Servo motors AM8000 and AM8500

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1 Documentation Fan cooled Version: Date:

2

3 Table of contents Table of contents 1 Foreword Notes on the documentation Documentation Issue Status Appropriate use Guidelines and Standards EC declaration of conformity For your safety Staff qualification Description of symbols Notes for the AM8000 and AM8500 (incl. Fan) Handling Transport Packaging Storage Maintenance / Cleaning Disposal Product identification AM8000 and AM8500, scope of supply AM8000 and AM8500 (fan) nameplate Type key AM8000 and AM8500 (fan) Technical description Design of the motors General technical data Power derating Standard features Style Shaft end, A-side Flange Protection class Overtemperature protection Insulation material class Vibration class Vibrations and shocks Connection technology Feedback System Holding brake Pole number Options Selection criteria Transport, assembly and disassembly Installation fan body Mechanical installation Important notes Flange mounts Version: 1.9 3

4 Table of contents 8 Electrical installation Important notes Connection of motors with pre-assembled cables Connection of the fan with power admission AX5000 connection diagram for motors with OCT-Feedback AX5000 connection diagram for motors with OCT-Feedback AX5000 connection diagram for motors with OCT-Feedback AX5000 connection diagram for motors with Resolver AX5000 connection diagram for motors with Resolver AX5000 connection diagram for motors with Resolver AX5000 connection diagram for motors with Resolver AX5000 connection diagram for mototrs with Hiperface Comissioning Important notes Guide for commissioning of the motor Guide for commissioning of the fan Troubleshooting Technical data AM805x and AM855x Dimensional drawing AM805x and AM855x Dimensional drawing AM805x-9000 and AM855x Radial / axial forces at the shaft end Characteristic torque / speed curves AM806x and AM856x Dimensional drawing AM8061 and AM Dimensional drawing AM806x and AM856x with K-N-L winding Dimensional drawing AM806x and AM856x with R-Q-T winding Radial / axial forces at the shaft end Characteristic torque / speed curves AM807x Dimensional drawing AM807x Dimensional drawing AM Radial / axial forces at the shaft end Characteristic torque / speed curves Support and Service Version: 1.9

5 Foreword 1 Foreword 1.1 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: EP , EP , DE , DE 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: EP , US 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. Version: 1.9 5

6 Foreword 1.2 Documentation Issue Status Issue Notice 1.9 Chapter update: Appropriate use 1.3; Guidelines and standards 2; For your safety 3; EC declaration of conformity 2.1; Notes on the AM8000 and AM8500 (incl. Fan) 3.3; Disposal 4.5; Type key 5.3; Installation fan body 6.8; Connection of the fan with power admission 8.3; Technical data New chapter: Dimensional drawing AM807x (OCT) ; Dimensional drawing AM ; Assignment planning of the Terminal box Deleted chapter: Documented motors 1.8 Chapter update: Foreword 1.0 and Safety 3.0; 6.7; 6.8; 8.3; 10.1; ; 10.2; ; 10.3; Chapter update: Documented motors; 5.2; 5.3; Chapter update: 5.3; Chapter update: ; Chapter update: 8.4; 8.5; 8.6; 8.7; 8.8; 8.9; 8.10; 8.11; 10.1; 10.2; New chapter: 8.3 Chapter update: 10.1; 10.2; Chapter update: 2.1; 5.3; ; 7.1; 10.1; Chapter update: ; ; First issue 6 Version: 1.9

7 Foreword 1.3 Appropriate use Beckhoff servo motors of the AM8000 and AM8500 (incl. Fan) series are designed as drives for handling equipment, textile machines, machine tools, packaging machines and similar machines with demanding requirements in terms of dynamics. The motors of the AM8000 and AM8500 series are exclusively intended for speed- and/or torque-controlled operation via digital servo drives from Beckhoff Automation GmbH & Co. KG. The thermal protection contact incorporated in the motor windings must be analysed and monitored. Damage of the environment or equipment The servo motors are operated in the drive system in conjunction with Beckhoff servo drives. Please observe the entire documentation which consists of: Attention AM8000 and AM8500 (incl. Fan) documentation this manual Complete documentation (online and paper) for Beckhoff servo drives available at Complete machine documentation (provided by the machine manufactor) Caution Risk of injury! CAUTION 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. Special safety instructions for AM8000 and AM8500! Note The notes for the AM8000 and AM8500 (incl. Fan) [} 13] sections are also essential. Read carefully! The servomotors from the AM8000 and AM8500 (incl. Fan) series are exclusively designed for installation as components in electrical systems or machines and may only be operated as integrated components of the system or machine. The motors may only be operated under the ambient conditions defined in this documentation. Reasonably foreseeable misuse Any use that deviates from the approved technical data (e.g. speed, force, temperature) is not use as intended and is therefore not permitted. Improper use The servo motors AM8000 and AM8500 (incl. Fan) are not suitable for use in the following areas: in ATEX zones without a suitable housing in areas with aggressive environments (e.g. aggressive gases or chemicals) The relevant standards and directives for EMC interface emissions must be complied with in residential areas. The servo motors may only be installed in housings with appropriate shielding attenuation. Version: 1.9 7

8 Guidelines and Standards 2 Guidelines and Standards CAUTION Danger for persons Servomotors of the AM8000 and AM8500 series are not classified as products within the meaning of the EC Machinery Directive. Operation of the servomotors in machines or systems is only permitted once the machine or system manufacturers has provided evidence of EC conformity of the complete machine or system. 8 Version: 1.9

