BECKHOFF AX5000 Servo Drive Maintenance Guide

Automatic commutation search is performed upon initial activation, and the drive operates normally upon successful completion.

5.3 Special precautions for linear motors

Enter the pole pair distance in the "Feed constant" (with decimals, such as 28.1mm).

Confirm that the counting direction of the encoder is consistent with the direction of motor motion. If they are inconsistent, exchange SIN+and REFSIN signals in the feedback connector, and do not reverse the parameters.

Use P-0-0166 to check if 'Equal Directions' is Yes, otherwise exchange U and V phases.

DC link group configuration (60... 170A devices)

Multiple high-power drivers can form a DC link group and share the DC bus. Configuration points:

Use a common main contactor (K0) to simultaneously connect all driver main power sources.

Use a common main network side fuse (F0) with a capacity equal to the sum of the rated currents of each driver multiplied by 1.1, rounded upwards.

Each driver still requires a separate DC link fuse (FDC1... FDCn) to protect the cable.

Parameterization: Set the P-0-0214 of each driver to 0x000B (DC link group mode), disable undervoltage monitoring but retain phase sequence detection in P-0-0204 (Disable Umain monitoring=0, Umain phase error detection=1).

External braking resistors can be connected only to some drivers, but the total peak/continuous braking power is the sum of each resistor.

Firmware update process

7.1 Preparation work

Ensure that the 24V control power supply (X03) is connected and the main power supply (X01) is disconnected to prevent accidental motor operation.

TwinCAT is in Config Mode and FreeRun is turned off.

7.2 Update Steps

In System Manager, select AX5000 under EtherCAT devices and switch to the Online tab.

Multiple drives can be selected for simultaneous updates.

Right click on "Firmware Update" and select the *. efw file.

Wait for download to complete, prompt successful.

Switch back to Run Mode and activate the configuration.

Note: It is recommended to update only within the same major version number (such as v2.0x → v2.0y), and cross version updates may require adjusting TwinCAT configuration. Try again or replace the firmware file when the update fails.

AX5801 Security Card and Security Features

AX5801 security card is inserted into the expansion slot of AX5000 (only ≤ 40A models) to achieve STO (Safe Torque Off) or SS1 (Safe Stop 1) function.

Wiring: 4-pin and 6-pin connectors, relay coil powered by 24V, feedback contacts connected in series to safety circuit.

Application: In case of emergency stop, the PLC first sends a quick stop command, and after a delay, cuts off the 24V safety card, the relay is released, and the internal safety shutdown circuit of the driver causes the motor to have no torque. The delay time must be greater than the maximum braking time for quick stopping.

Diagnosis: If the security card is not properly parameterized (P-0-2000), the driver will report FDD4; If unable to enter a safe state, report FDD5.

Maintenance and spare parts recommendations

Project cycle/conditions

Fan filter cleaning every 3-6 months (depending on environmental dust)

External brake resistor temperature switch inspection every year

DC link capacitor is regenerated (stored for>5 years) and powered on single-phase 230V for 30 minutes

Firmware version check visit Beckhoff official website every 2 years

Export TwinCAT configuration (*. tsm) after each modification of parameter backup