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Installation Manual PA 8000 LW2 AN, 1, en_US

1. 70 Ree 69 RE NOISC aoaaa 20 ee de ee le nenn 89 RMAform 117 RMA number 116 S Safetydevices 17 Schematic Analog axes wiring 35 89 CNCreadyrelay 97 Digital VO wiring 95 uiii POWER AUTOMATION Digitalinput llle 45 Digital output llli selle 53 Output monitor 35 Powerokrelay 98 Safety connector 71 Serial port 65 SEIVICE an na Es ex ue FORE Rs 113 Serviceaccess 88 Service Addresses 113 Shield 4444 UU RERO PI n pio eee 89 SPACING ex Eee ze a RU CRURA wa ae RUN 87 Spare Pas erences a aai anne 115 Structural reguirements 86 T Technician 12 Temperature 78 86 Training PM 118 Troubleshooting 111 Type PI AUA Wa 23 U Unintendeduse 14 USB esis 00 ww ma s a AH MANANE 62 V VGA osos Ue o atat BOR aa ea RT ae ed 63 Virus protection 21 WwW Waste disposal 22 Wiring Analogazes 35 89 CNCreadyrelay 97 Digital lO e EE 95 Power ok rela 98 06 02 2015 126
2. For proper compensation calculate the actual values as shown in the following section Conductor Specific Cable length Voltage drop cross section resistance m at 100 mA V mm AWG 2 m 0 08 AWG 28 0 235 10 0 47 20 0 94 35 1 65 0 14 AWG 25 0 131 10 0 26 20 0 52 35 0 92 0 25 AWG 23 0 075 10 0 15 20 0 30 35 0 53 0 5 AWG 20 0 040 10 0 08 20 0 16 35 0 28 0 75 AWG 18 0 025 10 0 05 20 0 10 35 0 18 B Use the actual data obtained from the cable s technical specifications Double the cable s physical length This is necessary as there are two lines one line to the RMS 5 V and one line from the RMS grounding Calculate the voltage drop as follows Voltage drop V 2 x L x Cg x Pc L Cable length m C Cp Specific resistance per meter Q m P Pc Power consumption A vull 06 02 2015 93 Compensation General PA 8000 LW CNC control unit Installation Personnel m Skilled electrician 1 Install a power supply with adjustable output voltage to supply the RMS supply input This is a requirement for voltage drop compensation 2 Calculate the actual voltage drop between RMS power supply and RMS 3 Adjust the external RMS power supply to feed a slight overvoltage of 5 1 V to 5 5 V depending on the measured drop A measurement system contains integrated electronic components Relating to the current consumption Power Automation only indicates mean values Curre
3. VDE 0113 1 Emitted Interference Standard Title Requirement Value EN 55011 2009 Limits of radio disturbance interference voltage class B A1 2010 characteristics EN 55022 2006 interfering field strength class B A1 2007 EN Generic standards Emission emitted interference class B 61000 6 3 2011 standard for residential commer cial and light industrial environ ments ul 06 02 2015 80 PA 8000 LW CNC control unit Technical data Interference Resistance Stan Title Requirement Value dard IEC Immunity standard for industrial environments EN 6100 0 6 2 EN Electrostatic discharge immunity ESD air discharge 8 KV 6100 0 4 2 contact discharge 4 KV EN Radiated radio frequency electromagnetic HF irradiation 80 1000 MHz 10 V m 6100 field immunity 0 4 3 EN Electrical fast transient burst immunity power line burst 2KV 6100 0 4 4 signal data line burst 1 KV EN Surge immunity symmetric 1KV 6100 0 4 5 asymmetric 2KV EN Conducted disturbances immunity HF power input into the net 10V 6100 signal data line 0 4 6 EN Magnetic field immunity magnetic field 50 Hz 30 A m 6100 0 4 8 EN Voltage variations voltage drops and interrupts 6100 0 4 1 1 Net Overtones Standard Title Requirement Value EN 61000 3 2 2006 Limits for harmonic current all met emissions EN 61000 3 3 2008 4 6 Installatio
4. indicates a potentially hazardous situation which if e unavoidable may result in property damage utili 06 02 2015 7 POWER AUTOMATION Special Safety Notes Additional symbols and high lighting PA 8000 LW CNC control unit General information emphasizes useful hints and recommendations as well as information for efficient and trouble free opera tion The following symbols are used in connection with the safety notes to highlight particular dangers DANGER highlights hazards caused by electric current There is a danger of serious injury or death if the safety notes are not complied with The following symbols and highlights are used to distinguish instructions descriptions of results cross references and other ele ments inside this manual gt Highlights a step as part of a procedure of instructions gt Highlights a state or an automatic process as a result of an instruction Highlights single or unordered instructions and lists amp 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 gt Submenu gt 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 ul
5. Input OFF delay Isolation Input ON display External connection ul POWER AUTOMATION Value 24 27 3 70 10 5 8 6 6 18 1 2 2 5 25 65 Unit mA mw kO kO V max V min V max V min us us by opto coupler LED 1 terminal block for 8 inputs 06 02 2015 44 PA 8000 LW CNC control unit Design and function 3 4 1 3 Input schematic This figure shows how the inputs are realized on each 2416 EL module 0v Fig 22 Input equivalent schematic 1 Input nti 2 Logic 3 CNC superbus 4 Input n 3 4 1 4 Handwheel I O On each 2416 EL input output module two special inputs for hand wheel connections are provided The inputs are located on bit 23 and 24 of the third byte of each 2416 EL module They are designed for 24 V encoder handwheels meeting the following spec ifications Special use of bits 23 and 24 of the 3rd input byte When connecting handwheels to the described inputs only use 24 V encoder handwheels When no 24V handwheel is connected the two inputs can be used in the same way as the other inputs of the 2416 EL module vull 06 02 2015 45 POWER AUTOMATION Required Handwheel Specifications Behavior PA 8000 LW CNC control unit Design and function Property Value Unit Supply level 24 VDC Signal level 24 V DC Encoder signals Track A and B shifted 90 Only handwheels with A B signals can be used No Pulse Direction signals are supporte
6. figuration would have to be set up from scratch in case of data loss Pay attention to all instructions regarding data safety as given in this and the other installation manuals provided by Power Automation 2 10 1 File backup A backup solution is preinstalled and configured It is neccessary to select and activate the backup function inside the CNC Personnel P Qualified personnel Instructed person 1 Follow the instructions to properly configure the control unit for use with the intended machine For further information on the configuration see the corre sponding configuration manual Ensure that the configuration is functioning as intended Ensure that the machine data is saved regularly see Chapter 9 Service and return process on page 113 4 Keep a record of all modifications to the configuration done by the operator 5 Ensure that backups are updated manually in case of modifi cations to the configuration ul 06 02 2015 20 POWER AUTOMATION Initial State Initial State Instructions PA 8000 LW CNC control unit 2 10 2 Virus protection Automated regular anti virus scanning and manual scanning of files copied to the control unit are advised by Power Automation as needed An anti virus software solution is not preinstalled or configured and therefore falls into the user s responsibility Personnel m Qualified personnel 1 Install an antivirus software solution Power automatio
7. 2 10 2 Virus Drotechon nenn 21 2 10 3 Registry Drotechon nn 21 2 11 Environmental protechon 22 2 12 Labels nn nennen 22 3 Design and functton cc cee eeettee eee e ee teeeennnaeeees 25 31 e E 25 3 2 Brief ASP 4 cette eeeteeeeeteneteeaeees 26 3 3 Module 4AXLX teeter aiaia 27 3 3 1 Digital Inputs 28 3 3 1 1 Input interfaces ennnnnnnnneennennn 28 3 3 1 2 Input charachertstce nenn 29 TI 06 02 2015 3 PA 8000 LW CNC control unit Table of contents 3 3 1 3 Input schemate eee cee ceeeeceeeeeeeeeeeeeeeeeeeeeeees 30 3 3 1 4 RMS encoder wiring example 31 3 32 Digital Outputs enint hereto eens 32 3 3 2 1 OutputinterfaceS w wwwwwmmwwamwwamamawmwwa 32 3 3 2 2 Output characteristics neennn 33 3 3 2 3 Output schematic nennen 34 3 3 2 4 Output Montor eee eee eeeeeeeeeeeeneeneeees 35 3 3 2 5 Analog axes wiring evample 35 3 3 3 RMS power supphy wima 37 3 34 Module 4AXLX LEDs waamini 38 3 4 Module 2416 EL oceniani aiana 39 3 4 1 Digital INpuls ansaa 40 3 4 1 1 InputinterfaceS w wwwwwwwmmmwmmmmmmmmwa A0 3 4 4 2 Input charachertstce nenne 44 3 4 4 3 Input schemate nn nennen 45 3 4 1 4 Handwheel UC 45 3 4 2 Digital outputs nee 48 3 4 2 1 OutputinterfaceS wwwwwwmmewamamanwmawwmawara 48 3 4 2 2 Output characteristics nennn 52 3 4 2 3 Output schemane ne neneeseeeeee nn 53 3 4 3
8. PA 8000 LW CNC control unit Design and function o o o o o o o o o o o o o o O Fig 7 Encoder input connector X31 X32 X33 X34 Pins Fig 7 Pin 1 Pin 2 Pin 3 Pin 4 Pin 5 Pin 6 Pin 7 Pin 8 Pin 9 11 13 15 Pin 10 12 14 3 3 1 2 Input characteristics Property Interface type Track common mode range Max track input voltage Min track input voltage Track input impedance Max track frequency no filter Max count frequency no filter External connector vull POWER AUTOMATION RMS Input Function Track A Track A Track B Track B Track R Track R Probe input Probe ground Ground RMS 5 V RMS Value Unit RS 422 7 7 V 11 14 V 500 mV 150 Q 5 MHz 20 MHz 15 pin Sub D female axis All signals on the RMS inputs are referenced against RMS ground 06 02 2015 29 Probe Inputs RMS Input Equivalent Schematic PA 8000 LW CNC control unit Design and function Property Value Unit Max measurement input voltage 27 M Measurement input current at 24 V 7 mA Measurement input impedance 2200 Q Measurement operating voltage 5 V DC max OFF Measurement operating voltage ON 11 V DC min Measurement input ON delay 200 ns Measurement input OFF delay 300 ns Measurement isolation Opto coupler Interface type digital input 24 V Each measurement input is referenced against its measurement ground Probe wiring When the RMS input is used in an appl
9. 06 02 2015 8 POWER AUTOMATION Liability Copyright Material Warranty PA 8000 LW CNC control unit General information 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 BW disregarding this installation manual unintended use employment of untrained personnel unauthorized conversions unauthorized modifications to the software technical modifications use of unapproved spare parts use 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 t
10. 68 S perb s 2c cepe bep o Ye 72 Customer s responsibility 11 D Data safety IIIA 20 FIGS uox ae aaah ae ae Oo DEN 20 RREGISUY EE 21 Viruses ee ee 21 Decomissioning 119 Differentialinputs 36 90 Dimension sheet 79 Dismounting WAWA 119 JAA Pn 36 90 Dni 64 E EC Declaration of Conformity 121 Electrical Cabinet 86 Electrical connechon 2222 22 77 Electrician 12 Electronic components 22 119 EMCshield 89 Environmentalhazard 22 BU M ECL 111 Ethernet i idu an rate 61 F FanSisg 0454444444444 shares 87 NSS CP 20 G General specifications 77 Ground screW 62 H Rum une abe nm es 78 Input Analog neha need bh ed RES RE E 28 AA 40 Installation 85 Installation Guidelines 81 Instructed person 12 Intendeduse 13 IP protection class 86 K Keyboard aang ott Rer oe Beare 60 66 L Labels 4 2 0200 eg x s 22 LED Digital VO status 57 109 Module 4AXLX status 38 105 Module 2416 EL input 43 Module 2416 EL output 51 Limitation ofliability 9 M
11. Hinweise Important indications Au erhalb der Gew hrleistung wird eine TestpauschaE von 100 berechnet Out of warranty period a testing flat rate of 100 will be charged Bitte verpacken Sie die Ware angemessen Please pack the goods in an adequate way Steuerungen k nnen nur in Originalverpackung oder geichwertiger Verpackung angenommen werden Contrds can only be accepted in original enclosures or equivalent Power Automation haftet nicht f r Transportsch den Power Automation does not bear any liability for damages in transit Lieferungen werden nur FREI angenommen Deliveries are only accepted FREE DOMICIL Lieferungen ohne RMA Nummer werden nicht angenommen Deliveries without RMA Number will be rejected Die RMA Nummer muss am Karton au en gut sichtbar s n The RMA number must be visible well from outside the cardbox Des RMA Formular muss den Begleitdokumenten beigef gt sein The RMA form must be added to the accompanying documents Fig 63 RMA Form POWER AUTOMATION 06 02 2015 117 Return Training Courses PA 8000 LW CNC control unit Service and return process 1 Pack the goods properly Controls must be packed in original or equivalent packaging NOTICE Damages due to inadequate packaging Inadequate packaging may result in damages to the control unit This will void the material war ranty PA does not bear any liabilities for dam ages in transit 2 g
