.g.
separate brake supply)
Us
24 VDC-15% + 20% - system
supply voltage
GND
GND

Current consumption
Depending on the connected consumers
(see X06 and X14)
60A – 72A = 3A
90A – 170A = 10A

9.8.5

Safe system stop in the event of power failure

Version: 2.4

Servo Drives AX5000

Electrical installation

9.9

Leakage currents

When operating servo drives, operationally related leakage currents occur in various frequency ranges
(capacitive): In addition, it is possible for a smooth DC residual current (ohmic) to be produced after the
rectifier. These currents would prevent a residual current circuit breaker (RCCB or RCD) of the type A or AC
from tripping. In the event of a fault, therefore, it would be possible for dangerous voltages to be present on
the housing parts. For 3-phase applications the statutory regulations in different countries (please check
whether your country is affected) require the use of AC/DC-sensitive RCDs. These should have a rated
residual current of ≤ 300 mA. In order to be able to meet these requirements it is necessary to know or
calculate the expected leakage currents.
Formulas
The leakage current level depends on the fixed leakage currents, the motor cable length and the supply
voltage. The following formulas were determined empirically.

Calculation basis
The values for the leakage current calculated with the equations are valid only if:
Note

• original Beckhoff motor cables are used and
• shielding and grounding concepts are adhered to
• In addition it should be noted that the calculated leakage current value is not exact but
merely reflects the maximum expected value, with associated dispersion.

Composition of the max. total leakage current
The max. total leakage current is composed of:
Note

• a device-dependent fixed part with 50 Hz (single-phase feed) or 150 Hz (three-phase
feed)
• plus a variable part that depends on the motor cable length and clock frequency. If no
other specifications are applied, the clock frequency is around 8 kHz.

Servo Drives AX5000

Version: 2.4

Electrical installation
Leakage currents for individual devices
ILCdevice = ILCfix + ILCvar
AX5000 up to 12 A – single-phase connection, leakage current in [mA]:

AX5000 up to 12 A – three-phase connection, leakage current in [mA]:

AX5118 - three-phase connection, leakage current in [mA]:

AX5125 - three-phase connection, leakage current in [mA]:

AX5140 - three-phase connection, leakage current in [mA]:

The total leakage current is composed of the sum of the individual device leakage currents:
ILCtotal = ILCdevice1 + ILCdevice2 +...+ ILCdevicen

Version: 2.4

Servo Drives AX5000

Electrical installation
Leakage currents in a DC link
If several devices are connected via a DC link, only the fixed leakage currents for 50 Hz or 150 Hz are
present, as long as no axis is enabled. As soon as an axis is released, the complete fixed leakage currents
(50 Hz or 150 Hz) are present and additionally a fixed portion of 8 kHz with a motor cable length of 0 m. The
following diagrams illustrate the individual leakage current components:
Sample
1 x AX5000 (enabled) without DC link
ILCtotal = ILCvar + ILCfix

2 x AX5000 (not enabled) in DC link
IABtotal = IABfix_1 + IABfix_2

1 x AX5000 (enabled) + 1 x AX5000 (not enabled) in DC link
IABtotal = IABvar_1 + IABfix_1 + IABfix_2
If the AX5000_2 is also enabled the equation is as follows:
IABtotal = IABvar_1 + IABvar_2 + IABfix_1 + IABfix_2

Influence of the motor chokes
Motor chokes are used in order to protect the power semiconductors and the motors through lower voltage
edges and therefore reduced peak values of the commutation or leakage currents. However, the reduction in
voltage edges has no influence on the RMS value of the leakage currents. Since this is precisely what an
RCD invariably assesses, motor chokes have no positive influence here.

Servo Drives AX5000

Version: 2.4

Electrical installation

9.10

EtherCAT

9.10.1

X04, X05: EtherCAT connection

The AX5000 is integrated in the EtherCAT strand via the RJ45 sockets X04 and X05.

RJ45
X04 (IN)

Signal
incoming EtherCAT line

X05 (OUT)

outgoing EtherCAT line

Version: 2.4

Servo Drives AX5000

Electrical installation

9.11

Digital I/Os

9.11.1

X06: Digital I/Os
Destruction of the AX5000!
This connector is not designed for external power supply. It is supplied via the 24 V supply
(periphery) of connector X03.

CAUTION

I/O plug connector without LEDs
ZS4500-2006

I/O plug connector with LEDs
ZS4500-2007 (optional)

ZS4500-2008 (optional)

Voltage level
-3 V ... 5 V
15 V ... 30 V

Terminal point Signal
Output current
24
Power supply for the
max. 1 A
external sensors (switches/
initiators)
(Up 24 VDC +)
0
Input 0
1
Input 1
2
Input 2
3
Input 3
4
Input 4
5
Input 5
6
Input 6
7
Input 7 or output
max. 0.5 A
(configurable)
(Up 24 VDC +)
0V
GND (-)

State
0 or "false"
0 or "false"

Configuration of the plug signal inputs:
The signal inputs of the plugs can be configured with the following functions (IDNs):
Note

P-0-0251, P-0-0400, P-0-0401, P-0-0402, P-0-0800, P-0-0801, P-0-0802.
For further information please refer to the documentation for the
S- and P-parameters of the AX5000 servo drive series.

Servo Drives AX5000

Version: 2.4

Electrical installation

9.11.2

Technical data

Technical data
Number of terminal points
Signal LEDs
Rated voltage
Rated current
Wire cross section
Strip length
Dimensions (W x H x D)
Weight
Permissible ambient temperature
range during operation
Permissible ambient temperature
range during storage
Permissible relative humidity
Vibration/shock resistance
EMC immunity/emission
Protection class
Installation position
Approval

9.11.3

approx. 42mm x
10.3mm x 26.9mm
approx. 10 g

ZS4500-2007
10
yes
24 VDC
2A
0.5 mm2 ... 1.5 mm2
10 mm
approx. 42mm x
12.7mm x 26.9mm
approx. 10 g
0°C ... + 55°C

ZS4500-2008
30
yes
24 VDC

approx. 42mm x
20.8mm x 26.9mm
approx. 20 g

-25°C ... + 85°C
95 %, no condensation
conforms to EN 60068-2-6 / EN 60068-2-27, EN 60068-2-29
conforms to EN 61000-6-2 / EN 61000-6-4
IP 20
variable
CE, UL, CSA

Ordering information for I/O plug connectors

Order identifier

Signal LEDs

ZS4500-2006
ZS4500-2007
ZS4500-2008

no
yes
yes

ZS4500-2006
10
no
24 VDC

Supports the following connection types
Single-conductor
Two-conductor
Three-conductor
yes
no
no
yes
no
no
yes
yes
yes

Version: 2.4

Servo Drives AX5000

Electrical installation

9.11.4

Connection of digital sensors/actuators

ZS4500-2006 (standard) and ZS4500-2007 (optional)
The connection type (single-conductor) in the two connectors ZS4500-2006 and ZS4500-2007 is identical.
The ZS4500-2007 is additionally equipped with LEDs. The following diagram shows the ZS4500-2006.
A sensor (F) is connected at terminal point "0" via a single-conductor connection. The 24 V supply for the
sensor is connected externally. It would also be possible to take the 24 V supply for sensor (F) directly from
terminal point "24", which would cover this option.
In this case terminal point "7" is configured as an output. The configuration is implemented on the software
side. A relay (G) is connected via a single conductor; the 0 V connection is external.

Ground potential

Note

• If sensor (F) or further initiators are supplied through a separate power supply unit, the
ground potential of the separate power supply unit must be connected with the ground
potential of terminal point "GND" of connector "X03" (24 V supply).
• The ground potential (0 V) of the relay (G) must be connected with the ground potential
of terminal point "GND" of connector "X03" (24 V supply).

Servo Drives AX5000

Version: 2.4

Electrical installation
ZS4500-2008 (optional)
A single-, two- or three-conductor connection may be used for this connector. The diagram shows the twoand three-conductor type. The single-conductor type matches the diagram for connector ZS4500-2006.
The terminal points at (B) are internally bridged. The two bridges (A) have to be established externally on the
plug, in order to use the terminal points.
A sensor (C) is connected at terminal point "2" via a two-conductor connection.
An initiator (D) is connected at terminal point "4" via a three-conductor connection.
In this case terminal point "7" is configured as an output. The configuration is implemented on the software
side. At this point a relay (E) is connected via a two-conductor connection.

9.12

Feedback

Information on commutation can be found in chapter 10.12: "Commutation techniques [} 200]".
Information about the limit frequencies can be found under the interface descriptions.

Absolute encoder

Note

When using an absolute encoder, it must be verified before moving the axis that the feedback system supplies the expected position data at the distinctive positions in the traversing range - ‘START’ and ‘MID’ and ‘END’ – and that these positions are retained after the
restart (Bootstrap -> OP) of the AX5000. Overflow in the traversing range must be avoided!

Version: 2.4

Servo Drives AX5000

Electrical installation

9.12.1

Rotational encoders

Heidenhain:
The Heidenhain company supplies feedback systems with the "EnDat 2.2" interface in 2 versions. One
version is without the analog signals (sine and cosine), one version includes the analog signal "1Vss". To
date, Beckhoff supports only EnDat 2.1 with analog signal. Since the EnDat 2.2 interface supports all of the
commands of EnDat 2.1, attention only needs to be paid to the provision of the analog signal 1Vss on the
Heidenhain feedback systems with EnDat 2.2; i.e. the Heidenhain order designation "EnDat02" must be
stated.
Type

System
Singleturn

Sin/Cos per
revolution
16

Supply
voltage
5V

ECI 1118
ECI 1319

Singleturn

ECN 413

Singleturn

512

5 V or
7 - 10 V
3.6 V - 14 V

ECN 413

Singleturn

2048

3.6 V - 14 V

ECN 1113

Singleturn

512

ECN 1313

Singleturn

2048

EQI 1130

Multiturn

EQI 1331

Multiturn

EQN 425

Multiturn

512

5 V or
7 - 10 V
3.6 V - 14 V

EQN 425

Multiturn

2048

3.6 V - 14 V

EQN 1125

Multiturn

512

EQN 1325

Multiturn

512

EQN 1325

Multiturn

2048

RCN 829

Singleturn

32768

3.6 – 5.25 V

ROQ 425

Multiturn

512

3.6 V - 14 V

ROQ 425

Multiturn

2048

3.6 V - 14 V

ERN 180
ERN 180
ERN 180
ERN 480
ERM 280

incremental
incremental
incremental
incremental
incremental

1024
2048
5000
2048
1200

5V
5V
5V
5V
5V

Servo Drives AX5000

Version: 2.4

Interface

Sampling

EnDat 2.1 + 1
Vpp
EnDat 2.1 + 1
Vpp
EnDat 2.1 + 1
Vpp
EnDat 2.1 + 1
Vpp
EnDat 2.1 + 1
Vpp
EnDat 2.1 + 1
Vpp
EnDat 2.1 + 1
Vpp
EnDat 2.1 + 1
Vpp
EnDat 2.1 + 1
Vpp
EnDat 2.1 + 1
Vpp
EnDat 2.1 + 1
Vpp
EnDat 2.1 + 1
Vpp
EnDat 2.1 + 1
Vpp
EnDat 2.2 + 1
Vpp
EnDat 2.1 + 1
Vpp
EnDat 2.1 + 1
Vpp
1 Vpp
1 Vpp
1 Vpp
1 Vpp
1 Vpp

Inductive
Inductive
Optical
Optical
Optical
Optical
Inductive
Inductive
Optical
Optical
Optical
Optical
Optical
Optical
Optical
Optical
Optical
Optical
Optical
Optical
Magnetic

Electrical installation
Hengstler:
Type

System

AD 34
AD 36
AD 36
AD 58
AD 58

Singleturn
Singleturn
Multiturn
Singleturn
Multiturn

Sin/Cos per
revolution
2048
2048
2048
2048
2048

Supply
voltage
5V
5V
5V
5V
5V

Interface

Sampling

BiSS + 1 Vpp
BiSS + 1 Vpp
BiSS + 1 Vpp
BiSS + 1 Vpp
BiSS + 1 Vpp

Optical
Optical
Optical
Optical
Optical

Sin/Cos per
revolution
2048

Supply
voltage
5V

Interface

Sampling

BiSS + 1 Vpp

Optical

Kübler:
Type

System

8.5853

Singleturn

Sick- Stegmann:
Type

System

SEK 37
SEL 37
SEK 52
SEL 52
SRS 50
SRM 50
SKS 36
SKM 36

Singleturn
Multiturn
Singleturn
Multiturn
Singleturn
Multiturn
Singleturn
Multiturn

Sin/Cos per
revolution
16
16
16
16
512
512
125
125

Supply
voltage
7 V - 12 V
7 V - 12 V
7 V - 12 V
7 V - 12 V
7 V - 12 V
7 V - 12 V
7 V - 12 V
7 V - 12 V

Interface

Sampling

HIPERFACE + 1 Vpp
HIPERFACE + 1 Vpp
HIPERFACE + 1 Vpp
HIPERFACE + 1 Vpp
HIPERFACE + 1 Vpp
HIPERFACE + 1 Vpp
HIPERFACE + 1 Vpp
HIPERFACE + 1 Vpp

Capacitive
Capacitive
Capacitive
Capacitive
Optical
Optical
Optical
Optical

Digital rotary encoders:
Type

System

EEK 37
EEL 37
EKS 36
EKM 36
EKS 36
EKM 36
ERS 50
ERM 50

Singleturn
Multiturn
Singleturn
Multiturn
Singleturn
Multiturn
Singleturn
Multiturn

Resolution per
revolution
16 bit
16 bit
18 bit
18 bit
20 bit
20 bit
23 bit
23 bit

Interface

Sampling

OCT
OCT
OCT
OCT
OCT
OCT
OCT
OCT

Capacitive
Capacitive
Optical
Optical
Optical
Optical
Optical
Optical

Universal rotary encoders:
Type
1

System

Sin/Cos per
revolution
512

Supply
voltage
5V

Version: 2.4

Interface

Sampling

1 Vpp

Servo Drives AX5000

Electrical installation

9.12.2

Linear encoders

Heidenhain:
Type

System
incremental
incremental
incremental
incremental

Measuring
steps
20 µm
20 µm
20 µm
20 µm

Supply
voltage
5V
5V
5V
3.6 V – 5.25 V

LS 388C
LS 486
LS 487
LC 483
LIDA 477
LIDA 483
LIDA 487
LIDA 287

Interface

Sampling

1 Vpp
1 Vpp
1 Vpp
EnDat 2.1 + 1
Vpp
1 Vpp
1 Vpp
1 Vpp
1 Vpp

Optical
Optical
Optical
Optical

incremental
incremental
incremental
incremental

20 µm
20 µm
20 µm
200 µm

5V
5V
5V
5V

Type

System

Magic

incremental

Measuring
steps
1 mm

Supply
voltage
5V

Interface

Sampling

1 Vpp

Magnetic

Measuring
steps
1 mm

Supply
voltage
5V

Interface

Sampling

1 Vpp

Magnetic

Measuring
steps
20 µm

Supply
voltage
5V

Interface

Sampling

1 Vpp

Optical

Measuring
steps
1 mm

Supply
voltage
5V

Interface

Sampling

1 Vpp

Magnetic

Supply
voltage
5V
5V
5Vuncontrolled
5Vuncontrolled

Interface

Sampling

Optical
Optical
Optical
Optical

HIWIN:

lika:
Type

System

SMS

incremental

Numerik Jena:
Type

System

LIA20

incremental

Siko:
Type

System

LE100/1

incremental

Universal linear encoders:
Type

System

1
2
3

incremental
incremental
incremental

Measuring
steps
20 µm
1 mm
20 µm

incremental

1 mm

1 Vpp
1 Vpp
1 Vpp
1 Vpp

Motor feedback database

Note

If your feedback system is not listed here, please follow the link to the Beckhoff download
area. By downloading and installing the "AX5000 setup" you will obtain the TwinCAT Drive
Manager, the latest firmware and the latest motor feedback database.

Servo Drives AX5000

Version: 2.4

Electrical installation

9.12.3

X11 and X21: Feedback, high-resolution

The X11 and X21 D-SUB sockets are available for connecting high-resolution feedback systems. In delivery
state X11 is assigned to axis A, X21 to axis B.

Pin
1
2
3
4
5
6
7
8
9
10
11
12
13
14
15
1)

EnDAT / BiSS
SIN
GND_5 V
COS
Us_5 V
DX+ (Data)
n.c.
n.c.
CLK+ (Clock)
REFSIN
GND_Sense
REFCOS
Us_5 V_Sense
DX- (Data)
n.c.
CLK- (Clock)

Hiperface
SIN
GND_9 V
COS
n.c.
DX+ (Data)
Us_9V
n.c.
n.c.
REFSIN
n.c.
REFCOS
n.c.
DX- (Data)
n.c.
n.c.

Sine / cosine 1 Vpp
SIN
GND_5 V
COS
Us_5 V
n.c.
n.c.
REF Z
n.c.
REFSIN
GND_Sense
REFCOS
Us_5 V_Sense
n.c.
Z
n.c.

TTL1)
n.c.
GND_5 V
n.c.
Us_5 V
B+
n.c.
REF Z
A+
n.c.
GND_Sense
n.c.
Us_5 V_Sense
BZ
A-

Output current

max. 250 mA /
channel

Attention: Wire break detection is not supported for TTL encoders.

Limit frequency:
1 Vpp = 270 kHz
TTL = 10 MHz
MES = 500 Hz

9.12.4

Resolver

Universal resolvers:
Number of poles
2
6
8

Frequency
8 kHz
8 kHz
8 kHz

Transmission ratio
0.5
0.5
0.5

Version: 2.4

Servo Drives AX5000

Electrical installation

9.12.5

X12 and X22: Feedback, resolver / Hall

The X12 and X22 D-SUB sockets are available for connecting resolvers or Hall sensors for commutation.
X12 is assigned to axis A in the factory, X22 to axis B.
Pin
1

2
3
4
5
6
7
8
9
10
11
12
13
14
15

Resolver
Temperature (only PTC,
Klixon or bimetal!).
Switching point: 1300 Ω ±
3%
AGND
COS - (S3)
SIN - (S4)
REF - (R2)
n.c.
n.c.
n.c.
Temp._GND
COS + (S1)
SIN + (S2)
REF + (R1)
n.c.
n.c.
n.c.

Analog Hall sensor
n.c.

n.c.
n.c.
n.c.
n.c.
Sin 1Vpp
-120° or -90° 1Vpp *
Us_9 V (supply)
n.c.
n.c.
n.c.
n.c.
REFSin 1Vpp
-120° or -90° 1Vpp *
GND (supply)

Limit frequency:
Resolver = 300 Hz

9.12.6

X14 and X24: Feedback, OCT (1.5 A - 40 A devices)

Servo Drives AX5000

Pin
T-

OCT / thermal contact
OCT -

T+

OCT +

Version: 2.4

Electrical installation

9.13

Motors

9.13.1

Concept

Both three-phase synchronous motors and three-phase asynchronous motors can be driven with the servo
drives from the AX5000 series. The operation of asynchronous motors with the AX5000 is useful if, in the
configuration of the drive system, a channel is still freely available and also if asynchronous motors are used
that are to be operated with open-loop control. In the case of the use of asynchronous motors intended for
closed-loop operation, the AX5000 series is a good alternative regardless of the configuration of the drive
system.

9.13.2

Motor data set

A motor dataset contains the motor data and control parameters, which the AX5000 requires for operating
the motor. Beckhoff is continually expanding the pool of available motor data sets and makes the latest
motor database available automatically when the TwinCAT Drive Manager is updated.

Creating motor data sets

Note

Further information on creating motor data sets can be found in
chapter 9.13.4: "Synchronous motors [} 86]",

Version: 2.4

Servo Drives AX5000

Electrical installation

9.13.3

TwinCAT Drive Manager

Servo drives are parameterized via the TwinCAT Drive Manager (TCDM). The screen masks required for the
parameterization will be explained at this point. If you need basic information about the TCDM, please read
the complete documentation, which is available on our website for download.
Start the TCDM and click the entry (2) under the relevant channel (1) in the tree; the motor/feedback
configuration appears in the TCDM working area. Click on the field (3) in order to open the ‘Motor selection
window’. In the ‘Motor selection window’ you can display all of the available motors, or enter your own
motors including motor parameters (asynchronous motors only).

Servo Drives AX5000

Version: 2.4

Electrical installation

9.13.4

Motor types

9.13.4.1

Synchronous motors

In the case of synchronous motors, you can only select an existing motor; it is not possible to register your
own motors. If your motor is not listed, please contact our support department.

9.13.4.2

Asynchronous motors

With the AX5000 you have the possibility to implement a good positioning drive with an inexpensive standard
motor in combination with a low-cost incremental encoder.
Linear
Linear asynchronous motors are not supported at present.
Rotary
1. Motor selection
You can either choose an existing motor (1) or generate parameters for a new motor (2). After selection, click
"OK" (3) to move to the next menu.

Version: 2.4

Servo Drives AX5000

Electrical installation
2. Characteristic motor data
In the next menu characteristic motor data are entered or selected. Expert mode (9) is not currently
supported. Parameters (4) and (5) are preset; you do not need to change them. You can enter a new motor
manufacturer or select an existing motor manufacturer in parameter (6). A new group is generated in
parameter (7) to suit the motor. If you wish to conform to the structure of the motor database, name the
group according to the nominal speed of the motor. Enter the exact type designation of the motor in
parameter (8). Check your entries and then click "Next" (10) to move to the next menu.

Servo Drives AX5000

Version: 2.4

Electrical installation
3. Basic motor data
The basic data are subdivided into three categories: "Basic" (1); "Temperature:" (2) and "Brake" (3).
Basic (1):

It is essential to observe the maximum permitted du / dt of the motor winding!
Note
a) Type of connection: Star or delta connection. If you wire and operate the motor in a star or delta
configuration, please note that the rated motor current changes along with the rated motor voltage and that
the AX5000 can supply a maximum rated voltage of 480 V. Please refer to the motor documentation or name
plate for the permissible motor voltages and currents for star and delta connection.
b) The derating is dependent upon your application. Derating is the difference between the effective rated
channel current and the rated motor current in %. Example: rated motor current = 4 A; effective rated
channel current = 3 A -> derating = 25 %.
c) The ratio of Ip to In (overload factor) is set to 1.5 as standard and must be checked against the motor
documentation or name plate.
d) The rated current must be adjusted in accordance with the type of connection and checked against the
motor documentation or name plate.
e) The maximum motor speed is dependent upon the mechanical properties and the maximum rotary field
frequency of the AX5000. Please observe the M / f curve and the field weakening according to the motor
documentation.
f) The rated voltage must be adjusted in accordance with the type of connection and checked against the
motor documentation or name plate.
g) The nominal speed is dependent upon the number of pole pairs and the nominal frequency and must be
checked against the motor documentation or name plate.
h) The nominal frequency is set to 50 Hz as standard and must be checked against the motor documentation
or name plate.
i) The power factor (cos phi) is set to 0.8 as standard and must be checked against the motor documentation
or name plate.
Temperature (2):
k) The type of motor temperature monitoring used and the AX5000 input used must be selected.

For further information on the combinations you intend to use please contact
the Beckhoff applications department.
Note
m) The temperature at which a warning is given is set to 80 °C. This parameter is effective only for KTY
sensors.
n) The temperature at which the motor is switched off is set to 140 °C and must be checked against the
motor documentation or name plate. This parameter is effective only for KTY sensors.
Brake (3):
o) The type of motor brake used must be selected and checked against the motor documentation or name
plate.
Double-check all entries and click ‘Next’ (4) to move to the next menu.

Version: 2.4

Servo Drives AX5000

Electrical installation

Servo Drives AX5000

Version: 2.4

Electrical installation
4. Summary
The motor data entered and the data calculated from them are displayed in this window. Please check ALL
parameters once more for plausibility and click ‘OK’ (5) to move to the next menu.

Version: 2.4

Servo Drives AX5000

Electrical installation
5a. Default storage folder for self-generated motor data sets
The default storage folder for user-generated motor datasets is called "CustomerGenerated" (1), and the
suggested file name (2) corresponds to the motor type entered above (see "Characteristic motor data"). This
storage folder has the advantage that you can find your self-generated motor data sets at a glance; however,
they are not included in the above list above under 1. ‘Motor selection’, but are only visible if you click the
‘Load’ button at the bottom right under 1. ‘Motor selection’. The suggested name designates only the XML
file of the motor data set. For the purposes of displaying in the lists, the XML file is read and the
corresponding identifying motor data (‘Vendor’, ‘Motor group’ and ‘Motor type’) are listed as a selection.
To save your data, click on "Save" (4), which then takes you to the last menu.
If your self-generated motor data sets are to be listed directly in the above list under 1. ‘Motor selection’, click
on the symbol (3) to open the "MotorPool" folder.

Servo Drives AX5000

Version: 2.4

Electrical installation
5b. Default storage folder for the motor data sets from the Beckhoff motor database
The default storage folder for the motor data sets provided is called "MotorPool" (4). All motor data sets from
the Beckhoff motor database are saved here in the form of XML files. We recommend that you assign a
unique file name to your self-generated motor data set, so that you can identify it (5):
Customer = name of your company
Mototec = The name (Vendor) assigned by you under 2. "Identifying motor data"
3000 = The motor group assigned by you under 2. "Identifying motor data"
17K456FGH = The motor type assigned by you under 2. "Identifying motor data"
Of course, you can also assign an arbitrary file name. The assigned name designates only the XML file of
the motor data set. For the purposes of displaying in the lists, the XML file is read and the corresponding
identifying motor data (‘Vendor’, ‘Motor group’ and ‘Motor type’) are listed as a selection.
You create one XML file for each motor data set; the motors from the same motor group of a manufacturer
(Vendor) are always summarized in the XML files for Beckhoff motor data sets.
To save your data, click on "Save" (6), which then takes you to the previous menu.

Version: 2.4

Servo Drives AX5000

Electrical installation
6. Mains voltage and further settings
This window also appears when you select an existing motor data set (synchronous motor or asynchronous
motor). You can adapt the following entries at any time.
a) You can select one of the pre-defined mains voltage variants or you can specify one of your own.
b) Enter the mains voltage (only possible if no mains variant was selected under a)).
c) Enter the upper tolerance of the mains voltage (only possible if no voltage was selected in a)).
d) Enter the lower tolerance of the mains voltage (only possible if no voltage was selected in a)).
e) + f) Phase monitoring is only useful for a 3-phase mains supply. Switch phase monitoring on or off (only
possible if no voltage was selected in a)).
g) Use this setting to enable automatic transfer of the resolution of the encoder and the scaling factor from
the AX5000 to the NC. (Only required if the motor was integrated via an NC axis).
h) The cycle time of the current controller is 125 μs.
i) Selection of the type of ASM connection. If you have generated the motor data set, you can only select the
type of connection entered under 3. "Basic motor data –a)". If Beckhoff has generated the motor data set,
you can choose between star connection and delta connection.
k) Selection of the ASM control mode. If you select "U/f control", only open-loop operation of the motor is
possible; the AX5000 then acts like a servo drive. If you select "i-control with feedback", closed-loop
operation of the motor is possible, but the motor must be equipped with a feedback system. Click on "OK" (1)
to complete the procedure.

Servo Drives AX5000

Version: 2.4

Electrical installation
Open-loop
If open-loop operation of the motor is desired, you can influence the operating behavior with the following
parameters.
Interdependence between the type of connection of the motor, the speed and the rated output
current of the AX5000
Example motor:
Asynchronous motor with rated voltage 230 V and rated current 6 A at 50 Hz for delta connection or rated
voltage 400 V, rated current 3.5 A at 50 Hz for star connection
If your application requires speeds above the nominal speed (1), this requirement can be realized without
having to use a bigger motor:
The AX5000 can provide 400 V of channel output voltage and thus operate the asynchronous motor in delta
connection at up to 87 Hz (2) without field weakening occurring, i.e. with the rated torque. You only need to
note that a rated current of 6 A is required.

