BECKHOFF AX5000 series EtherCAT servo drive

BECKHOFF AX5000 series EtherCAT servo drive

Product Overview and Model System

1. Product classification and naming conventions

The AX5000 is divided into two series: single channel AX51xx and dual channel AX52xx, with power levels divided by output current:

AX51xx (single axis): current coverage 1.5A~170A, subdivision AX5101~AX5140（1.5~40A）、AX5160~AX5172（60/72A）、AX5190~AX5193（90~170A）；

AX52xx (dual axis): AX5201/5203/5206, single channel 1.5/3/6A, two axes can be matched with different power motors to save cabinet space.

Model code: including product line, number of channels, rated current, hardware version, functional configuration. High version hardware can be backward compatible with old models.

2. Supply and labeling

Standard supply: drive body, terminals, quick start guide, supporting document CD; Motor/feedback plug and cable are optional.

Nameplate: The equipment is equipped with two nameplates of different sizes, indicating key information such as order number, serial number, input/output parameters, voltage, frequency, certification, and maximum ambient temperature. For use in North America, CUS identification must be verified.

3. Overall core characteristics

Wide voltage input: single-phase 100~240VAC, three-phase 100~480VAC, universal for global power grids;

Universal motor interface: supports synchronous motors, asynchronous motors, linear motors, and torque motors;

Multi feedback interface: compatible with mainstream encoders such as Resolvers, TTL, 1Vpp sine and cosine, EnDat, Hiperface, BiSS, OCT, etc;

High speed control: The current loop cycle is as low as 62.5 μ s, with excellent dynamic performance;

Bus: Native EtherCAT, supports distributed clock (DC), high multi axis synchronization accuracy;

Scalability: Optional security card, encoder expansion card, integrated brake management, temperature detection.

General Technical Parameters

1. Environmental and mechanical parameters

Working temperature: 1.5~40A model 0~55 ℃; 60-170A models require power reduction (2%/℃) for temperatures between 0 and 40 ℃;

Storage and transportation temperature: -25~70 ℃, temperature change rate ≤ 20K/h;

Humidity: Operating at 5%~95% (no condensation), pollution level 2;

Installation: Vertical installation only, high-power models come with temperature controlled fans; Protection level IP20;

Anti vibration/impact: Compliant with EN 60068 standard, reliable installation inside industrial cabinets.

2. Electrical core parameters

Divide key electrical indicators by power group (output current, peak current, loss, DC bus, braking capacity):

AX5101-AX5140&AX52xx (low-power 1.5~40A)

Single phase/three-phase universal, DC bus up to 875VDC, built-in braking resistor, can be externally connected with different resistance values and braking power as standard.

AX5160-AX5193 (high power 60~170A)

Only three-phase 400~480VAC power supply, no built-in brake, external brake resistor must be connected; It is necessary to equip the incoming reactor and filter to meet EMC requirements.

Leakage: The driver and cable will generate capacitive leakage current, and an AC/DC hybrid leakage protector should be selected.

3. Size and weight

There are significant differences in size and weight among different power models: low-power models have a width of 92/185mm, while high-power models have a maximum width of 283mm and a weight of 38kg. The manual provides a complete outline and installation dimension diagram.

Mechanical installation

Installation base: Standard 35mm DIN rail, the installation plate must be reliably grounded to ensure EMC and safety.

Ventilation requirements: Reserve designated ventilation gaps above, below, and in front and behind the driver, with larger gaps for high-power models; The wiring inside the cabinet distinguishes between power lines and signal lines.

Multi machine arrangement: Multiple machines should be installed side by side to ensure spacing, and the guide rails should be reinforced in high vibration scenarios.

Optional accessories: High power models can be equipped with protective covers, corresponding to specialized installation accessories and fixing specifications.

Electrical installation (emphasis)

1. Overall wiring architecture

The whole machine includes seven major interfaces: main power supply, 24V control power supply, EtherCAT bus, digital IO, encoder/feedback, motor, and braking resistor. All wiring must be disconnected for operation.

2. Power system wiring

Main circuit (X01): single-phase/three-phase connection method, limited to grounded star grid in North American UL scenarios, strictly matching fuse specifications (CE uses gG/gL type, UL uses RK5 type).

24V auxiliary power supply (X03): divided into two channels: system power supply and peripheral/brake power supply, which can be independently powered or short circuited and shared; When there is a power outage, UPS can be used to achieve safe stopping of the shaft and prevent the load from falling.

DC bus (X02): Supports parallel connection of multiple driver DC buses (only high-power models above 60A can form DC links) to achieve energy mutual benefit; Low power models are prohibited from being mixed with high-power ones.

Fuse selection: Distinguish between single machine and multi machine systems, provide rated fuse parameters for single-phase/three-phase and different models.

3. Multi drive system connection

AX Bridge Quick Connect Module (AX5901/AX5911): Used for small power units, fast series power supply, DC bus and 24V, bus current limit of 85A, simplified wiring.

Bridge free series connection: using cables for direct connection, connectors have limited current carrying capacity and are only suitable for low current systems.

DC Link Group (60A+models): Dedicated for high-power units, requiring shared main contactors, matching DC fuses, incoming reactors, and clear rules for bus voltage equalization and energy distribution.

UL Compliance System: Exclusive wiring and protection schemes must be followed in North American scenarios.

4. Functional interface wiring

EtherCAT (X04/X05): Standard RJ45 interface, Cat5 and above Ethernet cables, string topology, single segment up to 100m, automatic recognition of straight/cross lines.

