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.