Version: 2.4

Servo Drives AX5000

Electrical installation
Boost voltage
The operation of an asynchronous motor with a linear U/f characteristic curve results in a weakening of the
torque in the lower speed range due to the dominant resistive component. The standstill torque is zero
without a boost voltage. Furthermore, the asynchronous motor requires a certain time after the current is
applied in order to build up the magnetic field on the rotor and, hence, to generate the magnetic force or the
torque. If your application can not tolerate this delay, there is a possibility to reduce this time delay via the
so-called "boost voltage", which "premagnetises" the rotor. With "premagnetization" a magnetic field is
created in the rotor even though the rotor is not moving. Torque is hence immediately available to rotate the
rotor shaft if a target speed is specified. The interdependence between the boost voltage, speed and torque
is illustrated in the graphic below on the basis of an example motor. The influence of the boost voltage on to
the torque is clearly visible at low speeds.
Example motor:
Rated speed: 1410 rpm
Rated torque: 10.2 Nm
Breakdown torque: 28.6 Nm
Starting torque: 25.5 Nm
Power factor: 0.78
Efficiency: 0.79

The boost voltage is parameterized in the IDN-P-0-0103. Most applications will be covered by the default
setting of 10 V.

Attention: destruction of the motor

Attention

In an asynchronous motor without an external fan, the motor temperature must be monitored in the lower speed range when boost voltage is used. If necessary, you can change
the boost voltage online.

Servo Drives AX5000

Version: 2.4

Electrical installation
Settings for ramping up and down
In the open-loop operation of the asynchronous motor, the values you need to adjust for the ramps depend
on the application.
The ramp-up is parameterized in the IDN S-0-0136 and the ramp-down in the IDN S-0-0137.
Closed-loop
If closed-loop operation of the asynchronous motor is desired, you must select the feedback system used in
the motor in the TCDM.
Feedback
Start the TCDM and click the entry (2) under the relevant channel (1) in the tree; the motor/feedback
configuration appears in the TCDM working area. Click on the ‘Feedback 1’ (3) field to open the ‘Feedback
selection window’. You can view all available feedback systems in the ‘Feedback selection window’.

Version: 2.4

Servo Drives AX5000

Electrical installation
1a. Feedback selection - resolver
Only one of the listed feedback systems can be selected. Either choose the feedback system of an existing
manufacturer or choose a standard feedback system under "Unknown" (1). If your motor is equipped with a
resolver, determine the generic parameters of the resolver and select the appropriate resolver type (2).
Typical generic parameters for the classification of resolvers are the number of poles "p" and the gear ratio
"n". Click on "OK" (3) to complete the procedure.

Servo Drives AX5000

Version: 2.4

Electrical installation
1b. Feedback selection - 1Vpp encoder
You can only select one existing feedback system. Either choose the feedback system of an existing
manufacturer or choose a standard feedback system under "Unknown" (1). If your motor is equipped with a
1Vpp encoder, determine the parameters of the feedback system and select the appropriate encoder (2).
Typical parameters for the classification of 1Vpp encoders are the number of lines ‘s’ and the supply voltage
‘5 V or 5 V fixed’. The difference between the two voltage variants is the use of a sense line (5 V). Click on
"OK" (3) to complete the procedure.

Version: 2.4

Servo Drives AX5000

Electrical installation
1c. Feedback selection - TTL encoder
You can only select one existing feedback system. Either choose the feedback system of an existing
manufacturer or choose a standard feedback system under "Unknown" (1). If your motor is equipped with a
TTL encoder, determine the parameters of the feedback system and select the appropriate TTL encoder (2).
Typical parameters for the classification of TTL encoders are the number of lines ‘s’ and the supply voltage
‘5 V or 5 V fixed’. The difference between the two voltage variants is the use of a sense line (5 V). Click on
"OK" (3) to complete the procedure.

TTL Encoder!
Wire break detection is not supported for TTL encoders.
Note
Commutation
In asynchronous motors the rotor magnetic field is generated electrically by means of rotor windings, which
are energized by the servo drive. For this reason, neither a part-absolute nor an absolute encoder system is
required for commutation; wake+shake also does not need to be used. The magnetic field of the stator
induces a voltage in the rotor windings. This leads to a current flow in the rotor windings. This in turn
generates a magnetic field, which produces a torque.

Servo Drives AX5000

Version: 2.4

Electrical installation

9.13.5

Motor connections (1.5 A - 40 A devices)

9.13.5.1

X13 (A), X23 (B): AX5101 - AX5125 and AX520x

9.13.5.2

Terminal point
U

Signal
Motor connection U

Motor connection V

Motor connection W

Protective conductor

Shroud

Shield

Tightening torque

0.6 Nm

X13: AX5140
Terminal point Signal
Tightening torque
U
Motor connection U
V

Motor connection V

Motor connection
W
Protective
conductor
Shield

PE
Shroud

1.0 Nm

Shield connection!

Attention

100

The shield connection is established via the shroud of the motor connector. Please tighten
the knurled screw with a screwdriver (max. 1.0 Nm). Inadequately shield connection as a
result of a loose plug can lead to uncontrolled interference currents, which may also flow
via encoder or resolver cables. This approach can thus result in feedback problems.

Version: 2.4

Servo Drives AX5000

Electrical installation

9.13.5.3

X14 (A), X24 (B): Motor brake, thermal contact (1.5 A - 40 A devices)
Terminal
point
T-

Signal

T+

OCT + and
temp. + *
Protective
conductors and
inner shields of
the signal pairs
Brake, GND
Brake (Up) +
max. 2.2 A

BB+
*)

Current
load

Tightening
torque

Conductor crosssection

max. 0.25 Nm

0.2 – 1.5 mm²

OCT and temp.
-*

switch, KTY 83-1xx or KTY 84-1xx

Destruction of the AX5000!
Read the "Cables" chapter carefully and be sure to adhere to the specifications contained
in it.
Attention
Temperature monitoring for Beckhoff motors
AM2000 with resolver
Via resolver cable.
AM2000 with EnDat
The thermal protection contact is implemented in the encoder cable to the AX5000 and must be bridged to
the resolver connection via an adapter / Y cable.
AM2000 with BiSS
Not available.
AM3000 with resolver
Via resolver cable.
AM3000 with EnDat
Via motor cable.
AM3000 with BiSS
Via motor cable.
Linear motors AL2000
The thermal protection contact exits the motor via a separate cable.
1. If the pre-assembled Beckhoff motor and encoder cable is used, an additional thermal protection contact cable (ZK4540-0020-xxx) is required for connecting the thermal protection contact with the
AX5000 resolver interface, where temperature evaluation takes place.
2. If the AL2250 connector box is used, the thermal protection contact is automatically bridged to the motor cable.
Temperature monitoring and evaluation for motors from other manufacturers
1. Temperature monitoring via PTC, Klixon or bimetal
Evaluation either on the resolver interface (X12 / X22) or the temperature contact (X14 / X24)
2. Analog temperature evaluation (e.g. KTY)
Evaluation only on the temperature contact (X14 / X24)

Servo Drives AX5000

Version: 2.4

101

Electrical installation

9.13.6

Motor connections (60 A - 170 A devices)

9.13.6.1

X13: AX5160 and AX5172
Terminal point
U
V
W
PE

9.13.6.2

X13: AX5190 and AX5191
Terminal point
U
V
W
PE

9.13.6.3

Connection
Motor connection U
Motor connection V
Motor connection W
Protective conductor

X13: AX5192 and AX5193
Terminal point
U
V
W
PE

9.13.6.4

Connection
Motor connection U
Motor connection V
Motor connection W
Protective conductor

X14: Motor brake, thermal contact
Terminal point
TT+
PE
BB+

Connection
Temp. - *
Temp. + *
Signal pair shield
Brake GND
Brake (Up) +

Output current

max. 2.2 A

*) switch, KTY 83-1xx or KTY 84-1xx

102

Version: 2.4

Servo Drives AX5000

Electrical installation

9.14

External brake resistor
High voltage – Danger of death!

DANGER

9.14.1

9.14.2

Due to the DC link capacitors, the DC link terminal points "ZK+ and ZK- (DC+ and DC-)"
and "RB+ and RB-" may be subject to dangerous voltages of up to 875 VDC, even after the
servo drive was disconnected from the mains supply.
Wait 5 minutes for the AX5101 - AX5125 and AX520x; 15 minutes for the AX5140/AX5160/
AX5172; 30 minutes for the AX5190/AX5191; 45 minutes for the AX5192/AX5193 after disconnecting, and measure the voltage at the DC link terminal points "ZK+ and ZK- (DC+ and
DC-)". The device is safe once the voltage has fallen below 50 V.

X02 - AX5101-AX5125 and AX520x
Terminal point
DC+

Signal
DC link +

DC-

DC link -

X07 - AX5140
Terminal point
PE

Signal
Protective conductor

+RB

External brake resistor +

+RBint

Internal brake resistor +

-RB

Brake resistor GND

Operation of AX5140

Note

Commissioning the AX5140 can only be carried out when the terminal points "+RBint" and
"+RB" are bypassed (delivery state) or an external brake resistor is connected (terminal
points +RB" and "-RB"). If these measures are not taken then the AX5140 will be stopped
with the error message "FD4B – undervoltage".

Servo Drives AX5000

Version: 2.4

103

Electrical installation

9.14.3

AX5160 and AX5172
Terminal point
RB +
RB -

9.14.4

AX5190 and AX5191
Terminal point
RB +
RB -

9.14.5

Connection
Ext. brake resistor +
Ext. brake resistor -

AX5192 and AX5193
Terminal point
RB +
RB -

104

Connection
Ext. brake resistor +
Ext. brake resistor -

Version: 2.4

Connection
Ext. brake resistor +
Ext. brake resistor -

Servo Drives AX5000

Electrical installation

9.15

Motors and cables for servo drives

With longer motor cables the resulting commutation currents can lead to EMC faults. Use the tables below to
check whether mains chokes or mains filters have to be used in your application. When selecting the control
cabinet ensure that there is adequate space for mains chokes and mains filters, etc.
Lay 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 AX5160 to AX5193 series no motor chokes are required.
Note
Maximum cable length (including extensions) for a rated motor voltage up to 400 V:
Motor choke
Without
AX2090-MD50-0012
AX2090-MD50-0025
1)
2)

AX5101-AX5112 a. AX52xx
C21)
C3
< 25 m
< 25 m
< 100 m
< 100 m
-

AX5118 a. AX5125
C22)
C3
< 25 m
< 25 m
< 50 m
< 50 m

AX5140
C2
C3
< 35 m
-

For compliance with EN 61800-3 only with mains filter AX2090-NF50-0014.
For compliance with EN 61800-3 only with mains filter AX2090-NF50-0032.

In exceptional cases (sensitive sensors, etc.) it can be necessary to use a motor choke even for motor cable
lengths < 25 m.
Maximum cable length (including extensions) for a rated motor voltage up to 480 V
Motor choke
Without
AX2090-MD50-0012
AX2090-MD50-0025
1)
2)

AX5101-AX5112 a. AX52xx
C21)
C3
< 20 m
< 20 m
< 100 m
< 100 m
-

AX5118 a. AX5125
C22)
C3
< 20 m
< 20 m
< 50 m
< 50 m

AX5140
C2
C3
< 35 m
-

For compliance with EN 61800-3 only with mains filter AX2090-NF50-0014.
For compliance with EN 61800-3 only with mains filter AX2090-NF50-0032.

In exceptional cases (sensitive sensors, etc.) it can be necessary to use a motor choke even for motor cable
lengths < 20 m.
Mains choke
AX2090-ND50-0060
AX2090-ND50-0072
AX2090-ND50-0090
AX2090-ND50-0110
AX2090-ND50-0143
AX2090-ND50-0170

AX5160
AX5172
C2
C3 C2
C3
4)
5)
4)
5)
-

AX51901)
C2
C3
10 m 25 m
-

AX51912)
C2
C3
10 m 25 m
-

AX51922)
C2
C3
10 m 25 m
-

AX51933)
C2
C3
10 m 25 m

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.
3)
For compliance with EN 61800-3 only with mains filter AX2090-NF50-0180.
4)
Without mains choke up to 10 m max.
5)
Without mains choke up to 25 m max.
2)

Servo Drives AX5000

Version: 2.4

105

Advanced system characteristics

10.1

Commissioning

10.1.1

Important information for commissioning
Caution - Risk of injury!

WARNING

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. Analyze your system and take suitable
precautions to prevent damage being caused by these uncontrolled movements.
Potential causes of uncontrolled movements:
The diagnostic system of the AX5000 is equipped with complex plausibility checks, which constantly monitor
installation, operation, parameterization and operation and, if necessary, interrupt them with a diagnostic
message. The parameters listed below are monitored by default, although it is not possible to cover all
eventualities.
• Incorrect commutation results (e.g. on wake & shake), please note chapter Commutation techniques-->
Commutation error "F2A0".
• Take special care with third-party motors: When a motor or encoder is replaced or when a different
SysMan file (.TSM) is used, always execute the command "P-0-0166" without load connection and
analyze the result. If necessary, adjust the commutation offset, as described in the chapter on the
commutation process.
• Input of invalid parameters
• Measuring transducer and/or signal transducer defective or incorrectly adjusted
• Cables defective or not adequately shielded
• Incorrectly attached sensors

Increased attention in the case of vertical axes!

CAUTION

10.1.2

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.

Software requirements

Generally, two TwinCAT software modules are required for controlling the AX5000:
• TwinCAT NC PTP
• TwinCAT PLC
TwinCAT NC is a closed software module whose features the user can only influence via parameters. The
TwinCAT NC parameters can be set in the TwinCAT System Manager.
TwinCAT PLC is a program code which the user creates in the PLC Control development environment.

106

Version: 2.4

Servo Drives AX5000

Advanced system characteristics

Structure of TwinCAT NC PTP
TwinCAT NC has 2 tasks:
• NC task 1 SPP (Set PreParation task)
• NC task 1 SEC (Set ExeCution task)
The SPP task is responsible for planning the requested traversing task. The SAF task is responsible for
executing the motion command.
The traversing task leaves the PLC in the direction of the ADS router with destination NC-Task 1 SVB (NC
task 1 SPP). The router relays the telegram to this task.

The NC accepts or rejects the message. The response arrives back at the calling block in the PLC via the
same route. Instructions are issued based on blocks contained in TCMC.lib. Once the NC has accepted the
instruction, the system tries to calculate a solution taking into account the boundary conditions (max.
velocity, acceleration, deceleration, and jerk).

Servo Drives AX5000

Version: 2.4

107

Advanced system characteristics
If a solution exists, a table containing the position (s) velocity (v), acceleration/deceleration (a) and jerk (j) for
the whole travel time within the sampling time of the SEC task is transferred to the SEC.
If no solution exists, the system deviates downwards based on maximum jerk, maximum acceleration, and
maximum velocity (in this order).
Actual and set values shown in the diagram are served by the 1_Enc axis and 1_Drive axis components.

Since the AX5000 is known to the system as a slave, linking can take place automatically if required. In the
event of problems the link can be checked by the user.

108

Version: 2.4

Servo Drives AX5000

Advanced system characteristics
NC / AX5000 link specification:
NC set values
axis n_Drive / outputs/axis
n_DriveOut / nOutData1
axis n_Drive / outputs/axis
n_DriveOut / nOutData2
axis n_Drive / outputs/axis
n_DriveOut / nCtrl1

AX5000 set values
NC actual values
MDT n / position set value axis n_Enc / inputs / axis
(option)
1_Enc_In / nInData1
MDT n / velocity set value
MDT n / master control
word (Hi-byte)

AX5000 Actual values
AT n / actual position
value sensor 1

axis n_Drive / inputs/axis AT n / drive status word
n_DriveIn / nStatus1 &
nStatus2
axis n_Drive / inputs/axis WcState' / WcState
n_DriveIn / nStatus4

10.1.3

Rotary motors

10.1.3.1

Commissioning under TwinCAT 2

This tutorial describes the procedure for commissioning the servo drive AX5000. All the steps shown are
based on TwinCAT version 2.11. The individual sections build on each other and should be followed
sequentially.
The tutorial shows a possible approach as an example. Alternative approaches are possible.

Creating a project
• Open TwinCAT in the System Manager

• Create a project via the icon (1) in the toolbar or via the menu bar: File (2) → New
→ An empty project is created.

Servo Drives AX5000

Version: 2.4

109

Advanced system characteristics
Select target system
Target system available in selection list
In the System Manager select the target system (runtime system), to which the drive is connected as
EtherCAT slave.
In the System Manager, open System and press
Choose Target… (1).
The Choose Target System window opens. On the
left there is a list of all known target systems, for
which a route has already been entered.
Further target systems can be found via Search
(Ethernet) (2), if the system is not listed under the
known systems.
This opens the window Add Route.
Before starting the search for more target systems,
set the IP address as Address Info (3).

Start the search with Broadcast Search (4).
A list with all target systems that were found is
displayed.
Select the required target system.
For a CX the name CX_abcdef is assigned by
default; abcdef represent the last 6 digits of the MAC
ID, which is printed on the name plate.

Create link using Add Route (5).
You will see a password prompt for the Embedded
PC.

110

Version: 2.4

Servo Drives AX5000

Advanced system characteristics
Enter the required password (The Beckhoff default
password for Windows 7 is "1").
Confirm with OK.
Close the Add Route window with Close (6).

Select the newly added target system.
Press OK to confirm your selection.

→ The target system is selected.

Servo Drives AX5000

Version: 2.4

111

Advanced system characteristics
Adding EhterCAT master and drives
You can implement your drive in your TwinCAT project either manually or via an automatic scan. It is
advisable to scan, because this will insert the required drive devices directly into the project.
TwinCAT in ConfigMode
To start the scanning process, TwinCAT must be in ConfigMode. ConfigMode is one of several TwinCAT
states, which is displayed in the status bar of the System Manager. If the text is highlighted in blue,
ConfigMode is activated, and the scan can be started. If the text is highlighted in green or red, follow these
steps:
Click the blue gear icon in the toolbar.
You will see a query regarding the state change to be
carried out.
Confirm the state change with OK.

→

TwinCAT switches to ConfigMode, and the text highlighting
in the status bar turns blue.
TwinCAT is in ConfigMode.

Start drive scanning
If the right target system and ConfigMode are enabled, the scan can be started.
In the System Manager select I/O - Configuration → I/O
Devices.
Press the Scan in the toolbar or right-click on I/O Devices
and select Scan Devices….
In both cases, the following sequence starts:
Close the information window with OK.

Select the devices to be automatically added to the
TwinCAT project.
As a minimum, select the device with the supplement
(EtherCAT).
Complete the selection with OK.

112

Version: 2.4

Servo Drives AX5000

Advanced system characteristics
In the System Manager all selected devices are shown
below the "I/O Configuration" icon.
Confirm the subsequent query whether the boxes should be
scanned with Yes
If the query is answered in the negative, no boxes /
EtherCAT slaves and therefore no drives are scanned.

The message regarding a found servo drive or servo
terminal can trigger a special scan for motors. Reads the
electronic type plates of the motors and enters the data
directly in the TCDriveManager.
Confirm the query with Yes to read the electronic type
plates.
If the query is not confirmed, no name plates are read. In
this case, the motor types must be entered manually. See
Determining the motor type [} 115].
Wait for the scan to complete.
The System Manager then shows the servo drives and
terminals that were found. To control the motors via the
TwinCAT project, an NC or CNC axis configuration has to be
created.
Confirm the query with Yes to create an NC axis
configuration.

Servo Drives AX5000

Version: 2.4

113

Advanced system characteristics
As a result of the automatic axis configuration creation, an
axis is added for each motor that was found and linked
accordingly.
If you require a CNC axis, close the window with No and
create the configuration manually. See Create NC axis
configuration [} 118].
The created NC axis configuration is shown in the System
Manager.
Decline the request to activate Free Run with No.

→The drive is fully implemented in the TwinCAT project.
Also see about this
2 Configuring devices [} 115]

114

Version: 2.4

Servo Drives AX5000

Advanced system characteristics
Configuring devices

• In the System Manager, under I/O configuration → I/O devices, select the EtherCAT master, to which
the AX5000 units are connected. In this example select "Device 6" for the AX5000. Here, open "Drive
9" (1).
• Open the Configuration tab (2).
→ The TCDriveManager is open.
Motor settings
In the Configuration tab, a tree structure is shown on the left, which can be used to navigate to the individual
dialog pages. To check or set the motor type, edit the motor and feedback settings (3).
• Open either Channel A or Channel B → Parameter → Motor and Feedback (3).
The motor and feedback settings appear to the right of the tree.
If the fields Motor type (4) and Feedback 1 type (5) are empty, this may have two reasons:
1. The motor does not have an electronic name plate: Determine the motor without electronic type plate
[} 116]
2. The motor has an electronic name plate: Determine the motor with electronic type plate [} 117]

Servo Drives AX5000

Version: 2.4

115

Advanced system characteristics
Determine the motor without electronic type plate
Press the Select Motor button to add the motor type.
A selection window opens, which shows all motor
versions and their properties.

Look for the motor of your drive in the list.
Confirm the selection with OK.
A further window appears, in which you have to
select or set the mains voltage to which the AX5000
is connected.

Make the required settings.
Confirm the selection with OK.

Selecting a motor type makes it appear in the Motor
type field (1). When the motor type is selected, the
encoder system used in this motor type also
becomes known and is shown in the field Feedback 1
type.

When the motor type is specified, a further query
appears, as to whether the NC or CNC parameters
relating to this axis should also be set.
If you confirm this message with OK, you will be
directed to the corresponding settings. See Create NC
axis configuration [} 118].

→ The motor type is set.

116

Version: 2.4

Servo Drives AX5000

Advanced system characteristics
Determine the motor with electronic type plate
Press the “Scan motor and feedback 1*” button.
Wait until the loading process is complete and the
window closes.
A window opens, in which the feedback type that was
determined is displayed.

Confirm the display with OK.

If this error message appears, instead of the
message about the determined feedback type, this
may be because your scanned motor has no
electronic name plate.
In this case, proceed as described under Determine
the motor without electronic type plate [} 116].

→ The electronic name plate is read, and the motor type and the feedback type have been determined.

Servo Drives AX5000

Version: 2.4

117

Advanced system characteristics
Create NC axis configuration
Right-click on NC – Configuration (1) in the System
Manager.
Select Insert Task…

Name the NC task
Confirm the entry with OK.

The System Manager expands below the NC
configuration to show the added NC task. The logical
NC axes can now be added below the Axes icon.

Right-click on Axes within the axis configuration.
Select Append Axis….
Enter a name for the NC axis (2).
Determine the axis type (3).
Confirm with OK.
In the System Manager the new axis appears with its
name within the NC axis configuration. Now link the
logical NC axes with the physical axes (the channels
of the respective AX5000).
Open Axis 1 in the System Manager tree
Switch to the Settings tab
Link the NC axis with the hardware axis via
Link To I/O... (4).
Select the AX5000 channel to be linked from the list
You can filter the list based on the channel link
status. The filter Unused (5) only shows channels that
are not linked. The setting All (5) shows all channels,
irrespective of their link status.
Confirm the selection with OK.

118

Version: 2.4

Servo Drives AX5000

Advanced system characteristics
Create CNC axis configuration
Right-click on CNC – Configuration (1) in the System
Manager.
Select Inert Task in the context menu…

Name the CNC task
Confirm the entry with OK.

The System Manager expands in the CNC
Configuration section to show the added CNC task.
The logical CNC axes can now be added below the
Axes icon.
Right-click on Axes within the axis configuration.
Select Append Axis….

Select the axis type from the list.
Confirm the selection with OK.

In the System Manager the new axis appears with its
name below the CNC task. Link the CNC axes with
the drive, in order to enable control.
Open Axis_1 in the System Manager.
Open the Configuration tab (2).
Link the CNC axis with the hardware axis via Link to
I/O... (3).

Select the axis to be linked from the list
You can filter the list based on the axis link status.
The filter Unused (4) only shows axes that are not
linked. The setting All (4) shows all axes, irrespective
of their link status.
Confirm the selection with OK.

Servo Drives AX5000

Version: 2.4

119

Advanced system characteristics
Specifying the scaling factor
The scaling factor is an application-related parameter, which is required for converting the position
representations between the NC and the AX5000. The NC is usually parameterized in the application unit
(e.g. degree). The AX5000 operates with a position representation of 2x increments per revolution (with x =
[20...31]). If, for example, a motor revolution corresponds to an application revolution (360 degrees), and x =
20 was selected, the resulting scaling factor is 360 degrees / 220.
.
In the System Manager tree, open I/O –Configuration
→ I/O Devices → Device 6 → Drive 9 (1).
Open the TCDriveManager via the Configuration tab
(2).
In the TCDriveManager tree select Channel B →
Parameter → Scalings and NC Parameters (3).
A table with different NC parameters and the
corresponding values (4) can be found to the right of
the TCDriveManager tree. Since the initial parameter
values are default values that were not explicitly
saved by the user, they are regarded as invalid and
therefore shown in red font. The individual parameter
values depend on the scaling factor, so that all
parameter values can be adjusted by modifying the
scaling factor.
Adjust the scaling factor via the field Feed constant
(5).
Select the unit (6).
Confirm the change with Save (7).
Acknowledge the information window with OK.

By confirming the change, the parameter values and
their units are adjusted to the new reference value
and appear in black font.

→ Your motor parameters are set correctly.
The configuration of Channel A follows the same procedure as for Channel B.

120

Version: 2.4

Servo Drives AX5000

Advanced system characteristics
Specifying velocities
Checking the scaling factor
In the System Manager, open NC- Configuration →
NC-Task 1 SAF → Axes → Axis 1 → Axis 1_Enc (1).
Open the Parameter tab (2).
Compare the value of the Scaling Factor (3) with the
value of the scaling factor.
If the value does not match the scaling factor, select
the field (3) and enter the scaling factor.
ATTENTION: Please ensure decimal points are used,
not decimal commas, as used in Germany!
Save changes permanently with Save now.
Wait a moment and close the window with OK.

The value change is indicated by the blue color of the
field (4).
Select the field with the changed value (4) to activate
the Download button (5).
Press Download (5) to save the change.
Another window appears:

Check the value for the second axis.

Servo Drives AX5000

Version: 2.4

121

Advanced system characteristics
Setting the velocities
In the System Manager, open NC – Configuration →
NC-Task 1 SAF → Axes → Axis 1 (6).
Open the Parameter tab (7).
Set the velocities as required.
ATTENTION: Please ensure decimal points are used,
not decimal commas, as used in Germany!

The value change is indicated by the blue color of the
field.
→ The velocities are adjusted and take effect with the
next configuration.

Parameter
Reference Velocity

Description
The reference velocity must be set to a value ≥ the "maximum
velocity".
Maximum Velocity
Maximum velocity (= max. velocity of the NC motion command)
Manual Velocity (Fast)
Velocity in the manual test menu (F1 and F4)
Manual Velocity (Slow)
Velocity in the manual test menu (F2 and F3)
Calibration Velocity (towards plc cam) Homing velocity
Calibration Velocity (off plc cam)
Homing velocity

122

Version: 2.4

Servo Drives AX5000

Advanced system characteristics
Test mode
To test the TwinCAT project with all its settings on the drive, the settings have to be transferred to the
runtime system. To this end the whole configuration must be loaded into the runtime system of the target
hardware (e.g. a CX2000) and started there. After successful configuration, the motor control can be tested
manually in manual mode.
Before commissioning the manual control, it is advisable to check the control status of the drive.

Configure drive
Before you can start the controller, you must transfer the TwinCAT settings to the target system. To do this,
activate the configuration.
Click the Activate Configuration icon in the toolbar.
Confirm the warning with Yes.

Start the configuration with OK.

Start Run mode with OK.

→

Wait until the text highlighting turns green. Only then
is the application in Run mode.

→ All your settings were transferred to the runtime system. The drive is ready for operation.

Servo Drives AX5000

Version: 2.4

123

Advanced system characteristics
Checking the state
In the first step it makes sense to check the EtherCAT communication state of the system.

• In the System Manager, open I/O – Configuration → I/O Devices → Device 6 (EtherCAT) (1).
• Open the Online tab (2).
All slaves of the selected EtherCAT master and its communication states are displayed (3).
• Use the "buttons" in (4) to change the EtherCAT state of the master.
To ensure smooth operation, the states of all devices should be OP (see State status column the table
(3)).
→ Your system is checked and ready for operation.