9 Guidelines and Standards 2.1 EC declaration of conformity Version: 1.9 9

10 Guidelines and Standards 10 Version: 1.9

11 For your safety 3 For your safety Read the section on safety and heed the notices to protect yourself against personal injury and material damages. Liability limitations All the components of the servo motors AM8000 and AM8500 (incl. Fan) are aupplied in certain hardware and/or software configurations appropriate for the conditions of the application. Unauthorized modifications to the hardware and/or software configurations other than those described in the documentation are not permitted, and nullify the liability of Beckhoff Automation GmbH & Co. KG. In addition, the following actions are excluded from the liability of Beckhoff Automation GmbH & Co. KG: Failure to comply with this documentation Improper use Untrained personnel Use of unauthorized spare parts 3.1 Staff qualification Only technical personnel with knowledge of control and automation technology may carry out any of the illustrated work steps on the Beckhoff software and hardware, in particular on the servo motors AM8000 and AM8500 (incl. Fan). The technical personnel must have knowledge of drive technology and electrical systems and must also know how to work safely on electrical equipment and machines. This also includes: work preparation and securing of the working environment (e.g. securing the control cabinet against being switched on again). The technical personnel must be familiar with the current and necessary standards and directives for the automation and drive environment. Version:

12 For your safety 3.2 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! Symbols that warn of personal injury: Serious risk of injury! This is an extremely dangerous situation. Disregarding the safety notice will lead to serious permanent injuries or even death. DANGER Risk of injury! This is a dangerous situation. Disregarding the safety notice may lead to serious injuries. WARNING Personal injuries! This is a dangerous situation. Disregarding the safety notice may lead to minor injuries. CAUTION Symbols that warn of damage to property or equipment: Warning of damage to property or the environment! This notice indicates disturbances in the operational procedure that could damage the product or the environment. Attention Symbols indicating further information or tips: Tip or pointer! This notice provides important information that will be of assistance in dealing with the product or software. There is no immediate danger to product, people or environment. Note UL note! This symbol indicates important information regarding UL certification. 12 Version: 1.9

13 For your safety 3.3 Notes for the AM8000 and AM8500 (incl. Fan) The notes are intended to avert danger and facilitate the handling of the servo motors AM8000 and AM8500 (incl. Fan). They must be followed during installation, commissioning, production, troubleshooting, maintenance and trial or test assemblies. The servo motor series AM8000 and AM8500 (incl. Fan) is not capable of running alone. They 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. DANGER DANGER WARNING Note Danger to life due to high voltage on the DC link capacitors of the servo drive AX8000! The DC link capacitors RB+ and RB- and the test contacts DC+ and DC- on the supply, axis and option modules can carry life-threatening voltages of 875 V DC. Take the following measures to avert danger: After disconnecting the servo drive from the mains supply, wait until the voltage has fallen below 50 V DC. Only then is it safe to work. Measure the voltage on the test contacts properly. Secure the work area properly and wear the PPE. Danger of life due to high voltage at the DC link capacitors of the servo drive AX5000! Due to the DC link capacitors dangerous voltage (> 875V DC ) 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. Take the following measures for Safety: Wait at: AX5101 AX5125 and AX520x = 5 minutes AX5140/AX5160/AX5172 = 15 minutes AX5190/AX5191 = 30 minutes and AX5192/AX5193 = 45 minutes after disconnected the servo drive from the mains supply. The device is safe once the voltage has fallen below 50 V. Measure the voltage at the DC link contacts. Secure the work area properly and wear the PPE. Serious burns due to hot surfaces on the devices! The surface temperature of the servo motors can reach 100 C during operation of the system. There is an acute risk of sustaining burns to parts of the body and limbs. Take the following measures to avert danger: Do not touch any components (housing, etc.) shortly after or during operation. Wait until all components have cooled sufficiently. At least 15 minutes. Check the surface temperature with a thermometer. DO NOT wear work gloves with a rubber coating. These can fuse with the skin on account of the high temperature and cause serious injuries. Notes on operation of the servo motors AM8000 and AM8500 (incl. Fan): Read this manual completely and carefully before using the servo motors. Notify the responsible sales office immediately if any passages are not understandable. Refrain from working on the servo motor. Version:

14 For your safety Attention Damage to the environment or devices 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. 14 Version: 1.9

15 Handling 4 Handling 4.1 Transport Climate category: 2K3 according to EN Transport temperature: -25 C C, max. fluctuation 20 K/hour Transport humidity: relative humidity 5% - 95%, non-condensing The servomotor may only be transported by qualified personnel and in the manufaturer s original recyclable packaging. Avoid hard impacts, particularly at the shaft end. If the packaging is damaged, check the motor for visible damage. Inform the transport company and, if necessary, the manufacturer. Please check if the fan body was ordered included. Check the fan body for visible damage. Inform the transport company and, if necessary, the manufacturer. 4.2 Packaging Cardboard packaging (Packaging may consist of 2 cardboards!) Motor type Max. stacking height AM805x / AM855x 5 AM806x / AM856x 2 AM807x Storage Climate category: 2K3 according to EN Storage temperature: -25 C C, max. fluctuation 20 K/hour Air humidity: relative humidity 5% - 95%, non-condensing Max. stacking height: see table Packaging Storage time: without limitation Store only in the manufacturer s original recyclable packaging. Version:

16 Handling 4.4 Maintenance / Cleaning Maintenance and cleaning only by qualified personnel. The ball bearings have a grease filling with a service life of 30,000 hours under normal operating conditions. The bearings should be replaced after 30,000 hours of operation under rated conditions. Check the motor for bearing noise every 2,500 operating hours or once per year. If any noises are heard, stop the operation of the motor. The bearings must be replaced. In motors with optional shaft seal ring the ring must be lubricated every 5,000 hours. We recommend Mobilgrease TM FM 222 from Mobil. Opening the motor invalidates the warranty. Clean the housing with isopropanol or similar. Attention Destruction of the servomotor Never immerse or spray the servomotor. 4.5 Disposal In accordance with the WEEE 2012/19/EU 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 Verl 16 Version: 1.9

