power automation PA 9000 User manual

PA 9000
ETC Drive Micro
Installaon instrucons

Original installation instructions
© 2017 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 21.02.2017

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.......................................................... 16
2.5 Safety instructions..................................................... 17
2.6 Personal protective gear............................................ 18
2.7 Conduct in a dangerous situation and in case of
accidents.................................................................... 19
2.8 Environmental protection........................................... 20
2.9 Labels........................................................................ 20
3 PA ETC-Drives MC Overview............................................ 23
3.1 Supported Motor-Sensor Configurations................... 27
4 Technical Data.................................................................... 35
4.1 General Specification................................................. 35
4.2 Operating Conditions................................................. 36
4.3 Specific Data.............................................................. 38
4.4 Logic Supply Input (+VLOG)........................................ 39
4.5 Motor Supply Input (+VMOT)....................................... 40
4.6 Motor Outputs (A/A+, B/A-, C/B+, BR/B-).................. 42
4.7 Enable circuit inputs (ENA1, ENA2).......................... 46
4.8 Digital Inputs.............................................................. 47
4.9 Digital Outputs........................................................... 51
4.10 Digital Hall Inputs (Hall1, Hall2, Hall3)....................... 55
4.11 Encoder Inputs........................................................... 56
4.12 Linear Hall Inputs (LH1, LH2, LH3)............................ 59
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4.13 Sin-Cos Encoder Inputs (Sin+, Sin-, Cos+, Cos-)...... 60
4.14 Analog 0 - 5V Inputs (REF, FDBK)............................ 61
4.15 Axis ID Inputs (AxisID 0, AxisID 1, Axis ID 2)............ 63
4.16 RS-232....................................................................... 63
4.17 EtherCATâ................................................................ 64
4.18 Supply Output (+5V).................................................. 66
4.19 Graphical presentation............................................... 67
4.20 Conformance with European directives and UL-
standards................................................................... 71
4.21 Installation guidelines................................................ 72
5 Installation.......................................................................... 75
5.1 Important instructions................................................ 75
5.2 PA MC x04 ETC-Drive............................................... 76
5.2.1 Interfaces................................................................ 76
5.2.2 Mechanical construction and mounting................... 81
5.2.3 Connector properties............................................... 82
5.2.4 External Fusing....................................................... 83
5.3 Linear Feedback Types............................................. 84
5.4 Switchgear cabinet assembly.................................... 85
6 Interface.............................................................................. 91
6.1 PA MC x04 ETC-Drive............................................... 91
6.1.1 24V Digital I/O Connection...................................... 91
6.1.2 5V Digital I/O Connection........................................ 92
6.1.3 Analog Inputs Connection....................................... 93
6.1.4 Motor connections................................................... 94
6.1.5 Feedback connections............................................ 97
6.1.6 Power Supply Connection..................................... 100
6.1.7 Serial RS-232 connection..................................... 105
7 Transport, packaging, storage and disposal................. 107
7.1 Transport................................................................. 107
7.2 Packaging................................................................ 108
7.3 Storage.................................................................... 109
7.4 Disposal................................................................... 110
8 Maintenance...................................................................... 111
8.1 Safety notes............................................................. 111
8.2 Maintenance schedule............................................. 111
8.3 Measures after maintenance................................... 113
9 Troubleshooting............................................................... 115
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9.1 Safety notes............................................................. 115
9.2 Malfunction indicators.............................................. 117
10 Dismounting and decommissioning.............................. 119
11 Service and return process............................................. 121
11.1 Service..................................................................... 121
11.1.1 Service addresses................................................. 122
11.2 Spare parts.............................................................. 123
11.3 Return policy and procedure.................................... 124
11.4 Training.................................................................... 126
12 EC Declaration of Conformity......................................... 127
13 Proof of change................................................................ 129
14 Index.................................................................................. 131
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1 General information
1.1 Information on this manual
The manual describes the EtherCATâ drives of the PA ETC-Drive
Micro serie.
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.
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:
Content
Warnings
Special Safety Notes
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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.
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.
Service
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1.7 Glossary
AWG - American wire gauge
BGND - Ground of 24V-supply and holding brake supply
voltage
CDM - Complete Drive Module
CE - Communité Europeenne
CLOCK - Clock signal
CMOS - Complementary metal-oxide-semiconductor
CNC - Computerized Numerical Control
CSA - Canadian Standards Association
DDU - Delivered Duty Unpaid
DIN - DIN standard
EEC - European Economic Community
EMC - Electromagnetic compatibility
EMI - EMI-Filter, (electromagnetic interference)
EN - European standard (Euro Norm)
EU - European Parliament and Council of the European
Union
HMI - Human Machine Interface
The graphical user interface provided by the PA soft-
ware.
IEC - International Electrotechnical Commission
