power automation PA 8000 EL User manual

PA 8000 EL
CNC control unit
Installation instructions

Option: PA 8000 EL PRO-SDI / PA 8000E EL PRO-SDI
Original installation instructions
©2015 Power Automation GmbH
Power Automation GmbH
CNC-Automatisierungstechnik
Gottlieb-Daimler-Str. 17/2
74385 Pleidelsheim
Germany
Telephone: [phone]
Fax: [phone]
email: [email protected]
Internet: www.powerautomation.com
Version 2.0
2 24.09.2015

Table of contents
1 General information............................................................. 7
1.1 Information on this manual.......................................... 7
1.2 Explanation of symbols................................................ 7
1.3 Limitation of liability...................................................... 9
1.4 Copyright..................................................................... 9
1.5 Warranty terms............................................................ 9
1.6 Customer service....................................................... 10
1.7 Glossary..................................................................... 10
2 Safety.................................................................................. 11
2.1 Customer's responsibility........................................... 11
2.2 Personnel requirements............................................. 12
2.2.1 Qualifications........................................................... 12
2.2.2 Unauthorized persons............................................. 12
2.3 Intended use.............................................................. 13
2.4 Unintended use.......................................................... 14
2.5 Personal protective gear............................................ 14
2.6 Specific dangers........................................................ 15
2.7 Safety devices........................................................... 17
2.8 Machine safety........................................................... 17
2.8.1 'CNC ready' signal - Emergency stop interlocking.. 18
2.8.2 'Power ok' signal..................................................... 19
2.9 Conduct in a dangerous situation and in case of
accidents.................................................................... 19
2.10 Data safety................................................................. 20
2.10.1 File backup.............................................................. 20
2.10.2 System protection................................................... 20
2.11 Environmental protection........................................... 22
2.12 Labels........................................................................ 23
3 Design and function.......................................................... 27
3.1 Overview.................................................................... 27
3.2 Brief description......................................................... 27
3.3 Module 2416 EL......................................................... 28
3.3.1 Digital inputs............................................................ 29
3.3.1.1 Input interfaces..................................................... 29
3.3.1.2 Input characteristics.............................................. 33
3.3.1.3 Input schematic.................................................... 34
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3.3.1.4 Handwheel I/O...................................................... 34
3.3.2 Digital outputs......................................................... 37
3.3.2.1 Output interfaces.................................................. 37
3.3.2.2 Output characteristics........................................... 41
3.3.2.3 Output schematic.................................................. 42
3.3.3 Power connection.................................................... 43
3.3.4 Module 2416 EL LEDs............................................ 46
3.4 SDI interface.............................................................. 47
3.5 PC connectors........................................................... 49
3.6 Safety connector........................................................ 55
3.6.1 Safety connector specification................................ 56
3.6.2 Safety connector schematic.................................... 59
3.7 (X20) PA USB software dongle connector................. 59
3.8 PAMIO interface (superbus)...................................... 60
3.8.1 PAMIO boxes and modules.................................... 61
4 Technical data.................................................................... 65
4.1 General specifications............................................... 65
4.2 Connection values..................................................... 65
4.3 Operating conditions.................................................. 66
4.4 Dimension sheet........................................................ 67
4.5 Electromagnetic compatibility.................................... 68
4.6 Installation guidelines................................................ 69
5 Installation.......................................................................... 73
5.1 Prerequisites and preparations.................................. 73
5.1.1 General requirements............................................. 73
5.1.2 Electrical cabinet structural requirements............... 74
5.1.3 Cabinet temperature............................................... 74
5.2 Mounting the control unit in a cabinet........................ 75
5.3 Installing digital I/O.................................................... 80
5.3.1 Wiring example for 2416EL modules...................... 80
5.4 Wiring for machine safety.......................................... 81
5.4.1 Wiring example for 'CNC ready' relay..................... 82
5.4.2 Wiring example for 'Power ok' relay........................ 83
6 Transport, packaging and storage................................... 85
6.1 Transport................................................................... 85
6.2 Packaging.................................................................. 85
6.3 Storage...................................................................... 86
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7 Maintenance....................................................................... 87
7.1 Safety notes............................................................... 87
7.2 Maintenance schedule............................................... 87
7.3 Measures after maintenance..................................... 88
8 Troubleshooting................................................................. 89
8.1 Safety notes............................................................... 89
8.2 Malfunction indicators................................................ 90
8.2.1 Module 2416 EL LEDs............................................ 91
8.3 Troubleshooting chart................................................ 93
9 Service and return process............................................... 95
9.1 Service....................................................................... 95
9.1.1 Service addresses................................................... 95
9.2 Spare parts................................................................ 97
9.3 Return policy and procedure...................................... 97
9.4 Training.................................................................... 100
10 Dismounting and decommissioning.............................. 101
11 EC Declaration of Conformity......................................... 103
12 Proof of change................................................................ 105
13 Index.................................................................................. 107
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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 moderate injury.