12. Missing RF noise suppres sion Uncontrolled operation Cause Overheating Missing power supply Undetermined Undetermined Undetermined Inactive CNC Ready signal PA 8000 LW CNC control unit Troubleshooting Solution Personnel Ensure that all requirements Skilled electrician regarding spacing within the cabinet are met Chapter 5 2 Mounting the control unit in a cabinet on page 87 Ensure that the ambient tempera ture is within the specified limits amp Chapter 4 3 Operating condi tions on page 78 Ensure that none of the vents are blocked Check visually aurally if the fans are working If not contact Power Automation Check if the power supply wiring is Skilled electrician set up correctly Ensure that the external main power supply is working Return the control unit to Instructed person Power Automation for repair Follow the instructions given in amp Chapter 9 3 Return policy and procedure on page 115 Contact Power Automation in case Skilled electrician of malfunctions relating to the con trol unit s startup and date time set tings Do not open the casing or replace the battery manually Please contact the Power Automa tion service see 6 Chapter 9 Service and return process on page 113 Check if the noise suppression com Skilled electrician ponents are connected directly at the noise source Check if the power and signal line
13. Power Gonpnechon 54 3 4 4 Module 2416 EL LEDe errereen 57 3 5 PC eonnechoare A 58 3 0 Safety MBU aa 68 3 6 1 Safety connector specification 68 3 6 2 Safety connector schematic me 71 3 7 X20 PA USB software dongle connector 71 3 8 PAMIO interface superbus 72 3 8 4 PAMIO boxes and modules ennen 73 4 Technical data 77 4 1 General spechficatonsg eeen eeren 77 4 2 Connechonvalues RR 77 4 3 Operating condittons eect eee eeettteeeeeeeeaee 78 4 4 Dimension heet 79 4 5 Electromagnetic compatibility 80 4 6 Installation guidelineS wwmmmmmmeaa 81 5 Installation einen rh en 85 TI 06 02 2015 4 PA 8000 LW CNC control unit Table of contents 5 1 Prerequisites and preparations 85 5 1 1 General reourements Rn nennen 85 5 1 2 Electrical cabinet structural requirements 86 5 1 3 Cabinet temperatre aneen rrenen nenna 86 5 2 Mounting the control unit in a cabinet 87 5 3 Installing analog axyes cteeeee seeren 89 5 3 1 Analog axes wiring evample seen 89 5 3 2 RMS encoder wiring example 91 5 3 3 Setting up RMS supply voltage drop compensa iM X 92 5 4 Installing digital WC 94 5 4 1 Wiring example for 2416EL modules 95 5 5 Wiring for machine satety ern ennn nn 96 5 5 1 Wiring
14. accounted for when inductive loads like for example relays are connected When connecting inductive loads to outputs ensure that a recovery diode is connected in parallel as shown in the sche matic pos 9 il 06 02 2015 95 POWER AUTOMATION Safety Emergency Stop Interlocking PA 8000 LW CNC control unit Installation 5 5 Wiring for machine safety DANGER Uncontrolled operation due to improper installa tion and configuration The control unit s safety relay must be properly inte grated into the CNC machine emergency stop chain Improper wiring and configuration of the safety relay may result in uncontrolled operation of the CNC machine and in consequence may lead to irreversible personal injuries or death Only operate the CNC machine if the safety relay has been properly integrated into the machine emergency stop chain Only let qualified personnel Chapter 2 2 1 Qualifications on page 12 set up the emergency stop chain For information on safety devices integrated into the machine see the manual supplied by the machine s manufacturer Wm If in doubt regarding the configuration contact the manufac turers of the control unit and the CNC machine For information on the safety connector s specifications and purpose see Chapter 3 6 Safety connector on page 68 and Chapter 2 8 Machine safety on page 17 5 5 1 Wiring example for CNC ready relay DANGER Injuries due to unco
15. can be expected The packaging has the function of protecting the individual compo nents against damage corrosion etc until they are finally fitted The packaging material must therefore not be damaged and should only be removed just before assembly is to take place If there is no returns agreement for the packaging separate mate rials according to type and size and direct to further use or recy cling Environmental damage caused by incorrect waste disposal Packaging materials are valuable raw materials and can be sensibly reconditioned and recycled in many cases NOTICE e vull 06 02 2015 99 POWER AUTOMATION Storage Of Packages Storage Conditions Improper Storage PA 8000 LW CNC control unit Transport packaging and storage Dispose of packaging materials environmentally compliant W Follow the locally valid waste disposal regulations If necessary employ a special waste disposal company to dispose of pack aging material 6 3 Storage Store packages under the following conditions Do not store outdoors Store in a dry and dust free environment Do not subject to aggressive media Protect against direct sunlight Avoid mechanical vibrations For storage periods longer than 3 months check the general condition of all parts and packaging regularly m If necessary renew the packaging Property Value Unit Temperatures 20 60 C 4 140 F Humidity non condensing lt 80 Accelerati
16. control unit upon delivery are listed in the following chapters ul 06 02 2015 26 Overview PA 8000 LW CNC control unit Design and function 3 3 Module 4AXLX Not included in all models This module and its interfaces are only included in 54 models with analog axes The module 4AXLX provides an analog interface for up to four axes each provided with a separate RMS input The module includes 4 status LEDs z 00000 N D BH O O d CO QOOOOOO Fig 5 Module 4AXLX Pos Label No Function 1 X31 Measurement input 1 axis 2 X32 Measurement input 2 axis 3 X37 Analog out axis 1 to 4 4 X35 Power supply input for RMS encoders 5 X34 Measurement input 4 axis X33 Measurement input 3 axis 7 Status LEDs utili 06 02 2015 27 POWER AUTOMATION Connectors PA 8000 LW CNC control unit Design and function 3 3 1 Digital Inputs 3 3 1 1 Input interfaces Fig 6 Input interfaces Pos Label No 1 X31 2 X32 4 X35 5 X33 6 X34 POWER AUTOMATION OOOO O00000 Function Connector 1st axis Connector 2nd axis RMS supply Connector 3rd axis Connector 4th axis 00000 WS B D BH Connector 15 pin sub D female 15 pin sub D female 2 pole connector 15 pin sub D female 15 pin sub D female 06 02 2015 28 Pin Assignment RMS Inputs
17. executed in the same way as when the Emergency Stop button is pushed Properly integrate the CNC ready relay into the machine s emergency stop chain All safety related actions must ensure that at least all axes movements and spindle rotation or beam power are stopped as quickly as possible W Refer to the drive manufacturer manual to determine the best way of stopping movements and other dangerous power on the machine Wm If drive capability does not exist the use of external braking resistors might be necessary Unbalanced axes have to execute with the mechanical brake The contacts for CNC Ready and Power OK are available on connector X19 see 5 Chapter 5 5 Wiring for machine safety on page 96 ul 06 02 2015 18 POWER AUTOMATION Preventive Measures In Case Of Accidents PA 8000 LW CNC control unit 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 Use the contacts of the Power ok relay to switch off the main power supply of the control unit to avoid any unexpected dam ages to the control unit The contacts for CNC Ready and Power OK are available on connector X19 see Chapter 5 5 Wiring for machine safety on page 96 When an external 5V power supply R
18. following qualifications are specified for different areas of activity listed in the installation manual Instructed person was instructed by the operating company about the duties assigned to her him and the possible dangers that may arise from inappropriate conduct Qualified personnel are able to carry out assigned work and to recognize possible dan gers due to professional training knowledge and experience as well as profound knowledge of applicable regulations Skilled electrician A skilled electrician is able to carry out assigned work and to recognize and avoid possible dangers due to professional training knowledge and experience as well as profound knowledge of applicable regulations The skilled electrician has been trained specially for his working environment and he has profound knowledge of relevant standards and regulations 2 2 2 Unauthorized persons WARNING Danger for unauthorized persons Unauthorized persons who do not meet the require ments described in this installation manual are not aware of the dangers in the working area Keep unauthorized persons away from the working area Ifin doubt address such persons and ask them to leave the working area Interrupt your work as long as unauthorized per sons are in the working area ul 06 02 2015 12 POWER AUTOMATION Intended Use Dangers PA 8000 LW CNC control unit Only persons who are expected to perform their tasks reli
19. oo 0 000 0 k 4d A X UM kl o dt Gk vA Fig 62 Status LEDs 1 Status 2 Access 3 Bustest 4 Monitor The LEDs states are assigned the following status messages iul 06 02 2015 109 POWER AUTOMATION PA 8000 LW CNC control unit Troubleshooting LED Monitor 1 LED state Off OR Quick flash OR OR AND LED Bustest 2 LED state Off On LED Access 3 LED state Off On LED Status 4 LED state Off OR Slow flash Quick flash On uiii POWER AUTOMATION Module status Error 1 The ambient temperature is above 60 C 140 F and all outputs are disabled by the onboard logic Error 2 The watchdog is re triggered but the 24 V output supply has been interrupted for more than 60 seconds In this case the onboard logic switches off the corresponding 24 V outputs Warning 1 The ambient temperature is above 55 C 131 F Warning 2 The watchdog is re triggered but the 24 V output supply has been interrupted for more than 15 seconds Warning 3 Outputs are overloaded for more than 15s The 24 V output supply is correct There is no temperature error Module status Default Bustest between control unit and the last PAMIO module is active Module status Default Access to this module Module status No power supply 24 V Hardware error The module is not configured The module is configured but the outputs are disa bled because the watchdog is no
20. or parts and tools placed on top of each other are hazard sources Jf components have been removed ensure that they are properly mounted re install all mounting elements and comply with standard screw tight ening torque specifications 7T 2 Maintenance schedule Maintenance tasks that are required for optimum and trouble free operation are described in the sections below If increased dust pollution is detected at regular inspections do the following m Shorten the required maintenance intervals to correspond with the actual signs of pollution Check whether the cabinet still adheres to the requirements of its protection class IP For questions on maintenance work contact Power Automation Service Chapter 9 1 Service on page 113 ll 06 02 2015 101 POWER AUTOMATION Schedule Interval Once a year PA 8000 LW CNC control unit Maintenance Maintenance work Personnel Visual check whether all fan exhausts are clean and the fans are Instructed person properly working If required clean the fan exhausts with a dry cloth or if necessary use a vacuum Cleaner Check whether all fans inside the electrical cabinet are operating Instructed person accordingly m Use a sheet of paper and keep it in front of the fans inside the electical cabinet to check if it is moving Check whether all interface cables are installed properly in their Instructed person respective sockets Before re plugging lo