124

Version: 2.4

Servo Drives AX5000

Advanced system characteristics
Activating manual control
TwinCAT has a manual test menu, which allows you to start the drive manually in a test mode. The manual
test menu can be called up via the drive (Devices) or via the axis configuration.
Manual test menu for drive
In the System Manager, open I/O - Configuration → I/
O Devices → Device 6 → Drive 9 (1).
Switch to tab NC-B: Online (2) or NC-A: Online (3).
In this case you would test the drive for axis 2 by
selecting NC-B: Online (2). Select NC-A: Online (3) to
test axis 1.
Manual test menu for axis configuration
In the System Manager, select NC - Configuration →
NC-Task 1 SAF → Axes → Axis 2 (4) or Axis 1 (5).
Depending on which of the two axes is to be tested.
Open the Online tab (6).

Setting the drive enables
To operate the motors manually, manual drive control
must be enabled. The control is activated when
Enabling Controller (7) is active. In addition, the drive
requires Enabling Feed Fw** (7) activated for forward
travel, and Enabling Feed Bw (7) for reverse travel.
Use the Set button (8) to change the settings.
Use the All (10) button to set all settings and the
override (11) to 100%,
or all settings can be specified manually:
Tick the individual options (9) to activate them.
Enter the Override value (11).
The override (11) scaled the set velocity of the NC
motion command. The Override value can be
between 0% and 100%.

In the function view, the activated options are
indicated by ticks (12). In addition, the Status (log.)
(13) has changed with the activation, and the override
has been entered. The drive is ready for operation
and can be controlled with the manual mode menu.

*If this flag is set, the system tries to activate the drive control (of the AX5000) and to set the drive to a state
in which it follows the set value specifications of the NC. The "Ready" flag is set if the drive acknowledges
this request as successful.
**These so-called direction enables make it possible for the NC to accept motion commands in the
respective direction. The drive does not see these two flags.

Servo Drives AX5000

Version: 2.4

125

Advanced system characteristics
Manual control guide
The drive can be controlled using the buttons F1 to F9 and the fields Target Position and Target Velocity.

The following table provides an overview of all manual mode functions.
Function
F1
F2
F3
F4
F5

Description
Reverse travel with Manual Velocity (Fast)
Reverse travel with Manual Velocity (Slow)
Forward travel with Manual Velocity (Slow)
Forward travel with Manual Velocity (Fast)
Start a direct travel command
• Enter the Target Position
• Enter the Target Velocity

• Start the travel command with F5
Stop a direct travel command

F8
F9

NC reset; the current motion command is aborted.
Initiate homing (see TwinCAT documentation)

126

Version: 2.4

Servo Drives AX5000

Advanced system characteristics
Typical error messages
If you are in the manual mode menu and the position
value (2) is greyed out, this has the following reason:
A greyed out shown actual position for EtherCAT
drives indicates a "WC state error". In this case, the
WC state flag generated by the EtherCAT master is
"true", which means that the NC does not receive
valid position data from the drive.
The corresponding EtherCAT drive is probably not in
EtherCAT state SafeOp or Op. Further analysis is
required to ascertain why the drive is not in this state.

To investigate further, open the TCDriveManager via
Configuration (3). In the status bar, another error
code is shown at Diag Code (4). Check the drive
state (5). Select Diagnostics (6) from the tree
structure, in order to obtain further information about
the error. A list (7) on the right shows the whole error
history. Update the list via the button with the two
green arrows (8). Once the cause is identified and
corrected, reset the axis via the R button (9).

After a short time, the error indication will disappear
from the status line for the axis (10), and the drive will
be in OP state (operational) (11). Update the list of
error messages once more (8). It should contain no
more error messages (12).

In the manual mode menu for the axis, the position
value (13) is shown in black again.
Press the F8 button to acknowledge the NC error (14)
in the manual mode menu.
The drive is ready for operation again when the
"Ready" flag is set.

Servo Drives AX5000

Version: 2.4

127

Advanced system characteristics

10.1.3.2

Commissioning under TwinCAT 3

This tutorial describes the procedure for commissioning the servo drive AX5000. All the steps shown are
based on TwinCAT Version 3. The individual chapters build on each other and should be followed
sequentially.
The tutorial shows a possible approach as an example. Alternative approaches are possible, which are
referred to in several places.

Creating a project
Open TwinCAT in the Windows Start menu.
Create a new project using the option New TwinCAT
Project ... (1) on the start page.
If TwinCAT opens without the start page shown on
the left, create a new project via the menu bar: File
(2) → New → Project.
In both cases, the window for creating a project will
open.

Assign project name (3).
Specify storage location (4).
Confirm with OK.

→ The new project appears with the Solution Explorer on the left and the workspace on the right.

128

Version: 2.4

Servo Drives AX5000

Advanced system characteristics
Select target system
Target system available in selection list
In order to control your drive with TwinCAT, the software needs to communicate with the hardware. To this
end, the drive has to be selected as target system for the TwinCAT project.
The toolbar indicates which target system is
active (1).
Open the selection list using the small arrow (2)
to the right of the display window.
Select the drive as the target system.
Confirm query with Yes to change the platform
settings automatically.
This setting can be found in the toolbar (3).
If you answer No, this setting must be made
manually:
Open the platform selection list via the small
arrow (4) to the right of the display window (3).
Select a system-compatible platform.
→ The newly selected target system appears in
the display window (1).
→ The newly selected platform appears in the
display window (3).
Target system not available in selection list
If the target system is not in the list, follow these steps:
Choose Target System... select from the list,
or open System in the Solution Explorer and
press Choose Target... (5).
Both options take you to the Choose Target
System window. On the left is a list of all
target systems already in use. This list
should be identical to the previous selection
list.
Find more target systems via Search
(Ethernet) (6).
This opens the window Add Route.

Servo Drives AX5000

Version: 2.4

129

Advanced system characteristics
Before starting the search for more target
systems, set the IP address as Address Info
(7).
Start the search with Broadcast Search (8).
A list with all target systems that were found
is displayed.

Select the required target system.
Create link using Add Route (9).
You will see a password prompt for the
Embedded PC.

Enter the required password (The Beckhoff
default password for Windows 7 is „1“).
Confirm with OK.
Close the Add Route window with Close
(10).

Select the newly added target system.
Press OK to confirm your selection.
Because the platform to be used depends on
the respective target system, the platform
also needs to be adjusted if the target
system is changed.

130

Version: 2.4

Servo Drives AX5000

Advanced system characteristics
Confirm query with Yes to change the
platform settings automatically.
This setting can be found in the toolbar (3).
If you answer No, this setting must be made
manually:
Open the platform selection list via the small
arrow (4) to the right of the display window
(3).
Select a system-compatible platform.
→ The newly selected target system
appears in the display window (1).
→ The newly selected platform appears in
the display window (3).

Implementing devices
You can implement your drive in your TwinCAT project either manually or via an automatic scan. It is
advisable to scan, because this will insert the required drive devices directly into the project.
TwinCAT in ConfigMode
To start the scanning process, TwinCAT must be in ConfigMode. ConfigMode is one of several TwinCAT
states, which can be identified by the small gear icon in the status bar at the bottom of the screen. If the icon
is blue, ConfigMode is activated, and the scan can be started. If the icon is green or red, follow these steps:
Click the blue gear icon in the toolbar.
You will see a query regarding the state change to be
carried out.
Confirm the state change with OK.

TwinCAT switches to ConfigMode, and the icon in the
status bar turns blue.
→
→ TwinCAT is in ConfigMode.

Servo Drives AX5000

Version: 2.4

131

Advanced system characteristics
Start drive scanning
If the right target system and ConfigMode are enabled, the scan can be started.
In the Solution Explorer select I/O → Devices.
Press the Scan in the toolbar or right-click on
Devices and select Scan.
In both cases, the following sequence starts:
Close the information window with OK.

Select the devices to be automatically added to
the TwinCAT project.
As a minimum, select the device ending with
(EtherCAT).
Complete the selection with OK.
The Solution Explorer shows all selected
devices.
.

132

Confirm the following query with
Yes. If you answer No, the scan is
aborted. The message regarding a
found servo drive or servo terminal
can trigger a special scan for
motors. This would read the
electronic name plates of the
motors and enter the data directly
in the TCDriveManager.

Version: 2.4

Servo Drives AX5000

Advanced system characteristics
Confirm the query with Yes to read the
electronic type plates.
If the query is not confirmed, no name plates
are read. In this case, the motor types must be
entered manually. See Determining the motor
type [} 134].
Wait until the scan is complete.
The Solution Explorer then shows the servo
drives and terminals that were found.

To control the motors via the
TwinCAT project, an NC or CNC
axis configuration has to be
created. Confirm the query with
Yes to create an NC axis
configuration. As a result of the
automatic axis configuration
creation, an axis is added for each
motor that was found and linked
accordingly.
If you require a CNC axis, close the
window with No and create the
configuration manually. See Create
axis configuration [} 137].
The created NC axis configuration
is shown in the Solution Explorer.

Decline the request to activate
Free Run with No.

→The drive is fully implemented in the TwinCAT project.

Servo Drives AX5000

Version: 2.4

133

Advanced system characteristics

Free Run mode

Note

Free Run mode is used for synchronising the axes, if no NC is available. When NC is used,
a triggering task is activated, which synchronises the axes. This is not available if the system is operated without NC. In Free Run mode a virtual task is created, which enables axis
synchronisation and reading of I/O data.

If the system is in Free Run mode, the blue and red
status bar icons flash alternately.

→
←
→

Also see about this
2 Configuring devices [} 134]

Configuring devices

Determining the motor type
If a motor has no electronic name plate or the offer to scan for motors was declined, the motor type has to be
entered manually in the TCDriveManager.
Opening the TCDriveManagers
In the Solution Explorer, open I/O → Devices →
Device 1 → Drive 5 (1).
Open the Configuration tab (2).

→ The TCDriveManager is open.

134

Version: 2.4

Servo Drives AX5000

Advanced system characteristics
Motor settings
Under the Configuration tab you will see a tree
structure on the left-hand side, which can be used for
all the required settings.
To check or set the motor type, edit the motor and
feedback settings (3).
Open either Channel A or Channel B → Parameter →
Motor and Feedback (3).

The motor and feedback settings appear to the right
of the tree.
If the fields Motor type (4) and Feedback 1 type (5)
are empty, this may have two reasons:
The motor does not have an electronic name plate:
Determine the motor type without electronic name
plate [} 136]
The motor has an electronic name plate that was not
read: Determine the motor type with an electronic
name plate that was not read [} 137]

Servo Drives AX5000

Version: 2.4

135

Advanced system characteristics
Determine the motor type without electronic name plate
Press the Select Motor button to add the motor type.
This opens a selection window that lists all the motor
type versions and their features.

Look for the motor of your drive in the list.
Confirm the selection with OK.
Another window appears, in which you can make
advanced settings.

Make the required settings.
Confirm the selection with OK.

Selecting a motor type makes it appear in the Motor
type field (1). The field Feedback 1 type (2) is
completed automatically, since for each motor type a
corresponding feedback type is stored in the
TCDriveManager.

Once the motor type has been specified, a further
query appears relating to the parameters of the axis
configuration.
If you confirm this message with OK, you will be
directed to the corresponding settings. See Create
axis configuration [} 137].

→ The motor type is set.

136

Version: 2.4

Servo Drives AX5000

Advanced system characteristics
Determine the motor type with an electronic name plate that was not read
Press the “Scan motor and feedback 1*” button.
Wait until the loading process is complete and the
window closes.
A new window opens, in which the feedback type that
was determined is displayed.

Confirm the display with OK.

Create axis configuration
Right-click on Motion (1) in the Solution Explorer.
Select Add New Item....

Select Type (2) for your axis configuration.
Enter a name for the axis configuration (3).
Click OK to create the axis configuration.
The next steps depend on the axis type.

Servo Drives AX5000

Version: 2.4

137

Advanced system characteristics
Creating an NC axis
If an NC axis configuration has already been created, the individual axes can be created and linked.
The Motion section of the Solution Explorer expands and shows the new NC axis configuration.
Right-click on Axes within the axis configuration.
Select Add New Item....
Enter a name for the NC axis (1).
Determine the axis type (2).
Confirm with OK.

In the Solution Explorer the new axis appears with its
name within the NC axis configuration. Link the
individual NC axes with the drive, in order to enable
control.
Open Axis 1 in the Solution Explorer.
Switch to the Settings tab.
Link the NC axis with the hardware axis via Link to I/
O... (3).

Select the drive to be linked from the list.
You can filter the list based on the axis link status.
The filter Unused (4) only shows axes that are not
linked. The setting All (4) shows all axes, irrespective
of their link status.
Confirm the selection with OK.
→ Your NC axis is successfully linked with the drive.

138

Version: 2.4

Servo Drives AX5000

Advanced system characteristics
Creating a CNC axis
If a CNC axis configuration has already been created, the individual axes can be created and linked.
The Motion section of the Solution Explorer expands and shows the new CNC axis configuration.
Right-click on Axes within the axis configuration.
Select Add New Item....

Select the axis type from the list.
Confirm the selection with OK.
In the Solution Explorer the new axis appears with its
name within the CNC axis configuration. Link the
individual CNC axes with the drive, in order to enable
control.
Open Axis_1 in the Solution Explorer.
Open the Configuration tab (1).
Link the CNC axis with the hardware axis via Link to
I/O... (2).

Select the drive to be linked from the list.
You can filter the list based on the axis link status.
The filter Unused (3) only shows axes that are not
linked. The setting All (3) shows all axes, irrespective
of their link status.
Confirm the selection with OK.
→ Your CNC axis is successfully linked with the drive.

Servo Drives AX5000

Version: 2.4

139

Advanced system characteristics
Specifying the scaling factor
The scaling factor is an application-specific parameter, which is required for converting position values.
In the Solution Explorer, open I/O → Devices →
Device 1 → Drive 5 (1).
Open the TCDriveManager via the Configuration tab
(2).
In the tree structure select Channel A → Parameter
→ Scalings and NC Parameters (3).
On the right next to the tree structure, there is a table
showing various motor parameters and associated
values (4). Since the initial parameter values are
default values that were not explicitly saved by the
user, they are regarded as invalid and therefore
shown in red font. The individual parameter values
depend on the scaling factor, so that all parameter
values can be adjusted by modifying the scaling
factor.
Adjust the scaling factor via the field Feed constant
(5).
Select the unit (6).
Confirm the change with Save (7).
Acknowledge the information window with OK.

By confirming the change, the parameter values and
their units are adjusted to the new reference value
and appear in black font.
→ Your motor parameters are set correctly.
The configuration of Channel B follows the same
procedure as for Channel A.

140

Version: 2.4

Servo Drives AX5000

Advanced system characteristics
Specifying velocities
Checking the scaling factor
In the Solution Explorer, open Motion → NC-Task 1
SAF → Axes → Axis 1 → Enc (1).
Open the Parameter tab (2).
Compare the value of the Scaling Factor Numerator
(3) with the value of the scaling factor.
If the value does not match the scaling factor, select
the field (3) and enter the scaling factor.
ATTENTION: Please ensure decimal points are
used, not decimal commas, as used in Germany!
The value change is indicated by the blue colour of
the field (4).
Select the field with the changed value (4) to activate
the Download button (5).
Press Download (5) to save the change.
Another window appears:

Save changes permanently with Save now.
Wait a moment and close the window with OK.
Also check the settings of Channel B.

Setting the velocities
In the Solution Explorer, open Motion → NC-Task 1
SAF → Axes → Axis 1 (6).
Open the Parameter tab (7).
Set the velocities as required.
ATTENTION: Please ensure decimal points are
used, not decimal commas, as used in Germany!

The value change is indicated by the blue colour of
the field.

Servo Drives AX5000

Version: 2.4

141

Advanced system characteristics
Parameter
Reference Velocity
Maximum Velocity
Manual Velocity (Fast)
Manual Velocity (Slow)
Calibration Velocity (towards plc cam)
Calibration Velocity (off plc cam)

Description
Reference velocity of an analog servo drive
Maximum velocity (= maximum value of the field Target Velocity)
Velocity in the manual test menu (F1 and F4)
Velocity in the manual test menu (F2 and F3)
Homing velocity
Homing velocity

→ The velocities are adjusted and take effect with the next configuration.

142

Version: 2.4

Servo Drives AX5000

Advanced system characteristics
Test mode
To test the TwinCAT project with all its settings on the drive, the settings have to be transferred to the drive.
To do this, the entire system must be configured. After successful configuration, the motor control can be
tested manually in manual mode.
Before commissioning the manual control, it is advisable to check the control status of the drive.

Configure drive
Before you can start the controller, you must transfer the TwinCAT settings to the drive. To do this, activate
the configuration.
Click the Activate Configuration icon in the toolbar.
Activate the configuration with OK.
All settings are applied to the drive.

Start Run mode with OK.

Wait until the blue gear icon in the status bar turns
green. Only then is the application in Run mode.
→
→ All your settings were applied to your drive. The drive is ready for operation.

Servo Drives AX5000

Version: 2.4

143

Advanced system characteristics
Checking the state
Before you operate the motor control, check the system states of the drive.
In the Solution Explorer, open I/O → Devices →
Device 1 (EtherCAT) (1).
Open the Online tab (2).
All drive devices are displayed (3).
The function keys (4) can be used to change the
states of all devices.
To ensure smooth operation, the states of all devices
should be OP (see State status column the table (3)).

→ Your system is checked and ready for operation.

Activating manual control
TwinCAT has a manual test menu, which allows you to start the drive manually in a test mode. The manual
test menu can be called up either via the drive (Devices) or via the axis configuration.
Manual test menu for drive
In the Solution Explorer, open I/O → Devices →
Device 1 → Drive 5 (1).
Switch to tab NC-B: Online (2) or NC-A: Online (3).
In this case you would test the drive for axis 2 by
selecting NC-B: Online (2). Select NC-A: Online (3) to
test axis 1.

144

Version: 2.4

Servo Drives AX5000

Advanced system characteristics
Manual test menu for axis configuration
In the Solution Explorer, select Motion → NC Task 1
SAF → Axes → Axis 2 (4) or Axis 1 (5). Depending
on which of the two axes is to be tested.
Open the Online tab (6).

Setting the authorization permissions
To operate the motors manually, you have to enable
manual drive control. The control is enabled when
Enabling Controller (7) is activated. In addition, the
drive requires Enabling Feed Fw (7) activated for
forward travel, and Enabling Feed Bw (7) for reverse
travel.
Use the Set button (8) to change the settings.
Use the All (10) button to set all settings and the
override (11) to 100%,
or to set all settings manually:
Tick the individual options (9) to activate them.
Enter the Override value (11).
Override (11) overrides over all previous velocity
limits and indicates the ratio of the respective
velocity. The Override value can be between 0% and
100%.
In the function view, the activated options are
indicated by ticks (12). In addition, the Status (log.)
(13) has changed with the activation, and the override
has been entered. The motors are ready for operation
and can be controlled with the manual test menu.

→ Manual control is activated and can be used.

Servo Drives AX5000

Version: 2.4

145

Advanced system characteristics
Manual control guide
The drive can be controlled using the buttons F1 to
F9 and the fields Target Position and Target Velocity.

The following table provides a brief overview of all manual mode functions.
Function
F1
F2
F3
F4
F5

• Start the travel command with F5
Stop a direct travel command

F8
F9

Reset the control (if hand control has stopped responding)
Trigger homing (see TwinCAT documentation)

146

Version: 2.4

Servo Drives AX5000

Advanced system characteristics
Typical error messages
If you are in the manual test menu and the position
value (2) is greyed out, the manual test menu issues
an error message (1), and manual control is not
active. The error message gives no details about the
cause. To investigate further, open the
TCDriveManager via Configuration (3).

In the status bar for the axes, another error code is
shown at Diag Code (4). Check the drive state (5).
Select Diagnostics (6) from the tree structure, in order
to obtain further information about the error. A list (7)
on the right shows the whole error history. This list
can be used to identify the specific cause of the error
message. Update the list via the button with the two
green arrows (8), to show the latest error messages.
Once the cause is identified and corrected, reset the
axis via the R button (9).
After a short time, the error indication will disappear
from the status line for the axis (10), and the drive will
be in OP state (operational) (11).
Update the list of error messages once more (8). It
should contain no more error messages (12).

In the manual test menu for the axis, the position
value (13) is shown in black font once again.
Press the F8 button to reset the error (14) in the
manual test menu.
→ The drive is ready for operation again.

Servo Drives AX5000

Version: 2.4

147

Advanced system characteristics

10.1.4

Linear motors

10.1.4.1

Commissioning of linear motor axes

Beckhoff Automation GmbH & Co. KG does not sell complete linear motor units. Magnetic plates and coil
parts are offered for sale. The machine manufacturer selects a linear measuring system to suit the
application. The assembly takes place at the machine manufacturer’s premises. This leads to various
selection options, whose results usually cannot be determined until commissioning. For example, the
direction in which the measuring system counts may not be known.
An incremental measuring system is often used with linear motors. This necessitates the use and
configuration of "Wake & Shake".

Requirements for commissioning

XML motor description
The XML description matching the motor is required for the commissioning of a linear motor on the AX5000
servo drive. The associated XML files for Beckhoff linear motors are contained in the TwinCAT setup
(AX5000 Download Package).

XML files for third-party motors!
In the case of third-party motors the required XML descriptions can be generated with the
help of the "Tc Motor Data File Generator".
Note

XML measuring system description
If a measuring system is used, it must also be present in the form of an XML description. Without this XML
description the measuring system does not appear in the TC Drive Manager selection list. A missing XML
description can be generated exclusively by Beckhoff Automation GmbH & Co. KG.
If an incremental (non-absolute) measuring system with sine/cosine or TTL signals is used, a corresponding
system can be chosen as "Unknown" from the list shown below.

148

Version: 2.4

Servo Drives AX5000

Advanced system characteristics
An overview of feedback systems already used can also be found in the AX5000 system manual. The picture
detail below shows a selection of possible feedback systems that could come into question as a measuring
system.

Commissioning

Motor and feedback selection
The motor should be selected first, then the measuring system. This order ensures that the pole pair
distance of the linear motor is automatically taken into account in the feedback settings of the parameter.
In the case of linear encoders with TTL signals, a distinction must be made between the signal period and
the resolution. The manufacturers specify the resolution when evaluating all edges ("after quadrupling"). For
the AX5000 the signal period must be specified. A measuring system whose resolution is specified by the
manufacturer as 1 µm, for example, has a signal period of 4 µm and must be selected accordingly (picture
below):

Servo Drives AX5000

Version: 2.4

149

Advanced system characteristics
Motors with a pole pair distance that is not an integer represent a special case!
It is necessary to specify the "Signal periods per rotation" in parameter P-0-0150.
Sample:
With a pole pair distance of 28.1 mm and a sine period length of the linear encoder of 1 mm, a value of 28.1
would be correct. However, only integer values can be entered there. The Tc Drive Manager therefore enters
the value 28 in P-0-0150 (picture below):

The feedback gear unit is now automatically activated in order to correct the error described above (picture
below).

150

Version: 2.4

Servo Drives AX5000

Advanced system characteristics
Scaling factor
The pole pair distance of the linear motor in millimeters is to be entered in the field "Feed constant"(picture
below). After entering the correct “Feed constant”, all positions are specified in mm, all speeds in mm/s. A
non-integer input is possible at this point. 28.1 (decimal point!) is the correct value in the above example.

The values are confirmed in the NC with "Set NC Parameters". They are only valid when the configuration is
activated.

Checking the linear encoder
Once the motor and feedback have been selected and the scaling factor has been entered, the configuration
must be activated. Subsequently the measuring system must be checked. The AX5000 must not report any
feedback error when doing this. Please observe the notes in the section “Troubleshooting [} 160]”.
Observe the position in the NC. Push the motor by hand during this procedure. The distance by which the
motor is pushed must be correctly displayed in the NC.
If a measuring system is used that can read out absolute and incremental signals, then the absolute and
incremental tracks must have the same counting direction. Therefore, the two tracks have to be compared
beforehand. The absolute position is read by the AX5000 only when switching on/restarting. Then it switches
over and evaluates only the incremental information (sincos or TTL signals).
Important: Up to this step the counting direction should not be inverted via a parameter at any point!

Servo Drives AX5000

Version: 2.4

151

Advanced system characteristics
Now push the motor by hand. While doing this, observe the direction in which the position increases. Switch
the AX5000 to the "Init" state and then to the "Op" state (picture below). Using this procedure the absolute
position is read out again.

Note the absolute position read out. Now push the motor in the direction of the increasing position. Then
switch the AX5000 once again to the "Init" state and then to the "Op" state (picture below). If the absolute
position displayed after this procedure is larger than the one noted beforehand, both tracks are counting in
the same direction.
If a smaller position is displayed, the counting direction for the incremental encoder signals must be
reversed. This should be done by hardware means, for example by swapping the SIN+ and REFSIN signals
in the feedback connector.
Now repeat the test!

Counting direction doesn’t correspond to the application!

Note

152

If the counting direction of the linear encoder doesn’t correspond to the desired counting direction in the application, this can be ignored at this point. The necessary settings can be
made at the end of the commissioning. The requirement for this is that the motor drives
without errors.

Version: 2.4

Servo Drives AX5000

Advanced system characteristics
Checking the motor phases and the encoder counting direction
If the absolute and incremental positions of the linear encoder have the same counting direction (or if there is
only an incremental position), the phase sequence of the motor can be compared with the encoder counting
direction. This can be checked using the command P-0-0166 "Motor and feedback connection
check" (picture below).

If the command P-0-0166 has been selected for checking the motor and feedback connection (picture
above), the input mask of parameter P-0-0167 appears. The parameters in the upper area should not initially
be changed.
The main voltage (e.g. 400 V) must be switched on in order to execute the command. The AX5000 must be
ready but not enabled. The "Diag Code" is 0x0000D012.

The execution of this command causes a movement of the motor!
Before confirming the following message with "Yes", make sure that the motor can move
freely and cannot cause any damage.
Attention

Servo Drives AX5000

Version: 2.4

153

Advanced system characteristics
The following message appears during the first execution:

The linear motor first jerks and then makes a further movement a few seconds later.
If the command was executed successfully, the message "Succeeded to start the command" appears.
Values are hereby entered in parameter P-0-0167 "Results" (picture below).

It is important that the result "1:Yes" appears in the setting "Equal Directions" (picture above → red circle). If
"0:No" should appear there, two phases of the motor connection (AX5000 X13/X23) need to be swapped,
e.g. U and V.
The command can also be executed repeatedly.

Further information can be found in the parameters:
P-0-0150; P-0-0166 and P-0-0167.
Note

154

Version: 2.4

Servo Drives AX5000

Advanced system characteristics
Determination of the commutation offset
If the order of the motor phases matches the counting direction of the measuring system, the commutation
offset can be determined. In the case of absolute measuring systems, the commutation offset is only
determined once. The value is saved. In the case of incremental measuring systems, the "Wake & Shake"
must be configured. The commutation search then takes place automatically after each restart, when
enabling the servo drive for the first time.

With incremental measuring systems

Use of incremental measuring systems for vertical axes!

Attention

Beckhoff Automation GmbH & Co. KG urgently advises you not to use incremental measuring systems with vertical axes. A reliable commutation search is not possible with this combination!

Parameter P-0-0160 executes the commutation search. The behavior is configured with parameter
P-0-0165. The "Static current vector" method can be used for test drives. It is preferable to use "Wake &
Shake" in operation. It causes less movement of the axis. Both methods are executed using the command
"Start" (picture below → red circle). All settings should initially remain unchanged. The routine must be
completed without error. The message "Succeeded to start the command" (picture below → red circle)
should appear.

After successful execution of the command, the axis can be driven for test purposes; see below. Following a
successful test the entries "Command Mode" and "Activation" in parameter P-0-0165 should be changed to
"Wake & Shake" and "1:On enable request" respectively.
In most cases the default settings for "Wake & Shake" can be left unchanged. In many applications it is
useful to set the parameter "Commutation pos control: Kp" to 0. Details for this can be found under the
keyword "Electronic Commutation" in the Beckhoff Information System.