17 Product identification 5 Product identification 5.1 AM8000 and AM8500, scope of supply Please check that the delivery includes the following items: Motor from the AM 8000 or AM8500 series Leaflet (short info) Installation manual forced fan 5.2 AM8000 and AM8500 (fan) nameplate Item number Explanation 1 Servomotor type 2 Protection class 3 Thermo contact type 4 Country of manufacture 5 Serial number 6 Brake type 7 UL certification for USA / CAN 8 Insulation class 9 Rated output 10 Nominal speed 11 Rated voltage 12 Standstill current 13 Standstill torque Version:

18 Product identification 5.3 Type key AM8000 and AM8500 (fan) *) not for AM801x Motor Flange size Connector plug AM805x F5 M23-speedtec connector plug AM806x F6 M23-speedtec connector plug (up to winding P), M40-speedtec connector plug (from winding Q) AM807x F7 M40-speedtec connector plug AM855x F5 M23-speedtec connector plug AM856x F6 M23-speedtec connector plug (up to winding P), M40-speedtec connector plug (from winding Q) 18 Version: 1.9

19 Product identification This matrix should explain the motor flange sizes related to a gearbox mounting. Motor sizes, named in the same line use the same adapter unit for a gearbox coupling. Beckhoff Flange size AM3000 AM3100 AM3500 AM8000 AM8100 AM8500 F1 AM301x AM311x - AM801x AM811x - F2 AM302x - - AM802x AM812x - Exception - AM312x F3 AM303x - - AM803x AM813x AM853x F4 AM304x - AM354x AM804x - AM854x F AM805x - AM855x Exception AM305x - AM355x AM805x-xxxx F6 AM306x - AM356x AM806x - AM856x F7 AM307x - - AM807x - - Exception AM308x Version:

20 Technical description 6 Technical description 6.1 Design of the motors The synchronous servomotors of the AM8000 and AM8500 series are brushless three-phase motors for demanding servo-applications. In conjunction with our digital servo drives they are particularly suitable for positioning tasks in industrial robots, machine tools, transfer lines etc. with demanding requirements in terms of dynamics and stability. The servomotors are equipped with permanent magnets in the rotor. This advanced neodymium magnetic material makes a significant contribution to the motors exceptional dynamic properties. A three-phase winding is housed in the stator, and this is powered by the servo drive. The motor has no brushes, the commutation being implemented electronically in the servo drive. The winding temperature is measured with a KTY PTC (at 1 st quarter 2018: PT 1000) silicon sensor and monitored in the servo drive. The motors are available with or without built-in holding brake. The brake cannot be retrofitted. The motors have a matt black powder coating (RAL 7016). The finish is not resistant against solvents (e.g. trichloroethylene, thinners or similar). 6.2 General technical data Ambient conditions Admissible value Climate category 3K3 according to EN Ambient temperature (at rated values) Permissible humidity (at rated values) C for site altitudes up to 1000 m amsl. It is vital to consult our applications department for ambient temperatures above 40 C and encapsulated installation of the motors. 95% relative humidity, non-condensing Power derating (currents and torques) For site altitudes above 1000 m amsl and 40 C Ball bearing service life 6 % at 2000m amsl 17% at 3000m amsl No derating for site altitudes above 1000m amsl with temperature reduction of 10K / 1000m operating hours Technical data see section 10 Storage and transport data see section 4 20 Version: 1.9

21 Technical description 6.3 Power derating Ambient temperature f T = Temperature utilisation factor t A = Ambient temperature in C Calculation of the power data when exceeding the specified temperature limit > 40 C up to 55 C: M 0_red = M 0 x f T Installation altitude f H = Altitude utilisation factor h = Altitude in metres Calculation of the power data when exceeding the specified installation altitude > 1000 m up to 3000 m: M 0_red = M 0 x f H Ambient temperature and installation altitude Calculation of the power data when exceeding the specified limits: Ambient temperature > 40 C and installation altitude > 1000 m. M 0_red = M 0 x f T x f H Version:

22 Technical description 6.4 Standard features Style The basic style for the AM8000 and AM8500 synchronous servomotors is IM B5 according to DIN EN The permitted mounting positions are specified in the technical data. Attention Motor damage To avoid liquid entry damaging the motor, fluids (i.e. used for cleaning purposes) must be removed from shaft when motor is mounted according to IM V Shaft end, A-side Load transmission occurs force locked (zero-play) with a clutch on the cylindric end of the shaft A or optionally by keyed connection with feather key groove according to DIN The lifecycle of the bearings is operating hours. Radial force If the motor drive via pinions or toothed belts, then high radial forces will occur. The permissible values at the shaft end, depending on the speed, may be read from the diagrams in the Section 10. Please use the force calculation program Beckhoff AM8000-Motors Radial forces, life cycle available from our website for exact calculation of the radial forces. Axial force Axial forces arise when assembling pinions or pulleys on the shaft and using angular gearheads, for example. Please use the force calculation program Beckhoff AM8000-Motors Radial forces, life cycle available from our website for exact calculation of the radial forces. Coupling Double-coned collets, possibly in association with metal bellows couplings, have proven themselves as excellent, zero backlash coupling elements Flange Flange dimensions according to IEC standard, fit j6, accuracy according to DIN Tolerance class: N 22 Version: 1.9

