BECKHOFF AMP8000 Distributed Servo System Operation Manual

BECKHOFF AMP8000 Distributed Servo System Operation Manual

Overview of the entire system product

The four core components of AMP8000 distributed servo system adopt EtherCAT P one wire communication (power+24V control+bus cable):

AMP8620 power supply module (installed inside the control cabinet, IP65)

The system's main incoming unit is connected to industrial three-phase/single-phase mains power, generating a common DC bus DC link (430-848V) and 24V control power supply, providing multiple EtherCAT P output expansion distribution modules/servos.

Voltage version:

Standard three-phase type: 3 × 400~480V AC;

Wide voltage type: three-phase 230~480V/single-phase 120/220V dual specifications;

Hardware configuration: 5-way B23 power output, 2-channel M8 EtherCAT P communication port; Optional internal/external braking resistor (external maximum 1600W);

Output capability: DC bus peak value of 40A, 24V control total output of 12A, maximum external capacitance of 2820 µ F for a single segment bus.

AMP8805 power distribution module (on-site installation of equipment)

Bus relay expansion unit, input with one EtherCAT P, splits into 5 power outputs and 1 communication port, extends servo wiring distance, supports cascading, and has a maximum DC output of 20A per module.

AX8831/AX8832 coupling module (inside the control cabinet)

Traditional AX servo system adapter unit, AX8831 single axis, AX8832 dual axis; Used for connecting traditional AX8000 drives to AMP8000 distributed motors, converting DC bus, 24V, EtherCAT P signals.

AMP80xx/AMP85xx integrated servo motor (execution terminal IP65)

The motor body integrates the drive power stage, encoder, and EtherCAT P interface, and is divided into two major series:

AMP80: Standard rotor moment of inertia; AMP85: High inertia suitable for large loads;

Flange specifications F3/F4/F5, body length 1/2/3/4; Covering the power range of 0.2~1.8kW;

Core optional features:

Shaft type: optical axis/flat key shaft/with shaft seal+sealed gas interface (0.1 bar micro positive pressure protection in dust/liquid environment);

Brake: no brake/standard brake/M8 manual release brake (for maintenance only, must be equipped with a sealing cap during operation);

Safety level: Basic STO (Safe Torque Off), Full SafeMotion (SS1/SS2/SLS/SCA/SBC and other complete safety functions, meeting SIL3/Cat.4 PL e);

Encoder: Single cycle/multi cycle 24 bit absolute value encoder.

System architecture advantages

Eliminating the need for a large number of power cables in the control cabinet, a single EtherCAT P can simultaneously transmit strong, weak, and bus signals;

Drive down to the device end, significantly reducing the volume of the control cabinet;

The entire TwinSAFE series is integrated, and the safety signal multiplexing bus does not require hard wiring;

The whole machine has IP65 rating and can be directly installed on the side of machine tools/automation equipment without the need for a built-in control cabinet.

Cable length limit

power supply module ↔ Allocation module: maximum 75m;

Power supply/distribution/coupling module ↔ AMP servo motor: maximum 30m.

Complete technical specifications

1 Environmental indicators

Operating temperature: 0~40 ℃; Storage and transportation -25~+55 ℃;

Humidity ≤ 95%, no condensation, power rating reduced by 1%/100m above 1000m altitude;

Anti vibration and impact comply with EN60068, pollution level 2/3;

Protection: AMP8620/8805/motor housing IP65, AX coupling module IP20.

2 Electrical core parameters

Bus voltage: 155~848V DC;

The maximum mechanical speed of the motor is 9000/10000rpm, and it supports wide voltage speed regulation;

Insulation class F, with a built-in temperature sensor in the stator;

Capacitive storage: The device/module can be stored for up to 5 years for a long time, and if it exceeds the storage period, it must be charged without load for 60 minutes to reset;

Service life: servo motor bearings ≥ 30000 hours; There is no mandatory calibration cycle for the entire machine.

mechanical parameters

Installation: AMP8620/8805 vertical installation (interface facing downwards); Motor standard IM B5 flange, supports V1/V3 vertical installation (V3 liquid easily infiltrates, use with caution);

Torque specification: The tightening torque of each flange matching screw is clear, and eccentric installation of the output wheel is prohibited;

Differentiate motor bearing models and strictly control radial/axial loads to avoid brake failure and bearing failure.

safety standards

Meets IEC 61800-5-1/-2, Machinery Directive 2006/42 EMC、LVD、RoHS； Certification CE, cURus, UL, CCC exemption (AMP804x/805x).

Supply, transportation, and storage

Supply list: equipment body, installation instructions, and simple manual; Equipped with an external braking resistor version and B23 plug; The cable for repairing the motor brake needs to be ordered separately.