Further information can be found in the parameters:
P-0-0160 and P-0-0165.
Note

Servo Drives AX5000

Version: 2.4

155

Advanced system characteristics
With absolute measuring systems
The AL2200-MES-Feedback indicates only the absolute position in relation to a pole pair. Homing is
necessary each time after switching on. The commutation offset only needs to be determined once and
saved. The commutation offset is determined in the same way as with other absolute measuring systems.
For that reason the AL2200-MES-Feedback is not described separately here.
Set the values for "Commutation Mode" and "Adjustable Commutation Offset (mechanical)" in parameter
P-0-0150 (see picture below).

The configuration must be activated to confirm the settings. Command P-0-0166 is used to set the electrical
commutation offset.

The execution of this command causes a movement of the motor!
Wait for the message "Succeeded to start the command"!
CAUTION

156

Version: 2.4

Servo Drives AX5000

Advanced system characteristics
"Yes" must appear as result under "Equal Directions".

Read the value for "Commutation position difference". Subtract this value from the value in P-0-0057
"Electrical commutation offset". The result, if positive, is the new value for P-0-0057. Add 360° to the result if
it is negative.
Sample:
90° - 121.78° = -31.78°
-31.78° + 360° = 328.22°
The result is the new value for P-0-0057 "Electrical commutation offset". Enter the value in SetValue and
confirm with . Confirm the message that then appears with Yes (picture below).

The new value becomes active immediately upon pressing the download button (red arrow → picture below).

Servo Drives AX5000

Version: 2.4

157

Advanced system characteristics

The value is displayed in the setting "ActValue" after the download is complete. Execute command P-0-0166
again!
The value for "Commutation position difference" should now lie within the range:
355 ... 360 = 0 ... 5.
If this value is displayed you have successfully completed the commutation search!
The offset value has already been adopted into the startup list with the download button.
If the value lies outside the range, P-0-0057 can be corrected again using the method described. If no useful
value is found, the more detailed check should be performed with the help of command P-0-0166. In this
case, please observe the section: "Checking the motor phases and the encoder counting direction [} 153]".

Further information can be found in the parameters:
P-0-0057, P-0-0150 and P-0-0166.
Note

158

Version: 2.4

Servo Drives AX5000

Advanced system characteristics
Moving the axis for test purposes
Use the jogging buttons of the NC to move the axis at a slow speed. Do not execute the “Reversing
function”. Allow the motor to move by at least one pole pair in order to ensure that the commutation works
properly!

Lag error if the velocity controller is not optimized!
It is possible for large lag errors to occur as long as the velocity controller has not been optimized!
Note

• Test the travel movement at slow speeds and low acceleration.
• Allow a large lag error where possible.

If the axis travels only a few millimeters and then stops while drawing a high current, carry out the
commutation check [} 153] using command P-0-0166.

Determination of the control loop parameters
The determination of the control loop parameters of a linear motor axis is done in the same way as with a
standard axis. For that reason only an abridged procedure is described here.
In most cases the preset proportional gain in the velocity/speed controller is much too small. This is set in
relation to the motor mass. In particular in the case of linear motors, the external mass can be large in
comparison with the motor mass. This case requires a significant enlargement of Kp.

Servo Drives AX5000

Version: 2.4

159

Advanced system characteristics
Abridged procedure:
1. Set Tn to ≥ 30ms (to reduce oscillation of the axis).
2. Start a reversing function at a moderate speed.
3. While the axis is moving, increase Kp in the "Controller Overview" window in steps of, for example,
20% up to the oscillation limit. (It is possible to check by axis noise).
4. Reduce Kp by about 20% until the oscillation reliably stops.
5. Also check that the axis doesn’t oscillate when it is at a standstill.
6. Reduce Tn
A value of between 5 ms and 10 ms is useful if the load is coupled normally.
The value must be increased if oscillations occur.
7. Kv = 1 in the position controller is usually okay. Reduce Kv (for example to 0.5) if the axis overshoots
the position after optimizing the velocity controller.
Kv can also be increased if an overly large lag error occurs.

Troubleshooting

Feedback error
It is important to read all messages in order to identify the causes of errors. In the case of feedback errors in
particular, the AX5000 normally outputs several error messages at once.
Errors in connection with the feedback power supply
Make sure when selecting a feedback system with the designation “Unknown” that the power supply is set
correctly (picture below)!

160

Version: 2.4

Servo Drives AX5000

Advanced system characteristics
If the setting is "5V", the AX5000 expects a sense line to be connected. The setting "5V fixed" must be
deselected if the encoder employed does not have a sense connection.
The selection leads to different settings in the "Power Settings" in the feedback parameter P-0-0150 (picture
below).

An incorrect selection leads to AX5000 error messages (see section “Error codes”). [} 161]
Error during activation (enable) of the AX5000
If the shield of the motor cable and/or feedback cable is not connected over a large area with the housing of
the AX5000, this leads to a feedback error in the current feed to the linear motor. The position is then
correctly displayed only when pushing the motor by hand.
The shield of the motor cable is normally connected with a clip to the metal bracket of the motor connector.
The screws of the motor connector (X13/X23) must be screwed to the housing of the AX5000 and fastened
with a tightening torque of 0.6 Nm.

Error codes
Error code
F152

Error description
Channel Errors

F702
F70E
F707

If only this error is displayed, it is probably a two-channel device and the error cause is
located in the other channel. Otherwise, observe the other error messages!
Superordinate message. Please observe the other error messages!
Superordinate message. Please observe the other error messages!
No feedback voltage
• The power supply is not correctly connected.
• The sense line is not correctly connected.
• No sense connection exists.
Initialization error

FA01

• Incorrect setting in parameter P-0-0150.
• Wiring error
Feedback process channel error (1Vss)

FA49

The amplitude of the analog signal is too small -> check the connection.
F4A5

SoE Communication Parameter Error (see section “Error F4A5 [} 162]”)

Consequential error!
Please contact the Beckhoff applications department if the servo drive displays consequential errors that are not described in this section!
Note

Servo Drives AX5000

Version: 2.4

161

Advanced system characteristics
Error F4A5 "SoE Communication Parameter Error"
The parameter that caused error F4A5 is output in parameter S-0-0021 (picture below). This can be read in
the Diagnostics window.

In this case F152 and FA01 are consequential errors of F4A5. The cause of the error is an incorrect setting
in parameter P-0-0150.

A value > 0 must be entered for "Signal periods per rotation" (picture above). This takes place automatically
if, during the configuration, the motor is selected first and then the feedback.
The correct value is the pole pair distance / ("Length per signal period")
Sample:
Signal periods per rotation = 24mm / 1000000nm = 24

162

Version: 2.4

Servo Drives AX5000

Advanced system characteristics
The error message F4A5 can also occur with a reference to parameter S-0-0113 "Maximum motor speed":

In this case the additionally occurring error message FD15 allows a conclusion to be drawn about the cause:
the selected measuring system and the maximum velocity configured in S-0-0113 result in a too high input
frequency at the encoder input (X11/X21).
Sample:
Measuring system with 20 µm signal period. Maximum travel speed of the motor = 12 m/s.
12 m/s : 20µm = 1000000 1/s = 1 MHz
The max. permissible input frequency for sine/cosine signals at X11/X21 is 250 kHz.
Remedy: Reduce the value of S-0-0113. The maximum possible speed of the motor is required only in very
few applications.
Note: The value of the max. speed is shown in the parameter list in rpm. In the case of linear motors 1 rpm is
one pole pair distance per minute.

Conversion of the displayed value for a motor with a pole pair distance of 24 mm:
30000rpm * 0.024m / 60 = 12 m/s

Further information can be found in the parameters:
S-0-0021 and P-0-0150.
Note

Servo Drives AX5000

Version: 2.4

163

Advanced system characteristics
Error F107 "Status of the axis: current controller not ready"
If this error appears, the entry "Commutation Mode" in parameter P-0-0150 must be changed from "No
commutation" to "2:Commutation Offset 0 deg" or "3:Adjustable mechanical Offset". Refer also to section
"Determination of the commutation offset".

Nature and source of the danger

Attention

164

The setting "0: No commutation position" is intended to prevent an axis being inadvertently
activated and then moving in an unforeseeable manner or "running away". If not already
done, it is essential after the change to determine a valid commutation offset before the
axis is activated (enabled).

Version: 2.4

Servo Drives AX5000

Advanced system characteristics
Checking the motor connection and feedback
The motor can execute a defined movement independently of the feedback on the basis of command
P-0-0166. If the movement is observed (e.g. with the software oscilloscope), conclusions can be drawn
about the feedback settings.

Enter a value of 360 degrees in parameter P-0-0167 in the setting “Moving distance”. On execution of
P-0-0166 the motor is then moved by one electrical revolution. In the case of linear motors this corresponds
to one pole pair distance. Since the motor executes an undefined movement before that, it is a good idea to
record the complete movement with the software oscilloscope.
The following signals should be recorded:
• Torque Feedback (S-0-0084)
• Position feedback value 1 (S-0-0051)
• ActPos (from the NC)

Servo Drives AX5000

Version: 2.4

165

Advanced system characteristics

If the motor doesn’t move by the expected pole pair distance, check the value entered in parameter
P-0-0125 (Pole pair distance).
The jerky movement at the beginning (picture above → red arrow) is not included in the observation. The
motor aligns itself via the poles.
From the current curve it can be seen that the value initially ramps up and is then kept constant for a while.
During that time the direction is electrically turned once. The value set in parameter S-0-0051 should
increase by approx. 220 (1048576) increments. The NC position (ActPos) should increase by the value of a
pole pair distance. In the example the values are sufficiently precise with 1020612 and 23.357.
If the increase of S-0-0051 differs considerably from 220, the resolution of the linear encoder has not been
entered correctly.
If S-0-0051 proceeds correctly but ActPos displays a wrong difference, the scaling factor has been set
incorrectly.
The connection of the motor phases must be checked if the movement does not proceed evenly, but only a
jump takes place, for example.

166

Version: 2.4

Servo Drives AX5000

Advanced system characteristics

10.1.5

Third-party motors

10.1.5.1

Commutation offset for third-party motors

10.1.5.1.1

Preliminary remark

This section provides information on checking a direction of rotation and determining the commutation offset
for third-party motors.
Please observe the following notes:
A commutation offset can only be determined and stored for motors with resolver, absolute encoder (singleor multi-turn) or the part-absolute MES.
For incremental encoders (sine/cosine or TTL signals) the “Wake&Shake” routine must be configured. This is
necessary, since in this case the commutation offset is not constant. The “Wake&Shake” routine
redetermines the commutation offset after each start.

Do not use the electronic name plate!
If a motor with an EnDat or BISS encoder is used, we advise against not using an electronic name plate.
Note

Inversion of the count direction
All direction settings must have their default values. Do not invert a count direction before
the correct commutation angle was determined!
Attention
The offset to be determined can be a mechanical offset relative to the rotor position or an electrical offset
relative to the electrical rotation. Both procedures are explained below.

Further information can be obtained in the parameters:
P-0-0057, P-0-0058, P-0-0150, P-0-0160, P-0-0166, P-0-0167
Note

Servo Drives AX5000

Version: 2.4

167

Advanced system characteristics
10.1.5.1.2

Checking the direction of rotation
Please note that for proper operation the count
direction of the feedback system must match the
sequence of the motor phases.
Turn the motor shaft clockwise, viewed from the Aside. The parameter “Position feedback 1 value” (see
lower image) should be positive. If this is not the
case, the sine and cosine signals at the motor should
be swapped.
If the motor has a holding brake, it can be released in
the TCDriveManager under “Service functions/
Manual operation” (see lower image).
Now use the command P-0-0166 to check the
counting direction of the feedback system and
whether it matches the connection of the motor
phases.

Motor movement!

CAUTION

When you check the counting direction of the motor with the command P-0-0166, the motor
will move. Therefore, please keep a safe distance from the motor with all body parts before
you start the command P-0-0166!
The AX5000 must be set inactive without error (diag
code = 0x0000D012).
After selecting the command P-0-0166 press “Start”.
Confirm the selection (Do you really want to
continue?) with “Yes”.
The command P-0-0166 was successfully completed
when the message “Succeeded to start the
command” appears in the context menu.
The verification result can now be read in parameter
P-0-0167. If the “Equal Directions” selection area
shows 0: No, change the order of the motor phases
(The direction of rotation of the feedback system was
already checked and possibly corrected in the
previous step).

Please do not use a TwinCAT setting to change the motor phases at the motor connection.
Note

Swap motor phases U and V, for example, at the motor connector plug (X13/X23).

If the “Equal Directions” selection area now shows 1:Yes, the commutation offset can be determined based
on one of the following methods.

168

Version: 2.4

Servo Drives AX5000

Advanced system characteristics
10.1.5.1.3

Determining the electrical commutation offset
Execute the command P-0-0166 (see section
“Checking the direction of rotation”). To determine the
commutation offset we need the current value from
parameter P-0-0057 and the current value from
parameter P-0-0167:
Read the value for “Commutation position difference”.
Subtract this value from the value in P-0-0057
“Electrical commutation offset”. If the result is
positive, this is the new value for P-0-0057. If the
result is negative, add 360°.
Sample:
90° - 178.57° = -88.57°
-88.57° + 360° = 271° (fractions can be neglected.)
The result is the new value for P-0-0057 “Electrical
commutation offset”. Enter the value at SetValue and
confirm with . Confirm the message that is
displayed with .
Pressing the download button (red circle) activates
the new value immediately.
The value is displayed in the setting “ActValue” after
the download is complete. Execute command
P-0-0166 again!
The value for “Commutation position difference”
should now lie within the range: 355 … 360 = 0 … 5.
355 … 360 = 0 … 5 liegen.
If this value is displayed you have successfully
completed the commutation search! The offset value
has already been adopted into the startup list with the
download button.
To use the commutation angle, the “Commutation
mode” must be changed in parameter P-0-0150:
Change the entry “Commutation mode” to
“3:Adjustable offset”. Then reactivate the TwinCAT
configuration.
After changing the “commutation mode” once, this
method has the advantage (compared with the
mechanical offset) that the offset (P-0-0057) can be
changed at any time without having to restart the
system.

Servo Drives AX5000

Version: 2.4

169

Advanced system characteristics
10.1.5.1.4

Determining the mechanical commutation offset

Abridged procedure:

Adjustable commutation mechanical value!

Note

Before determining the mechanical commutation offset, check whether the value “Adjustable commutation mechanical” in P-0-0-0150 is set to 0. If this is not the case, set the
value to 0 and activate the TwinCAT configuration. Then perform the steps described below.
1.) Run command P-0-0166.
2.) Press the "Download" and "Start" buttons. Wait until the
"Suceeded to start the command" appears.
3.) You get a new value in parameter P-0-0058 "Mechanical commutation offset". Remember this value.
4.) Open the "Startup list". Open the parameter structure P-0-0150.
Open "Parameter Channel".
5.) Set parameter P-0-0150 "Feedback 1 Type" in "Commutation
mode": 3 Adjustable offset.
6.) Change the value in P-0-0150 "Feedback 1 Type" in the "Adjustable commutation offset (mechanical)" to the value which you
have previously read in parameter P-0-0058.
Confirm with OK and activate the configuration in the TwinCAT
System Manager.

7.) Change to the "Drive Commands" tab and execute command
P-0-0166 "Motor and feedback connection check".
8.) Leave the default values and confirm with Start. If the message
"Suceeded to start the command" appears, open the parameter
structure of the P-0-0167 "Results".
“Equal direction" must be "Yes" and "Command position difference" must be between 355 ° and 360 "(0 ° ... 5 °).

Motor movement!

CAUTION

170

If you execute the command P-0-0166, the motor performs a movement. Therefore, please
keep a safe distance from the motor with all body parts before you start the command
P-0-0166!

Version: 2.4

Servo Drives AX5000

Advanced system characteristics
10.1.5.1.5

Configuration of the Wake&Shake routine
A configuration requirement is that the count direction
of the feedback system matches the sequence of the
motor phases.
Details of the process for finding the commutation
with “Wake&Shake” can be found in the Beckhoff
Information System under the keyword: "Electronic
commutation".
This section only contains a brief overview.
The command P-0-0160 executes the routine. The
type of execution can be set in parameter P-0-0165.

For “Command mode” you can select between: Static current vector and Wake and Shake.
• 0:
• 1:
auswählen.
The “Static current vector” procedure results in a larger motor movement. It can be used for testing.
The “Wake and Shake” procedure minimizes the axis movement. This procedure is the one that tends to be
used in practice.
Both procedures determine a commutation offset, although this is not shown in parameter P-0-0058. This is
due to the fact that a new value has to be determined at each restart. This value depends on the axis
position. The numerical value is therefore meaningless for the user.
The result can then be checked with the command P-0-0166. Both procedures should initially be performed
with the default values.
The setting “Activation 1: On enable request” has the
effect that the AX5000 automatically executes a
commutation search with the first enable after a
restart.
With "Wake and Shake" it often makes sense to set
"Commutation pos control: Kp 0", in order to avoid
execution errors.

10.1.6

Homing

10.1.6.1

Homing

Homing refers to an axis initialization run during which the correct actual position is determined by means of
a reference signal. This procedure is referred to as homing, referencing or calibration. A switch that is
triggered at a known, unique position along the travel path serves as reference signal. Further signals such
as the encoder zero track can be analyzed in order to increase the precision.
In general a distinction is made between drive-controlled homing and NC-controlled homing. Drive-controlled
homing is carried out automatically by a suitable drive without input from the control system and is not
discussed in detail in this documentation. NC-controlled homing is fully controlled by the control system and
supports a wide range of drive types. The different NC-controlled homing mechanisms are described below.

Servo Drives AX5000

Version: 2.4

171

Advanced system characteristics
Position reference systems and encoder systems
A distinction is made between different position reference systems (measurement systems), depending on
which position measuring system is used. An absolute measurement system provides an absolute position
(directly after switching on) that is unique over the whole travel path. Such a measurement system is
calibrated once and set via a persistently stored position offset. In this case homing is not required even after
a system restart. In contrast, relative measurement systems provide a non-unambiguous position value (after
switching on) that must be calibrated through homing. Relative measurement systems are subdivided further
into purely relative systems (incremental encoders) and part-absolute systems, which only provide a unique
position during a motor or encoder revolution.
• Absolute position - e.g. multi-turn encoder
◦ BiSS
◦ EnDat
◦ Hiperface
◦ SSI
• Part-absolute position - e.g. single-turn encoder
◦ BiSS
◦ EnDat
◦ Hiperface
◦ MES (Beckhoff)
◦ Resolver
• Relative position - incremental encoders
◦ Sine / cosine (sine 1 Vss)
◦ HTL (rectangle)

172

Version: 2.4

Servo Drives AX5000

Advanced system characteristics
General description of a homing procedure
Figure A shows a schematic diagram of a homing procedure with individual velocity profile phases.
1.
2.
3.
4.

When the machine is switched on the axis is in a random position (1).
Homing is initiated, and the axis travels towards the reference cam.
Once the reference cam is detected, the axis stops and reverses.
The axis moves away from the reference cam and detects the falling edge of the reference cam signal.
5. The axis continues and searches for a sync pulse or another distinctive event, depending on the reference mode setting. This step may be omitted where appropriate.
6. The occasion is detected and the specified reference position is set.
7. The axis stops and thus stands slightly away from the reference position. The reference position was
set a short while before with maximum accuracy.
Figures B and C show the position and velocity profile during homing.

Servo Drives AX5000

Version: 2.4

173

Advanced system characteristics
Referencing modes
The NC system supports different referencing modes, depending on the encoder system type.
• Homing based on reference cam (Plc Cam)
The simplest axis referencing mode uses a reference cam that generates a digital signal at a defined
position along the travel path. During homing the NC determines the signal edge and allocates a
configurable reference position to this position. Referencing based on a reference cam is always
possible, irrespective of the encoder type, and is a prerequisite for other, more precise modes.
• Software Sync
Software Sync mode enhances the homing precision by additionally detecting the encoder count
overflow after an encoder or motor revolution, after the reference cam signal has been detected. This
mode requires a part-absolute encoder (e.g. resolver) with constant overflow interval relative to the
reference cam. Overflow detection is parameterized via the Reference Mask parameter (see System
Manager section).
• Hardware Sync
Some encoder systems provide a sync pulse per revolution (zero track) in addition to the count. The
homing precision can be enhanced by selecting this mode, if the encoder evaluation logic is able to
pick up the sync pulse. The precision is comparable with Software Sync. Hardware Sync mode may
require parameterization or special wiring of the drive or encoder system.
• Hardware Latch
Hardware Latch reference mode (Hardware Latch Pos or Hardware Latch Neg, depending on edge)
requires an external digital latch signal for storing the encoder position in the evaluation unit of the
encoder system. The encoder system must support such a latch function and may have to be
configured first in order to be able to utilize this function.
Absolute encoder system
NC

Referencing not required

Drive

Referencing not required

174

Part-absolute encoder system
Recommended reference
mode SoftwareSync
(also possible: PlcCam,
HardwareSync)
Drive setting not required

Version: 2.4

Relative encoder system
Recommended reference
mode HardwareSync
(also possible: PlcCam)
Drive parameterization
required
(for Sercos/SoE see Probe
Unit)

Servo Drives AX5000

Advanced system characteristics
Parameterization in the System Manager

Reference System : The encoder parameters Reference System determines whether the encoder system
used is incremental or absolute. In an absolute encoder system the encoder value is taken from the control
system without modification.
Not all NC encoders support this optional parameter, i.e. only those types that offer a choice between
absolute and incremental encoder reference system (measurement system) support it (e.g. SERCOS,
KL5001, M3000, ProfiDrive, Universal). This choice determines whether the actual encoder position is
interpreted and evaluated as an absolute or incremental position, based on an absolute or incremental
reference system (measurement system).
In an absolute reference system no further processing takes place with regard to encoder counter value
overflow or underflow. It is assumed that the counter value is unique within the axis traversing range and no
encoder counter value overflow or underflow occurs. Otherwise there would be a discontinuity in the actual
position, resulting in a position following error. Axis referencing via MC_Home is not possible. Instead, the
actual position is calibrated once via the parameter Position Bias (zero offset / position offset).
In an incremental reference system axis referencing via MC-Home is generally required. In addition the NC
automatically detects and accounts for encoder counter value overflow or underflow events, so that
continuous axis operation is possible over many months ("infinite range").
Encoder Mask (maximamum value): The encoder mask determines the bit width for the incremental
encoder position. The encoder mask is used for detecting and counting in range overflow events.
Scaling Factor: The scaling factor is multiplied by the incremental encoder position, including all overflows.
From this an absolute axis position can be calculated with the parameterized physical unit.
Position Bias (zero offset): Position offset; moves the axis coordinate system relative to the encoder
coordinate system. This value is mainly used in absolute encoder systems. In relative systems an offset is
usually not required, since the system moves to a parameterized reference position after homing.

Servo Drives AX5000

Version: 2.4

175

Advanced system characteristics
Invert Encoder Counting Direction: The encoder count direction can be inverted if it does not match the
required logical count and travel direction.

Reference Mode : Referencing mode as described above (Plc CAM, Hardware Sync, Hardware Latch Pos,
Hardware Latch Neg, Software Sync). The default mode corresponds to Plc CAM mode.
The Reference Mode parameter is used to specify the type of reference event (physical or logical event) for
the referencing process. Depending on the parameterized reference mode, during the referencing procedure
either the hardware property of the drive or encoder (e.g. hardware latch) is used, or the reference event is
exclusively detected within the control, i.e. without further hardware reference.
Reference Mask: The reference mask parameterizes overflow detection for Software Sync reference mode.
It is less or equal the encoder mask and defines an encoder value range, which is part-absolute. Examples
include the bit width of a motor revolution or the bit width of a sine period in a sine/cosine encoder. Software
Sync therefore always detects the same overflow position in a part-absolute encoder system.
Calibration Value: Reference position to which the axis position is set after homing.
Invert Direction for Calibration Cam Search: The parameter inverts the axis travel direction for searching
the referencing cam during homing. The standard direction is negative, i.e. towards the axis coordinate
system origin.
Invert Direction for Sync Impuls Search: The parameter inverts the axis travel direction for searching the
sync pulse during homing.

176

Version: 2.4

Servo Drives AX5000

Advanced system characteristics
Referencing of coupled axes
TwinCAT enables axis coupling during referencing. The coupled axes do not necessarily have to be
referenced. Axis coupling enables referencing of gantry axes, for example, provided the system can ensure
that the two axes are suitably oriented relative to each another before homing. In this case the procedure is
as follows:
• Ensure that both axes can be moved in coupled mode. (Position comparison is not possible at this
stage, because none of the axes is referenced.)
• Couple axis 2 with axis 1.
• Start homing for axis 1. Slave axis 2 will travel with axis 2.
• Decouple the axes after the homing procedure.
• Couple axis 1 with axis 2.
• Start homing for axis 2. Slave axis 1 will travel with axis 2.
• Decouple the axes after the second homing procedure.
• Move both axes to a set position for alignment. The travel path for both axes should be minimal and
may correspond to the mean value from both positions, for example.
• Couple the axes. The coupled system is now referenced.

Programming a homing procedure in the PLC
MC_Home
The MC_Home function block is used to initiate homing from the PLC. The reference mode and further
parameters are configured in the System Manager as described above. Only the reference cam signal
(bCalibrationCam) is fed into the block.

Drive types and I/O interface
Homing is largely independent of the drive types used. In some cases the drive has to be parameterized,
particularly if a drive latch function is used. The following chapter describes the version with the AX5000.

Servo Drives AX5000

Version: 2.4

177

Advanced system characteristics

10.1.6.2

Special characteristics in hardware end positions

If a SERCOS or SoE drive (e.g. AX50xx) is in a hardware end position (positive or negative), the drive blocks
further traversing commands in end position direction and beyond the end position (see also bit 3, drive
follows command value, in the SERCOS status word), and is therefore no longer operational from a control
system perspective. This means that, without special measures, the axis can often no longer be moved from
the end position into the valid traversing range via TwinCAT or the control system. This situation is
particularly likely to occur with drives in the velocity interface, because in this case the position control leads
to frequent changes in direction in the drive velocity output.
In order to rectify this special situation, a control bit in the PlcToNc axis interface (see bit 8 called
AcceptBlockedDriveSignal in nDeCtrlDWord) can be used to force TwinCAT to accept the AX50xx axis as
operational and therefore enable a move from the end position into the valid traversing range.
In the past, in many cases the only alternative was to mechanically move the axis away from the end
position.

NC interface
PlcToNc axis interface, bit 8 called AcceptBlockedDriveSignal in nDeCtrlDWord

PLC interface
TcNc-Lib, see PLC function AxisSetAcceptBlockedDriveSignal in the TwinCAT PLC Library NC.

Homing with latch function
During homing a trigger event is expected and a position value is latched, depending on the referencing
mode (hardware latch). Parameterization is required in order to be able to use the drive latch function (see
AX5000 Probe Unit).

178

Version: 2.4

Servo Drives AX5000

Advanced system characteristics

10.1.6.3

Probe Unit
Detailed method for configuration of the probe unit:
For further information of the probe unit, please look at the functional manual of the servo
drive AX5000: Probe unit function

Note

10.1.7

Error messages during commissioning

The greatest likelihood of error messages occurs during the commissioning process. Incorrectly assembled
cables, missing shield connection, wrongly parameterized motors / feedback systems, mechanical problems
and many other issues are detected at this stage. The drive can often not be started or stops after a short
time with a diagnostic message.

Documentation of all error messages

Note

10.1.7.1

If an error message occurs, first of all please refer to the error message information in the
documentation "AX5000_DiagMessages". You will usually find suggestions for solutions
there which can be implemented relatively easily.

FA49, Feedback process channel error (1Vss)

When this diagnostic message appears it may indicate an error in the analog signal for the feedback system
(1Vss). The AX5000 monitors the output signals from the sin/cos 1Vss feedback system and switches off the
drive when the signal lies outside the tolerance range between 0.53 Vss and 1.34 Vss. The feedback
systems are specified in such a way that they only supply exact values within the stated tolerance range.
Beyond this the values may be usable but are not necessarily so.