21. pin 5 5 input bit pin 5 13 input bit pin 5 21 input bit pin 6 6 input bit pin 6 14 input bit pin 6 22 input bit pin 7 7 input bit pin 7 15 input bit pin 7 23 input bit pin8 8 input bit pin 8 16 input bit pin 8 24 input bit POWER AUTOMATION 06 02 2015 42 PA 8000 LW CNC control unit Design and function Input Status LEDs Hun dn 00 O0 OD D on on no on on um ole 355555 A t P S oo oo un oo oo oo oo on 00 00 Hn Hn dn Hn oo on v 00 O0 O0 O0 O0 O0 nn ur 1 8 Fig 21 Input status LEDs The input LEDs are located in the circuit s input path and therefore show the real state of the 24 V inputs A HIGH input signal causes the corresponding LED to turn ON A LOW input signal causes the corresponding LED to turn OFF all 06 02 2015 43 POWER AUTOMATION PA 8000 LW CNC control unit Design and function 3 4 1 2 Input characteristics Property Number of inputs Maximum input DC voltage Input current at 24 V 5 V typical Power dissipation at 24 V 5 V per input Input impedance 24 V input Input impedance 5 V input operating DC voltage OFF 24 V input operating DC voltage ON 24 V input operating DC voltage OFF 5 V input operating DC voltage ON 5 V input Input ON delay
22. software dongle vull 06 02 2015 71 POWER AUTOMATION Overview Cable Specification PA 8000 LW CNC control unit Design and function 3 8 PAMIO interface superbus The control unit s interfaces are extendable via the Superbus inter face A variety of I O and axes extension modules PAMIO can be connected to the connector 7000000000000000001 3300000000000000001 00000000000000000 Ill SS fa ete up ed Fig 47 Superbus Connector For further information see amp Chapter 3 8 1 PAMIO boxes and modules on page 73 or the PA Accessories installation manual The interface cable required to connect PAMIO modules can be ordered from Power Automation NOTICE All cables connected to the control unit are intended e for stationary use only The cable shield is connected to both connector cas m ings ulli 06 02 2015 72 POWER AUTOMATION Basic Description PA 8000 LW CNC control unit Design and function 3 8 1 PAMIO boxes and modules 4ENC4A 4ENC4A PWM es 2416 2416 I Fig 48 PAMIO superbus schematic control unit PA superbus connection PAMIO box with two analog axes modules PA superbus connection termination plug max chain length 14 PAMIO boxes 30 m 98 ft A PAMIO box consists of its housing the PA superbus input and output connectors as wel
23. 0 dn dn 00 un un un on on dn oo e 0 0 20 89 0 0 I A A A A A A N A Fig 26 Pin assignment Byte 1 24 V output Byte 2 24 V output pin 1 1 output bit pin 1 9 output bit pin2 2 output bit pin2 10 output bit pin3 3 output bit pin3 11 output bit pin 4 4 output bit pin 4 12 output bit pin 5 5 output bit pin 5 13 output bit pin 6 6 output bit pin 6 14 output bit pin 7 7 output bit pin 7 15 output bit pin 8 8 output bit pin 8 16 output bit uiii 06 02 2015 50 POWER AUTOMATION PA 8000 LW CNC control unit Design and function Output Status LEDs 1 Don 00 HH 00 HE EHI I un 00 00 DD da 00 00 OO un 00 um unm O0 O0 00 00 oo oe oO un 00 DD 00 OD 00 00 00 DD DD oo op 0Oldo 0 0 060 8 090 A nAn Annn A Al 01020 80001 oe 00 0 0 AK A A A A lk A M o4 oi o Fig 27 Output status LEDs The output LEDs are located directly in the output path and there fore show the real state of the 24 V outputs Ifthe outputs are ON the corresponding LEDs are ON m Ifthe outputs are OFF the corresponding LEDs are OFF E In case of a short circuit the output LED is OFF even if the output is active 06 02 2015 51 PA 8000 LW CNC control unit Design and function 3 4 2 2 Output characteristics Property Value Unit Number of outputs
24. 16 Max continuous output DC per pin 1A Max total continuous 4 A output current per byte Power dissipation 0 20 W per pin at 24 V for 0 5 A Power dissipation 0 45 W per pin at 24 V for 1 5 A Output ON delay typical 100 us Output OFF delay typical 200 us Watchdog max 64 ms Short circuit output DC 0 7 2 5 A Delay time current limitation max 2 ms Isolation by opto coupler Output ON display LED External connection 1 terminal block for 8 Ge puts All outputs are referenced against 0 V power supply connector X30 pin 3 ul 06 02 2015 52 PA 8000 LW CNC control unit Design and function 3 4 2 3 Output schematic This figure shows how the outputs are realized on each 2416 EL module 24 VDC 0v Fig 28 Module 2416 EL output schematic 1 Supplied from PCI Superbus board 2 Output supply input 15 12 5 Yo 3 Output n 1 4 Outputn 5 Logic 6 Internal serial bus till 06 02 2015 53 PA 8000 LW CNC control unit Design and function 3 4 3 Power connection Overview tbe 5 e 0 1 V Y T V 7 yN roy SII E 0 6 o0o o0 0 0 0 0 jo 000 0 020 nr un uu on on du on on 00 00 Hn uu un un un D I e ojojo o On Hn 00 oo 00 00 00 dm oo oo oo un OI eieiei ele J LIH 00 00 oo 00 oo oo OO OD 00 Hu 00 oo oo oo D Lelelejelele le
25. 2 pos 4 Ensure that the built in PA keyboard cable Fig 32 pos 2 is connected to this PS2 connector Fig 32 pos 18 Supported panels m CP 121 m CP 121T Property Value Pins 6 Connector type PS2 mini DIN Gender female ul 06 02 2015 66 POWER AUTOMATION PA 8000 LW CNC control unit Design and function Pin Assignment Fig 32 1 data 2 3 GND 4 power supply 5V 5 clock 6 PS2 Connector For Mouse 3 The control unit is equipped with a PS2 connector that can be used for a standard mouse connection C qp 1 2 9 9 5 6 EL Jo Fig 42 Mouse connector PS2 mini Property Value Pins 6 Connector type PS2 mini DIN Gender female Pin Assignment Fig 32 1 data 2 3 GND 4 power supply 5V 5 clock 6 utili 06 02 2015 67 POWER AUTOMAT Overview Purpose Wiring Specification PA 8000 LW CNC control unit Design and function 3 6 Safety connector Fig 43 X19 Safety Connector All PA 8000 LW models have two relays for safety functions con nector X19 see amp Overview on page 58 pos 12 The connector provides both a normally closed and a 3 normally open contact for each relay For information regarding the safety connector s purpose and wiring examples see Chapter 2 8 Machine safety on page 17 and Chapter 5 5 Wiring for m
26. 9 299 Commercial Register Stuttgart Deutsche Bank AG Ludwigsburg Postbank AG Stuttgart Gottlieb Daimler Str 17 2 E Mail info powerautomation com HRB 205597 Account No 027745900 Account No 48816705 D 74385 Pleidelsheim Internet www powerautomation com Bank Code 604 700 82 Bank Code 600 100 70 VAT Ident No IBAN DE54604700820027745900 IBAN DE40600100700048816705 General Manager DE 811563976 BIC DEUTDESS604 BIC PBNKDEFF Marc Hilpert Jan Hilpert Tax number 71390 00450 Fig 64 EC Declaration of Conformity ill 06 02 2015 122 POWER AUTOMATION PA 8000 LW CNC control unit Proof of change 12 Proof of change Proof Of Change Version Change Date 1 Original Version 06 27 2013 2 Revised Version 11 28 2014 Chapter 9 11 and 12 included vull 06 02 2015 123 POWER AUTOMATION PA 8000 LW CNC control unit Proof of change alll 06 02 2015 124 POWER AUTOMATION PA 8000 LW CNC control unit 13 Index A Acceleration 78 Air circulation AI cee ee ee WA 87 Analogakes 27 WIN WA ee 35 89 B Bai IA 20 Batteries 22 C CNC machine 17 Connectionvalues 77 Connectors Analoginput 28 Analogoutput 32 Nii AA AUIWA 40 Digital output 48 PCinterfaces 58 Safetyrelays
27. MS is nec essary to supply incremental measuring systems use the corresponding entry in the control unit s drive configuration file DriveCfg ini to acti vate the monitoring of the correct range of these 5 V When the monitoring is activated an error on this power supply will cause the Power ok relay to drop 2 9 Conduct in a dangerous situation and in case of accidents m Stay informed about locations of first aid equipment first aid kit covers etc and fire extinguisher at the site of installation Instruct personnel about accident reporting first aid and rescue facilities at the site of installation Disconnect power supply immediately Initiate first aid measures Inform responsible persons at the site Call for rescue service if applicable vull 06 02 2015 19 POWER AUTOMATION General Information Initial State Instructions PA 8000 LW CNC control unit 2 10 Data safety To ensure the ability to restore critical data in case of control unit or storage malfunctions internal and external off site backup copies of all files that are critical to proper machine function must be cre ated regularly and kept in a secure environment To minimize the chance of data loss installation of virus and reg istry protection is recommended CAUTION Extended system outage in case of data loss If backup copies of critical control unit data are not cre ated regularly and kept securely the control unit con
28. Maintenance 101 Personnel 101 Schedule 101 Malfunction 111 Material Warrantyseals 24 Mounting orientation 87 le iure RE UE E nue inea ut 67 N Non differential inputs 36 90 O Operating conditions 78 Operating system 24 Orientation 87 Output Analog IIIA 32 Digital 22a anne 48 RMSpower 37 P PCconnectors 58 Personal protective gear 14 Personnel 12 Maintenance 101 06 02 2015 125 PA 8000 LW CNC control unit Pictures in the manual en 7 Pins Analoginput 29 Digital input IAA 42 Digital output 50 RMSpower 37 Safety connector 69 Powersupply AWA 59 Product key Operating System 24 Proof of change 123 Protectiveearth 62 St EE 66 67 Q Qualification electrician IA aidaa a eee 12 reguirements 12 technician 12 Unauthorized person 12 Qualified personnel 12 R Registry protection 21 Relay CNCReady
29. NC control unit Installation 5 2 Mounting the control unit in a cabinet H ir nie Lii Co i D ei a JE 52 gt 2244 59 6 5 319 2 52 tee R2 5 amp 2 s 29 9 _ I sy R3 5 e 14 8 ni i EN Fig 51 Mounting orientation Always mount the control unit with the PC connector side facing up Most of the CNC connectors axes and inputs outputs are located on the front side W Ensure that there is clearance of at least 50 mm 2 inches to allow accessibility to the connectors 50 mm 2 Lk E Yet e o SS Fig 52 Front spacing All PC connectors PS2 VGA USB etc and some CNC connectors X13 X19 and the grounding screw are located on the top side All PC connectors PS2 VGA USB etc and some CNC connectors X13 X19 are located on the top side Il 06 02 2015 87 POWER AUTOMATION PA 8000 LW CNC control unit Installation Ensure that there is clearance of at least 100 mm 4 inches to allow accessibility to the connectors The PC connectors are shown as examples and can vary from case to case On the bottom side of the control unit opposite to PC connectors is a grid for the air inlet Ensure that there is clearance of 40 mm 1 6 inches at min imum for air circulation The cabinet fan provides i
30. PA 8000 LW CNC control unit POWER AUTOMATION Power Automation GmbH CNC Automatisierungstechnik Gottlieb Daimler Str 17 2 74385 Pleidelsheim Germany Telephone 49 7144 899 0 Fax 49 7144 899 299 email info powerautomation com Internet www powerautomation com Original installation instructions Variante PA 8000 LW AN PA 8000E LW AN Version 2 0 2014 Power Automation GmbH 2 06 02 2015 PA 8000 LW CNC control unit Table of contents Table of contents 1 General information 4444444enennennnnneenn een 7 1 1 Information on this manuel 7 1 2 Explanation of symbols esnnnnneeeennenn 7 1 3 Limitation of liability 9 E See de 9 1 5 Warranty Iems eee 9 1 6 Customer senice ccc cee eeeeeeeeeeceeeeeeeeeeeeeeeees 10 Tq S ee NEE 10 MENTIS A 11 2 1 Customer s responslbiltvy een 11 2 2 Personnel reouirements een 12 2 2 4 Oualficatons cece cece eee ceeeeteeeeeeeeeeeeeeeeeeeneeee 12 2 2 2 Unauthorized persons sss 12 2 3 Intended use 13 2 4 Unintended use 14 2 5 Personal protective gear 14 2 6 Specific dangerg AI 15 2 1 Safety devices ee rs dd dd bed 17 2 8 Machine safety lt ww waamamanananwanaaanzananazwananazuzuwa 17 2 8 4 CNC ready signal Emergency stop interlocking 18 2 8 2 Power ok sonal 19 2 9 Conduct in a dangerous situation and in case of ruebficm EE 19 2 10 Data safely ien ae 20 2 10 1 File backup nn 20
31. PPLY JO access ov 5V JO sustest JO wonrron JO ax ox Ol axzo Sa Kaze JO axa ox INPUT O Power ox O n Le x34 AXIS 4 0000000 2000000 0000000 o o o o RMS INPUT ua an on nm pn mo wa on amp Fig 4 Modules O Ready Oo MODULE 1 1 PC connectors all models 2 Module 2416EL 1 all models 3 Module 2416EL 2 all models 4 Module 4AXLX models with analog axes only ailll 06 02 2015 25 POWER AUTOMATION Model Configurations Model PA 8000 LW SDI PA 8000 LW AN PA 8000 LW SDI AN Description SDI axes only Analog axes only SDI and analog axes PA 8000 LW CNC control unit Design and function The PA 8000 LW is shipped in three different models containing the following modules and interfaces PC con SDI Module 2416EL Module 4AXLX nectors included included 2 included not included included not included 2 included included included included 2 included included 3 2 Brief description The PA8000 LW is an open architecture CNC control unit providing a variety of interfaces to connect machine tools This control unit can be extended via a superbus interface and external input output modules PAMIO to connect a wide range of machine tools The Interfaces and modules included in this