The packaging is divided into five specifications, A-E, with strict stacking height restrictions. It must be packaged in the original factory during transportation to prevent collision and moisture.

Storage requirements: constant temperature and low humidity, no vibration; The motor can be stored for up to 2 years, and the power/coupling module can be stored for up to 5 years.

Handling: Suspension of equipment is prohibited, the yellow protective cap on the shaft end cannot be removed, and the encoder may be damaged by collision.

Mechanical installation

1 Control cabinet module (AMP8620/8805/AX883x)

Vertical installation, reserved heat dissipation space below, galvanized sheet metal with equipotential;

M5 screws are used for fixation, with a tightening torque of 6Nm, and the drilling drawings are unified and universal;

The AX bridge quick connector is connected to the busbar with a snap fit push-pull connection, and all power is turned off before installation.

Installation of servo motor flange

Select M5/M6/M8 flange screws according to specifications, corresponding to the specified torque;

The output coupling/synchronous wheel is prohibited from excessive compression of the shaft due to thermal expansion, and a professional puller should be used for disassembly;

Strictly control the radial and axial loads of the shaft to avoid early damage to the bearings;

Connect the sealed air model with clean and dry compressed air at 0.05~0.1 bar.

Electrical installation and wiring

Definition of various interface pins

AMP8620 incoming line B23: three-phase L1/L2/L3+PE;

EtherCAT P M8 interface: differential EtherCAT signal+24V Us/UP control power supply;

Power output B23: DC bus ±, 24V, PE, communication four wire integration;

External brake resistor dedicated B23 interface;

Motor M8 brake maintenance interface: only for temporary debugging use, must be blocked during operation.

Design of Power Supply System 2

Single phase/three-phase input selection, matched with isolation transformer for IT power grid;

Incoming fuse CE standard gG, UL standard Class J, maximum 25A;

All power and communication cable shielding layers are grounded at a single point, and the cabinet is fully equipotential.

3 Manual operation specifications for holding brakes

Special ZK2020 maintenance cable, 24V temporary release brake;

After the maintenance is completed, remove the cables and install the original factory sealing protective cap to prevent accidental operation.

4 EMC and Wiring

Separate the routing of power cables and communication cables, and isolate strong and weak electrical conduits; All connectors use original factory code B23/M8 plugs, and the drag chain cable is made of PUR bending resistant material.

Debugging and TwinCAT configuration

precondition

Check the mechanical fixation, grounding, and cables. For storage devices over 5 years old, perform capacitor reconstruction first;

Emergency stop, safety circuit fully connected, motor M8 sealing cap in place.

TwinCAT configuration process

Install TC3 Drive Manager 2 (TE5950);

Scan EtherCAT bus to automatically identify AMP power supply, distribution module, and servo motor; The built-in electronic nameplate of the motor automatically reads parameters such as torque and speed;

Select internal/external braking resistors, configure NC motion units, load inertia, and speed limits;

Distinguish between STO basic models and fully SafeMotion motors, and complete TwinSAFE safety engineering configuration (refer to AMP8911 manual);

Offline can be pre configured, online scanning can calibrate motor parameters, activate configuration and put into operation.

operation monitoring

Real time observation of device RUN, AXIS, L/A communication LED indicators, identifying no communication, fault, and enable status; Immediately stop the machine and cut off the power for troubleshooting abnormal noise and temperature rise.

Maintenance, cleaning, and accessories

Cleaning: After power off and cooling, wipe with a damp isopropanol cloth; Do not use strong acids, bleach, high-pressure water washing, or soaking.

Routine maintenance: Regularly check cable looseness, shell volume dust, motor temperature, and brake function;

Complete set of original accessories: prefabricated EtherCAT P cable, on-site crimping plug, B23/M8 protective cap, assembly tool AF27, IP65 external brake resistor, sealed air pipe component;

Cables are divided into three categories: drag chain specific, fixed wiring, and maintenance specific, with matching crimping pliers and terminals.

Equipment retirement and scrapping

Dismantling steps: The shaft comes to a complete stop → Power off and let it stand for 30 minutes to discharge → Remove all cables → Loosen the installation screws;

Classified scrap: Metal, plastic, circuit board, lubricating oil, and electronic waste are separated and comply with the WEEE EU electronic waste regulations. They can be sent back to the manufacturer for professional recycling;

The motor gearbox cannot be disassembled without authorization. If there is a malfunction, please contact Beifu after-sales service.

Certification and Standards

The whole machine meets the low voltage, EMC, and RoHS mechanical directives; Having CE, cURus, and UL certifications; AMP804x/805 series exempt from CCC certification; The isolation meets the requirements of double insulation, and the electrical clearance and creepage distance comply with VDE 0160.