power automation PA 9000 MC User manual

PA 9000
Micro CNC control
Installaon instrucons

Variante: PA 9000 MC2 BAS / PA 9000E MC2 BAS
Original installation instructions
© 2018 Power Automation GmbH
Power Automation GmbH
CNC-Automatisierungstechnik
Gottlieb-Daimler-Str. 17/2
74385 Pleidelsheim
Germany
Telephone: [phone]
Fax: [phone]
E-mail: [email protected]
Internet: www.powerautomation.com
Version 2.0
2 12.06.2018

Table of contents
1 General information............................................................. 5
1.1 Information on this manual.......................................... 5
1.2 Explanation of symbols................................................ 5
1.3 EtherCAT trademark.................................................... 7
1.4 Limitation of liability...................................................... 7
1.5 Copyright..................................................................... 7
1.6 Warranty terms............................................................ 8
1.7 Customer service......................................................... 8
2 Safety.................................................................................... 9
2.1 Customer's responsibility............................................. 9
2.2 Personnel requirements............................................. 10
2.2.1 Qualifications........................................................... 10
2.2.2 Unauthorized persons............................................. 11
2.3 Intended use.............................................................. 11
2.4 Unintended use.......................................................... 12
2.5 Personal protective gear............................................ 12
2.6 Specific dangers........................................................ 13
2.7 Safety devices........................................................... 15
2.8 Machine safety........................................................... 15
2.9 Conduct in a dangerous situation and in case of
accidents.................................................................... 15
2.10 Data safety................................................................. 16
2.10.1 File backup.............................................................. 16
2.10.2 System protection................................................... 17
2.10.3 PA Recovery Stick................................................... 18
2.11 Environmental protection........................................... 19
2.12 Labels........................................................................ 19
3 Design and function.......................................................... 23
3.1 Overview.................................................................... 23
3.2 Brief description......................................................... 23
3.3 EtherCATâ interface.................................................. 24
3.4 PC connectors........................................................... 26
3.5 (X20) PA USB software dongle connector................. 34
3.6 EtherCATâ-interface (PASIO).................................... 35
4 Technical data.................................................................... 37
4.1 General specifications............................................... 37
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4.2 Connection values..................................................... 37
4.3 Operating conditions.................................................. 38
4.4 Dimension sheet........................................................ 39
4.5 Electromagnetic compatibility.................................... 39
4.6 Installation guidelines................................................ 40
5 Installation.......................................................................... 43
5.1 Prerequisites and preparations.................................. 43
5.1.1 General requirements............................................. 43
5.1.2 Electrical cabinet structural requirements............... 44
5.1.3 Cabinet temperature............................................... 44
5.2 Mounting the control unit in a cabinet........................ 45
6 Transport, packaging and storage................................... 49
6.1 Transport................................................................... 49
6.2 Packaging.................................................................. 49
6.3 Storage...................................................................... 51
7 Maintenance....................................................................... 53
7.1 Safety notes............................................................... 53
7.2 Maintenance schedule............................................... 53
7.3 Measures after maintenance..................................... 54
8 Troubleshooting................................................................. 55
8.1 Safety notes............................................................... 55
8.2 Troubleshooting chart................................................ 56
9 Service and return process............................................... 59
9.1 Service....................................................................... 59
9.1.1 Service addresses................................................... 60
9.2 Spare parts................................................................ 61
9.3 Return policy and procedure...................................... 62
9.4 Training...................................................................... 64
10 Dismounting and decommissioning................................ 65
11 EC Declaration of Conformity........................................... 67
12 Proof of change.................................................................. 69
13 Glossary.............................................................................. 71
14 Index.................................................................................... 73
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1 General information
1.1 Information on this manual
This installation manual provides important information on how to
work with the control unit safely and efficiently.
The installation manual is part of the control unit, must always be
kept in the control unit's direct proximity and should be available for
the personnel at any time. All personnel working with the control
unit are obliged to have read and understood this installation
manual before starting any work. Strict compliance with all speci-
fied safety notes and instructions is a basic requirement for safety
at work.
Moreover, the accident prevention guidelines and general safety
regulations applicable at the place of use of the control unit must
also be complied with.
Illustrations in this installation manual are intended to facilitate
basic understanding, and may differ from the actual design of the
control unit.
The enclosed manuals for the installed components apply together
with this installation manual.
1.2 Explanation of symbols
Warnings are identified by pictures. These warnings are introduced
by signal words, which express the severity of a danger.