Voltage analysis

With an external oscilloscope
The values from the feedback system can be determined with the aid of an external oscilloscope (scope).
You can connect an external scope between the feedback connector and the AX5000 and determine the
sine and cosine voltages.

With the TwinCAT software oscilloscope
Parameterization of the IDNs P-0-0150 / P-0-0180

Feedback system 1 or 2

Note

The diagnostic message FA49 applies to both feedback systems 1 and 2. You can find out
which feedback system is currently affected by pointing the mouse cursor at the diagnostic
message in the TCDriveManager. A tool tip will then appear showing the faulty feedback
system. The IDN P-0-0150 described below applies to feedback system 1. The IDN
P-0-0180 applies to feedback system 2 and has the same structure as P-0-0150.

Open the System Manager and select the servo drive (1) which is generating the error. Open the
TCDriveManager (2) and select the faulty feedback (4) in the affected channel (3). In the IDN "P-0-0150" (5)
under the "Sin / Cos" parameter (6) open the value range (8) under the Parameter "SinCos 1Vss monitoring".
Four options appear.

Servo Drives AX5000

Version: 2.4

179

Advanced system characteristics

0 = Error monitoring (full error monitoring)
1 = Error monitoring and Sin/Cos logging (full error monitoring and logging of sin/cos signals)
2 = Error monitoring (only wire break detection) and Sin/Cos logging (only wire break detection and logging
of sin/cos signals)
3 = Error monitoring (only wire break detection)
To log the Sin/Cos signals, select either 1 or 2.
Whether to select option 1 or 2 should generally be decided depending on the application. However, there
are two rough indications for making the choice:
If the faulty axis can no longer be used because the error always occurs immediately, then you need to
select the "2 = (only wire break detection and logging of sin/cos values)" option so that the error can occur
and be logged.
If the faulty axis can be operated because the error only occurs sporadically, then you can select "1 = (full
error monitoring and logging of sin/cos values)" or "2 = (only wire break detection and logging of sin/cos
values)" so that the error can always be logged.

Warning, risk of injury from uncontrolled movements!
If a faulty axis is used then this axis may make uncontrolled movements. Make sure that no
one is in the machine's traversing range.
WARNING
In many cases the faulty axis can also be moved manually and this option should be used preferentially for
safety reasons.
Adding the debug pointer to the Startup list
In order for the sin/cos signals to be logged, the relevant debug pointers must be added to the AX5000
Startup list. Call the Startup list in the TCDriveManager using the button (9) and click on "Add" (10). A
window opens with a list of parameters including P-0-1006 to P-0-1010 (11).

180

Version: 2.4

Servo Drives AX5000

Advanced system characteristics

The IDNs need to be parameterized before being added to the Startup list. The IDNs P-0-1006 and P-0-1007
denote sine signals, the IDNs P-0-1009 and P-0-1010 cosine signals; the structures are the same for sines
and cosines.

Servo Drives AX5000

Version: 2.4

181

Advanced system characteristics
For the IDN "P-0-1006" under "Addr" select the address "0xA000 Sin/Cos ChA: Sin (Int16)" (12).

Under "Source" select the faulty feedback system, where "0: Front" refers to the feedback system on the
front of the AX5000 and "1: Option" refers to the feedback system on the AX5701 / 02 option card.

182

Version: 2.4

Servo Drives AX5000

Advanced system characteristics
For the IDN "P-0-1007" select the option "2: Decimal 16".

You now need to repeat the procedure with the IDNs "P-0-1009" and "P-0-1010". For the IDN "P-0-1009"
under "Addr" enter the value "0xA001: Sin/Cos ChA: Cos (Int16)".
Select the four IDNs and press "OK" so that the IDNs are entered in the Startup list.
Activate configuration
In the TCDriveManager (14), click in the tree on "Process Data/Operation Mode". A new window opens
where, under "AT or MDT", you select "AT" (16). Next highlight the two IDNs "P-0-1008" and "P-0-1011" (17)
and move them into the "Parameter for Process Data" window by clicking on the ">>" button (18).

Under the relevant EtherCAT Device (19), activate the ADS Server (20). Now check the boxes beside
"Enable ADS Server" and "Create symbols" (21). The "Port" (22) is entered automatically.

Servo Drives AX5000

Version: 2.4

183

Advanced system characteristics

Start "TwinCAT Scope2" and check whether the amplitude values are permissible. The scaling factor is 1 /
46602.

184

Version: 2.4

Servo Drives AX5000

Advanced system characteristics

10.2

EtherCAT

10.2.1

Parameter handling

The servo drives from the AX5000 series use a new method for managing their configuration parameters
(IDNs).
In contrast to conventional servo drives (e.g. AX2000), these parameters are not stored in a non-volatile
manner on the AX5000 itself, but they are transferred from the controller to the drive whenever the EtherCAT
fieldbus system starts up. This approach has the advantage that the parameter management takes place
exclusively in the corresponding TwinCAT project, without the need for separate data backup of drive
parameters. If a replacement is required, it is sufficient to replace the servo drive. There is no need to load
parameters onto the servo drive.

The parameters are transferred from the controller to the servo drive when the EtherCAT system starts up.
Due to the high data transfer rate offered by EtherCAT this process is very fast, even in larger systems.

Transitions
During startup the EtherCAT system passes through the following states: Init, Pre-Operational, SafeOperational, and Operational (see chapter EtherCAT state machine).
The diagram shows the following transitions:
IP:
Transition from Init to Pre-Operational
PS:
Transition from Pre-Operational to Safe-Operational
SO:
Transition from Safe-Operational to Operational
OS:
Transition from Operational to Safe-Operational
SP:
Transition from Safe-Operational to Pre-Operational
PI:
Transition from Pre-Operational to Init
In practice the parameters (IDNs) are transferred from the higher-level control system to the AX5000 during
transitions IP, PS and SO.
The TwinCAT System Manager indicates at which transition the individual AX5000 parameters can be
transferred.

Servo Drives AX5000

Version: 2.4

185

Advanced system characteristics

10.2.2

EtherCAT synchronization

The EtherCAT master sends EtherCAT telegrams to all connected EtherCAT slaves. In each slave an
EtherCAT slave controller (ESC) is implemented. In order to achieve high positioning precision and meet
stringent demands in terms of concentricity characteristics, it is necessary for the set value generation in the
master and all connected drives to be synchronized. In the EtherCAT system the so-called distributed clocks
are available for this synchronization task. For details see www.ethercat.org. The following description deals
exclusively with the synchronization of the data.

EtherCAT Master
From the TwinCAT project and the ESI files (EtherCAT slave information) of the connected slaves, the
System Manager determines the required parameterization for the distributed clocks of the connected
EtherCAT slaves when the configuration is generated. This parameterization is transferred to the slaves or
their slave controllers via Init commands whenever the EtherCAT segment starts up. Manual adjustment is
not required and should only be carried out in consultation with AX5000 support.

186

Version: 2.4

Servo Drives AX5000

Advanced system characteristics

EtherCAT slave controller (ESC)
The EtherCAT slave controller (ESC) of the AX5000 is parameterized by the master such that two
synchronization signals (Sync0 and Sync1) are generated. These signals are analyzed by the CPU and then
synchronized with the internal control algorithms.

Sync0
The "Sync0" signals are sent every 250 µs as standard. If a signal fails to materialize, the CPU generates the
error code F414, and the axes of the servo drive are stopped with the "EStop ramp".
Additional error messages:
The Sync0 cycle time may only be configured with 62.5 µs, 125 µs or 250 µs, otherwise the CPU generates
the error code F409.
If the signal "Sync0" is not activated in the ESC, the CPU generates the error code F410.
If the pulse length of the signal no longer conforms to the standard, the CPU generates the error code F411.
In the case of each error message the axes are brought to a standstill with the "EStop ramp".

Sync1
The "Sync1" signals are parameterized according to the NC cycle time as standard. This cycle time is always
a multiple of Sync0. If a signal fails to materialize (see F1), the CPU also generates the error code F414, and
the connected axes are stopped with the "EStop ramp".
Additional error messages:
The Sync1 cycle time must be a multiple of the Sync0 cycle time and must be identical to the parameters
"S-0-0001 and S-0-0002", otherwise the CPU generates the error code F412.
If the signal "Sync1" is not activated in the ESC, the CPU generates the error code F413.
If the pulse length of the interrupt no longer conforms to the standard, the CPU generates the error code
F411.
In the case of each error message the connected axes are brought to a standstill with the "EStop ramp".

End of telegram (EOT)
The EtherCAT state controller (ESC) in the slave processes the EtherCAT telegrams dynamically. At the end
of the telegram (EOT) it transfers the content to the addressed Sync Manager (if the telegram was intended
for this slave and no CRC error is present). The EOT thus lags slightly behind the signal of Sync1 by the time
DT2; the status of SyncManager2 is subsequently set to "SyncManager written". The CPU only copies the
data from SincManager2 into its own memory area if this status is "SyncManager written" at the time of
Sync1. At the time of the Sync1 signal, the CPU expects a written SyncManager2. The end of the telegram
must therefore occur just before the Sync1 signal is generated. The data are not copied if the status is not
"SyncMan written"; if the data cannot be copied twice in succession, the CPU generates the error code F415
and the connected axes are brought to a standstill with the "EStop ramp".

Jitter!
The tolerance for the existence of new data at the right time, due to "jitter" etc., is NULL.
The EtherCAT master must ensure that the data arrive at the SyncMan2 in time.
Note

Servo Drives AX5000

Version: 2.4

187

Advanced system characteristics

Special notes concerning the diagnostic message F415 "Distributed Clocks: process
data synchronization"
The real-time behavior of the machine is continuously monitored during operation. An important component
of this monitoring is the synchronization of all hardware and software components involved in data transfer.
The illustrations below represent a simplified example of this data transfer. The focus is on the drive tasks
"NC" and "PLC".
Sample 1
1. The CPU timer sends interrupts on a regular basis (default: base time = 1 ms)
2. The individual tasks are now processed in accordance with the rules of task management.
3. Task management:
Since the task takes up a greater or smaller amount of time due to a higher or lower number of computing processes, the "I/O update" should be parameterized directly after the entry point (a) at the start
of the task. This excludes one source of incorrect synchronization.
A further source of error is an unfavorable prioritization of the individual tasks (see below).
4. Following the "I/O update", the resulting data are transferred to the TwinCAT-IO system and subsequently dispatched by EtherCAT telegram to the connected devices. The EtherCAT telegram passes
through each physically connected device and hands over or picks up only the data for this device.

188

Version: 2.4

Servo Drives AX5000

Advanced system characteristics
5. The order of task calculation depends among other things on the prioritization of the tasks. If a task
has a higher priority, it is also calculated first and can send its data to the TwinCAT-IO system, which
then dispatches the telegram. Problems usually occur when individual tasks have different cycle times;
see below.

Prioritization
The following graph describes the effects of prioritization on the synchronization of the data.
Assumptions:
Sync1 = 3 ms
NC cycle time = 3 ms
NC priority = 10
PLC cycle time = 2 ms
PLC priority = 5
NC data are to be transmitted cyclically to the drive. Although the PLC requires time to compute, no data are
transmitted to the drive.
Due to its higher priority, the PLC task is always calculated before the NC task; these tasks affect each other
at the start point time "0 ms" and then repetitively every "6 ms", i.e. 2x Sync1. However, the ESC expects the
EtherCAT telegram with the NC data at each Sync1 (3 ms). That is not ensured, however, because the more
highly prioritized PLC task is always calculated before the NC task and thus in the case of synchronous
mapping the telegram start is delayed. For this reason the NC telegram arrives somewhat later every 6 ms
and can thus cause the F415 error in the AX5000.

Servo Drives AX5000

Version: 2.4

189

Advanced system characteristics
Sample 2
1. The CPU timer sends interrupts on a regular basis (default: base time = 1 ms)
2. The individual tasks are now processed in accordance with the rules of task management.
3. Task management:
Since the task takes up a greater or smaller amount of time due to a higher or lower number of computing processes, the "I/O update" should be parameterized directly after the entry point (a) at the start
of the task. This excludes one source of incorrect synchronization.
A further source of error is an unfavorable prioritization of the individual tasks (see below).
4. Following the "I/O update", the resulting data are transferred to the TwinCAT-IO system and subsequently dispatched by EtherCAT telegram to the connected devices. The EtherCAT telegram passes
through each physically connected device and hands over or picks up only the data for this device.
5. The order of task calculation depends among other things on the prioritization of the tasks. If a task
has a higher priority, it is also calculated first and can send its data to the TwinCAT-IO system, which
then dispatches the telegram. Problems usually occur when individual tasks have different cycle times;
see below.

190

Version: 2.4

Servo Drives AX5000

Advanced system characteristics
Prioritization
The following graph describes the effects of prioritization on the synchronization of the data.
Assumptions:
Sync1 = 3 ms
NC cycle time = 2 ms
NC priority = 5
PLC cycle time = 3 ms
PLC priority = 25
NC task serves only devices in SyncUnit 1, synchronous mapping
PLC task serves only devices in SyncUnit 2, synchronous mapping
NC and PLC data are to be transferred cyclically.
Due to its higher priority, the NC task is always calculated before the PLC task and the telegram is
accordingly also sent first; these tasks affect each other at the start point time "0 ms" and then repetitively
every "6 ms", i.e. 2x Sync1. However, the ESC expects an EtherCAT telegram at each Sync1 (3 ms). This is
not a problem in SyncUnit 1, which is served by the NC, since the more highly prioritized NC always sends
the telegram in the same time pattern. However, the PLC telegram arrives somewhat later every 6 ms and
can thus cause the F415 error in the AX5000 in SyncUnit 2.

Servo Drives AX5000

Version: 2.4

191

Advanced system characteristics

10.3

Operation modes

In drive technology a distinction is made between the following operation modes:
• Current / torque control
• Speed control
• Position control
In the SoE standard the individual operation modes are specified via the standard parameter S-0-0032 (main
operation mode).

10.3.1

Mode parameterisation according to SoE

Parametrization of the IDN S-0-0032
Bit

Operation mode

no mode of operation

torque control

velocity control

position control feedback 1

position control feedback 2

11 and 12

position ctrl feedback 1 + 2 lag less

32769

torque control using dynamic MDT

32770

velocity control using dynamic MDT

32771 and 32772

position control feedback 1 + 2 using dynamic MDT

32779 and 32780

position control feedback 1 + 2 lag less using dynamic MDT

Cascaded control structure
The diagram shows a typical control structure with higher-level position controller and subordinate speed and
current controller.

192

Version: 2.4

Servo Drives AX5000

Advanced system characteristics
A cascaded controller structure consisting of current, speed and position controllers has proven to be
necessary for achieving high dynamics and positioning accuracy. The diagram illustrates the time constants
of the individual control loops, rising from inside to outside. Two operating modes are suitable for positioning:
velocity set value specification or position set value specification.
For the position of operation, 2 modes are:
• • speed setpoint (speed interface):
Cyclic speed setpoints are sent from the controller to the drive. Of the Position controller is in this case
on the side of the controller (NC) implemented.
• • Position setpoint. (Position interface):
Cyclic setpoint positions are sent from the controller to the drive. The position controller is here
implemented in the drive. In the control (NC) only the setpoint profile is calculated. Here is a higher
bandwidth in the position control achieved (no EtherCAT dead in closed Loop). This mode should
always be used when the controller enables.
Profile generator
The profile generator generates curve profile of a positioning job of the PLC function block
MC_MoveAbsolute. In each NC cycle, at a specified time (node T1 - Tn), the Setpoints this positioning task
passed to the axis control. Thus, the servo amplifier optimally can proceed, the target values of the profile
generator with the SAF task of the EtherCAT fieldbus must be triggered. The SAF task ensures that the
support points (T1 - Tn) to the servo amplifier be transported.

MC_MoveAbsolute is primarily used for linear axis systems. This PLC function block, let to axes with a speed
v process of starting to target positions.

For further informations, please look at the following link:
PLC ( Libs ( TwinCAT 3 PLC lib: Tc2_MC2 ( Motion-Function block ( Point to Point Motion
Note

Servo Drives AX5000

Version: 2.4

193

Advanced system characteristics

10.4

Display and navigation rocker

10.4.1

Navigation rocker
The navigation rocker is used for navigating within the display. It has 5 contact points: “right”, “left”,
“top”, “bottom” and “centre”

10.4.2

Display
General

Starting from the standard display, you can access the configuration and command displays by pressing the
right side of the navigation rocker
. Except with the standard display, if you do not change the display
for approx. 25 seconds, the standard display is automatically shown again. The standard display is always
shown if the device is working perfectly.

Display

Description
The display consists of 2 lines. These two lines display independent,
configurable contents.
The contents can be arranged into 4 groups.
Cyclic values (standard display):
The so-called standard display is shown permanently. The values provided can
be displayed in the two lines. The two lines are preconfigured in the factory as
follows:
Line 1: EtherCAT status
Line 2: DC link voltage
Error messages:
If an error occurs, the diagnostic code (hex) and a short version of the message
(2+3) are shown alternately on the display. If the error concerns only channel
"A", then this display is shown only in the upper line; the standard text remains in
the lower line. If the error concerns only channel "B", then this display is shown
only in the lower line; the standard text remains in the upper line. In both cases
the display additionally flashes (2-5).

see error messages

194

If the error has been rectified and acknowledged with the reset command
(S-0-0099), the standard display with the cyclic values appears again (see
above).
Warnings:
If a warning occurs, the display behaves in the same way as with an error
message.
Information messages:
If an information message occurs, the display behaves in the same way as with
an error message, but does not flash.

Version: 2.4

Servo Drives AX5000

Advanced system characteristics

Cyclic values
The two lines with the cyclic values, which are shown on the standard display, are freely configurable. You
can choose from 51 different cyclic values. The values are saved in IDNs and retrieved from there. The
procedure for configuring line 1 and line 2 is identical:

Overview (example)

Changing the display

Starting from the standard display, press the right-hand side of the rocker
2); the display
Display

1x (for line 1) or 2x (for line

appears.

Description
1 = "M" indicates that the "menu mode" is activated.
2 = The "CycValuesLine1" menu is active. This means that the cyclic values are
displayed in line 1.
3 = Indicates which cyclic values are currently displayed.

The currently displayed value determines the point of entry into the list of the cyclic values. You can change
to the next cyclic value with the bottom

or the top

desired value has been reached, press the center
and the changed standard display is shown.

Servo Drives AX5000

side of the rocker, as shown below. If the
of the rocker for 3 seconds. The value is adopted

Version: 2.4

195

Advanced system characteristics

Error reset (command S-0-0099)
After rectifying an error, it is necessary to perform an error reset. The associated command is the IDN
S-0-0099. This command can also be given directly via the display. As soon as an error occurs the display
flashes continuously; the standard display is shown again and the flashing stops only after a successful error
reset.
Overview

196

Version: 2.4

Servo Drives AX5000

Advanced system characteristics
Executing the command

Press the right side of the rocker
Display

3x until the following display appears:

Description
1 = "M" indicates that the "menu mode" is activated.
2 = The "Reset" menu is active.
3 = Indicates which channel of the AX5000 the reset affects.

There are now 2 possibilities:

Press the center of the rocker
or

for approx. 3 sec. to execute the reset command for channel "A"

Press the upper or lower side of the rocker
rocker

and switch to channel "B". Now press the center of the

for approx. 3 seconds and execute the Reset command for channel "B". The following display
.

appears

The standard display should appear again after approximately 25 seconds. If the error display is still visible
after that, this means that you have not rectified the cause of the error, or that there are further errors.

Device ID
The Device ID is a configurable ID of the AX5000 in the system environment. It is saved in the IDN
P-0-0020.

Servo Drives AX5000

Version: 2.4

197

Advanced system characteristics
Overview (example)

Entering the Device ID
You can edit the 5-digit Device ID by entering the individual digits. The prerequisite for this is that the "Set
Device ID" menu is active. As mentioned above, the display of the AX5000 displays freely configurable cyclic
data in the upper and lower lines as standard.

Press the right side of the rocker
Display

4x until the following display appears:

Description
1 = "M" indicates that the "menu mode" is activated.
2 = The "Set Device ID" menu is active.
3 = Indicates which digit "X" of the Device ID is currently editable;
in this example it is the last digit, i.e. "nine".
4 = Device ID

You can now immediately edit the last digit of the Device ID by pressing the top or bottom side of the rocker
. The top side
increments the number, the bottom side
the digit, there are 2 possibilities:

Press the center of the rocker
current digit.

decrements it. After you have set

for approx. 3 sec. and you can then edit the digit to the left of the

198

Version: 2.4

Servo Drives AX5000

Advanced system characteristics

Press the right side of the rocker

; this takes you to the "Save Device ID" menu.

Temporary memory

Note

After you have finished editing, the changed Device ID is located in a temporary memory,
which is cleared when the AX5000 is switched off. You must execute the command "Save
Device ID", so that the Device ID is saved permanently in the AX5000.

Saving the Device ID
By means of saving the Device ID, the IDN P-0-0020 is written to the AX5000 and can be used further.

and the following display

If you have just changed the Device ID, press the right side of the rocker
appears:

If the standard display is visible, press the right side of the rocker

5x until the following display

appears:
Display

Description
1 = "M" indicates that the "menu mode" is activated.
2 = The "Save Device ID" menu is active.
3 + 4 = Indicates which Device ID will be saved.

Press the center of the rocker

for approx. 3 sec. in order to save the displayed Device ID.

If saving was successful, this display appears:

The standard display appears again after approximately 25 seconds.

Servo Drives AX5000

Version: 2.4

199

Advanced system characteristics

10.5

Motor brake management

10.5.1

IDNs involved

IDN
S-0-0206
S-0-0207
P-0-0058
P-0-0096
P-0-0097

10.5.2

Name
Drive on delay time
Drive off delay time
Motor brake type
Motor control word
Motor status word

Functioning

IDN S-0-0206 determines the time of the motor standstill after the motor current feed, so that the brake can
vent first.
IDN-S-0-0207 defines the switch-off delay between activation of the motor brake and deactivation of the
current feed.
IDN-P-0-0058 is used to configure the motor brake.
IDN-P-0097 displays the state of the motor brake.
IDN-P-0096 can be used to release the motor brake manually or requesting activation of the brake manually.
This bits overwrite the internal brake request. The brake is therefore released or engaged irrespective of the
motor current feed and any travel command.

Risk of injury!
Improper operation of IDN P-0-0096 can therefore lead to sagging of a non-energized Z
axis or closing of the motor brake at full speed!
WARNING

10.6

Commutation methods

The important characteristics of a servomotor, such as its very smooth running, high efficiency and optimum
thermal utilization, are strongly influenced by the commutation. Commutation refers to the transfer of current
from one winding to the next. The moment at which commutation takes place must be harmonized with the
magnetic field of the rotor if the servomotor is to operate most effectively.

10.6.1

Rotary servomotors

10.6.1.1

Mechanical commutation

These motors, which use brushes, generate the alternating fields necessary for operation of the motor
through sliding contacts, whose geometrical arrangement switches the current paths. Brush losses and wear
are disadvantages of this simple, mechanical commutation method.

10.6.1.2

Electronic commutation

These modern motors generate the alternating field needed for operation of the motor by means of an
electronic circuit which is not subject to either wear or friction. The type of motor and the encoder system in
use determine the commutation method.

200

Version: 2.4

Servo Drives AX5000

Advanced system characteristics
Absolute encoder system (motor feedback) within one rotation
Samples of this type of encoder system includes: Resolver, EnDat, BiSS and HIPERFACE
Two different commutation methods are involved here:
Mechanical adjustment of the encoder
The motor's encoder system is mechanically adjusted at the factory (the encoder and rotor are matched to
one another), but the rotor position is unknown.
The commutation angle is determined once by the P160 command, using the IDN "P0-0-165_Command
mode_Static current vector" and the IDN "P-0-057 "Electrical commutation offset". This means that the
corresponding mechanical angle coming from the encoder system is displayed and read out in P-0-0058,
and is saved in the IDN "P-0-0150_Parameter chanel_Adjustable commutation offset" (motor database). In
order for the parameter to be used, the IDN "P-0-0150_Parameter chanel_Commutation mode" (motor
database) must be set to 3: "Adjustable offset". The associated value of the IDN "P-0-057 "Electrical
commutation offset" is also saved in the motor database.
Electronic adjustment of the encoder system

Synchronous motors!

Note

Electronic adjustment is only required for synchronous motors. In the case of a synchronous motor, the magnetic field of the rotor is generated electronically, and therefore can be
set appropriately for the electromagnetic field of the winding.

Depending on the encoder system there are, again, two different commutation methods:
1. The encoder is always attached to the rotor by the manufacturer in the same rotary position, but the
rotor position is not known.
The commutation angle is determined once by the P160 command, using the IDN "P0-0-165_Command mode_Static current vector" and the IDN "P-0-057 "Electrical commutation offset". This means
that the corresponding mechanical angle coming from the encoder system is displayed and read out in
P-0-0058, and is saved in the encoder system's data store (exceptionally) and in the IDN
"P-0-0150_Parameter chanel_Adjustable commutation offset" (motor database). In order for the parameter to be used, the IDN "P-0-0150_Parameter chanel_Commutation mode" (motor database)
must be set to 3: "Adjustable offset". The associated value of the IDN "P-0-057 "Electrical commutation offset" is also saved in the motor database. This method requires a encoder system having a data
store and a data line.
2. The angle between the encoder system and the rotor is determined by the motor manufacturer using a
command that is specific to the encoder, and is communicated to the encoder system. The encoder
system stores this angle, using it for internal calculation, but the rotor position is unknown.
The commutation angle is determined once by the P160 command, using the IDN "P0-0-165_Command mode_Static current vector" and the IDN "P-0-057 "Electrical commutation offset". This means
that the corresponding mechanical angle coming from the encoder system is displayed and read out in
P-0-0058, and is saved in the encoder system's data store (exceptionally) and in the IDN
"P-0-0150_Parameter chanel_Adjustable commutation offset" (motor database). In order for the parameter to be used, the IDN "P-0-0150_Parameter chanel_Commutation mode" (motor database)
must be set to 3: "Adjustable offset". This angle is always included in internal calculation processes.
This method requires an intelligent encoder system.
Non-absolute encoder system (feedback) within one rotation
Samples of this type of encoder system includes: SIN / COS 1Vss
In this case, a special commutation procedure (wake&shake) must be run in order to determine the
commutation angle. This angle is stored internally, and is taken into account during operation. If the AX5000
is switched off, or if the "EtherCAT-State machine" is switched into "Pre-op" or a lower state, the
commutation angle will be lost because the encoder system is not absolute. "Wake&shake" can only operate
without error when the drive system is running steadily; in other words there must not be any vibrations
affecting the motor from outside. In addition, a stability investigation using the default values of the "IDN
P-0-0165" is necessary the first time the system is operated.

Servo Drives AX5000

Version: 2.4

201

Advanced system characteristics

Oscillatory system!

Note

It is important for this stability investigation to examine the application in advance and to
determine the oscillation that is potentially most problematic. This case can occur under
load conditions, or may be found when unloaded.

Warning, risk of injury from uncontrolled movements!

WARNING

In the method described below, the motor shaft is brought directly to a certain position.
Make sure that your application permits this movement, secure the surroundings to prevent
unintentional entry, and make sure that nobody is in the hazardous area.