32. S data 0 19 TMDS data 0 5 shield 20 TMDS data 5 21 TMDS data 5 22 TMDS clock shield 23 TMDS clock 24 TMDS clock ll 06 02 2015 64 PA 8000 LW CNC control unit Design and function Pin Assignment Fig 39 C1 RED C2 GREEN C3 BLUE CA SYNC C5 GND X5 Serial Port Connector 7 8 17 Fig 40 Serial port connector Sub D 9 Property Value Pins 9 Connector type sub D Gender male Signal type RS232 Maximum cable length 15 m 49 Pin Assignment Fig 40 1 DCD input 2 RXD input 3 TXD output 4 DTR output 5 GND 6 DSR input 7 RTS output 8 CTS input 9 RI The optional COM2 X5b and COMS X5c have the same layout and the same characteristics as serial port COM1 X5 06 02 2015 65 X3 PS2 Connector For Keyboard 4 PA 8000 LW CNC control unit Design and function The control unit is equipped with a PS2 connector that can be used for a standard keyboard connection 1 2 9 9 9 5 6 EL Jo Fig 41 Keyboard connector PS2 mini Keyboard installation This connector must be used when no operator s panel 5 js installed This connector can be used to connect an additional secondary keyboard Connection of PA operator s panel When connecting a PA operator s panel with keyboard 5 the following requirements have to be met Ensure that the panel s keyboard is connected to the CNC operator s keyboard connector Fig 3
33. ably are permitted as personnel Persons whose reaction capability is impaired e g through drugs alcohol or medication are not per mitted amp When selecting personnel ensure that the personnel can work with the control unit in terms of technical and content aspects 2 3 Intended use The control unit is exclusively intended and built for the use described in this installation manual The control unit is to be used exclusively to control CNC machines of a supported number of axes which are in accordance with the types cleared by Power Automation Prerequisite for the intended use of the control unit is proper configuration as described in the installation manuals provided by Power Automation WARNING Beware of unintended use Any use exceeding the scope of intended use and or different application of the control unit can result in hazardous situations Operate the control unit as intended only Observe all instructions in this installation manual Observe the permissible ambient conditions and electromagnetic compatibility mentioned in the technical data Claims of any kind for damage resulting from unintended use are void The operator is solely responsible for all damage resulting from unintended use vull 06 02 2015 13 POWER AUTOMATION Unintended Use PA 8000 LW CNC control unit 2 4 Unintended use WARNING Beware of unintended use In particular avoid using the control unit for th
34. achine safety on page 96 3 6 1 Safety connector specification Property Value Form factor 6 pin removable screw plug Maximum contact load 1A 24V DC I il 06 02 2015 68 POWER AUTOMATION Pin Assignment Relay 1 Power ok PA 8000 LW CNC control unit Design and function f EDI d immi 1 RITU 6 Kahi Fig 44 Safety connector pins Pin Fig 44 Assignment 1 2 3 4 5 6 Power ok common Power ok normally closed Power ok normally open CNC ready common CNC ready normally closed CNC ready normally open The first relay is called Power ok and switches when the following conditions are met The power supply voltages are in operating range The operating temperature is below 60 C 140 F Logic AND AND AND POWER AUTOMATION Condition Result 5VOK Ready relay active 12V OK 12V OK T 60 C 140 F NOTICE Damage to the control unit Voltage faults and or temperatures above the allowed specification can cause damage to the control unit Properly wire the Power ok relay to protect the con trol unit from damaging voltages and temperatures 06 02 2015 69 Relay 2 CNC ready PA 8000 LW CNC control unit Design and function The second relay is called CNC ready and switches when the fol lowing conditions are met The control unit is ready when The watchdog is re triggered The software is monitored and work
35. ack A and B has occurred Axis is connected and no wire break has been detected default 06 02 2015 106 PA 8000 LW CNC control unit Troubleshooting LED Axis 2 6 LED state Off OR Flashing On LED Axis 3 7 LED state Off OR Flashing On LED Axis 4 8 LED state Off OR Flashing On LED Power OK 9 LED state Off OR AND AND POWER AUTOMATION Module status Axis is not connected Axis is connected and an encoder wire break has been detected Axis is connected and a wrong sequence of signals on track A and B has occurred Axis is connected and no wire break has been detected default Module status Axis is not connected Axis is connected and an encoder wire break has been detected Axis is connected and a wrong sequence of signals on track A and B has occurred Axis is connected and no wire break has been detected default Module status Axis is not connected Axis is connected and an encoder wire break has been detected Axis is connected and a wrong sequence of signals on track A and B has occurred Axis is connected and no wire break has been detected default Module status The power supply voltage for the onboard logic is outside its tolerances The ambient temperature is above 60 C 140 F The power supply voltage for the onboard logic is in rated range The 15 V supply voltage for the analog UO func tions is in rated range Th
36. arranty Always contact Power Automation if extensions repairs or modifications are required see Chapter 9 Service and return process on page 113 uiii 06 02 2015 24 POWER AUTOMATION Top View PA 8000 LW CNC control unit Design and function 3 Design and function 3 1 Overview D MMM fla th flat def dal LIA Cc SSS uU Oo eT _ 3 V lt 2 X3IKEYB o E o CIT e TA N XSbICOM2 o o 2 amp dl ae fess X Syy oO o 293 M dd 529 EIS 992 Wa za amp 5 Mess amp 989 Xx d IL Set A m Wl e HE ES d X21 PA SDI INTERFACE x40 status B Access B BUSTEST B MONITOR B un un on on an un oo oo o 3 c ulii POWER AUTOMATION B 24V_OB1 E B S S D um seg ov Ng vom og2 BYTE 2 24V_0B2 X30 go oo oo 9000000 00000000 o o o o o o o 00000000 O 24V SUPPLY B B 8 yao swus B B our access B E susresr B B wous B B H REF X37 BE ANALOG OUT DUT REF E o onnnsns ell 1 OUT x35 RMS Ol status SU
37. assembly install all mounting elements and comply with screw tightening torques vull 06 02 2015 103 POWER AUTOMATION In Case Of Faults Overview PA 8000 LW CNC control unit Troubleshooting The following general rules apply Personnel El Protective equipment Qualified personnel Ground strap ESD safety shoes ESD safety pad ESD clothing Protective glasses Ear protection Antistatic gloves 1 In the event of faults that pose immediate danger to man or machine activate the emergency shutoff function immedi ately Determine the cause of the fault Disconnect the control unit from power supply gt Immediately inform the person in charge of the equipment where the fault is located 5 Depending on the type of fault eliminate the fault or have it eliminated by an authorized specialist 8 2 Malfunction indicators The following components indicate malfunctions or improper con figuration of the control unit Module 4AXLX LEDs 2416 EL LEDs POWER AUTOMATION Description The LEDs of the 4AXLX module indicate operating states and malfunctions regarding analog axes inputs and outputs The LEDs of the 2416EL module indicate operating states and malfunctions regarding digital inputs and out puts 06 02 2015 104 PA 8000 LW CNC control unit Troubleshooting 8 2 1 Module 4AXLX LEDs Overview The 4AXLX m
38. ated by him correspond to the current status of regulations and standards Whenever changes in regulations and standards occur instruc tions must be adapted accordingly W The customer must clearly specify the responsibilities for installation operation maintenance and cleaning W The 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 W The customer must make sure that the maintenance intervals specified in these operating instructions are complied with W The customer must regularly check all safety features for func tion and completeness The customer must supply his personnel with the necessary protective equipment vull 06 02 2015 11 POWER AUTOMATION PA 8000 LW CNC control unit 2 2 Personnel requirements 2 2 4 Qualifications WARNING Danger of injury in case of insufficient qualifica tion Improper operation can lead to severe personal inju ries and or material damage Only those persons who have been specified in the corresponding chapters of this installation manual should be entrusted with the listed types of work Employ certified experts if in doubt The
39. cost effective way to solve problems On Site If neccessary our service engineers will visit you to help you solve your problems on site Our engineers are trained continuously to be always up to date Thereby you always can expect the best support Due to our service centers worldwide our service staff can be on site normally within 24 hours at the latest 9 1 1 Service addresses Power Automation GmbH Headquarter Gottlieb Daimler Strasse 17 2 D 74385 Pleidelsheim Tel 49 7144 899 0 Fax 49 7144 899 299 service powerautomation com 06 02 2015 113 POWER AUTOMATION PA 8000 LW CNC control unit Service and return process Power Automation America Inc 8601 Jameel Road Suite 140 Houston Texas 77040 USA Tel 1 713 263 9400 Fax 1 281 715 2500 sales america powerautomation com Power Automation Office Turkey Kustepe Mah Mecidiyekoy Yolu Cad Trump Towers No 12 Kule 2 K 18 Daire no 3211022839 Sisli Istanbul Turkey Tel 90 212 306 3280 Fax 90 212 306 3101 sales turkey powerautomation com Shenzhen Double CNC Tech Co Ltd 8th Floor WeiXinDa Building Bao Min Road 2 Xi Xiang Town Bao an District Shenzhen Guangdong PR China Power Automation France SARL Cit de la Photonique B timent Pl ione 11 avenue Canteranne 33600 Pessac France Tel 33 559 4010 50 Fax 33 559 4010 59 pa france powerautomation com ul 06 02 2015 114 Spare Parts Policy PA 8000 LW CNC cont
40. ctor for mouse 12 Safety Connector X19 female 13 Ethernet connector RJ 45 4 Connector CNC operator s keyboard X3 14 USB 2 0 connectors 5 USB 2 0 connectors optional 15 DVI Connector X4 6 USB 2 0 connectors optional 16 VGA connector Sub D 15 pin female X4 7 Serial port connector COM1 Sub D 9 pin male 17 Serial port connector COM1 Sub D 9 pin male X5c X5a 8 Serial port connector COM1 Sub D 9 pin male 18 PS2 6 pin mini DIN connector for keyboard X5b female 9 PA SDI Interface X21 Hardware configuration subject to change Due to varying configurations of the mainboards pro 5 duced by the suppliers the number and positions of USB serial and parallel ports may differ from the example provided in this installation manual For information on the applicable number of interfaces see the specification provided in the sales records uill 06 02 2015 58 POWER AUTOMATION X1 Main Power Supply 1 PA 8000 LW CNC control unit Design and function Always use the line cable delivered with the control unit E Ensure that the line cable is only connected to either 115 V AC or 230 V AC Ensure that the power supply of the control unit is protected by an external fuse type 2A MDL at 230 V AC or 4A MDL at 115 V AC Fig 33 Power supply connector Power supply properties Property Value Unit Voltage 115 240 V AC Tolerances 10 15 Frequenc