23 Technical description Protection class Standard version housing Standard version shaft feedthrough Shaft feedthrough with shaft sealing ring IP20 IP54 IP Overtemperature protection The standard version of each motor is fitted with a KTY (at 1 st quarter 2018: PT 1000). Provided our preassembled motor cable is used, the KTY is integrated into the monitoring system of the digital servo amplifiers. Please configure the servo drive such that a motor temperature warning is issued at 100 C and the motor is switched off at 140 C Insulation material class The motors conform to insulation material class F according to IEC (UL 1446 class F) Vibration class The motors are made to vibration class A according to DIN EN For a speed range of rpm and a shaft centre height between mm, this means that the actual value of the permitted vibration severity is 1.6 mm/s. Speed [rpm] Max. rel. vibration displacement [µm] <= > Max. run-out [µm] Vibrations and shocks OCT and Multiturn: Vibration according to EN g / Hz Shocks according to EN g / 6 ms Connection technology The motors are fitted with rotatable, angular connectors for the power supply and the feedback signals (only resolver + Hiperface). The mating connectors are not included in the scope of supply. We can supply preassembled feedback (only resolver + Hiperface) and power cables. The fans are provided with a M12 flange socket for grounding and power. Version:

24 Technical description Feedback System Feedbacksystem Resolution System accuracy Comment OCT, Singleturn OCT, Multiturn 18 Bit ± 120 Angle sec. Ca. 0,03 Standard: AM805x AM8x6x Hiperface 18 Bit ± 120 Angle sec. ca. 0,03 Standard: AM807x OCT, Singleturn OCT, Multiturn 23 Bit ± 45 Angle sec. ca. 0,005 From Firmware v2.10 Resolver 14 Bit ± 600 Angle sec. ca. 0,17 Option Note Feedback exchange The feedback system installed can only be replaced with an identical system. Retrofitting a different system is not possible Holding brake WARNING Serious risk of injury! The holding brake is not personal safety. If the brake is released then the rotor can be moved without a remanent torque! The motors are optionally available with an in built holding brake. The permanent magnet brake blocks the rotor in de-energised state. The holding brakes are designed as standstill brakes and are not suited for repeated operational braking. The holding brakes can be controlled directly by the servo drive (no personal safety!). The brake voltage is then switched off in the servo drive no additional wiring is required. If the holding brake is not controlled directly by the servo drive, additional circuitry (e.g. varistor) is required. Consult our applications department beforehand. The maximum number of brake cycles is 10 million. Note Motor length The motor length depends on the built-in holding brake, among other factors. It is not possible to fit one at a later date Pole number Motor Poles AM805x, AM855x 8 AM806x, AM856x 10 AM807x Version: 1.9

25 Technical description 6.5 Options Holding brake The holding brake is integrated in the motor. It increases the motor length and the rotor moment of inertia. Radial shaft-sealing ring Radial shaft-sealing ring (FKM) for sealing against splash water. This increases the protection class of the shaft busching to IP65. Father key The motors are available with feather key groove and fitted feather key according to DIN The rotor is balanced with half a feather key. Resolver This model features a different feedback system in place oft he OCT or the hiperface. Installation options and reduction of rated values With the exception of the sealing ring, the options cannot be retrofitted. Note The option sealing ring can lead to a reduction oft he rated data. 6.6 Selection criteria The three-phase servomotors are designed for operation with the servo drive. Both together form a speed or torque control loop. The main selection criteria are: Standstill torque Maximal torque Rated speed at rated supply voltage Moment of inertia of motor and load Effective torque (calculated) M0 [Nm] Mmax [Nm] nn [min-1] J [kgcm²] Mrms [Nm] The static load and the dynamic load (acceleration/braking) must be taken into account in the calculation of the required motors and the servo drive. Formulas and calculation example are available from our applications department on request. Version:

26 Technical description 6.7 Transport, assembly and disassembly CAUTION Personal injuries! Protective clothing, protective gloves and safety boots must be worn at all times during transport, assembly and disassembly. Do not step under suspended motors. The motors of the AM8x6x series can be moved with loop belts. The motors of the AM8x1x to AM8x5x series can be moved without auxiliary equipment. The motors of the AM807x series are equipped with eyebolts as standard. These eyebolts are suitable for crane hooks. For mount the fan body, the eye bolts should be removed, after the motor is installed on the unit rack. 6.8 Installation fan body In the first step, mount the motor to the machine. For further information, see Chapter 7: "Mechanical Installation [} 27]". Remove the eyebolts on the motor housing (only AM807x). The eyebolts must be loosened in the right direction of rotation as shown in the left picture and pulled upwards. Slide the fan body to the mechanical stop on the motor housing. Fasten the fan cover with the four-head cap screw (4) and the cap nut on the side. Use an Allen key SW 2.5 for tightening the cap screws (4 pieces). The tightening torque is 3 Nm. For the cap nut on the side, use a SW 7 wrench. The tightening torque is 2.5 Nm. Make sure that there are no dirt particles in the tapped holes which prevent correct fastening of the screws. Now connect the M12 connector for the fan and check the plug for a tight fit. You will find further information in chapter 8.3: "Connection of the fan with power admission [} 31]". You have successfully installed your fan body. 26 Version: 1.9

