BECKHOFF AM8xxx Motor Guide

Electrical connection and cable selection

4.1 Connector Types

AM801x~AM803x: iTec connector (rotatable, 330 °)

AM804x~AM806x (to P winding): M23 Speedtec connector

AM806x (starting from Q winding) and AM807x: M40 Speedtec or terminal box

4.2 Power and Feedback Pin Allocation (Taking M23 as an Example)

Pin signal function

A U motor phase U (black/1)

B V motor phase V (black/2)

C W motor phase W (black/3)

PE PE protective grounding (green/yellow)

E Temp -/OCT-Temperature sensor or OCT data - (blue)

F Shield shielding

G Brake+Brake+24 V (Black/5)

H Temp+/OCT+temperature sensor or OCT data+(white)

L Brake - Brake GND (Black/6)

The allocation of iTec connectors is similar, but the brake power supply uses pins 5 and 6, and the temperature signal uses pins 3 and 4.

OCT (Single Cable Technology): Integrating power and feedback into the same cable, transmitting position by superimposing signals. When using OCT, Beckhoff dedicated cables (such as ZK4500-8023-xxxx) must be used, and ordinary encoder cables cannot be mixed.

4.3 Motor Cable Selection Table (AX5000 Drive)

Motor series cable model laying method

AM801x~803x ZK4500-8022-xxxx high dynamic/torsional

AM804x~806x (to P) ZK4500-8003-xxxx fixed installation

Same as above ZK4500-8023-xxxx high dynamic

AM806x (Q/R)~807x ZK4500-8025-xxxx high dynamic

AM807x high current ZK4504-8027-xxxx/ZK4506-8027-xxxx dynamic/fixed

Select ZK4530-8110-xxxx or ZK4510-8110-xxxx for the feedback cable (used for Resolving or OCT). All pre installed cables meet UL and EMC requirements.

Maintain Brake - Safety Guidelines for Use

The brake is a permanent magnet power-off brake with a voltage of 24 V DC (+6%/-10%). After being engaged, the rotor is released. Key parameters:

Release time (t_BRH): The time it takes for the brake to fully engage after a power outage (e.g. 25 ms for AM803x)

Suction time (t_BRL): The time required for complete release after power on (8 ms)

It is strictly prohibited to use the holding brake for dynamic braking (i.e. for deceleration and stopping). During emergency stop, it is allowed to brake up to 2000 times from a maximum of 3000 rpm and with a load inertia not exceeding 3 times the motor inertia. Exceeding this limit will result in excessive wear of the brake pads.

Vertical axis safety: Additional redundant brakes, mechanical counterweights, or fall protection devices must be added. Relying solely on the motor to maintain the brake does not comply with personal safety standards (ISO 13849-1).

Function check: In the power-off state, apply a force of approximately 1.2 times the nominal holding torque to the shaft end with a torque wrench, and the rotor should not rotate. Alternatively, position deviation can be monitored through TwinCAT Scope.

Forced air cooling (fan cover)

AM805x, AM806x, and AM807x can be equipped with an external fan cover (z=A/B/C/D in ordering features). The fan power supply is 24 V DC, power consumption:

AM805x：4.6 W

AM806x：9.8 W

AM807x：31.2 W

After installation, the continuous torque of the motor can be increased by about 30% (see the Mn value of the fan version in the technical data sheet for details). Special control cable ZK4054-6400-0xxx must be used to connect the fan and ensure that the ventilation outlet is unobstructed.

Power derating and high-altitude/high-temperature operation

When the ambient temperature exceeds 40 ° C or the installation altitude is higher than 1000 meters, the rated torque of the motor needs to be reduced.

Temperature derating: 40-50 ° C, with a decrease of approximately 2% (linear) for every 1 ° C increase. For example, f ₜ ≈ 0.8 at 50 ° C.

Altitude derating: For every 1000 meters increase above 1000 meters, the derating decreases by 6% (2000 meters → 0.943000 meters → 0.83).

Comprehensive derating: M ₀ -red=M ₀× f ₜ× f ₕ.

Example: AM8062 has an actual usable static torque of 21.1 × 0.8 × 0.94 ≈ 15.9 Nm at an altitude of 2000 m in an environment of 50 ° C. If this value is exceeded, the motor will overheat.

Common troubleshooting table

Possible causes and solutions for the fault phenomenon

The motor does not start, the brake is not released, the driver is not enabled, and the power supply is out of phase. Check the brake voltage (24 V ± 10%); Confirm the driver enable signal; Measure the resistance of the three-phase winding (should be balanced)

Rough motor operation, abnormal noise, encoder signal interference, bearing damage, and poor mechanical alignment. Check whether the feedback cable shielding is single ended grounded; Auscultation of bearings, if there is a metallic frosted sound, replace the bearings; Re calibrate the concentricity of the coupling

Motor overheating (>140 ° C), excessive load, poor ventilation, high ambient temperature, improper PWM switch frequency setting, reducing load or selecting a higher torque motor; Clean the fan and heat sink; Measure the actual ambient temperature; Reduce the switching frequency of the driver (≤ 8 kHz)

Measure the brake resistance (usually several tens of ohms) by keeping the brake failure coil open, insufficient voltage, and brake pad wear; Check if the power supply line is broken; Replace the brake

Encoder position jump OCT communication interference, connector poor contact inspection cable shielding layer; Re plug and unplug the connector (up to 500 insertions allowed)