Oscillatory system
It is necessary to analyze the vibration pattern of an oscillating system, and to take appropriate damping
measures. Oscillations always have their effect in Phase 2 of "wake&shake"; oscillations are not particularly
critical in Phase 1.
Decaying oscillation
The amplitude (k) and the decay time (l) of this
kind of oscillation must be found. The parameters
IDN-P-0-0165 "Commutation pos control: Kp" can
affect both the amplitude (k) and the decay time
(l). The parameter IDN-P-0-0165 " Second phase
duration" should be greater than the decay time
(l).
Constant oscillation
This kind of oscillation is unacceptable, as a
stable regulation process is not established. The
parameters IDN-P-0-0165 "Commutation pos
control: Kp" must be checked, and modified if
necessary. If this does not achieve the desired
result, you must damp the vibration mechanically.
Rising oscillation
This kind of oscillation is unacceptable, as a
stable regulation process is not established. The
parameters IDN-P-0-0165 "Commutation pos
control: Kp" must be checked, and modified if
necessary. If this does not achieve the desired
result, you must damp the vibration mechanically.
The motor shaft is brought to freely definable electrical positions by impressing an appropriate current in the
course of this investigation. When this injected current is switched off, the motor should remain in the
position that it has reached. BECKHOFF recommends positions of 0°, 90°, 180° and 270°. In critical
applications, eight positions (0°, 45°, 90°, 135° ...315°) should be selected instead of four. The current
injection is parameterized in the IDN P-0-0165 under "Static current vector", while the freely selectable
electrical position is set in the IDN P-0-0057. "Wake&shake" should be carried out in each position; stability
of the system is only ensured when this has been done successfully.

202

Version: 2.4

Servo Drives AX5000

Advanced system characteristics
Wake&shake

Oscillating system!

Note

A mechanical remedy must be provided if the application oscillates. You can carry out the
commutation up to a degree using wake&shake, but should carefully select the parameters
for the IDN "P-0-0165" to make the effect of the oscillation as small as possible, since too
much post-pulse oscillation will cause a commutation error. This is because the angle measured after completing the command will be entered as the commutation angle.

Warning, risk of injury from uncontrolled movements!

WARNING

The motor shaft will be moved in steps during the process described below. In Phase 1 the
maximum electrical movement is 8 x (the value from "P-0-0-0165_Fist phase position monitoring limit"). In Phase 2 it is 0.5 x (the value from "P-0-0-0165_Fist phase step width"). This
formula can only be applied if the previous investigation of stability has been concluded satisfactorily. Make sure that your application permits this movement, secure the surroundings
to prevent unintentional entry, and make sure that nobody is in the hazardous area.

The wake&shake commutation function consists of two phases. An approximate determination of the rotor
position is carried out in Phase 1, while Phase 2 determines the position more precisely. The aim of the
commutation function is to determine the precise position of the rotor with a minimum amount of movement.
Due to the pairs of poles, servomotors exhibit a direct relationship between the electrical and mechanical
rotation. One electrical rotation always corresponds to one mechanical rotation divided by the number of pole
pairs. A motor with a single pair of poles is illustrated in the following example for the sake of simplifying the
calculation.
Parameterization is carried out using the IDN P-0-0165 "Commutation offset calibration parameter". The
quoted angles always refer to electrical rotations!

Servo Drives AX5000

Version: 2.4

203

Advanced system characteristics
IDN P-0-0165 - Commutation offset calibration parameter
Parameter
Command mode

Default
0: Static current vector

Activation

0: manual

Static current vector
Current level

Stationary current in %

Duration

3000 ms

Wake and shake
First phase current vector

Stationary current in %

First phase ramp up time

100 ms

Second phase current level

Second phase ramp up time
Commutation pos control: Kp

500 ms
0.04

Wake and shake expert
First phase pos monitoring limit

0.5 degrees

First phase step width

22.5 degrees

150 ms

Second phase duration

3000 ms

Error monitoring (range of motion)

204

Current intensity of the current vector
(value = 100% x P0-0093 / P0-0092)
Time for the current vector "a" to reach
its parameterized magnitude

Stationary current in %

First phase waiting time after step

Description
Selection between two commutation
methods
Selection of when the commutation process
is started
Commutation methods
Current intensity of the current vector (value
= 100% x P0-0093 / P0-0092)
Period for which the parameterized current
is maintained so that any oscillations that
may be present can settle, allowing an
optimum commutation angle to be reached
Commutation methods

Current intensity of the current vector
(value = 100% x P0-0093 / P0-0092)
Time for the current vector "g" to reach its
parameterized magnitude
Amplification factor. Attention: If "0" then
Variant 2 will be carried out in Phase 2
Attention: Only experienced users should
change the following parameters!
Minimum angle of rotation of the rotor
required to detect movement
Current vector offset or segment
detection angle
The time from detection of movement
and the next step in Phase 1 or between
Phase 1 and Phase 2 (any oscillations in
the system have time to settle)

Period for which the parameterized
current is maintained so that any
oscillations that may be present can settle,
allowing an optimum commutation angle to
be reached
90 degrees
The maximum movement of the rotor
before it is switched off, since there would
otherwise be a risk that the motor would
make an uncontrolled movement.
= identifying characters for the description below

Version: 2.4

Servo Drives AX5000

Advanced system characteristics
Motor with 3 pole pairs

Servo Drives AX5000

Motor with one pair of poles

Version: 2.4

205

Advanced system characteristics
Phase 1 - approximate determination of the rotor position (motor shaft)
Step 1:
= see IDN P-0-0165 parameter description above
= flux vector of the rotor with permanent magnet.
Sequence:
A current vector "a" is developed during the time "b". Due to the
rising magnetic force, the rotor "c" is turned in the direction of the
current vector "a". The direction of rotation "d" is transmitted to the
feedback system and the AX5000, where it is stored.

Step 2:
= see IDN P-0-0165 parameter description above
= flux vector of the rotor with permanent magnet.
Sequence:
A current vector "a" is developed during the time "b". Due to the
rising magnetic force, the rotor "c" is turned in the direction of the
current vector "a". The direction of rotation "d" is transmitted to the
feedback system and the AX5000, where it is stored and analyzed.
If the analysis shows that the direction of rotation "d" of the rotor "c"
has not changed when compared with that of the previous
impressed current, the process continues.

Step 3:
= see IDN P-0-0165 parameter description above
= flux vector of the rotor with permanent magnet.
Sequence:
The current vector "a" is again set to the magnitude "e" in the
direction of the rotor "c".
The current vector "a" is now again developed during the time "b".
Due to the rising magnetic force, the rotor "c" is turned in the
direction of the current vector "a". The direction of rotation "d" is
transmitted to the feedback system and the AX5000, where it is
stored and analyzed. In this case, the analysis shows that the
direction of rotation "d" of the rotor "c" has changed when
compared with that of the previous impressed current. As a result,
the sector in which the rotor "c" is located has been found, and
Phase 1 is therefore completed.

206

Version: 2.4

Servo Drives AX5000

Advanced system characteristics
Example of an oscilloscope display of Phase 1:

Phase 2 - precise determination of the rotor position (motor shaft)
There are two variants of the precise localization that may be used in Phase 2. In the first variant, the rotor
only makes minimal movement, but this does require a very stable system with only a slight tendency to
oscillate. In the second variant, the rotor can move by up to a maximum of half the sector
method is much more tolerant against oscillation.

, but this

The value set in the parameter IDN-P-0-0165 "Commutation pos control: Kp" controls which variant is used:
IDN-P-0-0165 "Commutation pos control: Kp" > 0 --> Variant 1
IDN-P-0-0165 "Commutation pos control: Kp" = 0 --> Variant 2
Variant 1 (IDN-P-0-0165 "Commutation pos control: Kp" > 0 ):

Servo Drives AX5000

Version: 2.4

207

Advanced system characteristics

= see IDN P-0-0165 parameter
description above
= flux vector of the rotor with permanent
magnet.
= movement of the rotor
Sequence:
The current vector "g" is developed starting from
the final position of the current vector "a" in Phase
1. Due to the rising magnetic force, the rotor "c" is
turned in the direction of the current vector "g". The
movement is passed through the feedback system
to the AX5000, and supplied to a control loop. This
control loop immediately corrects the direction of
the current vector. This algorithm is executed until
the parameterized current intensity is achieved, and
the current vector approximately coincides with the
flux vector. The current is now maintained over the
period "h" which ensures that optimum
commutation takes place. In this control algorithm,
the rotor only moves minimally through "i".
Variant 2 (IDN-P-0-0165 "Commutation pos control: Kp" = 0 ):
= see IDN P-0-0165 parameter
description above
= flux vector of the rotor with permanent
magnet.
= movement of the rotor
Sequence:
After determining the sector "e" in Phase 1, the
current vector "g" is placed exactly in the center of
the sector "e", and this current is developed. Due to
the rising magnetic force, the rotor "c" is turned in
the direction of the current vector "g" until they
coincide. In this static alignment, the rotor cannot
move more than half the width of the sector "e".

208

Version: 2.4

Servo Drives AX5000

Advanced system characteristics
Using IDN P-0-0165 to affect wake&shake
Parameter

Default

First phase current level

Stationary current in %

First phase ramp up time

100 ms

First phase pos monitoring limit

0.5 degrees

First phase step width
First phase waiting time after step

22.5 degrees
150 ms

Second phase current level
Second phase ramp up time
Second phase duration
Error monitoring (range of motion)

Stationary current in %
500 ms
3000 ms
90 degrees

Commutation pos control: Kp

0.04

Possible causes that might require a
change in the default value
Sluggish system,
high attenuation --> increase value
Smooth system,
low attenuation --> reduce value
Sluggish system,
high attenuation --> increase value
Smooth system,
low attenuation --> reduce value
Application only permits very limited
uncontrolled changes in the movement
--> reduce value
The system has a small amount of
attenuation
--> reduce value
The loading relationships require more
overshoot
--> increase value
Decay behavior of the system:
Long settling time --> increase value
Short settling time --> reduce value

Application only permits very limited
uncontrolled changes in the movement
--> reduce value
The system has a small amount of
attenuation
--> reduce value
The loading relationships require more
overshoot
--> increase value
High load stiffness --> increase value
Low load stiffness --> reduce value
A special case "0": Variant 2 is carried out in
Phase 2

10.6.2

Linear motors

The above description of the commutation process applies equally to rotary motors and to linear motors.
Depending on the construction, there are merely some differences of nomenclature (e.g. motor shaft (rotor) =
primary part; "degree" = "mm" (conversion is needed))

Warning, risk of injury from uncontrolled movements!

WARNING

The primary part is moved in steps during "wake&shake". In Phase 1 the maximum electrical movement is 8 x (the value from "P-0-0-0165_Fist phase position monitoring limit"). In
Phase 2 it is 0.5 x (the value from "P-0-0-0165_Fist phase step width"). This formula can
only be applied if the previous investigation of stability has been concluded satisfactorily.
Make sure that your application permits this movement, secure the surroundings to prevent
unintentional entry, and make sure that nobody is in the hazardous area.

Servo Drives AX5000

Version: 2.4

209

Advanced system characteristics
Linear motors consist of a secondary assembly, whose position is fixed, onto which permanent magnets are
attached with alternating polarity and regular spacing. A primary assembly can undergo translatory
movement above this magnetic field. This movement is created by generating an electromagnetic field in the
primary assembly. Linear motors always have only one pair of poles, and the distance between the poles
therefore corresponds to one electrical rotation.

The "Electronic Commutation" section above can be applied to linear motors.

10.6.3

Commutation error "F2A0"

During operation of the motor the commutation is permanently monitored. The following conditions must
apply in order for the AX5000 to detect a commutation error:
1. The current velocity must be higher than the limit speed set in the IDN "P-0-0069 Commutation monitoring"
2. The power and acceleration vectors must have different signs.
3. The current power is greater than 95% of the value in the IDN "P-0-0092 Configured channel peak
current".
When these three conditions apply it is very likely that there is a commutation error and that the motor is
undergoing uncontrolled acceleration; the AX5000 generates a commutation error and switches the motor
torque-free i.e. it stops without control.

Warning, risk of injury from uncontrolled movements!

WARNING

A certain distance will have been travelled from the point when the error is detected until
the motor stops. Make sure that your application permits this movement, secure the surroundings to prevent unintentional entry, and make sure that nobody is in the hazardous
area. This applies in particular to vertical axes.

Occurrence of commutation error

Note

210

A commutation error almost always occurs when the axis is commissioned. If this error occurs during regular operation of the axis then special measures need to be adopted. See
next chapter.

Version: 2.4

Servo Drives AX5000

Advanced system characteristics

10.6.4

Commutation error during regular operation (very rare)

Under special operating conditions the regular operation of the axes can fulfil the three conditions cited
above and therefore trigger this error message despite correct commutation. A number of examples are
given below which, however, occur very seldom:
1. When the servo drive is operating at the limit (conditions 1 and 3 are met) and external forces cause
an opposing torque which then fulfils condition 2, the servo drive generates a commutation error.
2. The servo drive is operating at the limit (conditions 1 and 3 are met) and an oscillating current is produced due to a rapid change of direction or speed. Condition 2 is then also met and a commutation error arises.
If these examples do not apply to your application, analyze the application and try to find the cause. If you
are unable to remedy the cause but still wish to operate the axis, there is only one option for suppressing the
commutation error:
Parameterize the value of the IDN P-0-0069 to the permitted maximum speed of the motor so that point 1 of
the above-mentioned factors cannot apply and the commutation error will no longer appear.

Warning, risk of injury from uncontrolled movements!

WARNING

Increasing the value of the IDN "P-0-0069" to the highest speed always means that the
commutation monitoring will no longer cause errors, even when other conditions actually
call for this. This is particularly critical when the motor is being replaced. If the value of the
IDN "P-0-0069" is NOT reset, then uncontrolled movements of the motor may occur. Beckhoff recommends that you should NOT increase the value of the IDN "P-0-0069".

Drive design
As a rule the drive should not be designed at the limit i.e. the current power should reach a
max. of 90% of the P-0-0092 "Configured channel peak current" value.
Note

10.7

OCT

10.7.1

Precondition for operation

A prerequisite for operation of the OCT motor is a suitable AX5000 with a serial number > 105.000 and
firmware V 2.04 or higher.
AX5000 with hardware version 2
The AX5000 with hardware version 2 is marked
with "0200" (1) in the catalogue number. The
catalogue number can be found on the name
plates.

Servo Drives AX5000

Version: 2.4

211

Advanced system characteristics
AX5000 with hardware version 2 and set "Featureflag 0"
The feature flags (3) are documented in the IDN "P-0-0322" (2). The "Feature Flag 0" must have the value 1

AX5000 with hardware version 2 and firmware version 2.04 or higher.
The current firmware version of the AX5000 is
displayed under (4) in the "Watch Window".

212

Version: 2.4

Servo Drives AX5000

Advanced system characteristics

10.8

Decommissioning
Serious risk of injury through electric shock!

DANGER

Due to the DC link capacitors, the DC link terminal points "ZK+ and ZK- (DC+ and DC-)"
and "RB+ and RB-" may be subject to dangerous voltages exceeding 875 VDC, even after
the servo drive was disconnected from the mains supply. Wait 5 minutes for the AX5101 –
AX5125 and AX520x; 15 minutes for the AX5140/AX5160/AX5172; 30 minutes for the
AX5190/AX5191; 45 minutes for the AX5192/AX5193 after disconnecting, and measure the
voltage at the DC link terminal points "ZK+ and ZK- (DC+ and DC-)". The device is safe
once the voltage has fallen below 50 V.

Servo Drives AX5000

Version: 2.4

213

Advanced system characteristics

10.9

Integrated safety

10.9.1

Safety-Card AX5801

10.9.2

Intended use

The AX5801 Safety Card is exclusively intended for application in the safety slot of the servo drives AX5101
– AX5140 and AX52xx. The cards are installed together with the servo drive as components in electrical
systems and machinery and may only be used in this way.

10.9.3

Scope of supply

The scope of supply includes the following components:
AX5801 Safety Card, 4-pin connector, 6-pin connector, technical documentation and packaging
If one of the components is damaged please notify the logistics company and Beckhoff Automation GmbH
immediately.

10.9.4

Safety regulations
Serious risk of injury through electric shock!

DANGER

Caution - Risk of injury!

WARNING

Caution – electrostatic charging may lead to destruction of the Safety Card!
The Safety Card is an ESD-sensitive component. Follow the usual ESD safety procedures
when handling the card (anti-static wrist straps, earthing of the relevant components etc.).
Attention

214

Version: 2.4

Servo Drives AX5000

Advanced system characteristics

10.9.5

Personnel qualification

This description is only intended for trained specialists in control, automation and drive engineering who are
familiar with the applicable national standards. Knowledge of machine safety legislation is compulsory.

10.9.6

Product description

The AX5801 Safety Card from Beckhoff is used to realize the safe stop functions "STO or SS1 according to
IEC 61800-5-2". STO stands for SafeTorqueOff, SS1 for SafeStop1.
Thanks to the integrated two-channel monitoring of the AX5000, you can realize stop category 0 or 1
according to IEC 60204-1 with minimum effort and further TwinSAFE blocks from Beckhoff, thereby
achieving category 4, PL e according to ISO 13849-1:2006.
Two-channel monitoring is achieved through certified relays (Rel1 and Rel2). The relays are equipped with
positively driven contacts including feedback contacts (K1 and K2). The feedback contacts are connected in
series and potential-free with terminals (5) and (6) of the 6-pin connector.
The two coils (S1 and S2) have to be supplied with 24 V DC via terminals 1 and 2 or 3 and 4 of the 6-pin or
4-pin connector. Terminals 1-1, 2-2, 3-3 and 4-4 of the two connectors are bridged internally. If a relay
releases, the de-energizing circuit of the AX5000 servo drive range ensures that the connected motors (both
channels) become torque-free.

10.9.7

Technical data

Data
Relay operating voltage (terminal 1-4)
Feedback contacts operating voltage (5-6)
Max. switching current of the feedback contacts (5-6)
Conductor cross-section of terminals 1-6
Conductor strip length of terminals 1-6
Current consumption

Values
24 VDC -15% +20%
24 VDC -15% +20%
0.35 A
0.2 - 1.5 mm2
10 mm
50 mA

We recommend using wire end sleeves!

Servo Drives AX5000

Version: 2.4

215

Advanced system characteristics

10.9.8

Installation of the AX5801 Safety Card
Serious risk of injury!

DANGER

10.9.8.1

Mechanical installation

10.9.8.1.1

Installation of the two connectors on the AX5801 Safety-Card

• Insert the enclosed 4-pin connector (1) into the socket.
• Tighten the two bolts (2).
• Insert the 6-pin connector (3) into the socket.(4).
• Tighten the two bolts (5).

10.9.8.1.2

Installation of the AX5801 Safety-Card

• Fully release the bolt (6).
• Remove the insert (7) in the direction of the arrow (8).
• Carefully insert the Safety Card (9) into the opening in the direction of the arrow (10). The slot has
guides for the card on the short sides.
Ensure that the card is inserted into these guides.
• Tighten the bolt (11).

216

Version: 2.4

Servo Drives AX5000

Advanced system characteristics

10.9.8.2

Electrical installation

Configure the safety operation of servo drive via IDN P-0-2000. During the next system start-up the servo
drive automatically detects whether a Safety Card was inserted and whether the IDN P-0-2000
parameterization is correct. Error message "0xFDD4" indicates incorrect configuration. If the servo drive with
the Safety Card does not reach the safe state, error message "0xFDD5" appears on the display of servo
drive. In this case please contact Beckhoff.

Danger for persons and equipment!

CAUTION

10.9.9

If an error message appears on the display of the AX5000 the servo drive must not be put
into service if the servo drive in the system or machine represents a safety-relevant part of
the control system.

Application example (emergency stop – stop category 1)

Components involved:
• Emergency stop device (control switch S1) according to ISO 13850 and control switch S2
• 1 safety input terminal (KL1904) and 1 input terminal (KL 1404)
• 1 safety logic terminal (KL6904) with function block "ESTOP"
• AX5801 Safety Card and servo drive from the AX5000 range
• Programmable logic controller (PLC) and EtherCAT fieldbus
By activating the emergency stop device (S1) inputs EStopIn1 and EStopIn2 of FB "ESTOP" are switched to
state "0", resulting in outputs EStopOut and EStopDelOut of FB "ESTOP" being switched to state "0". As a
result, a quick stop command is issued to the PLC and therefore the AX5000 via EtherCAT. The output
EStopDelOut of FB "ESTOP" ensures that after a specified delay time the 24 V supply of the AX5801 Safety
Card is interrupted. This causes the relays (REL1 and REL2) to release and both channels (motors) to be
made torque-free via the internal deactivation procedure of the AX5000.
In the event of a fault the controlled shutdown (quick stop) may fail. The Safety Card becomes active once
the delay time has elapsed, and all motors connected to the device run out. The risk analysis for the machine
must indicate that this behavior can be tolerated. An interlock may be required.
The delay time must be set slightly longer than the maximum braking time of the quick stop.
Sticking relay contacts on the Safety Card are detected via input EDM1 of FB "ESTOP", and restarting is
prevented.
When the emergency stop device is released again, the control switch (S2) must be operated (first rising
then falling edge at the restart input of FB "ESTOP") in order to restart the AX5000.
Servo Drives AX5000

Version: 2.4

217

Advanced system characteristics

218

Version: 2.4

Servo Drives AX5000

Advanced system characteristics

10.9.10 Application example with several AX5000

Servo Drives AX5000

Version: 2.4

219

Project planning

11.1

Important information for project planning

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 chapter can only provide a brief overview of electrical project planning.

11.2

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.

11.3

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. If the mains supply does not meet the
specifications for operation of the AX5000, then isolating transformers, mains chokes, mains filters or other
measures may be required.

Only AX5101 – AX5140!

Note

11.4

An energy efficient drive system operates in a drive system with a shared DC link and
shared internal and possibly also external brake resistors or brake modules. If you are already using similar drive systems, the AX5000 offers a convenient diagnostic system for
determining the load on the brake resistors and for transferring the values. Previous experience with drive systems shows that in such a system much smaller or even no external
brake resistors / brake modules need to be used.

EMC, earthing, shield connection and potential
EMC information of the servo drive AX5000!

Note

11.5

For further information, please read the EMC – information brochure of the servo drive
AX5000. You will find the document on the Beckhoff homepage (www.beckhoff.com) under:
Motion → Documentation → EMC – leaflet.

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.

220

Version: 2.4

Servo Drives AX5000

Accessories

Accessories
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.

The following optional accessories are available (see Beckhoff main catalog or www.beckhoff.de):
• Motor and feedback cable (ready-made )
• Motor and feedback cable sold by the metre
• D-Sub connector X11, X12, X21, X22 individual (for feedback cable and resolver/Hall)
• Motor and sensor connector X13, X14, X23, X24
• EtherCAT bus cable, ready-made or sold by the metre
• Synchronous servomotors (linear or rotational)
• External ballast resistor
• Expansion cards
• Additional modules

Servo Drives AX5000

Version: 2.4

221

Accessories

12.1

AX-Bridge - quick connection system

12.1.1

Supply module for multi-axis system

If several AX5000 are to be linked to form a multi-axis system, a supply module for connecting the mains
voltage and the control voltage (24 VDC) for the control electronics and the motor brake is required.
Figure

Article no.
AX5901
AX5902

Description
AX-Bridge power supply module for connection of supply voltage and 24 V DC
for control and brake energy (pluggable), for AX5x01…AX5125, 85 A
AX-Bridge power supply module for connection of supply voltage and 24 V DC
for control and brake energy (pluggable), for AX5140, 85 A

To install the supply module connectors X01, X02 and X03 must be removed and replaced with the supply
module.

12.1.2

AX-Bridge connection module (AX5x01 - AX5112)

The connection between the two AX amplifiers is established by moving the three busbar sliders of the first
connection module of the next drive to the left.
Figure

12.1.3

Article no.
AX5911

Description
AX-Bridge power distribution module, quick connection system for power supply,
DC-Link and control voltage (pluggable), for AX5x01…AX5112, 85 A

AX-Bridge connection module (AX5118 and AX5125)

The connection between the two AX amplifiers is established by moving the three busbar sliders of the first
connection module of the next drive to the left.
Figure

222

Article no.
AX5912

Description
AX-Bridge power distribution module, quick connection system for power supply,
DC-Link and control voltage (pluggable), for AX5118 and AX5125, 85 A

Version: 2.4

Servo Drives AX5000

Accessories

12.2

Brake module - AX5021-0000

Figure

Art.-No.
AX5021-0000-0000

Description
Using a brake module it is possible to take up additional braking
power in a drive system, because the connection of an external
brake resistor without a brake module in a drive system with
devices up to max. 25 A rated current is not permissible. A
further advantage is the simple installation and the small space
requirement of the brake module. The brake module is equipped
with a complete DC link and an internal brake resistor and
enables the connection of an external brake resistor with the
integrated brake chopper. Several brake modules can be
integrated into a drive system.

Operating conditions

Note

12.2.1

The brake module may only be used together with servo drives of the AX51xx-xxxx-02xx or
AX52xx-xxxx-02xx series. These devices have serial numbers above 100.000. In addition
to the AX5021, the drive system must include at least two further servo drives from the
AX5000 range.

Electrical data

Electrcal data
int. Resistance1) [W]
int. Resistance2) [W]
ext. Resistance min. [Ω]
ext. Resistance3) [W]
ext. Resistance4) [W]
Power loss P [W]
Charging rate 24 VDC [A]
DC link capacity [µF]

AX5021
150
14.000
22
6.000
max. 32.000
max. 250
0.3 – 0.4
705

Durability break power Prms
Peak break power Ppeak
3)
Durability brake power Prms
4)
Peak brake power Ppeak
2)

Servo Drives AX5000

Version: 2.4

223

Accessories

12.2.2

Mechanical data

The external dimensions of the brake module are identical to the dimensions of the servo drives from the
AX5000 series up to 12 A.
Mechanical data
Weight
Width
Height without plugs
Depth without connectors / accessories

AX5021
approx. 4 kg
92 mm
274 mm
232 mm

Cable duct
93

5
6.
AX5021

AX5206

Min. 100

>2,5
>277,6
Control cabinet door

Mounting plate
contuctible (zinced)

277,6

299.2

317.2

(Incl. plug and cable for feedback)

Min.100

AX5021

60
92

Cable duct

12.2.3

General overview

No.

Name

Navigation rocker

Labelling field

X05 - socket for EtherCAT output

X03 – power supply 24 V DC
Input

X52 - connection of the temperature monitor
and the fan of the
external brake resistor

X51 - connection of the external brake resistor

X01 – mains supply
100 – 480 V

X02 – DC link output
(890 V DC voltage).

DANGER

Max. voltage 890 V DC at the DC link
terminals (X02). Once the device has
been switched off dangerous voltage
will still be present for a further 5 minutes. The device is safe once the voltage has fallen below 50 V.

X04 - socket for EtherCAT input

Display

224

Version: 2.4

Servo Drives AX5000

Accessories

12.2.4

Pin strip assignment of X51 and X52

No.

Name

T- = input of the temperature measurement sensor of the external brake resistor

T+ = input of the temperature measurement sensor of the external brake resistor

PE = protective conductor

F- = output to the fan controller
of the external brake resistor

F+ = output to the fan controller
of the external brake resistor

PE = protective conductor

B- = output to the controller of
the external brake resistor

B+ = output to the controller of
the external brake resistor

Please refer to the servo drive ‘Startup’ manual for the pin assignments of the remaining inputs and outputs.

Temperature rise in the external brake resistor
The temperature rise of the external brake resistor should be monitored continuously via
temperature contacts (1) and (2).
Note

12.2.5

Electrical connection (example)
Serious risk of injury through high electrical voltage!

DANGER

Due to the DC link capacitors dangerous voltage may persist at the DC link contacts "X02"
after the servo drive has been disconnected from the mains supply. Wait 5 minutes after
disconnection and measure the voltage on the DC link contacts DC+ and DC-. The device
is safe once the voltage has fallen below 50 V.
The example below describes the brake module and several servo
drives, which are linked via AX-Bridge modules to make up a drive
system. We recommend that the brake module be placed in the
first position with the AX-Bridge power supply module (AX5901)
and after that the servo drives with decreasing rated current; we
assume here that the most powerful servo drive also releases the
greatest brake energy.
CAUTION!
Uncontrolled movements!
If the drive system is disconnected from the mains due to a mains
failure, all axes of the drive system make uncontrolled movements.
Take suitable measures to ensure than no persons are endangered during this time. Vertical axes are particularly dangerous.

Pos.

Name

Pos.