Digital IO (X06): 24V level, multiple inputs+1 configurable output, providing multiple matching plugs (with/without indicator lights) for signals such as limit, enable, fault, emergency stop, etc.

Feedback interface (multiple sets of D-SUB interfaces)

X11/X21: High resolution encoder, supporting EnDat, BiSS, Hiperface, 1Vpp, TTL;

X12/X22: Resolver Rotary Transformer, Hall Sensor;

X14/X24: OCT single cable feedback, motor temperature detection, brake wiring;

The manual lists the parameters and pin definitions of mainstream brand encoders (such as Heidenhain, Huntsman, Kubler, etc.).

Motor wiring (X13/X23): three-phase UVW+PE, distinguishing star/delta connections, marking terminal torque and shielding grounding requirements.

Braking resistor: low-power built-in braking, high-power external connection for the entire series; Clearly define the minimum resistance value, continuous/peak braking power, wiring terminals, and safety distance requirements for braking resistors of different models.

5. Cable and EMC requirements

Power and signal lines are laid in separate slots, and the shielding layer is grounded at a single point;

Define the maximum length of cables for different motors. Long line scenarios must be equipped with motor reactors and inlet filters, otherwise EMC interference and equipment failure will be triggered.

EtherCAT communication system

EtherCAT state machine: Standard five states (Init → Pre Op → Safe Op → Op → Boot), where Op is the normal operating state and Boot is only used for firmware upgrades.

Watchdog: The process data watchdog defaults to 100ms and automatically switches to a safe state when communication is interrupted. The timeout period can be configured.

CoE (CANopen over EtherCAT): Manage parameters through index and sub index, divided into three major partitions: device information, process data, and motor/control parameters; Support parameter power-off storage and batch loading of startup lists.

Distributed Clock (DC): Supports high-precision synchronization, meeting scenarios such as multi axis linkage and electronic camshafts.

Accessory system

The manual provides a detailed introduction to the entire range of optional accessories, including their purpose, parameters, installation, and integration methods

AX Bridge: Multi axis fast power supply connection module;

Brake module AX5021: external brake expansion, compatible with high-power systems;

Encoder card AX5701/5702/5721: Expand feedback interface and adapt to special encoders;

AX5801 Safety Card: Integrated TwinSAFE safety function, achieving emergency stop and safe stop (Class 1 stop), meeting mechanical safety standards;

External braking resistor AX2090-BW5x: Different power specifications, corresponding installation and wiring;

Incoming reactors, filters, surge suppressors: suppress interference, protect the power grid and drivers;

Special motor/feedback cable, motor reactor: matching wiring and long line use.

Debugging, configuration, and operation functions

1. Software environment

Compatible with TwinCAT 2/TwinCAT 3, relying on TwinCAT NC (motion control)+TwinCAT PLC, paired with * * TwinCAT Drive Manager (TCDM) * * to complete drive parameters and motor configuration.

2. Complete debugging process

Engineering creation and hardware scanning: Select the target controller, enter Config mode to scan EtherCAT devices, and automatically identify AX5000;

Motor and feedback configuration:

Comes with electronic nameplate: automatically reads motor parameters;

Third party/Nameless Motors: Manually input motor type, rated voltage/current, number of poles, connection method, temperature sensor and other parameters, supporting self built motor parameter library;

Encoder configuration: Select the interface type (Resolver, 1Vpp, TTL, etc.) by model, set the resolution and counting direction;

Axis association: bind the drive channel to the NC/CNC logical axis, set electronic gears, scaling factors, speed/acceleration/deceleration parameters;

Phase change calibration: divided into rotary motors and linear motors, supporting Wake&Shake phase finding and manual phase change offset calibration, which is a prerequisite for operation;

Loop tuning: Debug speed loop and position loop PID to suppress oscillation and improve tracking performance;

Manual trial operation: jog and positioning tests to verify operation, limit, and braking functions.

3. Motor support and operation mode

Compatible motors: synchronous servo, asynchronous motor, linear motor, torque motor; Asynchronous motors support two modes: V/F open-loop and current closed-loop.

Reversing method: Provide multiple commutation solutions for rotary/linear motors, and mark the troubleshooting method for commutation errors (F2A0).

OCT single cable technology: integrated motor feedback solution, simplified wiring, and labeled usage prerequisites.

Brake management: Configure motor brake timing through IDN parameters, in conjunction with axis start stop logic.

4. Third party motor adaptation

Specially explain the debugging points of third-party motors: rotation direction verification, commutation offset calculation, incremental encoder phase finding setting, and differentiated configuration of different encoders (Resolvers, absolute values, incremental types).

Fault diagnosis, maintenance, and firmware

1. Diagnostic method

Hardware indicator lights: EtherCAT status light, fault light, quickly determine communication and hardware faults;

Process data and status words: read axis operating status, follow error, temperature;

CoE diagnostic register+fault code: subdivision of communication, encoder, motor, commutation, parameter faults, with typical fault interpretations attached (such as F4A5, F707, F107, etc.).

2. Typical faults and troubleshooting

Covering common problems and solutions such as feedback anomalies, communication interruptions, commutation errors, illegal parameters, overspeed, overload, EMC interference, etc.

3. Maintenance and firmware

Daily maintenance: The equipment itself is maintenance free; Only need to regularly clean the fan and ventilation openings; Clean with isopropanol and do not spray or soak.

Long term storage (over 5 years): The DC bus capacitor needs to be re energized before it can be powered on.

Firmware Upgrade: Supports single/batch upgrade, distinguishing between controller firmware and FPGA firmware, upgrade steps and compatibility instructions;

Factory reset: Reset all configurations through the CoE parameter.