Pay attention to these warnings and act cautiously in order to avoid
accidents, personal injuries and damage to property.
DANGER!
… indicates an imminently hazardous situation
which, if unavoidable, will result in death or serious
injury.
WARNING!
… indicates a potentially hazardous situation
which, if unavoidable, could result in death or
serious injury.
CAUTION!
… indicates a potentially hazardous situation
which, if unavoidable, may result in minor or mod-
erate injury.
General Information
Warnings
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NOTICE!
… indicates a potentially hazardous situation
which, if unavoidable, may result in property
damage.
… emphasizes useful hints and recommendations
as well as information for efficient and trouble-free
operation.
The following symbols are used in connection with the safety notes
to highlight particular dangers:
DANGER!
… highlights hazards caused by electric current.
There is a danger of serious injury or death if the
safety notes are not complied with.
The following symbols and highlights are used to distinguish
instructions, descriptions of results, cross-references and other ele-
ments inside this manual.
.. Highlights a step as part of a procedure of instructions.
ð.. Highlights a state or an automatic process as a result of
an instruction.
n.. Highlights single or unordered instructions and lists.
Ä “Additional symbols and highlighting” on page 6.. Highlights
cross-references to chapters or sections of this manual.
[Key].. Highlights captions of buttons, fields and other elements of
the software's graphical user interface.
“Menu è Submenu è ”.. Highlights a path to access a menu or
submenu in the software's graphical user interface.
Example/Extract.. Highlights verbatim examples and extracts
from configuration files.
Special Safety Notes
Additional symbols and high-
lighting
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1.3 EtherCAT trademark
EtherCATâ is a registered trademark and patented technology,
lisensed by Beckhoff Automation GmbH, Germany.
Fig. 1: EtherCAT
â
Branding logo
1.4 Limitation of liability
All information and notes in this installation manual were compiled
under due consideration of valid standards and regulations, the
present status of technology and our years of knowledge and
experience.
Power Automation can not be held liable for damage resulting
from:
ndisregarding this installation manual
nunintended use
nemployment of untrained personnel
nunauthorized conversions
nunauthorized modifications to the software
ntechnical modifications
nuse of unapproved spare parts
nuse in conjunction with machines not deemed compatible by
Power Automation
In case of customized versions the actual scope of delivery can
vary from the explanations and representations in this installation
manual, because of the utilization of additional options or due to
the latest technical changes.
Apart from this, the obligations agreed upon in the delivery con-
tract, the general terms and conditions, and the delivery conditions
of Power Automation and the legal regulations valid at the time of
contract apply.
We reserve the right to make technical modifications in order to
improve usability.
1.5 Copyright
This installation manual is protected by copyright law.
Passing this installation manual on to third parties, duplication of
any kind – even in form of excerpts – as well as the use and/or dis-
closure of the contents without the written consent of Power Auto-
mation is not permitted.
Liability
Copyright
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Violations oblige to compensation. The right for further claims
remains reserved.
1.6 Warranty terms
The material warranty terms are provided in Power Automation's
terms and conditions as well as inside the sales documents.
1.7 Customer service
Our Customer Service is always available for technical information.
For information on whom to contact by phone, fax, e-mail or via the
internet, see Power Automation's address on page 2.
Additionally, Power Automation staff is always interested in
receiving new information and experiences resulting from the use
of our products, which could be of great value for future improve-
ments.
Material Warranty
Service
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2 Safety
2.1 Customer's responsibility
The control unit is used for commercial purposes. The operating
company is thus subject to the legal obligations concerning indus-
trial safety.
The safety, accident prevention and environmental protection regu-
lations applicable for the area of application of the machine must
be complied with, along with the safety notes specified in this
installation manual. The following applies in particular:
nThe customer must become familiar with the industrial safety
regulations and identify additional dangers which may arise
due to the specific working conditions at the place of use of the
control unit, by means of a risk analysis. These must be con-
verted into operating instructions for operation of the control
unit.
nThroughout the time of use of the control unit the customer
must check whether the operating instructions created by him
correspond to the current status of regulations and standards.
Whenever changes in regulations and standards occur, instruc-
tions must be adapted accordingly.
nThe customer must clearly specify the responsibilities for
installation, operation, maintenance, and cleaning.
nThe customer must make sure that all employees who have to
work with the control unit have read and understood these
operating instructions.
In addition, the customer must train and inform his personnel
about potential dangers at regular intervals.