41. d When these particular inputs are used for a handwheel the soft ware of the control unit will only read the value of a hardware fast counter implemented on the 2416 EL module which is counting the track signals This avoids counting errors that could occur if the software was reading the tracks directly like standard I Os Prerequisites for the described functionality of the handwheel inputs control unit software revision above 2 3 8 special machine parameter settings For further information refer to the machine parameter manual or machine parameter tool MPTOOL online help ll 06 02 2015 46 POWER AUTOMATION PA 8000 LW CNC control unit Design and function Wiring Schematic DC 24V OV Fig 23 Wiring schematic handwheel inputs 1 Handwheel 3 Power supply connector 2 Input byte 3 The ground of the power supply used for the hand wheel must be connected to the one of the power sup plies ofthe 2416 EL module connector X30 pin 3 ailll 06 02 2015 47 POWER AUTOMATION Overview PA 8000 LW CNC control unit Design and function 3 4 2 Digital outputs 3 4 2 1 Output interfaces um oo un oo oo oo oo an 0e o ojo ojoj o 00 00 00 on on on on on e e oje e oO 00 OD DI Hn 00 um dn oo oo on on 06 o oj o o o o o nn oo un on du on oo oo 06 90 0 jojo o oeo0 uu 00 O0 uu O0 OO O0 OD ee 00 00 070 00 Fig 24 Output bytes 2 Output byt
42. d ul 06 02 2015 62 X4 VGA Connector 16 PA 8000 LW CNC control unit Design and function The control unit is equipped with a VGA connector to connect graphic displays Only use either with PA operator s panels or a standard VGA compatible monitor S AN IN 0 0 0 0 0 0 02 0 o7 o5 SS 05003020 NM Fig 38 VGA connector Sub D 15 Property Value Pins 15 Connector type Gender female Pin Assignment Fig 32 1 RED 2 GREEN 3 BLUE 4 not used 5 GND 6 RED GND 7 GREEN GND 8 BLUE GND 9 KEY 10 SYNC GND 11 Monitor ID 1 12 Monitor ID 2 13 HSYNC 14 VSYNC 15 not used till POWER AUTOMATION sub D high density 06 02 2015 63 X4 DVI Connector 15 PA 8000 LW CNC control unit Design and function Digital Visual Interface DVI is a video display interface developed by the Digital Display Working Group DDWG The digital interface is used to connect a video source such as a display controller to a display device such as a computer monitor SME mm AN PE aeaea J VA Fig 39 DVI connector Pin Assignment Fig 39 1 TMDS data 2 2 TMDS data 2 3 TMDS data 2 4 shield 4 TMDS data 4 5 TMDS data 4 6 Clock 7 Data 8 SYNC 9 TMDS data 1 10 TMDS data 1 11 TMDS data 1 3 shield 12 TMDS data 3 13 TMDS data 3 14 5 V 15 GND 16 Hot plug detect 17 TMDS data 0 18 TMD
43. e however is not generated on the module but must be externally supplied via a 2 pole connector X35 Fig 15 on the 4AXLX module Pin Assignment Pin Voltage Assignment Fig 15 1 5V RMS supply 2 OV RMS ground Technical Data Property Value Unit Operating 5 Vdc Voltage Tolerance 0 420 Yo For further reference see amp Chapter 5 3 3 Setting up RMS supply voltage drop compensation on page 92 vull 06 02 2015 37 POWER AUTOMATION PA 8000 LW CNC control unit Design and function 3 3 4 Module 4AXLX LEDs Overview The 4AXLX module has ten LEDs for diagnostic purposes 0000000 0000000 00000000 o o o o o o o o EES el o o o o o o o 00000000 0000000 00000000 OOOO OO OO HOEBRHEBEBBSE OO00000000 Fig 16 Status LEDs Status Access Bustest Monitor Axis 1 Axis 2 Axis 3 Axis 4 Power OK 10 CNC Ready For a detailed assignment of the LEDs states see amp Chapter 8 2 1 Module 4AXLX LEDs on page 105 OONDORWDN ill il 06 02 2015 38 POWER AUTOMATION PA 8000 LW CNC control unit Design and function 3 4 Module 2416 EL The control unit has optionally one or two 2416 EL module s Each module has 24 digital inputs and 16 digital outputs 24V DC The inputs and outputs are fully opto isolated from the internal logic Each module has its own monitoring sys
44. e 1 X41 1 Output byte 2 X40 The outputs are grouped in bytes 8 signals POWER AUTOMATION 06 02 2015 48 Connection PA 8000 LW CNC control unit Design and function Fig 25 Reference pin power connector Each byte is connected with an 8 pole terminal block W Each output byte has its own power supply connection This feature can be used to turn off a whole byte using an external switch The outputs are always referenced against 0 V located in the power connector X30 pin 3 Fig 25 The current limitation of each output is 0 7 2 5 A per pin in case of short circuits Consider that the power supply cable for one output byte has to be chosen accordingly Each output has a nominal output capability of 1 A Nevertheless each output byte 8 signals is globally limited to 4 A Take care of this specification by appropriate output definition toward the external actuator Outputs are monitored for faults In case of errors the output is switched off Since every 4 adjacent outputs have a common status signal the onboard monitor always switches off 4 out puts in such a case 1 4 5 8 9 12 13 16 vull 06 02 2015 49 POWER AUTOMATION PA 8000 LW CNC control unit Design and function Pin Assignment rf nr on uu un on on on on 00 00 HH Hu un DD un D I e ojo ele un 0
45. e ambient temperature is below 60 C 140 F rated range 06 02 2015 107 PA 8000 LW CNC control unit Troubleshooting LED CNC Ready 10 LED state Module status Off The CNC is not ready see Chapter 2 7 Safety devices on page 17 or the power supply for the RMS is outside of the tolerated values or the ambient temperature is T gt 55 C 131 F In all these cases the analog outputs are set to OV On The CNC is ready see amp Chapter 2 7 Safety devices on page 17 the power supply for the RMS is in rated range and the ambient temperature is T lt 55 C 131 F The analog outputs are released NOTICE A wrong sequence of axis signals is detected when the A and B track of an incremental measuring system shows incorrect sequence of rising and falling edges This can occur in case of Interferences on the signals Status directly after power up Signal frequency is too high Phase displacement between the input signals is unlike 90 ll 06 02 2015 108 POWER AUTOMATION Overview PA 8000 LW CNC control unit Troubleshooting 8 2 2 Module 2416 EL LEDs The 2416 EL module has four LEDs for diagnostic purposes OO UU un uu 00 O0 O0 00 au OO DV DD 00 OO 00 00 00 00 0e olojo o un 00 dn 00 OD 00 00 00 DD gg ag on oo 6060060606 0 A A An A A NA Gon on on oo oe ooo 00 uu uu mu O0 OD O0 mm di 06 0 o o o o oeo
46. e fol lowing purposes as these are regarded as not intended Operation using software not approved by Power Automation Operation connected to machines drives not deemed compatible by Power Automation Operation using wrong number of axes Wrong or missing execution of the mainte nance intervals Operation by not instructed personnel 2 5 Personal protective gear Wearing of personal protective gear is required to minimize health hazards and damage when working with the control unit W Always wear the protective equipment that is necessary for the respective task when working W Follow the instructions on personal protective equipment that are listed in this installation manual and other installation man uals provided by Power Automation W The environment in which the control unit is installed may require users to wear additional personal protective gear Observe the instructions on personal protective gear provided by the operating company Antistatic gloves for protection of the hands during the work Wear the antistatic gloves always until the work is finished ESD clothing for protection of components susceptible to electrostatic discharge Wear the ESD clothing during the work on electrostatic compo nents ESD safety pad for protection of components susceptible to electrostatic discharge Put the ESD safety pad on the floor before starting to work ESD safety shoes for protection of components
47. ections to both pins 1 2 and 3 4 respectively The current limitation of each output is 0 7 2 5 A per pin in case of short circuits Consider that the power supply cable for each output byte has to be chosen accordingly ull il 06 02 2015 56 POWER AUTOMATION Overview PA 8000 LW CNC control unit Design and function 3 4 4 Module 2416 EL LEDs The 2416 EL module has four LEDs for diagnostic purposes OO OO un uu 00 O0 O0 00 au OO DV DD 00 OO 00 00 00 00 0e olojo o un 00 dn 00 OD 00 00 00 DD gg ag on oo 6060060606 0 A A An A A NA Gon on on oo oe ooo 00 uu uu mu O0 OD O0 mm di 06 0 o o o o oeo oo 0 000 0 k 4d A X UM kl o dt Gk vA Fig 31 Status LEDs 1 Status 2 Access 3 Bustest 4 Monitor For a detailed assignment of the LEDs states see Chapter 8 2 2 Module 2416 EL LEDs on page 109 ul 06 02 2015 57 POWER AUTOMATION PA 8000 LW CNC control unit Design and function 3 5 PC connectors Overview The control unit provides a number of standard PC interface con nectors for various input and output applications see Fig 32 X21 PA SDI IN Fig 32 Overview PC connectors 1 Main power supply X1 10 Protective earth ground screw X2 2 Operator s panel keyboard cable 11 PAMIO Connector X13 3 PS2 6 pin mini DIN conne
48. ent air temperature before using The components must not put to power until their temperature is the same as the ambient temperature vull 06 02 2015 85 POWER AUTOMATION Fixed Values Notes PA 8000 LW CNC control unit Installation 5 1 2 Electrical cabinet structural requirements The control unit must be installed in an electrical cabinet meeting the following minimum requirements Requirement IP protection class DIN 40050 IEC 60529 Mounting hole sizes and spacing NOTICE Value IP 54 Standards defined in DIN 41494 Equipment practices for electronic equipment mechanical structures of the 482 6 mm 19 inch series dimensions of electrical cabinets and suites of racks Control unit malfunctions Excessive strain on cables can cause malfunctions due to disruption of connections nstall strain reliefs for all cable holes NOTICE For shielded cables it is necessary to apply the shield Screen at the cable inlet into the electrical cabinet 5 1 3 Cabinet temperature Heat input generated by fitted components The heat generated by the operator s station influ 5 ences the operating conditions inside the cabinet When installing the control unit take the station s heat dissipation into consideration Ensure an adequate cooling using fans or air con ditioning POWER AUTOMATION 06 02 2015 86 Mounting Orientation Spacing Top Bottom Spacing PA 8000 LW C
49. ent via the cable shield grounded at both sides vull 06 02 2015 83 POWER AUTOMATION PA 8000 LW CNC control unit Technical data all 06 02 2015 84 POWER AUTOMATION Safety PA 8000 LW CNC control unit Installation 5 Installation WARNING Danger of injury due to improper installation and commissioning Improper installation and commissioning can result in severe personal injury or material damage Prior to beginning installation ensure that there is sufficient space to work Handle open sharp edged components with care amp Make sure that the assembly location is clean and well organ ized Components that are loosely stacked or lying around can cause accidents B Assemble components properly P Secure components so that they cannot fall or tip over 5 1 Prerequisites and preparations 5 1 1 General requirements Prerequisites for installation are influenced by the con trol unit s required operating conditions and must also take into account the machine to be controlled Ensure that the control unit s operating condition requirements are met For further information see amp Chapter 4 3 Operating conditions on page 78 Ensure that the operating conditions requirements of the machine to be connected to the control unit are met For further information see the CNC machine s manuals Electronic components e g mainboards power sup plies hard disks have to be adjusted to the ambi
50. erating 3 5 Protection class EN 60529 IP20 NOTICE Functional defects Unit Se Ar C F sc RS 96 G G e The module casing does not provide sufficient protec tion against environmental influences Dust and mois ture may cause malfunctions Only operate the control unit inside a cabinet that complies with the requirements as listed in the technical data see Table on page 86 ul 06 02 2015 78 POWER AUTOMATION PA 8000 LW CNC control unit Technical data 44 Dimension sheet 130 125 1 5 i j 16 5 aoe 45H a2 ud gt a1NGOW i n o n B 257 L 254 U amm ALES S m oo en LT II Ga Ir rd rd El lt gt lt 52 n 2244 59 6 544 319 2 J ji U 52 leet R2 5 25 1 TI d 29 9 14 8 EI 5 i ER ut Fig 50 dimension sheet uult 06 02 2015 79 POWER AUTOMATION PA 8000 LW CNC control unit Technical data 4 5 Electromagnetic compatibility The control unit meets the requirements specified in the following standards Safety Of Machinery Standard Title Requirement Value EN 60204 1 Electrical equipment of machines all met