Name

PC with TwinCAT and PLC

Patch cable

Output terminal

Control cable from the output terminal

Output "8" of the servo drive digital I/Os

Control cable from output ‘8’ of the servo drive digital I/
Os

Brake module

Mains fuses

Servo drive (with the greatest brake energy)

Mains contactor

Servo Drives

Servo Drives AX5000

Version: 2.4

225

Accessories

12.2.6

Integration into TwinCAT

Integration of the brake module by TCDriveManager and Powermanagement
The brake module can be integrated and
parameterized in the TCDriveManager as a
completely digital I/O device.
The position descriptions are in the table below.

Pos. Description

Pos.

Powermanagement

Activation / deactivation of the internal brake resistor

Mains voltage selection

External brake resistor parameter list

Phase monitoring (deactivate for single-phase mains)

0 = Deactivation of the external brake resistor
(not recommended)
1 = Standard energy management with external brake resistor
2 = Energy management with external brake resistor
(standalone)

Delay time until the phase monitoring responds
(activate if mains is unclean)

Enabling / disabling the fan of the external brake resistor and
setting the switching thresholds Switch on Level: Percentage
specification of the rated capacity value of the external brake
resistor. Switch on Temp.: Max. temperature value for the
external brake resistor in °C.

Internal brake resistor parameter list

226

Version: 2.4

Servo Drives AX5000

Accessories

12.2.7

DC link (only for 60A-170A devices)
Connection example DC link group!

Note

12.2.8

For further information of the production for an DC link group you will find in the system
manual of the servo drive AX5000 under: "Connection example – DC link group [} 50]"

Operation modes of the AX5021

It can be assumed that a brake module is used only if the brake energy cannot be dissipated despite a DC link system and internal
brake resistors. The brake module can be operated in two different operation modes, which have a direct influence on the energy management. The operation modes can be selected when using the external brake resistor. The following sketches show the storage capacity of the DC link of the individual devices in relation to the operation modes.
Ext. brake resistor enabled (system / standard)
In this operation mode the capacity of the DC link of the brake
module is reduced by approx. 10%. At 90% DC link load the brake
chopper then directs the generated braking energy to the external
brake resistor and, when this has reached its capacity limit, into the
internal brake resistor. In this case the brake energy is first fed into
the brake module, since the brake choppers in the other servo
drives are only activated at 100% utilization of the DC link. This operation mode is set as the default, because no further configuration
of the devices in the DC link system is necessary apart from the
basic configuration of the brake module. If the external brake resistor of the brake module is mounted outside the control cabinet,
then the thermal load in the control cabinet is also lower.

Ext. brake resistor enabled (standalone brake chopper)
In this case the capacity of the DC links is fully utilized. This operation mode must be selected and, apart from the basic configuration
of the brake module, the internal brake resistors of the devices in
the DC link system should be deactivated, as otherwise the thermal load in the control cabinet will also increase. In order to reduce
the thermal load further, it is a good idea to mount an external
brake resistor on the brake module outside the control cabinet.

12.2.9

Braking power diagnosis
Power Management of the servo drive AX5000!
Further information for the diagnostics of the external brake resistors you will find in the
function description of the servo drive AX5000 under: “Power Management”.

Note

Servo Drives AX5000

Version: 2.4

227

Accessories

12.3

Optional encoder card - AX5701 / AX5702

Figure

12.3.1

Art.-No.

Description

AX5701-0000

encoder option card for one additional
encoder input 1 Vpp, BiSS B, Hiperface,
EnDat

AX5702-0000

encoder option card for two additional
encoder inputs 1 Vpp, BiSS B, Hiperface,
EnDat

The optional encoder card enables connection of an additional feedback systems per channel. The system parameters match the standard parameters that
are analyzed via inputs X11 and X21.
Through simple configuration via
jumpers up to six further digital inputs
(In "A" to In "F") can be analyzed, which
are provided through special feedback
systems via parameter channels. The
X41 and X42 sockets are compatible
with the plugs of the X11 and X21 front
sockets of the AX5000, which means
that the tried and tested cables from the
ZK4510 series can be used. To analyze
the additional digital inputs you simply
have to insert an adapter or establish a
suitable wiring. This optional card cannot be used as commutation feedback
system (primary).

Intended use

The optional encoder cards are exclusively intended for application in the optional rear slot of a servo drive
from the AX5000 series. The cards are installed together with the servo drive as components in electrical
systems and machinery and may only be used in this way.

12.3.2

Safety regulations

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 and guidelines.

Caution - Danger of death!

DANGER

Even when the AX5000 is disconnected from the mains voltage, dangerous voltage continues to be present at the "X02" terminals of the DC link for at least 5 minutes. Wait until the
DC link capacitors are discharged before touching live terminals. The voltage measured between the DC+ and DC- terminals (X02) must have dropped to below 50 V.

Caution - Risk of injury!

WARNING

Caution – Destruction of the optional encoder card through electrostatic
charging!
Attention

The optional encoder card is an ESD-sensitive component. Follow the usual ESD safety
procedures when handling the card (anti-static wrist straps, earthing of the relevant components etc.).

UL approval
If you intend to operate an AX5000 in a region that requires UL approval, please refer to
the chapter "Guidelines and Standards".

228

Version: 2.4

Servo Drives AX5000

Accessories

12.3.3

Product identification

12.3.3.1

Type key

AX5701 – optional encoder card for single-channel servo drives
AX5702 – optional encoder card for two-channel servo drives

Operation of the optional encoder card
The AX5701 can only be used in single-channel servo drives, the AX5702 can only be used
in two-channel servo drives.
Note
Inputs A to D are single-wire inputs (single-ended). They have a certain potential to ground, which is
analysed.
Inputs E to F are two-wire inputs (differential). Thy require (+) and (-) and analyse the voltage difference
between the conductions.
Firmware revision
AX5000-xxxx-02xx = mind. 2.03 build 0009

12.3.3.2

Description of the digital inputs
Configuration of the digital inputs and outputs!
Further information on the control and configuration of the digital inputs and outputs can be
found in the function description of the servo drive AX5000 under: "Digital Inputs and Outputs".

Note

12.3.3.3

Overview of sockets X41 (channel A) and X42 (channel B)
Pin EnDAT /
BiSS

Hiperface

Sin / Cos 1Vpp TTL1)

SIN +

n.c.

GND_5 V

GND_9 V

GND_5 V

COS +

n.c.

Us_5 V

n.c.

Us_5 V

DX+ (Data)

DX+ (Data) n.c.

B+

n.c.

Us_9 V

n.c.

REF Z

CLK+ (Clock) n.c.

n.c.

A+

REF SIN

n.c.

GND_Sense

n.c.

GND_Sense

REF COS

n.c.

Us_5 V Sense n.c.

DX - (Data)

DX - (Data) n.c.

n.c.

Z+

CLK - (Clock) n.c.

n.c.

In "A"

In "B"

In "C"

In "D"

In "E"

In "F"

X (+)
X

X (+)

Y
X

X (-)
X

X (-)

Us_5 V Sense Us_5 V Sense
Y
Y

Attention: Wire break detection is not supported for TTL encoders.
The digital inputs "A" to "D" can be connected to X or Y.
The digital inputs "E" and "F" must be connected to X (+) and X (-).

Servo Drives AX5000

Version: 2.4

229

Accessories

12.3.3.4

Configuration of jumpers J-"A" for channel "A" and J-"B" for channel "B"
Jumpers J-"A" and J-"B" (1) are located at the center of the printed circuit
board near the front panel of the card. For each channel there are 2 row of
jumpers, each with 20 pins. The default setting without analysis of the additional inputs is shown in the following figure.

The opposite figure shows the basic jumper configuration, which is the same
for channel A and channel B. The pins of input sockets X41 and X42 are
wired firmly to the corresponding pins of the jumpers rows. The non-configurable pins are not shown. To use the additional inputs proceed as follows:
• Reposition the relevant jumpers und set IDN P-0-0180-->Feedback
options-->Digital Inputs "Input A" to "Input D" to "used" or set
IDN P-0-0180-->Feedback options-->Digital Inputs "Input E" or "Input
F" to "used" without repositioning the jumpers.
• Connect the encoder cable as required for the relevant inputs or use
an adapter.

The following table shows a selection of combination options.
Feedback system

Input "A"

Input "B"

Input "C"

EnDat

Input "D"

Sin / Cos
1 Vpp

TTL1)

X2)

X3)

X2)

X3)

not available

Hiperface

Input "F"

not available

BiSS

Input "E"

Attention: Wire break detection is not supported for TTL encoders.
Either inputs "A" and "B" or input "E" can be used
Either inputs "C" and "D" or input "F" can be used.

12.3.3.4.1

Technical data

Description
Digital inputs "A" to "D" (single-ended)
Digital inputs "E" to "F" (differential)

230

Value
Open collector with max. 1 mA
0 - 5 V at the input resistance 120 W

Version: 2.4

Servo Drives AX5000

Accessories

12.3.4

Installation of the optional encoder card
Caution - Danger of death!
Even when the AX5000 is disconnected from the mains voltage, dangerous voltage continues to be present at the "X02" terminals of the DC link for at least 5 minutes. Wait until the
DC link capacitors are discharged before touching live terminals. The voltage measured between the DC+ and DC- terminals (X02) must have dropped to below 50 V.

DANGER

Destruction of the optional encoder card through electrostatic charging!
The optional encoder card is an ESD-sensitive component. Follow the usual ESD safety
procedures when handling the card.
Attention
• Fully release the screw (1).
• Remove the panel (2).
• Carefully insert the optional card (3) into the
opening in the direction of the arrow. The slot
has guides for the card on the short sides.
Ensure that the card is inserted into these
guides. Tighten the bolt (4).

12.3.5

Sample: Renishaw RGH 22Z30D00

Feedback and inputs

12.3.5.1

Scaling

Overview of socket X41 (channel A) and jumper configuration

Socket X41 Pin

Renishaw

Alarm +

GND_5 V

Limit switch

Us_5 V

B+

n.c.

REF Z

A+

Alarm -

GND_Sense

n.c.

Us_5 V Sense

B-

Z+

A-

Servo Drives AX5000

In "C"

In "E"

Jumper configuration

X+
X

X-

Version: 2.4

231

Accessories

12.4

Optional encoder card - AX5721 / AX5722

Figure

Art.-No.
AX5721-0000
AX5722-0000

Description
encoder option card for one additional The optional encoder card enables connection of
encoder input EnDat 2.2, BiSS C
an additional feedback systems per channel. The
encoder option card for two additional system parameters match the standard parameters that are analyzed via inputs X11 and X21.
encoder inputs EnDat 2.2, BiSS C
Through simple configuration via jumpers up to
six further digital inputs (In "A" to In "F") can be
analyzed, which are provided through special
feedback systems via parameter channels. The
X41 and X42 sockets are compatible with the
plugs of the X11 and X21 front sockets of the
AX5000, which means that the tried and tested
cables from the ZK4510 series can be used. To
analyze the additional digital inputs you simply
have to insert an adapter or establish a suitable
wiring. This optional card cannot be used as
commutation feedback system (primary).

12.4.1

Intended use

12.4.2

Safety regulations

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 and guidelines.

Danger of death!

DANGER

Due to the DC link capacitors dangerous voltage (> 875VDC) may persist at the DC link contacts “ZK+ and ZK- (DC+ and DC-)“ and “RB+ and RB-“ after the servo drive has been disconnected from the mains supply. After disconnecting the servo drive wait at AX5101 AX5125 and AX520x; 5 minutes, at AX5140/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- (DC+ and DC-). The device is safe once the voltage has
fallen below 50 V.

Warning – Risk of injury!

WARNING

Electronic equipment is not fail-safe. The machine manufacturer is responsible for ensuring
that the connected motors and the machine are brought into safe state in the event of a
fault in the drive system.

Destruction of the digital encoder card through electrostatic charging!
The digital encoder card is an ESD-sensitive component. Follow the usual ESD safety procedures when handling the card.
CAUTION

UL approval
If you intend to operate an AX5000 in a region that requires UL approval, please refer to
the chapter "Guidelines and Standards".

232

Version: 2.4

Servo Drives AX5000

Accessories

12.4.3

Product identification

12.4.3.1

Type key

AX5721 – High Resolution Digital Encoder Option Card for single-channel servo drives.
AX5722 – High Resolution Digital Encoder Option Card for dual-channel servo drives.

No safety functions!
Safety functions cannot be implemented with the encoder option card.
Note
The encoder option card enables the connection of one digital feedback system per channel. The sockets
X41 or X42 respectively are not plug-compatible with the front sockets X11 or X21 respectively of the
AX5000. The following interfaces are supported:
• EnDat 2.2
• BiSS “C” mode
Firmware revision:
AX5000: 2.06 or higher and AX572x: 2.06 or higher.

12.4.3.2

Overview of sockets X41 (channel A) and X42 (channel B)
Pin

EnDat 2.2

BiSS C

Output current

n.c.

0.25 A / Channel

GND

n.c.

5V+ ±10%

Data+

12V

n.c.

CLK+

n.c.

GND sense

n.c.

5V sense ±10%

Data-

n.c.

CLK-

Attention: Wire break detection is not supported for TTL encoders.
The digital inputs "A" to "D" can be connected to X or Y.
The digital inputs "E" and "F" must be connected to X (+) and X (-).

12.4.3.2.1

Technical data

Max. single turn resolution: 32 bit

Servo Drives AX5000

Version: 2.4

233

Accessories

12.4.4

Installation of the optional encoder card
Caution - Danger of death!

DANGER

12.4.5
No.
F870
F872
F873
F874
F875
F876
F877
F879
F87A
F87C
F87D

234

Error messages

Description
„Encoder not ready“ – execute the RESET command (S-0-0099)
„Error flag active“ – status changes to „Safe-Op“. Restart required.
„Get position timeout“ – status changes to „Safe-Op“. Restart required.
“Crc memory error”– execute the RESET command (S-0-0099)
“No EnDat 2.2 encoder connected”– execute the RESET command (S-0-0099)
“UART Error”– execute the RESET command (S-0-0099)
“Out of memory”– execute the RESET command (S-0-0099)
“Callibration error”– execute the RESET command (S-0-0099)
“AX572x power supply error”– execute the RESET command (S-0-0099)
“AX572x protocol not supported”– execute the RESET command (S-0-0099)
“AX572x wrong parameter”– execute the RESET command (S-0-0099)

Version: 2.4

Servo Drives AX5000

Accessories

12.5

External Brake Resistor AX2090-BW5x

Figure

Art.-No.
AX2090-BW5x

Description
The external brake resistors of the AX2090-BW5x
series are able to convert the dynamic energy
generated during braking of a servomotor into heat.
The built-in temperature switch enables the system to
respond immediately to any overload of the brake
resistor through analysis in the AX5000 or the PLC.
All brake resistors of the AX2090-BW5x-xxxx series
are UL and CSA approved.

Caution - Destruction of the equipment
The brake resistor may only be connected to individual AX5000 devices or AX5021 brake
modules. It must never be used in a drive system without the AX5021 brake module, since
this may lead to its destruction through overload.

Attention

Caution - Destruction of the brake resistor and consequential damage
The built-in temperature switch must be monitored, so that the machine can be stopped in
a controlled manner and switched off in the event of an overloading of the brake resistor.
Attention

12.5.1

Appropriate use

The brake resistors from the AX2090-BW5x-xxxx series are exclusively designed for direct application with
an AX5000 series servo drive or the AX5021 brake module. They are designed for installation as
components in electrical installations and machines together with the servo drive or the brake module, and
this is their only purpose.

12.5.2

Safety rules

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 and guidelines.

Serious risk of injury through electric shock!

DANGER

Due to the DC link capacitors dangerous voltage (> 890VDC) may persist at the DC link contacts “ZK+ and ZK- (DC+ and DC-)“ and “RB+ and RB-“ after the servo drive has been disconnected from the mains supply. After disconnecting the servo drive wait at AX5101 AX5125 and AX520x; 5 minutes, at AX5140/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- (DC+ and DC-). The device is safe once the voltage has
fallen below 50 V.

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

UL-Listing!
It is essential to observe directives and standards if you wish to operate an AX5000 in an
economic area that requires a UL-Listing.

Servo Drives AX5000

Version: 2.4

235

Accessories

12.5.3

Product identification

Name plate
Figure

Pos.-No.

Description

Type power at 40 °C

Resistance

Switching temperature

Product no

Barcode

UL-Recognized Component – certification

CE – certification

E no.

Serial no.

Catalog no.

Type key
Figure

236

Pos.-No.

Description

Drive Technology Acessories

BW = brake resistor

Servo drive AX5000

0 = AX5000 up to 12 A rated channel current
1 = AX5118 up to AX5140
2 = AX5160 up to AX5172
3 = AX5190 up to AX5191
4 = AX5192 up to AX5193

AX5000

Version: 2.4

Servo Drives AX5000

Accessories

12.5.4

Mechanical installation

12.5.4.1

Mounting positions and distances

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

AX2090-BW50-xxxx
AX2090-BW51-1000

AX2090-BW51-3000 and AX2090-BW51-6000
AX2090-BW52-3000 and AX2090-BW52-6000
AX2090-BW53-3000 and AX2090-BW53-6000
AX2090-BW54-3000 and AX2090-BW54-6000

For all mounting positions the following minimum distances must be adhered to:
200 mm to adjacent components, walls etc. and 300 mm to components, ceilings etc. above. If the device is
installed vertically (A), the minimum distance to components, floors etc. below is 200 mm in order to allow
unobstructed flow of air to the brake resistor.

12.5.5

Electrical installation

12.5.5.1

Important notes
Serious risk of injury through electric shock!
Only staff qualified and trained in electrical engineering are allowed to wire up the brake resistors.

DANGER

• Check the assignment of the servo drive and the brake resistor. Compare the rated
voltage and the rated current of the devices.
• Always make sure that the brake resistors are de-energized during assembly and
wiring, i.e. no voltage may be switched on for any piece of equipment which is to be
connected. Ensure that the control cabinet remains turned off (barrier, warning signs
etc.). The individual voltages will only be turned on again during commissioning.
• Due to the DC link capacitors, the DC link contacts "ZK+ and ZK- (DC+ and DC-)" and
"RB+ and RB-" may be subject to dangerous voltages exceeding 890VDC, even after the
servo drive was disconnected from the mains supply.
Wait 5 minutes for the AX5101 - AX5125 and AX520x; 15 minutes for the AX5140/
AX5160/AX5172; 30 minutes for the AX5190/AX5191; 45 minutes for the AX5192/
AX5193 after disconnecting, and measure the voltage at the DC links "ZK+ and ZK(DC+ and DC-)". The device is safe once the voltage has fallen below 50 V.

Servo Drives AX5000

Version: 2.4

237

Accessories

12.5.5.2

Connection the brake resistor

Remove the two screws (1) and remove the cover (2) in direction of the arrow. Connect an adequately
dimensioned cable (see chapter "Cables") to the connections (3) of the resistor and the earthing stud (5) and
take it out of the terminal box through the strain-relief assembly (9). Ensure adequate strain relief with the
two screws (8). Connect the other side of the cable to the DC link contact connector "X2" of the AX5000. The
connector is supplied with the AX5000. Connect the earthing cable to the earthing conductor of the control
cabinet.
Connect an adequately dimensioned cable to the potential-free N/C contact (4) of the temperature switch
and take it out of the terminal box through the strain-relief assembly (7) (see chapter "Temperature switch").
Ensure adequate strain relief with the nut (6).
Install the cover (2) in reverse order.

238

Version: 2.4

Servo Drives AX5000

Accessories

12.5.5.3

Cables

Beckhoff offers pre-assembled cables for safe, faster and flawless installation of the motors. Beckhoff cables
have been tested with regard to the materials, shielding and connectors used. They ensure proper
functioning and compliance with statutory regulations such as EMC, UL etc. The use of other cables may
lead to unexpected interference and invalidate the warranty.

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

EMC safety
Use only shielded cables.
Attention

Type

Brake resistor
[mm ]
[AWG]
1,5
16
1,5
16
1,5
16
2,5
12
2,5
12
2,5
12
4,0
12
4,0
12
6,0
12
6,0
12
6,0
12
6,0
12
2

AX2090-BW50-0300
AX2090-BW50-0600
AX2090-BW50-1600
AX2090-BW51-1000
AX2090-BW51-3000
AX2090-BW51-6000
AX2090-BW52-3000
AX2090-BW52-6000
AX2090-BW53-3000
AX2090-BW53-6000
AX2090-BW54-3000
AX2090-BW54-6000

Temperature switch
[mm2]
[AWG]
0.75
18
0.75
18
0.75
18
0.75
18
0.75
18
0.75
18
0.75
18
0.75
18
0.75
18
0.75
18
0.75
18
0.75
18

We recommend wire end sleeves.

Servo Drives AX5000

Version: 2.4

239

Accessories

12.5.5.4

Temperature switch
Destruction of the brake resistor!
The temperature switch is exclusively used for temperature monitoring. The brake resistor
is not switched off.

Attention
The temperature switch has a potential-free N/C contact, which enables immediate response to any overload
of the brake resistor through analysis in the AX5000 or the PLC. Connect the cable directly to a free input of
plug "X06". Then parameterize it such that the AX5000 stops the motor(s) with an emergency ramp or the
PLC reads and processes this input.
Type

Switching temperature

12.5.5.5

[°C]
180
180
180
180
85
85
85
85
85
85
85
85

Switching current
24 VDC or 230 VAC
[A]
2
2
2
2
2
2
2
2
2
2
2
2

Short-term capacity

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

12.5.5.5.1

Duty cycle

The duty cycle is a relative value that depends on the switch-on time (ton) and the cycle time. Cycle times up
to 120 sec. are used directly in the calculation. Should the cycle time exceed 120 sec., the maximum
relevant cycle time of 120 sec. is used in the calculation.
Sample 1
Ton = 60 s
Cycle time = 280 s
Duty cycle = 50%

Sample 2
Ton = 40 s
Cycle time = 100 s
Duty cycle = 40 %

Further information of external brake resistors:

Note

240

For further information on the configuration and diagnostics of external brake resistors,
please refer to the function description of the servo drive AX5000: “Diagnostic of external
brake resistors”.

Version: 2.4

Servo Drives AX5000

Accessories
12.5.5.5.2

Overload factor

Calculation formula
Short-term capacity = continuous power x overload factor

12.5.5.6

Overtemperature and continuous power at 100% duty cycle

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

Normal operating range,
max. 130%

Permitted operating range,
max. 160%

Inadmissible operating range,
more than 160%

This operating range is recommended for
maximum service life and error-free operation.

This operating range is still permitted, although it results in shorter service life with
higher failure probability

In this operating range there is a risk of destruction of the brake resistor through overheating. Due to the high temperatures the
adjacent components are also at risk.

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

Servo Drives AX5000

Version: 2.4

241

Accessories

12.5.6

Technical data

Dimensions
Type1)

Type power Resistance
[W] * at 40 °C [Ω]

O
R
[mm [mm]
]

H
[mm]

M
[mm]

U
[mm]

Weight
[kg]

AX5000

AX2090-BW50-0300

300

349

120

230

AX5x01-AX5112

AX2090-BW50-0600

600

549

120

430

AX5x01-AX5112

AX2090-BW50-1600

1600

649

185

120

530

150

5,8

AX5x01-AX5112

AX2090-BW51-1000

1000

749

120

630

AX5118-AX5140

AX2090-BW51-3000

3000

23,4

490

355

255

380

270

AX5118-AX5140

AX2090-BW51-6000

6000

23,2

490

455

255

380

370

AX5118-AX5140

AX2090-BW52-2000

3000

13,2

490

355

255

380

270

AX5160-AX5172

AX2090-BW52-6000

6000

13,0

490

455

255

380

370

AX5160-AX5172

AX2090-BW53-3000

3000

10,2

490

355

255

380

270

AX5190-AX5191

AX2090-BW53-6000

6000

490

455

255

380

370

AX5190-AX5191

AX2090-BW54-3000

3000

6,6

490

355

255

380

270

AX5192-AX5193

AX2090-BW54-6000

6000

6,5

490

455

255

380

370

AX5192-AX5193

*) 4% decrease in performance per 10K temperature difference
1)

All external brake resistor have the protection class IP20

Technical drawings

242

Version: 2.4

Servo Drives AX5000

Accessories

12.6

Cables

12.6.1

General specification

Wire cross-section depending on the cable length (according to EN60402)
Beckhoff offers pre-assembled motor and feedback
cables for faster and flawless installation. Design,
dimensioning and installation have significant
influence on the function of a servo system. Beckhoff
servo cables have been tested with regard to the
material used, shielding and connection, in order to
guarantee proper function and compliance with
statutory requirements such as EMC. The use of
other may invalidate the warranty.

12.6.1.1

Line load for different types of installation
Fire hazard!

WARNING

If several servo drives are operated at the same time the resulting total current of the configuration must be taken into account for dimensioning of the cables. The information provides in this section should be regarded as guidance. It is not intended as a substitute for
professional design based on the specific application.

Cable cross-section

[mm²]
1.5
2.5
4
6
10
16
25
35

[AWG]
16
12
10
10
8

Three-core non-metallic Three-core non-metallic Three-core non-metallic
sheathed cable or con- sheathed cable, stacked sheathed cable, side by
duit
on wall
side, horizontal
[A]
[A]
[A]
12.2
15.2
16.1
16.5
21.0
22
23
28.0
30
29
36.0
37
40
50.0
52
53
66.0
70
67
84.0
88
83
104.0
114

Line load according to EN60204-1, Table 5, at an ambient temperature of 40°C
The cable descriptions can be found on the Beckhoff website at http://www.beckhoff.de/motion/
documentation.

Servo Drives AX5000

Version: 2.4

243

Accessories

12.6.2

Order key for motor and feedback cables

ZK4tuv-wwxy-zzzz
t

Servo drive series

AX5000

Function

Motor cable

Encoder cable EnDat, Hiperface, BiSS

Encoder cable Sin/Cos with zero pulse

Resolver cable

Temperature cable AL2000

Hall cable for AL2000

Motor - drive

Extension cable

Motor – choke (only AM3000 cable)

Motor - other side
The free end is fitted with wire end sleeves

Drive - other side
The free end is fitted with wire end sleeves

Raw material

AL2000/AM2000/AM3000/AM3500

01 to 19

Beckhoff

80 to 89

Beckhoff

20 to 29

Alpha EnDat / Alpha resolver

30 to 39

Lenze

40 to 49

SEW

50 to 59

Siemens

60 to 79

Further

90 to 99

Further

fixed installation / no motion

dynamic / drag chain

high dynamic / high-speed chain

high torsion cable

Feedback

1 to 8

0.75=1 / 1.0=2 / 1.5=3 / 2.5=4 / 4.0=5 / 6.0=6 / 10=7 / 16=8

special

applies only if Y ≠ 9

0001 to 9999

1 to 1000 m

applies only if Y > 9

_001 to _999

1 to 100 m

zzzz

Function

Motor series

Quality

Cross-section [mm²]

Length in dm

12.6.3

SEW motors from the “DFS / CFM” range with stopping brake
The stopping brake of the SEW motors has to be connected via a
brake rectifier, to guarantee the “quick activation of the brake”. A 3
wire connection cable is required for this. The following schematic
diagram shows the correct connections of the motors to the
AX5000.
• SEW servo motor of the DFS/ CFM range (1)
• Motor brake cable ZK4500-4xxx (2)
• SEW- BMV5 brake rectifier (3)
• Power supply unit with 5A minimum output current (4)

244

Version: 2.4

Servo Drives AX5000

Accessories

12.6.4

Special motor connections

12.6.4.1

Linear motors of the AL2xxx series

12.6.4.1.1

Installation

Caution – Risk of injury through electric shock!
Remove the motor and feedback lines from the connector box to the servo drive when you
open the connector-box.
WARNING

Attaching the connector box!
The linear motor cables are not for trailing cables, hence the connector box has to be fixed
on the moving part of the linear motor.
Note
Unscrew the cover and fix the connector box with 2 M4 screws on the carriage of the linear motor.
Motor cable:
Strip the wires of the motor cable and fit wire end sleeves. Twist the screen of the motor cable and solder on
a cable with a minimum diameter of 1.5 mm2. Fit wire end sleeves or a cable lug to the free end. Place the
nut of socket “A” over the motor cable and feed the wires through the socket “A” in the box and screw the nut
onto socket “A”. Fit the shielded and PE cables with a “PE” connection and the power wires on connection
“X1”.
Encoder cable:
Strip the wires of the encoder cable and fit wire end sleeves. Twist the screen of the encoder cable and
solder on a cable with a minimum diameter of 0.75 mm2. Fit wire end sleeves or a cable lug to the free end.
Place the nut of socket “B” over the encoder cable and feed the wires through the socket “B” in the box and
screw the nut onto socket “B”. Fit a “PE” connection to the shielded cable. Wire the signal wires to the “X2”
connection as per the table.
Connection pin

Signal description

MES
AL2200

LIKA
SMS-V1

SIKO
LE100

NJ*
LIA 1 Vss

X1-PE

PE / GND

shield

wh / gn

X2-1

COS -

red

orange

green

red

X2-2

GND

white

black

white

X2-3

SIN -

yellow

blue

orange

yellow

X2-4

+ 5V DC

brown

red

brown

X2-5

DATA + / Z +

---

white

blue

grey

X2-6

n.c.