Moreover, the customer is also responsible for keeping the control
unit in technically good condition, and therefore the following
applies:
nThe customer must make sure that the maintenance intervals
specified in these operating instructions are complied with.
nThe customer must regularly check all safety features for func-
tion and completeness.
nThe customer must supply his personnel with the necessary
protective equipment.
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2.2 Personnel requirements
2.2.1 Qualifications
WARNING!
Danger of injury in case of insufficient qualifi-
cation!
Improper operation can lead to severe personal
injuries and/or material damage.
– Only those persons who have been specified in
the corresponding chapters of this installation
manual should be entrusted with the listed
types of work.
– Employ certified experts, if in doubt.
The following qualifications are specified for different areas of
activity listed in the installation manual.
Instructed person
was instructed by the operating company about the duties
assigned to her/him and the possible dangers that may arise from
inappropriate conduct.
Qualified personnel
are able to carry out assigned work and to recognize possible dan-
gers due to professional training, knowledge, and experience as
well as profound knowledge of applicable regulations.
Skilled electrician
A skilled electrician is able to carry out assigned work and to
recognize and avoid possible dangers due to professional training,
knowledge, and experience as well as profound knowledge of
applicable regulations.
The skilled electrician has been trained specially for his working
environment and he has profound knowledge of relevant standards
and regulations.
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2.2.2 Unauthorized persons
WARNING!
Danger for unauthorized persons!
Unauthorized persons, who do not meet the
requirements described in this installation manual,
are not aware of the dangers in the working area.
– Keep unauthorized persons away from the
working area.
– If in doubt, address such persons and ask
them to leave the working area.
– Interrupt your work as long as unauthorized
persons are in the working area.
Only persons who are expected to perform their tasks reliably are
permitted as personnel. Persons whose reaction capability is
impaired, e.g. through drugs, alcohol or medication are not per-
mitted.
nWhen selecting personnel, ensure that the personnel can work
with the control unit in terms of technical and content aspects.
2.3 Intended use
The control unit is exclusively intended and built for the use
described in this installation manual.
The control unit is to be used exclusively to control CNC machines
of a supported number of axes which are in accordance with the
types cleared by Power Automation. Prerequisite for the intended
use of the control unit is proper configuration as described in the
installation manuals provided by Power Automation.
WARNING!
Beware of unintended use!
Any use exceeding the scope of intended use
and/or different application of the control unit can
result in hazardous situations.
– Operate the control unit as intended only.
– Observe all instructions in this installation
manual.
– Observe the permissible ambient conditions
and electromagnetic compatibility mentioned in
the technical data.
Claims of any kind for damage resulting from unintended use are
void.
Intended Use
Dangers
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The operator is solely responsible for all damage resulting from
unintended use.
2.4 Unintended use
WARNING!
Beware of unintended use!
– In particular, avoid using the control unit for the
following purposes as these are regarded as
not intended:
– Operation using software not approved by
Power Automation.
– Operation connected to machines/drives
not deemed compatible by
Power Automation.
– Operation using wrong number of axes
– Wrong or missing execution of the mainte-
nance intervals
– Operation by not instructed personnel
2.5 Personal protective gear
Wearing of personal protective gear is required to minimize health
hazards and damage when working with the control unit.
nAlways wear the protective equipment that is necessary for the
respective task when working.
nFollow the instructions on personal protective equipment that
are listed in this installation manual and other installation man-
uals provided by Power Automation.
nThe environment in which the control unit is installed may
require users to wear additional personal protective gear.
Observe the instructions on personal protective gear provided
by the operating company.
Antistatic gloves
for protection of the hands during the work. Wear the antistatic
gloves always until the work is finished.
ESD clothing
for protection of components susceptible to electrostatic discharge.
Wear the ESD clothing during the work on electrostatic compo-
nents.
ESD safety pad
for protection of components susceptible to electrostatic discharge.
Put the ESD safety pad on the floor before starting to work.
Unintended Use
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ESD safety shoes
for protection of components susceptible to electrostatic discharge.
Wear the ESD safety shoes to protect electrostatic-discharge-sen-
sitive devices due to inadequate derivative electrostatic energy.
Ear protection
for protection of the ears during the work. Wear the ear protection
always until the work is finished.
Ground strap
for protection of components susceptible to electrostatic discharge.
Wear the ground strap on your wrist and connect it to a suitable
equipotential bonding.
