Renishaw apply innovation SPA2 User manual

Installation guide
H-1000-5234-03-A
SPA2servo power amplifier

© 2006 Renishaw plc. All rights reserved.
This document may not be copied or reproduced in whole or in
part, or transferred to any other media or language, by any means,
without the prior written permission of Renishaw.
The publication of material within this document does not imply
freedom from the patent rights of Renishaw plc.
Disclaimer
Considerable effort has been made to ensure that the contents of
this document are free from inaccuracies and omissions. However,
Renishaw makes no warranties with respect to the contents of
this document and specifically disclaims any implied warranties.
Renishaw reserves the right to make changes to this document
and to the product described herein without obligation to notify any
person of such changes.
Trademarks
RENISHAW® and the probe emblem used in the RENISHAW logo
are registered trademarks of Renishaw plc in the UK and other
countries.
apply innovation is a trademark of Renishaw plc.
All brand names and product names used in this document are
trade names, service marks, trademarks, or registered trademarks
of their respective owners.
Renishaw part no: H-1000-5234-03-A
Issued: 10 2006

SPA 2
Installation guide

2
FCC
Information to user (FCC section 15.105)
This equipment has been tested and found to comply with the limits for a class A digital device, pursuant
to part 15 of the FCC rules. These limits are designed to provide reasonable protection against harmful
interference when the equipment is operated in a commercial environment. This equipment generates,
uses and can radiate radio frequency energy and, if not installed and used in accordance with the
installation manual, may cause harmful interference to radio communications. Operation of this equipment
in a residential area is likely to cause harmful interference, in which case you will be required to correct the
interference at your expense.
Information to user (FCC section 15.21)
The user is cautioned that any changes or modifications not expressly approved by Renishaw PLC or
authorised representative could void the user’s authority to operate the equipment.

3
EC declaration of conformity
Renishaw plc declare that the product: -
Name Description
SPA
2 Servo amplifier
has been manufactured in conformity with the following standards: -
BS EN 61326:1998/ Electrical equipment for measurement, control and laboratory
inc. amendments use - EMC requirements.
A1:1998/A2:2001 Immunity to annex A - industrial locations.
Emissions to class A (non-domestic) limits.
BS EN 61010-1:2001 Safety requirements for electrical equipment for measurement,
control and laboratory use.
Part 1: General requirements.
BS EN 60204-1:1998 Safety of machinery - Electrical equipment of machines -
Part 1: General requirements
and that it complies with the requirements of directives (as amended): -
89/336/EEC - Electromagnetic compatibility (EMC)
73/23/EEC - Low voltage
The above information is summarised from the full EC declaration of conformity. A copy is available from
Renishaw on request.

4Care of equipment
Care of equipment
Renishaw probes and associated systems are precision tools used for obtaining precise measurements
and must therefore be treated with care.
Changes to Renishaw products
Renishaw reserves the right to improve, change or modify its hardware or software without incurring any
obligations to make changes to Renishaw equipment previously sold.
Warranty
Renishaw plc warrants its equipment for a limited period (as set out in our Standard Terms and Conditions
of Sale) provided that it is installed exactly as defined in associated Renishaw documentation.
Prior consent must be obtained from Renishaw if non-Renishaw equipment (e.g. interfaces and/or
cabling) is to be used or substituted. Failure to comply with this will invalidate the Renishaw warranty.
Claims under warranty must be made from authorised service centres only, which may be advised by the
supplier or distributor.
Machine safety
WARNING: Switching off or isolating the SPA 2 may NOT prevent unexpected machine
movement. The user is advised to isolate the machine from the electricity supply, compressed air
or other energy sources in accordance with the machine manufacturer's instructions before
entering the danger zone or performing any maintenance operations.
If the equipment is used in a manner not specified by the manufacturer, the protection provided by the
equipment may be impaired.
!

References and associated documents 5
References and associated documents
It is recommended that the following documentation is referred to when installing the SPA 2 .
Renishaw documents
Documentation supplied on Renishaw UCC software CD.
Document number Title
H-1000-5223 UCC
2 controller installation guide
H-1000-5057 UCC controller programmer’s guide
H-1000-5058 RENICIS user’s guide
H-1000-5067 MCU installation and user’s guide
H-1000-5109 UCC
lite installation guide
H-1000-5227 Digital SPA tuning user’s guide
External documents
National and international standards including the following may be applicable to the finished machine or
installation:
BS EN ISO 12100-2:2003 (Safety of machinery - Basic concepts, general principles for design - Part 2:
Technical principles and specifications.
BS EN (IEC) 60204-1:1997 (Safety of machinery - Electrical equipment of machines -
Part 1: General requirements).