27 Mechanical installation 7 Mechanical installation 7.1 Important notes Motor damage Take care, especially during transport and handling that components are not bent and that insulation clearances are not altered. Attention The site must be free of conductive and aggressive material. For V3-mounting (shaft end upwards), make sure that no liquids can enter the bearings. If an encapsulated assembly is required, please consult our applications department beforehand. Ensure unhindered ventilation of the motors and observe the permissible ambient and flange temperatures. For ambient temperatures above 40 C please consult our applications department beforehand. Servomotors are precision devices.the flange and shaft are especially vulnerable during storage and assembly.it is important to use the locking thread which is provided to tighten up couplings, gear wheels or pulleys and warm up the drive components, where possible.blows or the use of force will lead to damage to the ball bearings, shaft, holding brake and feedback System. Wherever possible, use only backlash-free, frictionally-locking collets or couplings. Ensure correct alignment of the couplings. A displacement will cause unacceptable vibration and the destruction of the ball bearings and the coupling. For toothed belts, it is vital to observe the permissible radial forces. An excessive radial load on the shaft will significantly shorten the life of the Motor. Avoid axial loads on the motor shaft, as far as possible. Axial loading significantly shortens the life of the Motor. Furthermore, it must be ensured that when using a collet, the motor shaft is degreased. In any case, avoid creating a mechanically constrained motor shaft mounting by using a rigid coupling with additional external bearings (e.g. in a gearbox). Take note of the no. of motor poles and the no. of resolver poles and ensure that the correct setting is made in the used servo terminals. An incorrect setting can lead to the destruction of the motor, especially with small Motors. Check compliance the permitted radial and axial loads FR and FA.When using a toothed belt drive, the minimum permitted diameter of the pinion follows from the equation: Version:

28 Mechanical installation 7.2 Flange mounts Motor Bore diameter [mm] Cheese head screw DIN EN ISO 4762 (8.8) Tightening torque [Nm] AM8x5x 9,0 M8x25 25,0 8,3 AM8x6x 11,0 M10x30 50,0 10,5 AM807x 13,5 M12x40 85,0 13,0 Plain washer DIN EN ISO Version: 1.9

29 Electrical installation 8 Electrical installation 8.1 Important notes DANGER DANGER Attention Danger to life due to high voltage on the DC link capacitors of the servo drive AX8000! The DC link capacitors RB+ and RB- and the test contacts DC+ and DC- on the supply, axis and option modules can carry life-threatening voltages of 875 V DC. Take the following measures to avert danger: After disconnecting the servo drive from the mains supply, wait until the voltage has fallen below 50 V DC. Only then is it safe to work. Measure the voltage on the test contacts properly. Secure the work area properly and wear the PPE. Danger of life due to high voltage at the DC link capacitors of the servo drive AX5000! Due to the DC link capacitors dangerous voltage (> 875V DC ) 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. Take the following measures for Safety: Wait at: AX5101 AX5125 and AX520x = 5 minutes AX5140/AX5160/AX5172 = 15 minutes AX5190/AX5191 = 30 minutes and AX5192/AX5193 = 45 minutes after disconnected the servo drive from the mains supply. The device is safe once the voltage has fallen below 50 V. Measure the voltage at the DC link contacts. Secure the work area properly and wear the PPE. Failure-free operation Ensure that the servo drive and the motor are earthed properly. See below for further information regarding EMC shielding and earthing. Earth the mounting plate and motor housing. Further details of connection types can be found in section 8.2. Only use cables approved by Beckhoff for operating the AM8000 and AM8500 with the one-cable technology (OCT). Route the power and control cables as separately as possible from one another (separation > 20 cm). This will improve the immunity of the system to electromagnetic interference. If a motor power cable is used which includes integral brake control leads, then these brake control leads must be shielded. The shielding must be connected at both ends (see Section ). Install all cables carrying a heavy current with an adequate cross-section, as per EN The recommended cross-section can be found in the technical data of the cables. Wiring: ð Connect the feedback cable ð Connect the motor cables ð Connect shields to shield terminals or EMC connectors at both ends ð Connect the motor holding brake Version:

30 Electrical installation Attention Note HF interference The ground symbol, which you will find in the wiring diagrams, indicates that you must provide an electrical connection, with as large a surface area as possible, between the unit indicated and the mounting plate in the control cabinet. This connection is to suppress HF interference and must not be confused with the PE (protective earth) symbol (protective measure according to EN 60204). Follow the instructions in the circuit diagrams in Sections 8.3 to 8.6. Motor cable length at servo drives up to 25 A Motors with max. 400 V rated voltage: If the length of the motor cable is 25 m, then a motor choke is required for each motor. Motors with max. 480 V rated voltage: If the length of the motor cable is > 20 m, then a motor choke is required for each motor. The control cabinet should then have adequate space for motor chokes. In exceptional cases (sensitive sensors etc.) it can be necessary to use a motor choke even for motor cable lengths < 25 / 20 m. The motor choke is supplied with a connection cable. Do not alter the configuration (cable length, cross-section etc.). 8.2 Connection of motors with pre-assembled cables Beckhoff offers preassembled motor and feedback 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. Carry out the wiring in accordance with the valid standards and regulations. Only use our preassembled shielded cables for the power and feedback connections. Connect up the shielding according to the wiring diagrams in sections 8.3 to Incorrectly installed shielding inevitably leads to EMC interference. Detailed specifications of the cables are listed on our homepage Download Documentation Drive Technology Cable. 30 Version: 1.9

31 Electrical installation 8.3 Connection of the fan with power admission Connect the prefabricated control cable ZK xxx at the fan. To do this, proceed as follows: Connect the M12 connector for the fan. The M12 connecter is at the control cable. Check the connector for a tight fit. For further information, please see chapter 6.8: "Installation fan body [} 26]". You have successfully connected your fan body. Data of the power admission from the external fan Data Symbol [Unit] AM8x5x AM8x6x AM8x7x Supply voltage U LA [V DC ] 24 Electrical power P LA [W] Current I [A] Assignment planning of the connector plug View of the sockets Contact at the connector plug Cable assignment 1 PE (green / yellow) VDC (brown) 3 not connected 4 GND (blue) 5 not connected Further information about the control cable ZK xxx: The data sheet of the control cable can be found at: Note Download Data sheets Cable and lines Version:

32 Electrical installation 8.4 AX5000 connection diagram for motors with OCT- Feedback Servo drives: AX5101 AX5125 and AX52xx Motors: AM804x AM806x and AM854x AM856x (until P winding) 32 Version: 1.9

33 Electrical installation 8.5 AX5000 connection diagram for motors with OCT- Feedback Servo drive: AX5125 Motors: AM806x, AM856x (from Q-winding) and AM807x Version:

34 Electrical installation 8.6 AX5000 connection diagram for motors with OCT- Feedback Servo drive: AX5140 Motors: AM806x, AM856x (from Q-winding) and AM807x 34 Version: 1.9

35 Electrical installation 8.7 AX5000 connection diagram for motors with Resolver Servo drives: AX5101 AX5125 and AX52xx Motors: AM804x AM806x and AM854x AM856x (until P-winding) Version:

36 Electrical installation 8.8 AX5000 connection diagram for motors with Resolver Servo drive: AX5125 Motors: AM806x, AM856x (from Q-winding) and AM807x 36 Version: 1.9

37 Electrical installation 8.9 AX5000 connection diagram for motors with Resolver Servo drive: AX5140 Motors: AM806x, AM856x (from Q-Winding) and AM807x Version:

38 Electrical installation 8.10 AX5000 connection diagram for motors with Resolver Servo drives: AX5160 and AX5172 Motors: AM806x, AM856x (from Q-winding) and AM807x 38 Version: 1.9

39 Electrical installation 8.11 AX5000 connection diagram for mototrs with Hiperface Servo drives: AX5160 and AX5172 Motors: AM806x, AM856x (from Q-winding) and AM807x Version:

40 Comissioning 9 Comissioning 9.1 Important notes DANGER DANGER Danger to life due to high voltage on the DC link capacitors of the servo drive AX8000! The DC link capacitors RB+ and RB- and the test contacts DC+ and DC- on the supply, axis and option modules can carry life-threatening voltages of 875 V DC. Take the following measures to avert danger: After disconnecting the servo drive from the mains supply, wait until the voltage has fallen below 50 V DC. Only then is it safe to work. Measure the voltage on the test contacts properly. Secure the work area properly and wear the PPE. Danger of life due to high voltage at the DC link capacitors of the servo drive AX5000! Due to the DC link capacitors dangerous voltage (> 875V DC ) 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. Take the following measures for Safety: Wait at: AX5101 AX5125 and AX520x = 5 minutes AX5140/AX5160/AX5172 = 15 minutes AX5190/AX5191 = 30 minutes and AX5192/AX5193 = 45 minutes after disconnected the servo drive from the mains supply. The device is safe once the voltage has fallen below 50 V. Measure the voltage at the DC link contacts. Secure the work area properly and wear the PPE. 40 Version: 1.9

41 Comissioning 9.2 Guide for commissioning of the motor The procedure for commissioning is described as an example. A different method may be appropriate or necessary, depending on the application of the Equipment. Check the assembly and orientation of the Motor. Check the drive components (coupling, gear unit, pulley) for the correct seating and setting (observe the permissible radial and axial forces). Check the wiring and connections to the motor and the servo terminal. Check that the earthing is correct. Test the function of the holding brake, if used. (apply 24 V DC, the brake must be released). Check whether the rotor of the motor revolves freely (release the brake, if necessary). Listen out for grinding noises. Check that all the required measures against accidental contact with live and moving parts have been carried out. Carry out any further tests which are specifically required for your System. Now commission the drive according to the commissioning instructions for the servo terminal. In multi-axis systems, individually commission each drive unit (servo terminal/motor(s)). 9.3 Guide for commissioning of the fan The procedure for commissioning is describe as an example. A different method may be appropriate or necessary, depending on the application of the Equipment. Check the assembly and orientation of the fan body. Check the fan body for the correct seating and setting. See that the tightening torque of the screw is correct. Check the wiring and connection on the strip terminal. Check that the grounding is correct. Check whether the fan revolves freely. Listen out for grinding noises. Check that the grounding of the fan body is correct. Check the direction of rotation of the fan. The air flow must blow over the motor. Now take the fan in operation. Version:

42 Comissioning 9.4 Troubleshooting The following table is to be seen as a First Aid box. There can be a large number of different reasons for a fault, depending on the particular conditions in your system. The fault causes described below are mostly those which, directly influence the motor. Peculiarities which show up in the control behaviour can usually be traced back to an error in the parameterization of the servo drive. The documentation for the servo drive and the commissioning software provides information of these matters. For multi-axis systems there may be further hidden reasons for faults. Our application department can give you further help with your problems. Fault Possible cause Measures to remove the cause of the fault Motor doesn t rotate Servo drive not enabled Break in setpoint lead Motor phases in wrong sequence Brake not released Drive is mechanically blocked Supply ENABLE signal Check setpoint lead Correct the phase sequence Check brake control Check mechanism Motor runs away Motor phases in wrong sequence Correct the phase sequence Motor oscillates Error message: brake Error message: output stage fault Error-message: feedback Break in the shielding of the feedback cable Amplification to high Short-circuit in the supply voltage lead to the motor holding brake Faulty motor holding brake Motor cable has short circuit or earth leakage Motor has short circuit or earth leakage Connector is not properly plugged in Break in cable, cable crushed or similar Error-message: motor temperature Motor thermostat has switched Loose connector or break in cable Brake does not grip Required holding torque too high Brake faulty Replace feedback cable Use motor default values Remove the short circuit Replace motor Replace motor cable Replace motor Check connector Check cables Wait until the motor has cooled down. Then investigate why the motor becomes so hot. Check connector, replace cable if necessary Check the dimensioning Replace motor 42 Version: 1.9