51. example for CNC ready relay 96 5 5 2 Wiring example for Power ok relay 97 6 Transport packaging and storage 99 GT MANE ott e td Eae Seed ees Ran es a etd de 99 6 2 Packaging seme 99 6 9 ui eR e ads 100 7 Maintenance une denen RELATES 101 7 1 Safety notes teo ea 101 7 2 Maintenance schedule nennen 101 7 3 Measures after maintenance 102 8 Troubleshooting AA 103 8 1 Safety notes 103 8 2 Malfunction mdicators 104 8 2 1 Module 4AXLX LEDs ereere 105 8 2 2 Module 2416 EL LEDs nennen 109 8 3 Troubleshooting chat 111 9 Service and return process Henn 113 MEE Tum 113 9 1 1 Service address6S lt wwwamwananamwnaaaanzwanaazamaaaaa 113 9 2 Spare parts n ete n Re naa NE Xe ERR 115 9 3 Return policy and Drocecdurge nen 115 9 4 Trammmg eme 118 10 Dismounting and decommissioning 119 11 EC Declaration of Contormity eee 121 12 Proof of change sse 123 TI 06 02 2015 5 PA 8000 LW CNC control unit Table of contents 13 Index EE 125 m 06 02 2015 6 POWER AUTOMATION General Information Warnings PA 8000 LW CNC control unit General information 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 installatio
52. g OO E oo A Scope of delivery PAMIO hardware PAMIO boxes are shipped without connection cables Cables of the following lengths can be ordered from Power Automation 2 m 6 5 ft 5 m 16 5 ft 10 m 33 ft 20 m 66 ft 25 m 82 ft see Chapter 9 Service and return process on page 113 Cable length Ensure that the total cable length between the control unit and the last PAMIO box does not exceed 25 m 82 ft The PAMIO hardware consists of the following components m PAMIO boxes WB PAMIO modules 2 per box options listed below HB cable between control unit and PAMIO box P termination plug always required lateral rail stoppers required if more than one module box is used on the same rail BW slot cover required when a module slot is not occupied by a PAMIO module ul 06 02 2015 74 PAMIO 2416 PAMIO AEN AA PAMIO 2ENC4A PAMIO PWM Characteristics PA 8000 LW CNC control unit Design and function Feature Value Specifications digital inputs 24 3 bytes 24V DC digital outputs 16 2 bytes 24V DC isolation optical Feature Value Specifications encoder inputs 4 analog inputs 4 10 V 12 bit analog outputs 4 10 V 16 bit Feature Value Specifications encoder inputs 2 analog inputs 4 10 V 10 bit analog outputs 4 10 V 16 bit termination plug integrated Feature Value Specifications digital outputs 2 24 V DC The main characteristics for the digital i
53. gister 16 BitD A p4 Output channel 3 o channel 3 converter MEN Reference Channel 3 Input register 16 Bit D A channel d Pi converter KA Output channel 4 ME Reference Channel 4 Fig 11 Module 4AXLX analog output schematic Analog output wiring The wiring of the analog output to the drive depends 5 on the type of drive analog inputs During drive installation check whether the drive analog inputs are grounded Ifthe analog inputs are grounded connect the drives according to the schematic for non differen tial inputs Ifthe analog inputs are not grounded connect the drives according to the schematic for differential inputs ul 06 02 2015 34 POWER AUTOMATION PA 8000 LW CNC control unit Design and function 3 3 2 4 Output Monitor The functionality of the analog output to the drive is permanently monitored by the system The real analog output signal is read in and compared to fixed voltage level Thus in case of defective dig ital analog converter the system can react and avoid machine damages PAMIO 4AXLX Output monitor Output channel p WENN Ref Channel 0 5V 2 c amp 2 D A Output a3 defective Error 4 o z 0 5V o Sign of nominal output value Fig 12 4AXLX output monitor Analog output monitor In case of errors the system A Deactivates the safety relay CNC Ready
54. handling of environmentally hazardous sub stances especially incorrect waste disposal can cause considerable damage to the environment Do not release environmentally hazardous substances or com ponents into the environment m Always 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 Follow the standard return procedure as described in Chapter 9 3 Return policy and procedure on page 115 2 12 Labels The following labels are attached to the control unit NOTICE Readability Of Labels Over the course of time labels may become dirty or nonreadable for any other reason Improper input vol tages applied due to readability of labels can damage the control unit Keep labels in readable condition at all times Replace damaged labels not including material warranty seals Replacements can be obtained from Power Automation ul 06 02 2015 22 POWER AUTOMATION PA 8000 LW CNC control unit Over
55. he 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 TI 06 02 2015 9 POWER AUTOMATION Service PA 8000 LW CNC control unit General information 1 6 Customer service Our Customer Service is always available for technical information For information on whom to contact by phone fax e mail or via the internet see Power Automation s address on page 2 Additionally Power Automation staff is always interested in receiving new information and experiences resulting from the use of our products which could be of great value for future improve ments 1 7 Glossary CMOS Complementary metal oxide semiconductor CNC Computerized Numerical Control DDU Delivered Duty Unpaid HMI Human Machine Interface The graphical user interface provided by the PA soft ware IPC Insulating Piercing Connector MDI Manual Data Input MTBP Machine Tool Builder s Panel Panel including the basic requirements for a machine tool operator emergency stop push button cycle start and stop push buttons jog plus and minus push but tons feed rate and spindle speed override pots and a number of auxiliary push buttons NC Start Numerical Control Start Bu
56. ication each 5 input of all used axes must be wired in parallel 3 3 1 3 Input schematic RMS power supply 5V RMS RMSGND RMS Monit A 2 48V lt U 69V A B SB END lt suPERBUS R gt Measurement input 2x2 Measurement reference Fig 8 RMS input equivalent schematic ll 06 02 2015 30 POWER AUTOMATION PA 8000 LW CNC control unit Design and function 3 3 1 4 RMS encoder wiring example RMS Encoder Wiring Example The following schematic demonstrates the recommended way of connecting the CNC RMS inputs to the encoders or any other device with incremental output RMS Encoder Fig 9 RMS encoder wiring example ul 06 02 2015 31 Connection PA 8000 LW CNC control unit Design and function 3 3 2 Digital Outputs 3 3 2 1 Output interfaces 9 o o o o o o o o o o o lo IC o o o o o o o 0000000 00000000 OOOOOOOOOO0 00000000 Fig 10 Analog axes output connector The signals of the four analog output channels are connected via a 9 pin connector Fig 10 Each output channel has its own reference connection Potential malfunctions of the control unit Different references of the channels have different voltage potential Contact between the reference wiring
57. ion was set up as described in this installation manual In the event of faults that cannot be eliminated through the fol lowing instructions please contact Power Automation see Chapter 9 Service and return process on page 113 Return procedure In the event of an error that requires the control unit to be sent to Power Automation follow the instructions given in amp Chapter 9 3 Return policy and procedure on page 115 8 1 Safety notes The troubleshooting procedures described in this installation manual can be performed by the operator unless otherwise marked P Some work may be performed only by specially trained per sonnel or only by Power Automation in which case special notice is given in the description of the individual faults W All work on the electrical system must be performed by a quali fied electrician WARNING Unauthorized troubleshooting procedures can result in injury Improper troubleshooting procedures can result in severe personal injury or material damage m Observe the personnel requirements for repairs specified in the troubleshooting chart If in doubt contact Power Automation for help or support by an authorized service technician m Ensure that the power supply has been disconnected Make sure that the assembly location is clean and well organ ized Components that are loosely stacked or lying around can cause accidents m If components have been removed ensure proper
58. l as two plug in slots for UO modules PAMIO boxes can be snapped onto DIN rails and plugged into each other side by side or connected through optional cables The last box carries a termination plug OO E Go A Limited cable length The limits for the I O system are 31 I O modules 1 5 internal 4AXLX module 2 internal 2416EL modules plus a maximum of 14 PAMIO boxes The maximum cable length from the control unit to the last PAMIO box cannot exceed 30 m 98 ft This has to be considered as a maximum global length when several PAMIO boxes are placed at different locations and connected with interconnection cables IO modules can be mounted where needed without requiring bus couplers Each PAMIO module has its own watchdog timer for the PA superbus temperature and voltage monitoring as well as corre sponding LED displays on the front side vull 06 02 2015 73 POWER AUTOMATION PAMIO Hardware PA 8000 LW CNC control unit Design and function Scope of delivery control unit The PAMIO modules listed below are not included in 5 the control unit s basic scope of delivery They can be ordered from Power Automation see Chapter 9 Service and return process on page 113 For further information on the modules specifications refer to the PA Accessories installation manual Fig 49 PAMIO hardware connection cable 30 m 98 ft max lateral rail stoppers module box stopping bracket termination plu
59. ld be higher than 80 W The cables have a copper braid shield screen Normally the cable shield must be connected to ground in both sides of the cable Double sided grounding is necessary to achieve high quality interference suppression in the higher fre quency range The cable shield can be connected to single sided grounding in exceptional cases but if that is done only lower frequencies will be absorped A single sided ground connection of the cable shield may be convenient if the conduction of a potential compensating line is not pos sible analog signals some mV respectively yA are transferred foil screens static screens are used instead of screens made of copper braid When using data lines always use metallic or metallized plugs for serial couplings Fix the cable screen of the data line at the plug rack Itis convenient to strip the insulated cable interruption free and lay it on the isolation protected ground conductor line sta tionary operation m Metal cable clamps to fix the cable shield have to be used The clamps must clasp the copper braid extensively and have good contact The cable shield has to be laid on a protective earth rail directly after the entry of the cable in the cabinet Do not attach the cable shield again on the CNC control PAMIO device CAUTION Please observe at installation At potential differences between the grounding points there may be a compensation curr
60. machine s manufacturer Safety connector For information on the safety connector s purpose 5 Specification and wiring see Chapter 3 6 Safety connector on page 68 Chapter 2 8 Machine safety on page 17 and Chapter 5 5 Wiring for machine safety on page 96 Data safety For information on data safety see Chapter 2 10 54 Data safety on page 20 2 8 Machine safety For information regarding the safety connector s specification and wiring examples see Chapter 3 6 Safety connector on page 68 and Chapter 5 5 Wiring for machine safety on page 96 vull 06 02 2015 17 POWER AUTOMATION Further Applicable Documents Personal Injury PA 8000 LW CNC control unit For information on the machine s safety devices and emergency stop chain see the manual provided by the CNC machine s manufacturer The manufacturer of the CNC machine is responsible for the proper installation of the emergency stop 2 8 1 CNC ready signal Emergency stop inter locking DANGER Injuries due to uncontrolled operation An inactive CNC Ready signal represents a safety related situation The CNC Ready relay is switched off when the PA CNC control unit is in a situation where the axes movements are not controlled As the axes may continue to move in an uncontrolled manner the contacts of the CNC Ready relay must be used to disconnect the machine s emergency stop safety chain All actions necessary for safety must be