6Electrical requirements
Electrical requirements
The SPA 2 is powered from the a.c. mains supply via an IEC 320 connector. The electrical ratings of the
unit are as follows:
100 – 240 V ac +10%, -15% 47 – 63 Hz 650 W maximum
This equipment must be connected to a protective earth conductor via a three core mains (line) cable. The
mains plug shall be inserted only into a socket outlet provided with a protective earth contact. The
protective earth contact shall not be negated by the use of an extension cable without protective
conductor.
An earth stud (M5 thread) is provided to allow bonding of the CMM metal parts to the protective earth.
WARNING: Any interruption of the protective conductor may make the equipment dangerous.
Make sure that the grounding requirements are strictly observed.
Environmental requirements
The following environmental conditions comply with (or exceed) BS EN 61010-1:1993
Indoor use IP20 (no protection against water)*
Altitude up to 2000 m
Operating temperature 0 °C to +50 °C (local to SPA
2 )
Storage temperature -10 °C to +70 °C
Relative humidity 80% maximum (non-condensing) for
temperatures up to +31 °C.
Linear decrease to 50% at +40 °C
Transient overvoltages Installation category II
Pollution degree 2
Weight 8 kg (17.6 lb)
NOTE: If a higher IP rating is required an additional external enclosure will be required to house the
SPA 2 . This enclosure must facilitate an airflow to allow the internal temperature to maintain the ambient
within the SPA
2 operating range.
!

Contents 7
Contents
1 System description .................................................................................................................................. 9
1.1 Electrical specification ................................................................................................................. 10
1.2 SPA
2 system components .......................................................................................................... 10
1.2.1 SPA
2 DC motor kits ...........................................................................................................10
1.2.2 SPA
2 DC motor connector kit ............................................................................................11
1.2.3 SPA
2 encoder interface card kit ........................................................................................11
1.2.4 SPA
2 4th axis interface card kit ..........................................................................................11
1.2.5 Dual SPA
2 integration kit ...................................................................................................12
1.2.6 SPA
2 DC connector kit ......................................................................................................12
1.2.7 SPA
2 and UCC 2 system layout .........................................................................................13
1.2.8 SPA
2 and UCC lite ..............................................................................................................13
2 Front panel description .......................................................................................................................... 14
2.1 Axes status LEDs........................................................................................................................ 14
2.1.1 LED positions and axis link 3 axis / 6 axis .........................................................................14
2.2 ESTOP LED ................................................................................................................................ 14
2.3 Air cooling fan inlet ...................................................................................................................... 14
3 Rear panel description........................................................................................................................... 15
3.1 Rear panel – 3 axis system ......................................................................................................... 15
3.2 Rear panel – 6 axis system ......................................................................................................... 16
3.3 Connections ................................................................................................................................ 16
3.3.1 Encoder card......................................................................................................................16
3.3.2 Motor connector .................................................................................................................17
3.3.3 Mains connection ...............................................................................................................17
3.3.4 UCC
2 emergency stop connection ....................................................................................17
3.3.5 SPA-A/-B/-C/-D connections..............................................................................................17
3.3.6 Earth stud...........................................................................................................................18
3.3.7 External emergency stop connection.................................................................................18
3.4 Motor connectors ........................................................................................................................ 19
3.4.1 DC motor connection card termination ..............................................................................19
3.4.2 Additional axis interface card termination ..........................................................................20
3.5 Encoder interface card ................................................................................................................ 21
4 Hardware configuration of the SPA
2 ..................................................................................................... 22
4.1 Fitting a motor connection card................................................................................................... 22
4.1.1 Recommended procedure to install the motor connection cards ......................................22
4.2 Installing the encoder option card ............................................................................................... 24
4.2.1 Recommended procedure to install the encoder interface card ........................................24
4.3 Fitting the 4th axis option card ..................................................................................................... 26

8Contents
4.3.1 Recommended procedure to install the 4th axis interface card ......................................... 26
4.4 Mounting the SPA
2 ...................................................................................................................... 29
4.4.1 Stand alone mounting .......................................................................................................29
4.4.2 Mounting in a 19” rack....................................................................................................... 29
5 System installation................................................................................................................................. 30
5.1 General........................................................................................................................................ 30
5.2 Testing and verification ............................................................................................................... 30
6 Interconnection schemes....................................................................................................................... 31
6.1 UCC
2 DC motor and tacho connection....................................................................................... 31
6.2 UCClite DC motor and tacho connection .................................................................................... 32
6.3 Dual SPA
2 DC motor and tacho configuration ............................................................................ 33
6.4 Preparation of integration kits...................................................................................................... 34
6.4.1 Motor connectors .............................................................................................................. 34
6.4.2 Emergency stop and reset switch ..................................................................................... 35
7 Revision history...................................................................................................................................... 36

