power automation PA 8000 LW Series User manual

PA 8000 LW
CNC control unit
Installation instructions

Variante: PA 8000 LW PRO SDI-AN / PA 8000E LW PRO SDI-AN
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 25.09.2015

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........................................................................... 11
2 Safety........................................................................................ 13
2.1 Customer's responsibility................................................. 13
2.2 Personnel requirements................................................... 14
2.2.1 Qualifications................................................................. 14
2.2.2 Unauthorized persons................................................... 14
2.3 Intended use.................................................................... 15
2.4 Unintended use................................................................ 15
2.5 Personal protective gear.................................................. 16
2.6 Specific dangers.............................................................. 16
2.7 Safety devices................................................................. 18
2.8 Machine safety................................................................. 19
2.8.1 'CNC ready' signal - Emergency stop interlocking........ 19
2.8.2 'Power ok' signal........................................................... 20
2.9 Conduct in a dangerous situation and in case of acci-
dents................................................................................ 20
2.10 Data safety....................................................................... 21
2.10.1 File backup.................................................................... 21
2.10.2 System protection......................................................... 21
2.11 Environmental protection................................................. 23
2.12 Labels.............................................................................. 24
3 Design and function................................................................ 27
3.1 Overview.......................................................................... 27
3.2 Brief description............................................................... 29
3.3 Module 4AXLX................................................................. 30
3.3.1 Digital Inputs................................................................. 31
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3.3.1.1 Input interfaces........................................................... 31
3.3.1.2 Input characteristics.................................................... 32
3.3.1.3 Input schematic.......................................................... 33
3.3.1.4 RMS encoder wiring example..................................... 34
3.3.2 Analog Outputs............................................................. 35
3.3.2.1 Output interfaces........................................................ 35
3.3.2.2 Output characteristics................................................. 36
3.3.2.3 Output schematic........................................................ 37
3.3.2.4 Output Monitor............................................................ 38
3.3.2.5 Analog axes wiring example....................................... 38
3.3.3 RMS power supply........................................................ 40
3.3.4 Module 4AXLX LEDs.................................................... 42
3.4 Module 2416 EL............................................................... 43
3.4.1 Digital inputs.................................................................. 44
3.4.1.1 Input interfaces........................................................... 44
3.4.1.2 Input characteristics.................................................... 48
3.4.1.3 Input schematic.......................................................... 49
3.4.1.4 Handwheel I/O............................................................ 49
3.4.2 Digital outputs............................................................... 52
3.4.2.1 Output interfaces........................................................ 52
3.4.2.2 Output characteristics................................................. 56
3.4.2.3 Output schematic........................................................ 57
3.4.3 Power connection.......................................................... 58
3.4.4 Module 2416 EL LEDs.................................................. 61
3.5 SDI interface.................................................................... 62
3.6 PC connectors................................................................. 64
3.7 Safety connector.............................................................. 75
3.7.1 Safety connector specification...................................... 75
3.7.2 Safety connector schematic.......................................... 78
3.8 (X20) PA USB software dongle connector....................... 78
3.9 PAMIO interface (superbus)............................................ 79
3.9.1 PAMIO boxes and modules.......................................... 80
4 Technical data.......................................................................... 83
4.1 General specifications..................................................... 83
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4.2 Connection values........................................................... 83
4.3 Operating conditions........................................................ 84
4.4 Dimension sheet.............................................................. 85
4.5 Electromagnetic compatibility.......................................... 87
4.6 Installation guidelines...................................................... 88
5 Installation................................................................................ 91
5.1 Prerequisites and preparations........................................ 91
5.1.1 General requirements................................................... 91
5.1.2 Electrical cabinet structural requirements..................... 92
5.1.3 Cabinet temperature..................................................... 92
5.2 Mounting the control unit in a cabinet.............................. 93
5.3 Installing analog axes...................................................... 95
5.3.1 Analog axes wiring example......................................... 96
5.3.2 RMS encoder wiring example....................................... 97
5.3.3 Setting up RMS supply voltage drop compensation..... 98
5.4 Installing digital I/O........................................................ 100
5.4.1 Wiring example for 2416EL modules.......................... 101
5.5 Wiring for machine safety.............................................. 102
5.5.1 Wiring example for 'CNC ready' relay......................... 102
5.5.2 Wiring example for 'Power ok' relay............................ 103
6 Transport, packaging and storage....................................... 105
6.1 Transport....................................................................... 105
6.2 Packaging...................................................................... 105
6.3 Storage.......................................................................... 106
7 Maintenance........................................................................... 107
7.1 Safety notes................................................................... 107
7.2 Maintenance schedule................................................... 107
7.3 Measures after maintenance......................................... 108
8 Troubleshooting..................................................................... 109
8.1 Safety notes................................................................... 109
8.2 Malfunction indicators.................................................... 110
8.2.1 Module 4AXLX LEDs.................................................. 111
8.2.2 Module 2416 EL LEDs................................................ 115
8.3 Troubleshooting chart.................................................... 117
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9 Service and return process................................................... 119
9.1 Service........................................................................... 119
9.1.1 Service addresses....................................................... 119
9.2 Spare parts.................................................................... 121
9.3 Return policy and procedure.......................................... 121
9.4 Training.......................................................................... 124
10 Dismounting and decommissioning.................................... 125
11 EC Declaration of Conformity............................................... 127
12 Proof of change...................................................................... 129