61. may cause control unit malfunctions NOTICE e Always connect reference wiring separately Never tie reference wiring together Il il 06 02 2015 32 POWER AUTOMATION Pin Assignment Axes Output PA 8000 LW CNC control unit Pins Fig 10 Pin 1 Pin 2 Pin 3 Pin 4 Pin 5 Pin 6 Pin 7 Pin 8 Pin 9 3 3 2 2 Output characteristics Property Number of analog output chan nels Output signal range max Output current load max Output capacitive load max Bipolar zero error max Full scale error max Channel to channel mismatch max Linearity error max Resolution Conversion time max Output slew rate Watchdog max External connector vull POWER AUTOMATION Design and function RMS Input Function output channel 1 ground for channel 1 output channel 2 ground for channel 2 output channel 3 ground for channel 3 output channel 4 ground for channel 4 analog ground ACOM Value Unit 10 V 15 mA 350 pF 40 mV 1 96 1 96 2 44 mV 305 uV 10 u 0 4 uV s 64 ms 1 terminal block 06 02 2015 33 PA 8000 LW CNC control unit Design and function 3 3 2 3 Output schematic Input register 16 Bit D A Output channel 1 channel 1 converter Reference Channel 1 Input register wv 16BitD A J 4 mm Output channel 2 channel 2 converter j Reference Channel 2 o gt z Input re
62. n 00 Hn ug on ai e 0 0 DD uu 00 DD DD O0 OD OO o Jojo 0e ojlojo Fig 19 Reference pin power connector m Each byte is connected with an 8 pole terminal block The conductor cross section of the wire must be 0 3 to 1 75 mm AWG 22 to 15 The inputs are always referenced against the 0 V connector of the module X30 pin 3 amp Connection on page 41 ailll 06 02 2015 41 POWER AUTOMATION PA 8000 LW CNC control unit Design and function Pin Assignment efelefelelelefe an on on 00 nn an dn on 00 on on on on oD oD On an an un on DD DD 00 dnm O0 un dm OD oeleieleieleielei oo un un oo oo oo oo on O0 00 O0 Hn on Hn oo on o 09 0 090 Jr Fig 20 Pin assignment Byte 1 24 V input Byte2 24 V input Byte 3 24 V input pin 1 1 input bit pin 1 9 input bit pin 1 17 input bit pin2 2 input bit pin2 10 input bit pin2 18 input bit pin3 3 input bit pin 3 11 input bit pin 3 19 input bit pin 4 4 input bit pin 4 12 input bit pin 4 20 input bit
63. n guidelines Meaning Of EMC Electromagnetic compatibility EMC refers to the ability of an elec trical device to work flawlessly in an electromagnetic environment without generating or being susceptible to disturbances All PA Control units are designed for use in industrial environments and meet high EMC specifications vull 06 02 2015 81 Important Rules For EMC Possible Interferences PA 8000 LW CNC control unit Technical data Cabling The cabling must be in line groups high voltage current supply signal and data lines High voltage lines and signal respectively data lines must be laid in separate channels or bundles The signal and data lines have to be routed as near as pos sible beside ground areas Reference potential and ground of all electrical operating supplies Installation parts and cabinets with your CNC control unit have to be connected in star topology with the isolation protected ground conductor system to avoid ground loops m Sufficiently dimensioned potential compensation lines have to be laid if there are potential differences between installation parts and cabinets Area wide grounding of the inactive metal parts A central connection between the ground and the protected ground conductor system have to be installed E Allinactive metals have to be connected extensively and impe dance low Fixing of the cable shield m Data cables and analog cables must be laid separately from each
64. n manual is part of the control unit must always be kept in the control unit s direct proximity and should be available for the personnel at any time All personnel working with the control unit are obliged to have read and understood this installation manual before starting any work Strict compliance with all speci fied safety notes and instructions is a basic requirement for safety at work Moreover the accident prevention guidelines and general safety regulations applicable at the place of use of the control unit must also be complied with Illustrations in this installation manual are intended to facilitate basic understanding and may differ from the actual design of the control unit The enclosed manuals for the installed components apply together with this installation manual 1 2 Explanation of symbols Warnings are identified by pictures These warnings are introduced by signal words which express the severity of a danger Pay attention to these warnings and act cautiously in order to avoid accidents personal injuries and damage to property DANGER indicates an imminently hazardous situation which if unavoidable will result in death or serious injury WARNING indicates a potentially hazardous situation which if unavoidable could result in death or serious injury CAUTION indicates a potentially hazardous situation which if unavoidable may result in minor or moderate injury NOTICE
65. n rec ommends the software ESET NOD32 Antivirus See www eset com 2 Configure the anti virus software to regularly and automati cally scan the control unit 3 Ensure that the software s virus definition database is kept up to date 4 Ensure that all data copied to the control unit is scanned for viruses and malware regardless of the means by which the data reaches the control unit floppy disk USB optical media serial connections local remote network 2 10 3 Registry protection The software preinstalled on the control unit keeps various entries in the control unit s registry database that are critical for system operation Therefore registry protection and backup are prerequi sites for proper control unit operation A registry backup and recovery tool is preinstalled by Power Automation on every control unit Personnel m Qualified personnel Regularly create backup copies of the the control unit s reg istry database using the registry backup tool The preinstalled registry backup tool ERUNT creates a backup automatically with every start of the CNC control unit Please contact Power Automation if you need to restore your registry see amp Chapter 9 Service and return process on page 113 vull 06 02 2015 21 POWER AUTOMATION Batteries Electronic Components PA 8000 LW CNC control unit 2 11 Environmental protection CAUTION Environmental hazard caused by incorrect han dling Incorrect
66. nputs CNC DRIVE Unipolar with unbalanced input Drives With Differential Inputs Fig 55 Schematic differential inputs ul 06 02 2015 90 POWER AUTOMATION PA 8000 LW CNC control unit Installation 5 3 2 RMS encoder wiring example RMS Encoder Wiring Example The following schematic demonstrates the recommended way of connecting the CNC RMS inputs to the encoders or any other device with incremental output RMS Encoder Fig 56 RMS encoder wiring example ul 06 02 2015 91 Precondition PA 8000 LW CNC control unit Installation 5 3 3 Setting up RMS supply voltage drop compen sation The distance between the measuring systems and the m power supply can be relatively long The ohmic resist ance of the power supply cable and the RMS current consumption generate a voltage drop Fig 57 Schematic encoder power supply voltage drop 1 Power supply 2 Rotating measurement system RMS U Supply output voltage U Voltage drop U Voltage at the RMS U Voltage drop As shown in the figure the voltage U equals the difference between the output voltage U and the voltage drop U U3 Adjusted voltage U UA U4 U3 uiii 06 02 2015 92 Examples Calculation PA 8000 LW CNC control unit Installation The voltage drop depends on the cable length and the conductor s cross section The following table shows some cable examples The values are typical and only offered as guidelines
67. nputs and outputs of the PAMIO 2416 are similar to the ones of the integrated 2416EL mod ules see Chapter 3 4 Module 2416 EL on page 39 Likewise the characteristics of the measuring systems inputs and of the analog outputs of the PAMIO 4ENC4A are similar to the ones of the integrated 4AXLX modules see Chapter 3 3 Module 4AXLX on page 27 For detailed information about PAMIO modules their installation and electric requirements refer to the PA Accessories installation manual vull 06 02 2015 75 PA 8000 LW CNC control unit Design and function uiii 06 02 2015 76 POWER AUTOMATION General Information Electrical PA 8000 LW CNC control unit Technical data 4 Technical data 4 1 General specifications Property Value Dimensions 332 2 x 125 x 257 WxDxH 13 12 x 4 92 x 10 12 Weight 6 2 13 7 4 2 Connection values Property Input voltage Tolerance Frequency Maximum current at 115 V Maximum current at 240 V Maximum power consumption till POWER AUTOMATION Unit mm inch kg Ib Value Unit 115 240 VAC 10 15 50 60 Hz 4A 2A 180 W 06 02 2015 77 General PA 8000 LW CNC control unit Technical data 4 3 Operating conditions Property Value Operating temperature 5 45 41 113 Storage temperature 20 60 4 140 Temperature gradient within 10 10 minutes 50 Relative humidity non condensing 80 Maximum acceleration non operating 4 0 Maximum acceleration op
68. nt peaks of a multiple of the mean value may occur for several microseconds during operation Select a conductor cross section which guarantees a maximum voltage drop of 0 2 V Set the power supply to the upper limit of the RMS supply voltage These steps guarantee that the RMS supply voltage does not drop below the required minimum 5 4 Installing digital UO The following chapters provide instructions and examples for installation of digital inputs and outputs Due to the versatility of the control unit not all possible configuration options can be covered in detail m If in doubt contact the Power Automation s customer support For contact information see Chapter 9 Service and return process on page 113 ul 06 02 2015 94 POWER AUTOMATION Schematic PA 8000 LW CNC control unit Installation 5 4 1 Wiring example for 2416EL modules 24v E ov K Fig 58 Cabling example for 2416EL modules Qo o o0o01 0n2N Power supply Fuse slow Input signals Inputs Module 2416EL Outputs Output signals Resistive load Inductive load Personnel m Skilled electrician gt Set up inputs according to the schematic Setup outputs according to the schematic gt Set up power supply for outputs Ensure that the circuit is protected by a fuse of appropriate ratings Inductive loads Digital outputs switch very quickly This fact must be 5
69. nternal air circulation for the control unit Its proper operation is a prerequisite for safe operation of the con trol unit Ensure that there is clearance of at least 30 mm 1 2 inches next to the fan s exhaust W Install an additional fan inside the cabinet directed toward the control unit 100mm 4 MODULE 1 E 40 1 6 Fig 53 Top bottom spacing Service access For service or maintenance purposes access to the 5 control unit may be necessary Install the control unit and adjacent components in a way that allows for access to all mounting points cables etc by service personnel uult 06 02 2015 88 POWER AUTOMATION EMC Shield RF Noise Suppression General PA 8000 LW CNC control unit Installation Electrical noise may influence the control unit s operation Locate the control unit at least 300 mm 12 inches from areas which may transmit electrical noise Electrical noise may be caused by components such as e g transformers coils drive amplifiers or relays W To decrease the influence of electrical noise mount 1 5 mm 0 06 inch metal shields between the control unit and the ex
70. ntrolled operation An inactive CNC Ready signal represents a safety related situation The CNC Ready relay is switched off when the PA CNC control unit is in a situation where the axes movements are not controlled As the axes may continue to move in an uncontrolled manner the contacts of the CNC Ready relay must be used to disconnect the machine s emergency stop safety chain All actions necessary for safety must be executed in the same way as when the Emergency Stop button is pushed Properly integrate the CNC ready relay into the machine s emergency stop chain The contacts for CNC Ready and Power OK are available on connector X19 see Fig 59 ul 06 02 2015 96 POWER AUTOMATION Schematic Suggested Wiring Power Supply Interlocking PA 8000 LW CNC control unit Installation Aux Power Supply 24 Vdc 24V OV o E Stop limit switches 14 CNC Ready E E d Machine E Stop PB A E Stop Fig 59 Wiring example CNC ready relay 4 connector X19 pin 4 6 connector X19 pin 6 5 5 2 Wiring example for Power ok relay 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 supply voltages do not match the allowed range or the internal temperature is too high Use the contacts of the Power ok relay to swi