System description 9
1 System description
The SPA 2 is a digital servo power amplifier solution designed specifically for use with the Renishaw UCC 2
or UCC lite controller.
The SPA
2 is capable of controlling up to seven axes of movement but is customer configurable to the
requirements of the installation.
The features offered by the SPA
2 are:
•Two base units
•SPA
2 3-axis: This is the basic 3-axis configuration suitable for conventional CMMs fitted with
brushed dc motors. It can accommodate both tacho and tacholess velocity feedback systems
and, with the addition of an encoder interface card, it can also accommodate encoder velocity
feedback. An additional axis card can be fitted to extend this unit to a 4-axis system.
•SPA
2 6-axis: This configuration is suitable for installations requiring between 5 or 6 axis
amplifiers. Like the 3-axis version it can accommodate both tacho and tacholess velocity
feedback systems and, with the addition of encoder interface cards, it can also accommodate
encoder velocity feedback. An additional axis card can be fitted to extend this unit to a 7-axis
system.
•Two SPA
2 units can be combined in a single system permitting a servo power amplifier solution
with an overall power rating of 1200 W.
•Configurable motor voltage
•The SPA
2 motor voltage can be configured by software to support a wide range of motor
voltages within the range of 12 and 60 V. The current limit can also be configured up to a
maximum of 5 A continuous, 10 A peak.
•The voltage setting of each axis is independent and therefore it is possible to have each
machine motor driven by a different voltage.
•DC analogue tacho or tacholess compatibility
•The UCC
2 or UCC lite and SPA 2 control solution has the ability to support different types of
velocity control loop based on the feedback to the controller.
•Two control loop feedback methods are integrated into the standard design of the system, these
are either an analogue tacho based feedback system from the motor or obtaining the feedback
from the scales of the CMM.
•Optional encoder (digital) tacho compatibility
•The SPA
2 offers the ability to support encoder tacho based feedback to close the velocity
control loop as an optional interface card.
NOTE: The UCC
lite product only permits 3-axis of machine control.

10 System description
1.1 Electrical specification
The SPA 2 has the following electrical output specification:
Motor output voltage range 12 V to 60 V
Maximum peak current output per channel
(peak current for ≤50 s at a duty cycle of ≤20%) 10 A
Maximum continuous current output per
channel (operating ) 5 A
Maximum output wattage of whole SPA
2
600 W
Emergency stop system specification Category 2 to EN 954-1:1996
(ISO 13849-1:1999) (refer to section 6.4.2)
1.2 SPA 2 system components
The SPA 2 family of products are capable of being configured to enable support of a wide range of motor
and tacho feedback giving compatibility with most machine constructions.
Part number Description Number of axis
supported Refer to
A-5121-0010 SPA
2 3-axis DC motor kit 3 1.2.1
A-5121-0012 SPA
2 6-axis DC motor kit 6 1.2.1
A-5121-0023 SPA
2 Revo kit 3 + Revo 1.2.1
A-5121-0018 SPA
2 DC motor connector kit 3 1.2.2
A-5121-0014 SPA
2 encoder interface card kit 4 1.2.3
A-5121-0015 SPA
2 4th axis interface card kit 1 1.2.4
A-5121-0016 Dual SPA
2 integration kit 6 1.2.5
A-5121-0028 SPA DC connector kit 3 1.2.6
1.2.1 SPA 2 DC motor kits
These kits contain all the necessary components to connect the SPA 2 to either the Renishaw UCC 2 or
UCC
lite controller and to a CMM fitted with brushed DC motors with a tacho or tacholess velocity
feedback system.
These kits contain the following components:
A-5121-0010
SPA
2
3-axis DC
A-5121-0012
SPA
2
6-axis DC
A-5121-0023
SPA
2
3-axis Revo
3-axis SPA 2 1- -
6-axis SPA 2 -1 1
DC motor connector I/F 3 6 3
Revo connector I/F - - 1
UCC 2 or UCC lite to SPA 2
comms cable
23 4
Emergency stop cable 1 1 1