Protective glasses
for protection of the eyes during the work. Always wear the protec-
tive glasses until the work is finished.
2.6 Specific dangers
The following section lists the residual risks.
nObserve the safety instructions listed here, and the warnings in
subsequent chapters of this installation manual, to reduce
health hazards and to avoid dangerous situations.
DANGER!
Danger to life caused by electric current!
Touching conductive parts causes a direct danger
to life. Damage to insulations or individual compo-
nents can cause danger to life.
nIn the event of damage to insulation, switch off the power
supply immediately and have the defective parts repaired.
nWork on the electric system must be carried out only by skilled
electricians.
nBefore maintenance, cleaning or repair work, switch off the
power supply and secure it against being switched on again.
nDo not bridge fuses or make them ineffective. When changing
fuses make sure you use the correct amperage.
nKeep moisture away from conductive parts. This can cause
short-circuits.
nDe-energize the machine for all work on the electrical system.
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DANGER!
Uncontrolled operation due to improper instal-
lation and configuration!
The control unit's safety relay must be properly
integrated into the CNC machine emergency stop
chain. Improper wiring and configuration of the
safety relay may result in uncontrolled operation of
the CNC machine and in consequence may lead to
irreversible personal injuries or death.
nOnly operate the CNC machine when the safety relay has been
properly integrated into the machine emergency stop chain.
nOnly let qualified personnel (
Ä Chapter 2.2.1 “Qualifications”
on page 10) set up the emergency stop chain.
nFor information on safety devices integrated into the machine
see the manual supplied by the machine's manufacturer.
nIf in doubt regarding the configuration, contact the manufac-
turers of the CNC machine and the control unit.
WARNING!
Risk of injury due to improper handling of bat-
teries!
Batteries must be handled with special care.
nDo not throw batteries into fire or expose to high temperature.
Explosion hazard!
nDo not charge batteries. Explosion hazard!
nBattery fluid leaking due to wrong usage may cause skin irrita-
tion. Avoid contact with the battery fluid. In case of contact,
flush the battery fluid with large amounts of water. If the battery
fluid enters the eyes, flush immediately with water for 10 min.
and consult a physician without delay.
CAUTION!
Malfunction due to discharged buffer battery!
The control unit's CMOS settings are buffered by a
battery. If this battery is discharged completely the
CMOS settings are lost. Malfunctions of the control
unit may result.
nFor further information, see Ä Chapter 8.2 “Troubleshooting
chart” on page 56.
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2.7 Safety devices
DANGER!
Malfunctioning safety devices may pose a fatal
risk!
Safety devices must be intact and properly inte-
grated into the control unit's configuration and soft-
ware in order to guarantee safety.
nBefore initial commissioning of the machine, ensure that all
safety devices are fully functional and correctly installed.
nEnsure that safety related inputs/outputs of the CNC control
unit are fully functional and perform as intended.
nNever disable safety devices.
nHeed regulations concerning hardwiring of safety circuits.
Superior CNC Control unit or PLC
For information on required connections between
the PA control unit and safety devices integrated
into the CNC machine see the documentation pro-
vided by the machine's manufacturer.
Data safety
For information on data safety see Ä Chapter 2.10
“Data safety” on page 16.
2.8 Machine safety
For information on the machine's safety devices
and emergency stop chain see the manual pro-
vided by the CNC machine's manufacturer. The
manufacturer of the CNC machine is responsible
for the proper installation of the emergency stop.
2.9 Conduct in a dangerous situation and in
case of accidents
nStay informed about locations of first aid equipment (first aid
kit, covers, etc.) and fire extinguishers at the site of installation.
nInstruct personnel about accident reporting, first aid and rescue
facilities at the site of installation.
Safety
Superior Control Units
Software
Further Applicable Documents
Preventive Measures
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nDisconnect power supply immediately.
nInitiate first aid measures.
nInform responsible persons at the site.
nCall for rescue service if applicable.
2.10 Data safety
To ensure the ability to restore critical data in case of control unit or
storage malfunctions, internal and external (off-site) backup copies
of all files that are critical to proper machine function must be cre-
ated regularly and kept in a secure environment.
To minimize the chance of data loss, it is recommended to protect
the system patition (C:) with the File Based Write Filter (FBWF)
and use a second partition for user data.
CAUTION!
Extended system outage in case of data loss!
If backup copies of critical control unit data are not
created regularly and kept securely, the control unit
configuration would have to be set up from scratch
in case of data loss.
nPay attention to all instructions regarding data safety as given
in this and the other installation manuals provided by Power
Automation.