13 Index........................................................................................ 131
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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 per-
sonnel 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 specified safety notes and
instructions is a basic requirement for safety at work.
Moreover, the accident prevention guidelines and general safety regu-
lations 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.
… indicates an imminently hazardous situation which, if unavoid-
able, will result in death or serious injury.
… indicates a potentially hazardous situation which, if unavoid-
able, could result in death or serious injury.
… indicates a potentially hazardous situation which, if unavoid-
able, may result in minor or moderate injury.
… indicates a potentially hazardous situation which, if unavoid-
able, may result in property damage.
… emphasizes useful hints and recommendations as well as informa-
tion for efficient and trouble-free operation.
The following symbols are used in connection with the safety notes to
highlight particular dangers:
General Information
Warnings
L DANGER
L WARNING
L CAUTION
NOTICE
Special Safety Notes
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… highlights hazards caused by electric current. There is a
danger of serious injury or death if the safety notes are not com-
plied 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 sub-
menu in the software's graphical user interface.
Example/Extract.. Highlights verbatim examples and extracts from
configuration files.
L DANGER
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 experi-
ence.
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 tech-
nical changes.
Apart from this, the obligations agreed upon in the delivery contract,
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 disclosure
of the contents without the written consent of Power Automation 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 prod-
ucts, which could be of great value for future improvements.
Service
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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 software.
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 buttons, 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 con-
nected to the motherboard.
PLC - Programmable Logic Controller
POU - Program Organization Unit PLC functions, function blocks
and programs are POUs
RMS - Rotating Measuring Systems (Encoder)
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2 Safety
2.1 Customer's responsibility
The control unit is used for commercial purposes. The operating com-
pany is thus subject to the legal obligations concerning industrial
safety.
The safety, accident prevention and environmental protection regula-
tions 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 regu-
lations 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 converted into oper-
ating 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 corre-
spond to the current status of regulations and standards. When-
ever changes in regulations and standards occur, instructions 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 oper-
ating 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 function
and completeness.
nThe customer must supply his personnel with the necessary pro-
tective equipment.
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2.2 Personnel requirements
2.2.1 Qualifications
Danger of injury in case of insufficient qualification!
– Only those persons who have been specified in the corre-
sponding chapters of this installation manual should be
entrusted with the listed types of work.
– Employ certified experts, if in doubt.
Improper operation can lead to severe personal injuries and/or
material damage.
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 dangers
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 envi-
ronment and he has profound knowledge of relevant standards and
regulations.
2.2.2 Unauthorized persons
Danger for unauthorized persons!
– 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.
Unauthorized persons, who do not meet the requirements
described in this installation manual, are not aware of the dan-
gers in the working area.
Only persons who are expected to perform their tasks reliably are per-
mitted as personnel. Persons whose reaction capability is impaired,
e.g. through drugs, alcohol or medication are not permitted.
L WARNING
L WARNING
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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 man-
uals provided by Power Automation.
Beware of unintended use!
– Operate the control unit as intended only.
– Observe all instructions in this installation manual.
– Observe the permissible ambient conditions and electromag-
netic compatibility mentioned in the technical data.
Any use exceeding the scope of intended use and/or different
application of the control unit can result in hazardous situations.
Claims of any kind for damage resulting from unintended use are void.
The operator is solely responsible for all damage resulting from
unintended use.
2.4 Unintended use
Beware of unintended use!
– In particular, avoid using the control unit for the following pur-
poses as these are regarded as not intended:
– Operation using software not approved by
Power Automation.
– Operation connected to machines/drives not deemed com-
patible by Power Automation.
– Operation using wrong number of axes
– Wrong or missing execution of the maintenance intervals
– Operation by not instructed personnel
Intended Use
Dangers
L WARNING
Unintended Use
L WARNING
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2.5 Personal protective gear
Wearing of personal protective gear is required to minimize health haz-
ards 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 manuals pro-
vided 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 components.
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-sensitive
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 protective
glasses until the work is finished.
2.6 Specific dangers
The following section lists the residual risks.
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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 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.
Uncontrolled operation due to improper installation and configu-
ration!
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 opera-
tion of the CNC machine and in consequence may lead to irrever-
sible 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 14) 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 manufacturers
of the CNC machine and the control unit.
Risk of injury due to improper handling of batteries!
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 irritation.
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.
L DANGER
L DANGER
L WARNING
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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. Mal-
functions of the control unit may result.
nFor further information, see Ä Chapter 8.3 “Troubleshooting chart”
on page 117.
2.7 Safety devices
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 documen-
tation provided by the machine's manufacturer.
Safety connector
For information on the safety connector's purpose, specification and
wiring see
Ä Chapter 3.7 “Safety connector” on page 75,
Ä Chapter 2.8 “Machine safety” on page 19 and Ä Chapter 5.5 “Wiring
for machine safety” on page 102.
Data safety
For information on data safety see
Ä Chapter 2.10 “Data safety”
on page 21.
L CAUTION
Safety
L DANGER
Superior Control Units
Safety Connector
Software
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2.8 Machine safety
For information regarding the safety connector's specification and
wiring examples see Ä Chapter 3.7 “Safety connector” on page 75 and
Ä Chapter 5.5 “Wiring for machine safety” on page 102.
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
Injuries due to uncontrolled operation!
An inactive 'CNC Ready' signal represents a safety related situa-
tion. 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 emer-
gency 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 pos-
sible.
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 resis-
tors might be necessary.
Unbalanced axes have to execute with the mechanical brake.
The contacts for 'CNC Ready' and 'Power OK' are available on con-
nector X19 (see
Ä Chapter 5.5 “Wiring for machine safety”
on page 102).
Additional Information
Further Applicable Documents
Personal Injury
L DANGER
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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 damages
to the control unit.
The contacts for 'CNC Ready' and 'Power OK' are available on con-
nector X19 (see
Ä Chapter 5.5 “Wiring for machine safety”
on page 102).
–When an external 5V power supply (RMS) is necessary 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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