---

X2-7

PTC

---

X2-8

Clock+

---

X2-9

COS +

blue

green

yellow

blue

X2-10

GND sense

grey

---

X2-11

SIN +

green

yellow

red

green

X2-12

+ 5V sense

pink

---

X2-13

DATA - / Z -

---

violet

pink

X2-14

PTC

---

X2-15

Clock-

---

Thermal protection cable:
Strip both wires of the thermal protection contact cable and fit wire end sleeves. Twist the screen of the
thermal protection contact cable and solder on a cable with a minimum diameter of 0.75 mm2. Fit wire end
sleeves or a cable lug to the free end. Place the nut of socket “C” over the thermal protection contact cable
and feed the wires through the socket “C” in the box and screw the nut onto socket “C”. Fit a “PE” connection
to the shielded cable. Fit both thermal protection contact wires to contacts “7” and “14” of connection “X2”.
Retighten the connector box cover.

Servo Drives AX5000

Version: 2.4

245

Accessories

12.7

Motor chokes AX2090-MD50

Figure

Art.-No.

Description

AX2090-MD50-0012
motor choke for AX5000 (1.5…12 A),
necessary for motor cable ≥ 25 m, up to 12
A rated current, necessary for motor cable ≥
25 m, max. 100 m, with integrated
connection cable (150 mm)

A motor choke must be installed between
the AX5000 and the motor from a certain
motor cable length onwards. The motor
choke reduces the commutation current
flowing via the screen back into the AX5000
to a permissible value and can also provide
a solution to EMC problems.

AX2090-MD50-0025
motor choke for AX5000 (18…25 A), up to
25 A rated current, necessary for motor
cable ≥ 25 m, max. 50 m, with integrated
connection cable (150 mm)

12.7.1

Electrical connection

The motor chokes are connected based on the "plug & play" principle. Pull the two plug connectors from the
existing motor cable of the AX5000 and plug them into the sockets of the motor choke. The two plugs of the
integrated motor choke cable are then plugged into the socket of the AX5000.

Caution - Risk of injury through electric shock!
De-energize all electrical components (servo drive, control cabinet etc.) before commencing the installation or deinstallation of the motor choke.
WARNING

Connection cables

Note

Use exclusively Beckhoff motor cables and firmly tighten the connecting plugs. Max. tightening torque - M4 thread = 1.5 Nm ±0.1 Max. tightening torque - M3 thread (motor connector) = 0.6 Nm ±0.1.

Connection example

12.7.2

Technical data

Rated motor current

Motor cable length

Servo Drives

Motor choke

max. 400 V

>20 m to 100 m

AX2090-MD50-0012

max. 480 V

>20 m to 100 m

AX5101, AX5103, AX5106,
AX5112,
AX5201, AX5203, AX5206

max. 400 V

>20 m to 50 m

AX5118 and AX5125

AX2090-MD50-0025

max. 480 V

>20 m to 50 m

246

Version: 2.4

Servo Drives AX5000

Accessories
Data

AX2090-MD50-0012

AX2090-MD50-0025

Rated voltage

480 V AC

Rated frequency

0 - 60 Hz

0 – 60 Hz

Test voltage cable/cable for 2 s

1770 V DC

Test voltage cables/housing for 2 s

2700 V DC

Rated temperature

50 °C

Inductance

0.2 mH

0.12 mH

Continuous load operation (S1)

12 A

25 A

Climate category (IEC 60068-1)

25/100/21

Approval

UL 1283

Resistance [type]

25 mΩ

15 mΩ

Power loss

5 - 25 W1)3)

10 -35 W2)4)

Weight

2.9 kg

8.5 kg

rated current 1 - 12 A
rated current 18 – 25 A
3)
measured at max. cable length of 100 m
4)
measured at max. cable length of 50 m
2)

Servo Drives AX5000

Version: 2.4

247

Accessories
Insertion attenuation (reference value Z = 50 Ω)

12.7.3

Installation of the motor choke AX2090-MD50-0012
Destruction of the motor choke!

CAUTION

• Always install the motor choke vertically on an earthed metallic mounting plate. If no
metallic mounting plate is available, you must earth the motor choke; an earthing bolt is
provided on the motor choke for this purpose.
• Ensure adequate ventilation of the motor choke. The permissible ambient conditions
are specified in the chapter "Technical data".
• It is essential to maintain the necessary distances to the AX5000 (see sketches below).

248

Version: 2.4

Servo Drives AX5000

Accessories
The motor chokes for the AX5000 (a) with a max. rated channel current of 12 A are bolted to the mounting
plate (d) below the device.
‘Figure 1’ shows a motor choke (b) for one channel.
In the case of 2-channel devices, the motor chokes are bolted on top of one another; see ‘figures 2 and 3’.
The spacer (e) is supplied with the motor choke.

Servo Drives AX5000

Version: 2.4

249

Accessories

12.7.4

Dimensions

12.7.4.1

AX2090-MD50-0012

250

Version: 2.4

Servo Drives AX5000

Accessories

12.7.4.2

AX2090-MD50-0025

Servo Drives AX5000

Version: 2.4

251

Accessories

12.8

Mains choke AX2090-ND50

12.8.1

Technical data

Environmental conditions
Rated voltage
Overload factor
Ambient temperature
Mounting height
Relative humidity
Storage temperature
Protection class
Short-circuit voltage
Permissible level of contamination
Thermal configuration
Material
1)

Three-phase mains chokes AX2090-ND50
3 x 460 V, -25% +10%, 50/60 Hz1)
2.0 x IN for 30 s
-25 °C to +45 °C, with 1.3% (/°C) power derating to +60 °C
1000 m, with 6% (/1000 m) power derating to 4000 m
15%…95%, condensation not permitted
-25 °C to +70 °C
IP00
UK 4% at 400 V = 9.24 V
UK 2 % at 400 V = 4.6 V
P2 according to EN 61558-1
Ieff < IN
The AX2090-ND50 devices are UL-certified for the US and Canadian
markets

at 60 Hz mains frequency the power loss is approx. 10% higher!

Three-phase mains chokes

Data
Rated current [A]
Power loss [W]
Inductance [mH]
Weight [kg]
Connection [mm²]
Short-circuit voltage

12.8.2

0060
60
70
0.25
7
16

0072
72
80
0.20
10
16

AX2090-ND500090
0110
90
110
120
140
0.16
0.13
13
15
35
35
4 % UK

0143
143
160
0.10
25
70

0170
170
170
0.09
25
70

Installing the mains chokes
Caution - Risk of injury through electric shock!
De-energize all electrical components (servo drive, control cabinet etc.) before commencing the installation or deinstallation of the mains choke.

WARNING

Caution - risk of injury through high voltages!

WARNING

Mains chokes contain components that can store electrical charge. Wait 10 minutes after
disconnecting the mains chokes and measure the voltage on conductors L1 to L3. You can
ensure safe working by letting the voltage drop below 50 V.

Beware of improper earthing!
Ensure proper earthing during installation of the mains chokes. The installation should take
place on a mounting plate (chromated / galvanized) suitable for earthing.
CAUTION

252

Version: 2.4

Servo Drives AX5000

Accessories

12.8.2.1

Circuit diagram and installing
Assembly sequence:
• Position the mains choke on the mounting
surface.
• Mark the positions of the thread holes on the
mounting surface.
• Centre and drill the thread holes. Then cut the
threads in the holes.
• Secure the mains choke on the mounting
surface with suitable screws.
Connection:
• Connect the protective conductor connection of
the mains choke with the PE rail.
• Connect the connecting cable of the mains
choke to the appropriate terminals of the servo
drive.
• Connect the mains choke to the supply
network.

Serious risk of injury!
Due to the DC link capacitors dangerous voltage (> 890VDC) 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.

DANGER

12.8.2.2

Dimensional drawing
AX2090-ND50-

Dimension [mm]

0060

0072

0090

0110

0143

0170

B (Wigth)

190

230

240

H (Height)

200

240

300

330

T (Depth)

120

110

160

180

200

170

180

190

122

125

Servo Drives AX5000

Version: 2.4

253

Accessories

12.9

Mains filter - AX2090-NF50

12.9.1

Technical data

Data
Rated voltage [VAC]
Rated frequency [Hz]
Rated current [A]
Voltage cable/cable for 2 sec.
[VDC]
Voltage cable/housing for 2 sec.
[VDC]
Rated temperature [°C]
Climate category (IEC 60068-1)
Resistance [mΩ]
Leakage current [mA]
Weight [kg]
Approvals

12.9.2

0014

14.6
2236

AX2090-NF-500032
0063
480
50 / 60
32.8
63
--

2720
50
25/100/21
9

0100

0150 0180

100
--

150
--

180
--

--6.8
5.0
--

---

--9.8
6.8
--

---

40
4

15
0.9
1.75
EN 133200, UL 1283, CSA C22.2 No.8

6.0
--

7.0
--

Installing the mains filter
Caution - Risk of injury through electric shock!
De-energize all electrical components (servo drive, control cabinet etc.) before commencing the installation or deinstallation of the mains filter.

WARNING

Caution - Risk of injury through electric shock!

WARNING

Mains filters contain components that can store electrical charge. Wait 5 minutes after disconnecting the filters and measure the voltage on conductors L1 to L3. The device is safe
once the voltage has fallen below 50 V.

Personal injuries!

CAUTION

When installing the mains filter, the protective earth cables must be connected first as a
matter of principle. They must be disconnected last when deinstalling. Depending on the
size of the leakage current, the special regulations for the implementation of the protective
earth connection must be observed. Minimum requirement for the protective conductor KUvalue 1) = 4.5 for leakage currents IL < 10 mA or KU = 6 for IL > 10 mA.

The KU-value is a variable for the classification of safety-related types of failure for protection against
dangerous shock current and excessive heating. A value of KU = 4.5 in relation to interruption is attained:
• with a permanently attached protective conductor ≥ 1.5 mm2
• for protective conductor connection ≥ 2.5 mm2 with plug connector for industrial systems (IEC
60309−2).
KU = 6 in relation to interruption is attained with permanently connected conductors ≥ 10 mm2, wherein the
type of connection and routing must comply with the standards applicable to PEN conductors.

Destruction of the mains filter
The mains filters must be protected by means of an appropriate overcurrent protection device against the impermissible exceeding of the rated current.
Attention

254

Version: 2.4

Servo Drives AX5000

Accessories

12.9.2.1

Circuit diagram

Connection cables
The length of the connecting cable from the mains filter to the AX5000 must not exceed 0.4 m. Use
exclusively shielded connecting cables.

12.9.2.2

Dimensions and dimensional drawings

Dimensions
B1 [mm]
B2 [mm]
B3 [mm]
H1 [mm]
H2 [mm]
K [mm²]
K1 [mm]
K2 [mm]
K3 [mm]
L1 [mm]
L2 [mm]
L3 [mm]
L4 [mm]
PE1 [mm]
PE2 [mm]
PE [mm²]
T [Nm]

0014
38-0.3
46.4

0032
35-0.3
58
Ø 4.5

90
1.5

4
----

10
---200

231
221-0.5
-60
9

265
255-0.5
-70
8
M5

0.5 – 0.6

Servo Drives AX5000

1.2 – 1.5

AX2090-NF500063
0100
40
45
62
75
Ø7
180
200
--0.6-16
16-50
------240
250
280
290
270
305
336
----M6
---

Version: 2.4

0150
60
90
220
-35-95
---280
320
300
380
--M8
--

0180
180
200
Ø 8.5
120
-Busbars
45
86
91
160
310
180
410
30
-M10
--

255

Accessories
Figure

Mains filter
AX2090-NF50-0014
AX2090-NF50-0032

AX2090-NF50-0063
AX2090-NF50-0100
AX2090-NF50-0150

AX2090-NF50-0180

256

Version: 2.4

Servo Drives AX5000

Accessories

12.10

Transient voltage suppressor - AX2090-TS50

Figure

Art.-No.
AX2090-TS50-3000

Description
The Beckhoff transient box of the series
AX2090-TS50 enables voltage peaks, by
means of switching operations in electrical
circuits or by electrostatic discharges to be
recorded.

12.10.1 Guidelines and Standards
12.10.1.1 Appropriate use
The AX2090-TS50-3000 transient boxes are accessory components for the AX5000 servo drive series. They
are specifically designed for the Canadian market, to protect supply networks from overvoltages and to
absorb current peaks.
The AX2090-TS50-3000 transient boxes are always installed as control cabinet components and may only
be commissioned as integrated system components.

Caution - Risk of injury!

WARNING

The transient boxes may only be operated in closed control cabinets, under the conditions described in the
"Technical data [} 258]" section.

12.10.1.2 CSA approval
The AX2090-TS50-3000 transient box series was approved by the American UL certification authority for the
Canadian market, in accordance with the standards and guidelines applicable in Canada.
Transient box with CSA approval:
AX52090-TS50-3000 – certified according to CAN / CSA C22.2 no. 274.
The cRU logo should be shown on the name plate. If you wish to operate an AX2090-TS50-3000 in Canada,
please check whether the name plate shows the cRU logo.

Servo Drives AX5000

Version: 2.4

257

Accessories

12.10.2 Technical data
This section contains general technical data and ordering information for the Beckhoff AX2090-TS50-3000
transient box. See below for name plate information (technical approvals, certifications, mains supply, etc.).
AX2090-TS50-3000
Electrical data
Rated input voltage [VAC]

100 – 480

Max. pulse peak current [A]

3000 at 25 °C

Power derating

20% at 50 °C

Transient protection

Fuse AX3-430C or similar according to E128662

AX2090-TS50-3000
Mechanical data
Material

Housing: Cast aluminum
Cover: Cast aluminum with CR foam rubber perimeter seal

Surface

Textured paint

Color

RAL 7001

Ambient temperature [°C]

-25 to +85

IP protection class

IP 66 (closed state) according to IEC 60 529

NEMA protection class

NEMA 4

Weight [kg]

1,56

AX2090-TS50-3000
Ordering information

Transient protection for servo drives of the AX5101 – AX5125 and AX520x
series, required for CSA certification

12.10.2.1 Name plate

Item no.
1
2
3
4
5
6
7
8

258

Name
Order number
Max. pulse peak current
Rated input voltage
Input frequency
Barcode
Protection class
cRU-compliant (E195162)
Standard mains supply with earthed center

Version: 2.4

Servo Drives AX5000

Accessories

12.10.3 Installation of the transient box
12.10.3.1 Connection example

Item no.
1
2

Name
Transient box AX2090-TS50-3000
Mains filter (optional) AX2090-NF50-0014 (AX5101 - AX5112 and AX520x)
Mains filter (optional) AX2090-NF50-0032 (AX5118 and AX5125)

Connection cables
When assembling the connecting cables note the following lengths:
• cable between the transient box and the mains filter (optional): min. 200 mm.
• cable between the mains filter and the AX5000 servo drive: max. 400 mm.

EMC-compliant installation of the components and shield concept

Note

For further information on EMC-compliant installation and the shield concept
please refer to the Beckhoff website (www.beckhoff.com) under:
Motion → Documentation → AX5000 – EMC leaflet.

Servo Drives AX5000

Version: 2.4

259

Accessories

12.10.3.2 Installation in the control cabinet
Beckhoff Automation GmbH & Co. KG recommends M6 screws with through-hole thread of strength grade
8.8 for installation of the transient box in the control cabinet. The screws should be tightened with a
maximum tightening torque of 7.3 Nm.

Caution - Risk of injury through electric shock!
The mounting plate must be earthed according to the statutory regulations.
WARNING

Earthing!
Improper earthing of the AX2090-TS50-3000 transient box can result in EMC problems.
Attention

12.10.3.3 Dimensions
AX2090-TS50-3000

Tightening torques for the fastening screws (cover)
M6 x 40 (4 screws)
2 +1 Nm

260

Version: 2.4

Servo Drives AX5000

Appendix

13.1

Error management

13.1.1

General

Fatal errors are error types requiring reinitialization of the connected AX5000 feedback systems. For this the
communication status of the EtherCAT Slave State Machine must be changed from Operational (Op) to
Safe-Operational (Safe-Op), which takes place automatically on the occurrence of a fatal error in the case of
standard parameterization. In such a case the drive is in ErrSafe-Op, since an error is additionally signaled.
Since two-channel devices possess only one communication unit and no axis operation is possible in the
SafeOp state, both channels are stopped by default. In this particular case, the change from Op to ErrSafeOp results in the working counter of the SyncUnit becoming invalid, since the AX5000 can no longer supply
valid actual values, resulting in all servo drives in this SyncUnit being disabled.

13.1.2

Requirement

The measures described in this section assume the following software versions.
• TwinCAT v2.10 b1329 or later versions
• Firmware v2.x or later versions

13.1.3

Parameterization

A fatal error completely stops a two-channel device by default, i.e. the error-free channel and the associated
SyncUnit are also stopped. If such a behavior is not permitted in the application, the default behavior can be
changed with the following parameterization of IDN P0-0350.
P-0-0350: Change of communication state in the event of fatal errors
0: Immediate state change (default)
If the servo drive is in "Op" state when the fatal error occurs, it immediately changes from "Op" to "ErrSafeOp" and sets the error bit in the EtherCAT state.
1: No change in communication state while the other channel is enabled
In this case the AX5000 initiates the state change from Op to ErrSafe-Op in the event of a fatal error on one
channel only once the error-free channel has been deactivated. The error-free channel can therefore
continue to operate until it is deactivated.
2: Change of status when the reset command is called (S-0-0099)
In the case of an active fatal error, the AX5000 only changes to "ErrSafeOp" if the Reset command is
executed in the drive; hence, the change of state can be initiated at the best possible time from the
application by means of the Reset command.

Servo Drives AX5000

Version: 2.4

261

Appendix
PLC
The IDN P-0-0040 is used in order to be able to diagnose in the PLC whether a fatal error situation has
occurred that will lead to a change of status when next deactivating a channel or when calling the Reset
command. This IDN should be read acyclically in the PLC with block "FB_SoERead". Cyclic evaluation is not
meaningful, since the AX5000 no longer supplies valid inputs in ErrSafe-Op state after a fatal error, and
therefore no valid information is transferred cyclically.
Bit 0: this bit indicates whether the other channel has an error that will lead to a change of communication
from ‘Op’ to ‘ErrSafe-Op’ on deactivation of this channel.
Bit 1: this bit indicates whether this channel has a fatal error that will lead to a change of communication from
‘Op’ to ‘ErrSafe-Op’ on deactivation of the other channel. An error reset is not possible as long as this bit is
set.
Bit 2: this bit indicates whether this channel has a fatal error that will lead to a change of communication from
‘Op’ to ‘ErrSafe-Op’ on executing the Reset command.

13.1.4

SyncUnit diagnostics

The individual servo drives should be consolidated in meaningful groups, depending on the application. Each
of these groups is allocated to a SyncUnit. Since each group has its own working counter, the individual
groups can continue to operate independently in the event of fatal errors. For particularly critical applications,
each AX5000 can be allocated a separate Sync Unit. However, this step should only be implemented in
cases where it is actually required, because each further Sync Unit results in additional data traffic on the
EtherCAT strand.
Allocation of servo drives to a Sync Unit
Start the TwinCAT System Manager and left-click on
the associated EtherCAT strand (1). Select the
"EtherCAT" tab (2) and left-click on "Sync Unit
Assignment" (3). The "Sync Unit Assignment"
submenu appears. Section (4) shows the servo
drives and their allocation to the Sync Units. Servo
drives AX5203 and AX5118 belong to Sync Unit
"Cycle Process", 5206 belongs to Sync Unit
"Transport".

262

Version: 2.4

Servo Drives AX5000

Appendix

13.1.5

Reinitialization, troubleshooting and reset

1. Analyze and rectify the fatal error.
2. Carry out an error reset via IDN S-0-0099. To this end the blocks "FB_SoEReset" or "FB_SoEReset_ByDriveRef" are available in the PLC.
3. Automatic change of communication state from "ErrSafe-Op" to "Op".
4. NC axis reset. To this end the block "NC_Reset" is available in the PLC.
Re 3:
In order for the communication state to automatically
switch back to "Op", flag "Wait for WcState is OK"
must be activated on the corresponding AX5000. This
is automatically the case for new configurations. In
existing configurations it may have to be set
accordingly.
Start the TwinCAT System Manager and left-click on
the associated servo drive (1). Select the "EtherCAT"
tab (2) and left-click on "Advanced Settings...." (3).
(3). The "Advanced Settings" submenu appears.
Select the flag "Wait for WcState is OK" with the left
mouse button (4).

13.2

Firmware Update

The firmware of the AX5000 is a complex software, which is absolutely necessary for the operation of the
servo drive. The servo drives are subject to a constant process of further development and improvement
and, hence, the firmware is also under constant development, so that the latest technological innovations
can also be used.

13.2.1

Firmware version on the AX5000
The current firmware version of the AX5000 is
located in "IDN S-0-0030 - Manufacturer Version" and
can be displayed using the TCDriveManager as
follows: In the TwinCAT System Manager, mark the
servo drive (1) whose firmware version you would like
to know. Open the TCDriveManager (2) and click
"Device Info" (3). A window opens and the current
firmware version (4) appears in the "IDN S-0-0030".

Servo Drives AX5000

Version: 2.4

263

Appendix

13.2.2

Update to a new firmware version

Read please the Release Notes carefully before the update. All important changes and additions to the
individual firmware versions for the servo drives are located in the corresponding file in the download area on
our homepage.

Never touch a running system!
This old IT concept applies more than ever today, in these times of the most complex systems with ever decreasing cycle times. Please do not perform firmware updates on a system that is working well without a reason, unless requested to do so by Beckhoff Automation.

Note

Update only within a version number!
We recommend firmware updates only within the same version number (e.g.: V.1.05 (Build
0003) to V.1.05 (Build 0007). If you want to update from V.1.05 to V.1.06, for example, you
would need to make further adjustments in TwinCAT. In accompaniment to that, we do not
recommend performing a so-called "downgrade" to a lower version number.

Note

Do not work on live equipment!

CAUTION

13.2.2.1

The 24 V supply (plug "X03") must be connected to the servo drive in order to be able to
perform a firmware update. Make sure that the power supply (plug "X01") is disconnected
from the servo drive, so that uncontrolled movements of the equipment cannot occur.

Update preparation

So that you can perform a firmware update, a connection must be made to the computer with TwinCAT that
controls the AX5000. It is quite usual for you not to be in the area where the equipment is operated. That is
not also necessary, because there are three different procedures for establishing a connection:
Direct accesses to the control computer
You are in the same place where the equipment is
operated and can work directly on the control
computer. In this case you can continue immediately
with the next chapter "Performing the update".
Remote access to the control computer
You are in a different place and have no direct
access to the control computer. In this case you can
also perform a firmware update on the control
computer using one of the remote connections (VPN
tunnel with remote desktop, VNC etc.) that are usual
in the IT world. Please make sure that the firewall is
configured accordingly for the remote connection and
that you have the necessary rights. After establishing
the remote connection you can continue with the next
chapter "Performing the update".
Remote access by ADS
You are in a different place and have no direct access to the control computer, or the control computer is
located in a cleanroom or the like. In this case you can also perform a firmware update via remote access by
ADS. Please read in the Online Information System how to implement remote access by ADS. Afterwards
you can continue with the chapter "Performing the update". The Online Information System is multilingual!

264

Version: 2.4

Servo Drives AX5000

Appendix

13.2.2.2

Performing the update
Click the button (1) in the TwinCAT System Manager
to enter the configuration mode. Confirm the query
with OK (2). After that a further window appears
which must be confirmed with Yes (Ja) (3).
Deactivate the "Free Run" with No (Nein) (4).
The system is now in "Configuration mode".

In order to perform the firmware update, you must
click the "Online" tab (6) in the "EtherCAT
Device" (5). If you want to update several devices,
you can select the respective servo drives (7)
together; in the case of one device, select only the
one servo drive. Subsequently, click with the right
mouse button inside the selected area and select the
command "Firmware Update" (8) in the command
overview.

In the place where you have stored the desired
firmware version, select the firmware file (9) and click
"Open" (10). Confirm the window that then opens with
"OK"; the firmware update is then performed. After
successful completion you must click OK (11) in the
concluding "Function Succeeded" window.

Subsequently, TwinCAT must be brought from
configuration mode back into operation mode. To do
this, click the button (12) and confirm the query that
appears with "OK" (13).

Update failed!

Note

If the firmware update is aborted with an error message, you should try again. If the abortion occurs several times, please start a further attempt with another copy of the firmware
file.

Servo Drives AX5000

Version: 2.4

265

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.
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:
http://www.beckhoff.com
You will also find further documentation for Beckhoff components there.
Beckhoff Headquarters
Beckhoff Automation GmbH & Co. KG
Huelshorstweg 20
33415 Verl
Germany
Phone:
Fax:
e-mail:

+49(0)5246/963-0
+49(0)5246/963-198
info@beckhoff.com

Beckhoff Support
Support offers you comprehensive technical assistance, helping you not only with the application of
individual Beckhoff products, but also with other, wide-ranging services:
• support
• design, programming and commissioning of complex automation systems
• and extensive training program for Beckhoff system components
Hotline:
Fax:
e-mail:

+49(0)5246/963-157
+49(0)5246/963-9157
support@beckhoff.com

Beckhoff Service
The Beckhoff Service Center supports you in all matters of after-sales service:
• on-site service
• repair service
• spare parts service
• hotline service
Hotline:
Fax:
e-mail:

266

+49(0)5246/963-460
+49(0)5246/963-479
service@beckhoff.com

Version: 2.4

Servo Drives AX5000

Source Exif Data:

File Type                       : PDF
File Type Extension             : pdf
MIME Type                       : application/pdf
PDF Version                     : 1.7
Linearized                      : Yes
Language                        : en-US
XMP Toolkit                     : Adobe XMP Core 5.4-c006 80.159825, 2016/09/16-03:31:08
Format                          : application/pdf
Creator                         : Beckhoff Automation GmbH & Co. KG
Description                     : Servo Drives AX5000
Title                           : System manual Servo Drives AX5000
Create Date                     : 2017:09:14 11:38:32+02:00
Creator Tool                    : SCHEMA ST4
Modify Date                     : 2017:09:14 11:39:49+02:00
Metadata Date                   : 2017:09:14 11:39:49+02:00
Producer                        : ST4 PDF Engine (Build 7.0.2.0)
Document ID                     : uuid:3981741d-0cfc-43a6-b227-80b920642573
Instance ID                     : uuid:1f0eb8a7-ad02-4629-a0eb-be11ef1ab395
Page Mode                       : UseOutlines
Page Count                      : 266
Author                          : Beckhoff Automation GmbH & Co. KG
Keywords                        : System, manual, Servo, Drives, AX5000, ax5000_system_manual_hw2_en
Subject                         : Servo Drives AX5000

EXIF Metadata provided by EXIF.tools

System Manual Servo Drives AX5000 Ftp://ftp.beckhoff.com//motion/ax5000_system_manual_hw2_en Hw2 En

Navigation menu

Versions of this User Manual:

Views

Navigation