System description 11
1.2.2 SPA 2 DC motor connector kit
This kit contains the motor output connection cards to permit three DC motors to be connected to the
SPA
2 unit. Normally these would be supplied with the SPA unit and do not need to be ordered separately,
unless you are converting an existing system.
1.2.3 SPA 2 encoder interface card kit
This kit contains the optional encoder interface card for the SPA 2 system, this permits connection of up to
4 encoder (digital) motor feedback systems.
NOTE: Each SPA
2 unit can only support one encoder interface card permitting:
•four encoder inputs on a 3 + 1 axis system (using 4th axis card)
•three encoder inputs on a 6 axis system
This kit contains the following components:
•1 off SPA
2 encoder interface card
•1 off internal connection loom
1.2.4 SPA 2 4th axis interface card kit
This kit contains the optional 4th axis interface card for the SPA 2 system. This permits connection of an
additional machine axis to the SPA
2 when using the UCC 2 controller.
NOTE: Each SPA
2 unit can only support one 4th axis interface card.
This kit contains the following components:
•1 off 4th axis interface card
•1 off internal connection loom
•1 off internal connection power loom
•4
th axis hardware mounting kit
•1 off mating motor connector for machine wiring

12 System description
1.2.5 Dual SPA 2 integration kit
This cable kit is designed to permit a high power solution for CMM installations where the power capacity
of a single SPA
2 will not address the requirements for the machine.
This system enables two SPA
2 units to be combined in a single system and configured to drive the CMM
installation (e.g. if required a single SPA
2 can power a single axis, or if in a dual drive configuration the
two dual axis motors by supplied from separate SPA
2 units and the other two axis be integrated such that
each SPA
2 drives two motors).
This kit contains the following component:
•1 off UCC
2 to dual SPA 2 emergency stop connection cable
1.2.6 SPA 2 DC connector kit
This kit has been designed to assist in the connection of either a UCC 2 or UCC lite and SPA 2 to a
machine installation.
This kit contains the following components:
•3 off 7W2 motor connectors including backshells to permit connection of the motor and analogue
tacho signals to the SPA
2
•1 off 9-way D connector including backshell to permit the connection of an external emergency stop
device to the Renishaw emergency stop chain

System description 13
1.2.7 SPA 2 and UCC 2 system layout
1.2.8 SPA 2 and UCC lite

14 Front panel design
2 Front panel description
The diagram below shows the front panel of the SPA 2 :
Key
1. Axes status LEDs
2. ESTOP LED
3. Air cooling fan inlet
2.1 Axes status LEDs
2.1.1 LED positions and axis link 3 axis / 6 axis
These LEDs indicate the status of the servo engagement within the SPA 2 unit as shown in the table
below:
Axis status LED colour System status
Off The SPA
2 has no power being applied to the system
Orange The servo system is active but not engaged for this axis
Green The servo system is engaged for this axis
Red There is a fault on this axis of the system
Status 1 indicates the status of axis 0 and 1, status 2 indicates the status of axis 2 and 3 (if fitted), status 3
indicates the status of axis 4 and 5 of a 6 axis system and status 4 indicates the status of axis 6.
2.2 ESTOP LED
This red LED indicates if the emergency stop system has been activated.
2.3 Air cooling fan inlet
The SPA 2 requires air cooling, the inlet being through this fan.
The airflow to the fan must not be obstructed. A minimum of 50 mm clearance in front of the fan is
required.

Rear panel description 15
3 Rear panel description
When the SPA 2 is delivered it will be in a configurable format and it will be necessary for the motor
connection cards to be fitted by the installer prior to applying power.
3.1 Rear panel – 3 axis system
Key Description Refer to
section Key Description Refer to section
1Power input and ON/OFF
switch 3.3.3 6Axis 1 motor input connector 3.3.2
2Axis 0-3 encoder tacho
input connectors 3.3.1 7Axis 0 motor input connector 3.3.2
3Axis 3 motor input
connector (optional) 3.3.2 8External emergency stop and reset connector 3.3.7
4
UCC
2 and UCC lite
communication link
connectors
3.3.5 9UCC
2 and UCC lite
emergency stop connector 3.3.4
5Axis 2 motor input
connector 3.3.2 10 Earth stud 3.3.6
1
2
3
4
567
8
9