43 Technical data 10 Technical data All data, excluding the voltage constant, valid for 40 C ambient temperature and 100 K overtemperature of the winding. The data can have a tolerance of +/- 10%. If a gear unit is attached the power may be reduced by up to 20%. This loss in performance has thermal reasons, since a gear unit that is subject to warming is installed at the motor flange intended for heat dissipation. Term definitions Standstill torque M0 [Nm] The standstill torque can be maintained indefinitely at a speed n < 100 rpm and rated ambient conditions. Rated torque Mn [Nm] The rated torque is produced when the motor is drawing the rated current at the rated speed. The rated torque can be produced indefinitely at the rated speed in continuous operation (S1). Standstill current I0rms [A] The standstill current ist he effective sinusoidal current which the motor draws at n < 100 rpm to produce the standstill torque. Peak current (pulse current) I0max [A] The peak current (effective sinusoidal value) is approximately equivalent to 5-times the rated standstill current (3-times at AM806x, AM807x and AM856x). The configured peak current of the servo drive used must be smaller. Torque constant KTrms [Nm/A] The torque constant defines how much torque in Nm is produced by the motor with standstill current. The relationship is M0=I0 x KT. Voltage constant KErms [mvmin] The voltage constant defines the induced motor EMF, as an effective sinusoidal value between two terminals, at 20 C per 1000 rpm. Rotor moment of inertia J [kgcm²] The constant J is a measure of the acceleration capability of the motor. For instance, at l0 the acceleration time tb from 0 to 3000 rpm is given as: with M0 in Nm and J in kgcm2 Thermal time constant tth [min] The constant tth defines the time for the cold motor, under a load of l0 to heat up to an overtemperature of 0,63 x 100 Kelvin. This temperature rise happens in a much shorter time when the motor is loaded with the peak current. Release delay time tbrh [ms] / Application delay time tbrl [ms] of the brake These constants define the response times of the holding brake when operated with the rated voltage from the servo drive. Winding inductance L [mh] The winding inductance is an specification of the motor inductance. This is get as an average value on two energized phases at 1 KHz. The saturation of the motor must be taken into account. Version:

44 Technical data 10.1 AM805x and AM855x Technical data Electrical data UN = 115V UN = 230V UN = 400V UN = 480V Symbol [Unit] AM80xx / AM85xx 51F 51J 51L 52G 52K 52N 53J 53L 53P Standstill torque* M 0 [Nm] 6,20 6,30 6,30 10,70 10,70 9,60 15,40 15,40 13,30 Standstill current I orms [A] 3,50 5,80 11,10 4,30 8,50 13,60 6,40 11,90 18,60 Max. mechanical speed N max [min -1 ] 9000 Max. rated mains voltage U N [VAC] 480 Rated speed Nn [min-1] Rated torque* M n [Nm] 6,10 6,20 5,90 10,50 10,30 9,50 15,30 15,10 12,30 Rated output P n [kw] 0,32 0,71 1,42 0,44 0,97 1,90 0,65 1,58 2,45 Rated speed Nn [min-1] Rated torque* M n [Nm] 6,00 5,80 5,30 10,30 9,60 8,10 15,10 14,80 8,40 Rated output P n [kw] 0,88 1,58 2,72 1,08 2,11 3,40 1,58 3,40 3,52 Rated speed Nn [min-1] Rated torque* M n [Nm] 5,80 5,70 3,60 9,70 9,10 9,10 14,90 12,90 7,10 Rated output P n [kw] 1,52 2,74 3,02 2,03 3,77 4,08 3,12 5,41 3,72 Rated speed Nn [min-1] Rated torque* M n [Nm] 5,70 5,40 3,60 9,20 8,80 4,50 14,70 12,10 4,10 Rated output P n [kw] 1,79 3,22 3,01 2,21 4,14 4,24 3,54 5,84 3,00 Peak current I 0max [A] 12,10 20,90 37,70 17,90 33,60 60,70 26,90 50,90 89,70 Peak torque M 0max [Nm] 17,74 17,76 17,78 35,32 35,34 35,34 53,13 53,13 53,14 Torque constant K Trms [Nm/A] 1,77 1,09 0,57 2,48 1,30 0,72 2,42 1,29 0,73 Voltage constant K Erms [mvmin] 125,0 73,00 40,00 167,0 89,00 49,00 168,0 89,00 51,00 Winding resistance Ph-Ph Winding resistance Ph-Ph** R 20 [Ω] 11,40 3,60 1,14 8,50 2,30 0,70 5,10 1,40 0,45 L [mh] 42,7 14,4 4,6 36,9 10,5 3,2 23,7 6,6 2,1 Connector plug M23-speedtec *reference flange aluminium 305 mm x 305 mm x 12,7 mm. **measured at 1kHz. The installation of a shaft seal ring leads to a reduction of the rated values. Mechanical data AM8051 AM8551 AM8052 AM8552 AM8053 AM8553 Rotor moment of inertia (without brake) J [kgcm 2 ] 2,24 8,75 4,080 10,600 5,920 12,500 Rotor moment of inertia (with brake) J [kgcm 2 ] 2,90 9,41 4,74 11,20 7, Pole number Static friction torque M R [Nm] 0,021 0,021 0,036 0,036 0,050 0,050 Thermal time constant t TH [min] Weight (without brake) G [kg] 5,20 6,60 6,80 8,10 8,50 9,90 Weight (with brake) G [kg] 6,00 7,40 7,70 9,00 9, Permitted radial force at shaft end F R [N] see Permitted axial force F A [N] Data of the power admission from the external fan See chapter 8.3 Connection of the fan with power admission Data for optional brake Data Symbol [Unit] AM8051 / AM8052 AM8551 / AM8552 AM8053 AM8553 Holding torque at 120 C M BR [Nm] 9 13 Supply voltage U BR [V DC ] % % Electrical power P BR [W] Current I on [A] 0,54 0,51 Release delay time t BRH [ms] Application delay time t BRL [ms] Version: 1.9

