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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