16 Rear panel description
3.2 Rear panel – 6 axis system
Key Description Refer to
section Key Description Refer to section
1Axis 4 - 6 encoder tacho
input connector 3.3.1 8Axis 2 motor input connector 3.3.2
2Axis 6 motor input
connector 3.3.2 9Axis 1 motor input connector 3.3.2
3Axis 5 motor input
connector 3.3.2 10 Axis 0 motor input connector 3.3.2
4Axis 4 motor input
connector 3.3.2 11 External emergency stop and reset connector 3.3.7
5Power input 3.3.3 12 UCC
2 and UCC lite
emergency stop connector 3.3.4
6Axis 3 motor input
connector (optional) 3.3.2 13 Earth stud 3.3.6
7
UCC
2 and UCC lite
communication link
connector
3.3.5
3.3 Connections
3.3.1 Encoder card
The encoder interface card is a machine installer configurable option and, if installed, permits the
connection of digital encoders to the SPA
2 and UCC 2 or UCC lite system to provide motor feedback for
inclusion into the machines control loop.
For further details on these connections please refer to section 3.5.
5
2
6
7
8910
11
12
234
1
13

Rear panel description 17
3.3.2 Motor connector
These connections are used for the DC motor connector kit placement.
Axis position 3 is for the additional axis interface card that can be fitted by the machine installer to the
SPA
2 unit.
For further details on these connections please refer to section 3.4.
3.3.3 Mains connection
The SPA 2 is isolated by disconnecting the IEC mains connector on the rear panel. If any additional
means of isolation is required, it must be specified and fitted by the machine manufacturer or the installer
of the product.
The SPA
2 is powered from the a.c. mains supply via this IEC 320 connector. The electrical requirements
of the unit are as follows:
100 – 240 V ac +10%, -15% 47 – 63 Hz 650 W maximum
The SPA
2 is isolated from AC power by disconnection of the IEC mains connector on the rear panel. If
any additional means of isolation is required, it must be specified and fitted by the machine manufacturer
or the installer of the product.
The use of a suitable RCD (residual current device), for automatic disconnection in the event of an
insulation failure, is recommended. This should be sited within easy reach of the CMM operator and must
meet the requirements of IEC61010 and any national wiring regulations in the country of installation.
3.3.4 UCC 2 emergency stop connection
This 9-way D-connector links the emergency stop system between either the SPA 2 and the UCC lite or the
SPA
2 and the MCU1 joystick via the UCC 2 controller, the necessary cable for this connection is supplied
within the SPA
2 kit.
3.3.5 SPA-A/-B/-C/-D connections
These RJ45 connections permit the dedicated servo system communication link between the SPA 2 and
the UCC
2 or UCC lite controller for an effective control system.
NOTE: Connections A and B are used for a three or four axis SPA
2 system, connections C and D are
only used when a six or seven axis system is contained within a single box. Refer to section 6 for further
details.

18 Rear panel description
3.3.6 Earth stud
The SPA 2 has an earth stud to permit equipotential bonding of the CMM control system to that of the rest
of the CMM.
NOTE: When the SPA
2 is used with the UCC 2 or UCC lite controller the CMM frame should be bonded to
the SPA 2 earth stud and not the UCC 2 or UCC lite earth stud.
3.3.7 External emergency stop connection
This 9-pin D-type connection is designed to permit connection of external emergency stop devices to the
Renishaw controller emergency stop system.
Emergency stop devices must meet the requirements of IEC 60947-5-1 (low-voltage switchgear and
controlgear – part 5-1: control circuit devices and switching elements – electromechanical control circuit
devices) or UL1054 (standard for special-use switches).
The machine manufacturer or product installer must perform a risk assessment to determine the
requirements for emergency stopping and emergency switching off. The SPA
2 emergency stop safety
system is designed to achieve category 2 to standard EN954-1:1996 (ISO 13849-1). The risk assessment
should therefore have determined that a category 2 safety function is satisfactory.
There are three connection pins available on this connector. Please refer to the table below for their
functions:
Pin number Function
6 ESTOP A
7 ESTOP B
9 RESET B
Any additional emergency stop component that is fitted to this connector must have the following electrical
characteristics:
Emergency stop system voltage : 24 V
Emergency stop system current : 1 A
NOTE: If the emergency stop reset function is not required then it will be necessary to connect pins 5 and
9 so that when an emergency stop is removed from the system, it will automatically reset.
If no additional emergency stop devices are to be added to a UCC
2 or UCC lite controller system, connect
pins 6 and 7 to permit the MCU1 emergency stop switch to function.
It is strongly recommended that all connections to this connector be fitted by a competent technician or
engineer and that all wires should be sleeved. See also 6.4.2.
It should not be necessary to switch off the SPA
2 in an emergency but if a requirement is indicated by the
user’s risk assessment, emergency switching off for the complete machine must be implemented
externally to the SPA
2 .