45 Technical data Dimensional drawing AM805x and AM855x Version:

46 Technical data Dimensional drawing AM805x-9000 and AM855x-9000 Flange compatible with AM Version: 1.9

47 Technical data Radial / axial forces at the shaft end Characteristic torque / speed curves Dimensioning software for motor characteristics: Characteristic torque / speed curves can be found on the Beckhoff-website under Motion. Note Version:

48 Technical data 10.2 AM806x and AM856x Technical data Electrical data Symbol [Unit] AM80xx / AM85xx 61H 61L 61N 62K 62N 62R 63L 63Q 63T Standstill torque* M 0 [Nm] 17,10 17,10 15,50 29,90 29,90 28,10 41,40 41,40 40,10 Standstill current I orms [A] 5,20 10,10 15,80 8,70 17,40 28,70 11,60 24,00 39,80 Max. mechanical speed N max [min -1 ] 6000 Max. rated mains voltage U N [VAC] 480 UN = 115V Rated speed Nn [min-1] Rated torque* M n [Nm] 17,00 16,80 14,40 29,00 28,00 24,00 40,40 38,20 32,50 Rated output P n [kw] 0,50 1,00 2,00 0,90 2,30 3,50 1,30 3,20 4,80 UN = 230V Rated speed Nn [min-1] Rated torque* M n [Nm] 16,80 16,00 12,70 28,20 25,80 19,90 38,50 32,30 23,70 Rated output P n [kw] 1,40 2,70 3,70 2,40 4,60 5,80 3,00 5,80 7,20 UN = 400V Rated speed Nn [min-1] Rated torque* M n [Nm] 16,10 14,70 10,70 26,40 22,20 13,40 33,90 25,50 15,10 Rated output P n [kw] 2,36 4,60 5,60 3,87 7,00 7,00 4,97 8,00 6,30 UN = 480V Rated speed Nn [min-1] Rated torque* M n [Nm] 16,00 14,30 10,70 25,80 21,10 11,80 33,00 23,20 6,80 Rated output P n [kw] 2,50 5,10 6,20 4,30 7,50 6,80 5,50 8,30 3,60 Peak current I 0max [A] 13,90 27,00 45,20 27,00 54,00 88,40 38,90 80,90 130,0 Peak torque M 0max [Nm] 37,10 37,08 37,07 74,16 74,16 74,17 110,9 110,8 111,1 Torque constant K Trms [Nm/A] 3,20 1,64 0,97 3,40 1,70 1,03 3,33 1,68 0,98 Voltage constant K Erms [mvmin] 223,0 115,0 69,00 234,0 117,0 71,00 240,0 116,0 72,00 Winding resistance Ph-Ph Winding resistance Ph-Ph** R 20 [Ω] 7,00 1,85 0,66 2,95 0,75 0,28 1,95 0,45 0,18 L [mh] 53,7 14,2 5,1 27,0 6,8 2,5 18,0 4,2 1,6 Connector plug M23-speedtec M40- speedtec *reference flange aluminium 380 mm x 170 mm x 10 mm. **measured at 1kHz. The installation of a shaft seal ring leads to a reduction of the rated values. M23- speedtec M40-speedtec Mechanical data AM8061 AM8561 AM8062 AM8562 AM8063 AM8563 Rotor moment of inertia (without brake) J [kgcm 2 ] 11,10 48,20 20,00 57,10 29,00 66,10 Rotor moment of inertia (with brake) J [kgcm 2 ] 13,40 50,60 22,30 59,60 34, Pole number Static friction torque M R [Nm] 0,045 0,045 0,102 0,102 0,150 0,150 Thermal time constant t TH [min] Weight (without brake) G [kg] 11,90 15,40 15,80 19,20 19,60 23,10 Weight (with brake) G [kg] 13,50 17,00 17,60 20,90 22, Permitted radial force at shaft end F R [N] see Permitted axial force F A [N] Data of the power admission from the external fan See chapter 8.3 Connection of the fan with power admission Data for optional brake Data Symbol [Unit] AM8061 / AM8062 AM8561 / AM8562 Holding torque at 120 C M BR [Nm] AM8063 AM8563 Supply voltage U BR [V DC ] % % Electrical power P BR [W] Current I on [A] 0,72 0,79 Release delay time t BRH [ms] Application delay time t BRL [ms] Version: 1.9

49 Technical data Dimensional drawing AM8061 and AM8561 Version:

50 Technical data Dimensional drawing AM806x and AM856x with K-N-L winding 50 Version: 1.9

51 Technical data Dimensional drawing AM806x and AM856x with R-Q-T winding Version:

52 Technical data Radial / axial forces at the shaft end Characteristic torque / speed curves Dimensioning software for motor characteristics: Characteristic torque / speed curves can be found on the Beckhoff-website under Motion. Note 52 Version: 1.9

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