2.10.1 File backup
A backup solution is preinstalled and configured.
It is neccessary to select and activate the backup-function inside
the CNC.
Personnel: nQualified personnel
nInstructed person
1. Follow the instructions to properly configure the control unit
for use with the intended machine.
2. Ensure that the configuration is functioning as intended.
3. Ensure that the machine data is saved regularly (see
Ä Chapter 9 “Service and return process” on page 59).
4. Keep a record of all modifications to the configuration done
by the operator.
5. Ensure that backups are updated manually in case of modifi-
cations to the configuration.
In Case Of Accidents
General Information
Initial State
Instructions
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2.10.2 System protection
Automated regular anti-virus scanning and manual scanning of
files copied to the control unit are advised by Power Automation as
needed.
To protect the system against virus attacs or other system failures,
it is recommended to take the following measures:
nEither don't connect the CNC to the Internet or assure it is con-
nected via a managed firewall.
nBe sure that there is no virus software already behind the fire-
wall in your intranet. Only then, it is save to use the internal
ethernet connection for data transfer.
nUse only virus free and verified USB memory sticks for data
transfer to the CNC control. Don't allow users to transfer data
with unverified USB memory sticks. If you are not sure whether
you can guarantee this, please consider the usage of a USB-
Guardian software (see http://www.trinit-soft.de/usb-waechter/).
In Windows 7, the FBWF is already part of the system. There is no
special graphical user interface (GUI) necessary. The FBWF inter-
face can be started in the taskbar, see Fig. 2.
Fig. 2: Start of the FBWF interface
Click on the little lock and the FBWF interface shows up the folling
window (Fig. 3).
After delivery, the FBWF is in state "enabled". You must put it into
the state "disabled" if you want to install further software on the
system partition, or if you need to do other modifications there.
Initial State
Filebased Write Filter (FBWF)
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Fig. 3: Overview FBWF interface
2.10.3 PA Recovery Stick
For various reasons it may become necessary to re-install or to
repair the operating system (Windows 7 Embedded) of the control
unit. Power Automation offers a Recovery Stick which is necessary
for re-installation or repair. for more information about this
Recovery Stick please look into the PA Accessories Manual.
The PA Recovery Stick is an All-in-One Solution for checking,
testing and most of all recovering and restoring the PA 8000 / PA
9000 control. The main feature of the PA Recovery Stick is to give
the user the ability to recover and restore the complete HDD of his
PA 8000 / 9000 control if somehow a data loss or a system crash
has occurred. It also gives the user the opportunity to perform an
Antivirus scan if an infection is suspected. Also located on the PA
Recovery Stick are other helpful tools like a RAM test. The fol-
lowing manual will show what the various possibilities of the PA
Recovery Stick are.
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2.11 Environmental protection
CAUTION!
Environmental hazard caused by incorrect han-
dling!
Incorrect handling of environmentally hazardous
substances, especially incorrect waste disposal,
can cause considerable damage to the environ-
ment.
nDo not release environmentally hazardous substances or com-
ponents into the environment.
nAlways properly dispose of environmentally hazardous compo-
nents/substances in accordance with local law and regulations.
The following environmentally hazardous components or sub-
stances are contained in the control unit:
Batteries contain toxic heavy metals. They are considered haz-
ardous waste and must be disposed of by approved specialized
waste disposal companies.
Electronic components are considered special waste. They must
be properly disposed of.
Power Automation will accept the control unit to properly dispose of
its components upon decommissioning.
nFollow the standard return procedure, as described in
Ä Chapter 9.3 “Return policy and procedure” on page 62.
2.12 Labels
The following labels are attached to the control unit.
NOTICE!
Readability Of Labels
Over the course of time labels may become dirty or
nonreadable for any other reason. Improper input
voltages applied due to readability of labels can
damage the control unit.
– Keep labels in readable condition at all times.
– Replace damaged labels (not including mate-
rial warranty seals).
– Replacements can be obtained from
Power Automation.
Batteries
Electronic Components
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The labels listed hereunder are located at the positions shown in
Fig. 4.
Fig. 4: Label Positions
1 Material Warranty seal
2 Type Plate
3 License Operating system
The type plate includes the following information:
nManufacturer address
n'CE'-sign
nControl unit model
nSerial number
nArticle number
nConnection values
Fig. 5: Type Plate (Example)
Overview
Type Plate
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