NOTICE!
… indicates a potentially hazardous situation which, if
unavoidable, may result in property damage.
General Information
Warnings
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… emphasizes useful hints and recommendations as
well as information for efficient and trouble-free opera-
tion.
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 8.. 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 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.
1.4 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.
Violations oblige to compensation. The right for further claims
remains reserved.
1.5 Warranty terms
The material warranty terms are provided in Power Automation's
terms and conditions as well as inside the sales documents.
Liability
Copyright
Material Warranty
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1.6 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.
1.7 Glossary
CMOS - Complementary metal-oxide-semiconductor
CNC - Computerized Numerical Control
DDU - Delivered Duty Unpaid
HMI - Human Machine Interface
The graphical user interface provided by the PA soft-
ware.
IPC - Insulating Piercing Connector
MDI - Manual Data Input
MTBP - Machine Tool Builder's Panel
Panel including the basic requirements for a machine
tool operator: emergency stop push button, cycle start
and stop push buttons, jog plus and minus push but-
tons, feed rate and spindle speed override pots and a
number of auxiliary push buttons.
NC-Start - Numerical Control Start Button
NC-Stop - Numerical Control Stop Button
PA - Power Automation
PAMIO - Power Automation Modular Input Output
Extendable Superbus based interface allowing
connection of additional I/O modules.
PASIO - Power Automation Slot Input Output
Extendable EtherCATâ based interface allowing
connection of additional I/O modules.
PC - Personal Computer
PCI - Peripheral Component Interconnect
Personal computer extension for periphery devices
connected to the motherboard.
PLC - Programmable Logic Controller
POU - Program Organization Unit PLC functions, function
blocks and programs are POUs
RMS - Rotating Measuring Systems (Encoder)
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 qualifica-
tion!
Improper operation can lead to severe personal inju-
ries 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.
2.2.2 Unauthorized persons
WARNING!
Danger for unauthorized persons!
Unauthorized persons, who do not meet the require-
ments 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 per-
sons are in the working area.
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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.
The operator is solely responsible for all damage resulting from
unintended use.
Intended Use
Dangers
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2.4 Unintended use
WARNING!
Beware of unintended use!
– In particular, avoid using the control unit for the fol-
lowing 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.
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.
Unintended Use
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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 components
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.
DANGER!
Uncontrolled operation due to improper installa-
tion and configuration!
The control unit's safety relay must be properly inte-
grated 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.
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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 12) 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 8.3 “Troubleshooting
chart” on page 93.
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2.7 Safety devices
DANGER!
Malfunctioning safety devices may pose a fatal
risk!
Safety devices must be intact and properly integrated
into the control unit's configuration and software 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 PAMIO compo-
nents and 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 provided by the
machine's manufacturer.
Safety connector
For information on the safety connector's purpose,
specification and wiring see Ä Chapter 3.6 “Safety
connector” on page 55,
Ä Chapter 2.8 “Machine
safety” on page 17 and Ä Chapter 5.4 “Wiring for
machine safety” on page 81.
Data safety
For information on data safety see Ä Chapter 2.10
“Data safety” on page 20.
2.8 Machine safety
For information regarding the safety connector's specification and
wiring examples see
Ä Chapter 3.6 “Safety connector” on page 55
and Ä Chapter 5.4 “Wiring for machine safety” on page 81.
Safety
Superior Control Units
Safety Connector
Software
Additional Information
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For information on the machine's safety devices and
emergency stop chain see the manual provided by the
CNC machine's manufacturer. The manufacturer of the
CNC machine is responsible for the proper installation
of the emergency stop.
2.8.1 'CNC ready' signal - Emergency stop inter-
locking
DANGER!
Injuries due to uncontrolled operation!
An inactive 'CNC Ready' signal represents a safety
related situation. The "CNC Ready" relay is switched
off when the PA CNC control unit is in a situation
where the axes' movements are not controlled.
As the axes may continue to move in an uncontrolled
manner, the contacts of the "CNC Ready" relay must
be used to disconnect the machine's emergency stop
safety chain. All actions necessary for safety must be
executed in the same way as when the
Emergency Stop button is pushed.
nProperly integrate the 'CNC ready' relay into the machine's
emergency stop chain.
All safety related actions must ensure that at least all axes
movements and spindle rotation (or beam power) are stopped as
quickly as possible.
nRefer to the drive manufacturer manual, to determine the best
way of stopping movements and other dangerous power on the
machine.
nIf drive capability does not exist, the use of external braking
resistors might be necessary.
Unbalanced axes have to execute with the mechanical brake.
The contacts for 'CNC Ready' and 'Power OK' are available on
connector X19 (see
Ä Chapter 5.4 “Wiring for machine safety”
on page 81).
Further Applicable Documents
Personal Injury
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2.8.2 'Power ok' signal
The "Power ok" relay is triggered by the hardware monitoring of the
internal supply voltages and the temperature sensor.
The "Power ok" relay is switched off when the power supplies do
not match the allowed range or the internal temperature is too high.
nUse the contacts of the "Power ok" relay to switch off the main
power supply of the control unit to avoid any unexpected dam-
ages to the control unit.
The contacts for 'CNC Ready' and 'Power OK' are available on
connector X19 (see
Ä Chapter 5.4 “Wiring for machine safety”
on page 81).
–When an external 5V power supply (RMS) is nec-
essary to supply incremental measuring systems,
use the corresponding entry in the control unit's
drive configuration file (DriveCfg.ini) to acti-
vate the monitoring of the correct range of these 5
V.
When the monitoring is activated, an error on this
power supply will cause the "Power ok" relay to
drop.
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.
nDisconnect power supply immediately.
nInitiate first aid measures.
nInform responsible persons at the site.
nCall for rescue service if applicable.
Preventive Measures
In Case Of Accidents
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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 cre-
ated regularly and kept securely, the control unit con-
figuration 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 95).
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.
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.
General Information
Initial State
Instructions
Initial State
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