IGBT - Insulated Gate Bipolar Transistor
IPC - Insulating Piercing Connector
LED - Light-emitting diode
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.
MTC - Motor thermal contact
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.
PC - Personal Computer
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PCI - Peripheral Component Interconnect
Personal computer extension for periphery devices
connected to the motherboard.
PELV - Protected extra low voltage
PLC - Programmable Logic Controller
POU - Program Organization Unit. PLC functions, function
blocks and programs are POUs
RCD - Residual-current-operated protective device
RMS - Rotating Measuring Systems (Encoder)
RES - Resolver
RMS - Root mean square
Rint. - Connection internal regen resistor
Rtr - Connection regen chopper
SELV - Safety extra low voltage
SVM - Space vector modulation
UL - Underwriters Laboratory
VAC - AC voltage
VDC - DC voltage
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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.
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.
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2.3 Intended use
The ETC drives are exclusively intended and built for the use
described in this installation manual.
The ETC drives of Power Automation are developed and produced
according to the current state of the technology.
They are components which are built in into electrical equipment
and can only be used as integrated component of such equipment.
Before the products are installed, the following requirements have
to be fulfilled to meet the intended use.
nEveryone who is working in any way with the products, has to
read and understand the safety instructions, the intended use
and the unintended use.
nThe ETC drive has to run under the mounting and installation
conditions, described in this installation manual. Especially the
environmental conditions (temperature, protection class,
humidity, mains input, EMC and the mounting position) have to
be considered.
nThe ETC drive has to be assembled in a closed switchgear
cabinet.
nThe ETC drive has to be used in original delivery condition
(without any mechanical or electrical modification).
nDo not mount or use mechanical or electrical damaged or
faulty servo drives.
nThe ETC drive is intended to control synchronous servo
motors, in closed loop control of torque, speed or position.
nThe ETC drive is developed for usage in industrial environ-
ment. If it is used in residential areas, an additional filter must
be installed in the mains input line.
WARNING!
Beware of unintended use!
Any use exceeding the scope of intended use
and/or different application of the ETC drives can
result in hazardous situations.
– Operate the ETC drive 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 ETC drive for the
following purposes as these are regarded as
not intended:
– Operation by not instructed personnel
– It is not allowed to be used in electrical
equipment on ships (service afloat) or in
offshore applications because of the con-
ductive pollution.
– It must be used in environmental conditions
according to the conditions described in
this installation manual (not too hot, with
closed switchgear cabinet, correct
mounting position, etc.).
Be very carefully in plants, were conductive material (carbon fiber,
graphite with machining of graphite cast iron or similar) is easy
purge able on the factory floor.
In this case, the switchgear cabinet has to be sealed very carefully
(no forced ventilation with blower filter) or has to be placed outside
the factory floor.
Especially at setup of the machine, the risk is high because of
open switchgear cabinet doors. ETC drives, which are contami-
nated in that way, must not be used anymore.
Unintended use
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2.5 Safety instructions
DANGER!
– Wait at least 7 minutes after disconnecting the
ETC drive from the mains supply voltage
before touching live sections of the equipment
(e.g. contacts) or undoing connections. Up to 7
minutes after switching off the supply voltages,
capacitors can still have dangerous voltages
present. To be sure, check the voltage of the
DC-link circuit and wait until it has fallen below
40V.
– Never remove the electrical connections to the
EtherCATâ amplifier while it is enabled. There
is a danger of electric arcing with damage to
contacts and danger to persons.
– If a leakage current sensor is used in the mains
supply of the ETC drive, a leakage current
sensor RCD type B has to be used in any
case. If a RCD type A or AC is used, there is a
risk, that the DC ground current of the ETC
drive inhibits the leakage current sensor.
–Failure to observe one of these instructions
will lead to death, serious injury or equip-
ment damage.
DANGER!
Hot Surface
PA MC 106 ETC-Drive / PA MC 107 ETC-Drive
– During operation, the ETC drive can become a
hot surface and may reach high temperatures.
Check (measure) the temperature and wait
until it has cooled down below 40°C (104°F)
before touching it.
–Failure to observe this precaution can
result in severe injury.
PA MC 114 ETC-Drive
– During operation, the heat sink of the servo
drive can become hot and may reach tempera-
tures above 80°C (176°F). Check (measure)
the heat sink temperature and wait until it has
cooled down below 40°C (104°F) before
touching it.
–Failure to observe this precaution can
result in severe injury.
Shock Current
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CAUTION!
General
– The utilization of the ETC drive is limited
according to DIN-EN 61800-3. This product
can cause radio interference problems in living
quarters. In this case it can be necessary for
the operator to accomplish adequate measure-
ments.
– The ETC drive contains electro statically sensi-
tive components which may be damaged by
incorrect handling. Ground yourself before
touching the ETC drive by touching any
grounded unpainted metal surface. Avoid con-
tact with highly insulating materials (artificial
fabrics, plastic film etc.). Place the ETC drive
on a conductive surface.
– Do not open the unit. Keep all covers and
switchgear cabinet doors closed during opera-
tion. Otherwise there are deadly hazards, with
the possibility of severe danger to health or
material damage.
– During operation, EtherCATâ amplifiers,
according to their degree of enclosure protec-
tion, may have uncovered life components.
Control and power connections may be live,
even if the motor is not rotating.
–Failure to observe these precautions can
result in severe injury and equipment
damage.
2.6 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.
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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.
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.
2.7 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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2.8 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 11.3 “Return policy and procedure” on page 124.
2.9 Labels
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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