71. odule has ten LEDs for diagnostic purposes 28 RE S D 5 oH i O D OB a Og OB a o D o P O cl E T og 9 Ol 92 ER s J Om Fig 61 Status LEDs Status Access Bustest Monitor Axis 1 Axis 2 Axis 3 Axis 4 Power OK 10 CNC Ready The LEDs states are assigned the following status messages OMONDORWN tl 06 02 2015 105 POWER AUTOMATION LED Status 1 LED Access 2 LED Bustest 3 LED Monitor 4 LED Axis 1 5 PA 8000 LW CNC control unit Troubleshooting LED state Off OR Slow flash Quick flash On LED state Off On LED state Off On LED state Off Flashing On LED state Off OR Flashing On POWER AUTOMATION Module status No power supply 24 V Hardware error The module is not configured The module is configured and the analog outputs are set to 0 V The module is configured and the analog outputs are enabled Module status Default Access to this module Module status Default Bustest between control unit and the last PAMIO module is active Module status Error The ambient temperature is above 60 C 140 F and all analog outputs are set to 0 V Warning The ambient temperature is above 55 C 131 F Default Module status Axis is not connected Axis is connected and an encoder wire break has been detected Axis is connected and a wrong sequence of signals on tr
72. omer No Adresse Adress Name T Name POWER AUTOMATION Return of Material Authorization Power Automation GmbH Gotllieb Daimler Strasse 17 2 74385 Pleidelsheim Germany Phone 49 0 7144 899 321 kitaani Pin Fera Fax 49 0 7144 899 299 E Mail rma powerautomation com GEN Artikelbezeichnung Part Description bal PA 8000 e PA 8000 L2 PA 8000 NT Zubeh r Accessories Antrieb Drive P1 P2 other PA 8000 e2 PA 8000 LW PA 8000 EL Bedienfeld Panel Motor Seriennummer Serial No Lieferschein Nr Delivery Note No Express Sofortige Bearbeitung garantiert Es entstehen zus tzliche Kostenl Grund der Warenr cksendung Reason for return of the goods Musterr cksendung Sample Return Gutschrift Credit Reparatur Repair Umbau Conversion Detaillierte Fehlerbeschreibung Detailed Error Description Notizen Notes Andere Other Pflichtfeld Mandatory Field To be filled out by Power Automation RMA Nummer erteilen Accept RMA number RMA Nummer nicht erteilen Reject RMA number Zust ndig bei PA Responsible at PA Vermerke Notes RMA Nummer RMA number Unterschrift Signature Stempel Chop Wichtige
73. on lt 4 0 G Additional requirements Packages may be marked with notes for storage 5 which may exceed the requirements mentioned here These must be adhered to CAUTION Improper storage can result in damage Improper storage can cause extensive material damage Always store the control unit in its original packaging When storing the control units observe the specifications regarding maximum and minimum storage temperature and permitted maximum acceleration given in chapter Technical data Chapter 4 Technical data on page 77 ul 06 02 2015 100 POWER AUTOMATION Personnel Safety Messages PA 8000 LW CNC control unit Maintenance 7 Maintenance 7 1 Safety notes Some maintenance tasks can only be executed by trained qualified personnel or only by Power Automation In these cases this is separately indicated in the description of the specific maintenance tasks All work on the electrical equipment shall only be executed by a qualified electrician DANGER Danger to life caused by electric current Touching conductive parts causes a direct danger to life Damage to insulations or individual components can cause danger to life NOTICE Property damage due to improperly executed maintenance work Improper maintenance can cause property damage Prior to starting work ensure that there is sufficient assembly space Ensure order and cleanliness at the assembly site Loose parts and tools
74. ose a rate for the estimate of costs which will be absorbed if a repair order is coming about vull 06 02 2015 115 POWER AUTOMATION Acquiring RMA Number PA 8000 LW CNC control unit Service and return process 1 Contact Power Automation to receive an RMA form in Excel format RMA Form on page 117 2 Open the RMA Process form provided by Power Automa tion Use one form for each single part you want to ship back to Power Automation 3 gt Fill in the form The fields marked with a red star are mandatory fields Only fill in the fields next to the yellow bar on the left side of the form Do not fill in the fields next to the blue bar on the left side of the form These fields are for internal notes only and blocked 4 Send the completed form as Excel file by email to rma powerautomation com to your local support see webpage c We will check the data and send the form back to you as a PDF file including a RMA number or tell you what infor mation is missing if necessary 5 gt Print the RMA form and add it to the accompanying compo nents and documents 6 After the check and repair the components will be shipped to you immediately ul 06 02 2015 116 POWER AUTOMATION RMA Form PA 8000 LW CNC control unit Kontakt bei PA Contact at PA Kunde Customer Service and return process Datum Date 05 06 2014 Unternehmen Company Kundennummer T Cust
75. ose cables properly shut down the control unit and machine and secure against inadvertent restart Unplug the respective cables and re plug them afterwards m Follow instructions in amp Chapter 7 3 Measures after mainte nance on page 102 Make a backup of the data Skilled electrician Forthe exact procedure to make the backups see Chapter 2 10 Data safety on page 20 7 3 Measures after maintenance Perform the following steps after completing maintenance and before switching on the control unit and the machine 1 Check all previously loosened screw connections for a tight fit 2 Check whether all previously removed protective devices and covers are properly installed again 3 Make sure that all tools materials and other equipment used were removed again from the cabinet 4 Clean up work area and remove any substances left over such as fluids cleaning material or the like Dispose them according to the current applicable regulations 5 Make sure that all safety features on the control unit and relating to the machine are fully functional ul 06 02 2015 102 POWER AUTOMATION General Information Personnel Authorization PA 8000 LW CNC control unit Troubleshooting 8 Troubleshooting The following chapter describes possible causes of faults during installation and configuration and the steps required to eliminate them Inthe event of frequent faults re check if the configurat
76. other The cable shield has to be laid extensively on a protected ground conductor rail directly after the cabinet entry and the fix ation of the shield with cable clamps W The isolation protected ground rail has to be connected impe dance low with the cabinet The metallic or metallized plug cases for shielded cables must be used When transmitting signals with small amplitudes the one sided grounding of the cable shield may be favorable Electromagnetic interferences may interfere with the control unit Electromagnetic fields RF coupling Magnetic fields with power frequency Power supply Protected ground conductor Superbus system Depending on the spreading medium and the distance to the inter ference cause interferences to the control unit occur by means of capacitive galvanic inductive or radiant coupling mechanisms ul 06 02 2015 82 POWER AUTOMATION Shielding Of Conductors PA 8000 LW CNC control unit Technical data Electrical magnetic and electromagnetic interference fields are weakened by means of shielding Via the shielding rail which is connected with low impedance to the rack interference currents are shorted by the cable shield to the ground It s important that the connection to the protected ground conductor is impedance low because otherwise the interference currents may cause interference For the use of shielded cables the following rules are important W The screen cover shou
77. refer 8 Outputs an error message CNC 75 D A output defective or missing where indicates the number of the defective axis CAUTION This monitoring is able to detect as well effective defectiveness of the digital analog converter but more frequently it detects noise or signal interference on the cable to the drives Therefore Check carefully the analog wiring between CNC and drive refer amp Disconnect the cable that goes to the drive and check if the error still occurs Check machine parameter and Drive cfg values related to this error monitoring 3 3 2 5 Analog axes wiring example The following schematics demonstrate the recommended way of connecting the CNC analog outputs to the analog inputs of the drives depending on the analog input type of the drive vull 06 02 2015 35 POWER AUTOMATION PA 8000 LW CNC control unit Design and function Drives With Non Differential Inputs CNC DRIVE Unipolar with unbalanced input Drives With Differential Inputs Fig 14 Schematic differential inputs ul 06 02 2015 36 POWER AUTOMATION PA 8000 LW CNC control unit Design and function 3 3 3 RMS power supply D D pg pg pg OOOOOOOOOO0 Fig 15 RMS power supply connector X35 If required the rotating measurement systems RMS can get their power from the module The supply voltag
78. rface wiring Secure the control unit against unwanted movement Loosen the screws that fix the control unit inside the cabinet Dismount the control unit 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 To return the control unit follow the instructions given in amp Chapter 9 3 Return policy and procedure on page 115 CAUTION Environmental hazard caused by incorrect han dling Incorrect handling of environmentally hazardous sub stances especially incorrect waste disposal can cause considerable damage to the environment tll 06 02 2015 119 POWER AUTOMATION PA 8000 LW CNC control unit Dismounting and decommissioning uiii 06 02 2015 120 POWER AUTOMATION PA 8000 LW CNC control unit EC Declaration of Conformity 11 EC Declaration of Conformity vull 06 02 2015 121 PA 8000 LW CNC control unit EC Declaration of Conformity POWER AUTOMATION EC Declaration of Conformity The units in the PA 8000 LW series are intended for installation in a machine or for assembly with a machine They are no more than components of a machine and can therefore not conform to the required standards and guidelines that are applicable to the complete installation The applicable connection conditions of the control system must be observed Device designation CNC Control Uni
79. rol unit Service and return process ACE Automation A 721 Twinrex B D Deokpungdong ro 111 10 Hanam si Gyeonggi do 465 831 South Korea 9 2 Spare parts Due to the high quality of our products we can assure you that you will not need this service often Spare parts are often urgent so Power Automation provides the relevant spare parts at the local service centers for immediate dispatch Our 3 service centers in Europe North America and Asia allow us to deliver all needed parts typically within 24 hours Only trust PA s original parts because every part passes our tight quality checks We also offer consulting services to identify the most critical parts for the machines in your production facilities We suggest what crit ical stock may be required to ensure a minimum downtime of your machines Our specialists look for common parts to keep your inventory levels at a minimum 9 3 Return policy and procedure Power Automation will only accept control units and components for replacement or repair if they have been returned in adherence to the provisions given below W If material warranty is void or if no error is detected a testing flat rate will be charged For present values please contact the Power automation Service amp Chapter 9 1 1 Service addresses on page 113 f material warranty is void you will receive a repair offer Before the repair starts we need a repair order from you W Power Automation will imp
80. ry fluid In case of contact flush the battery fluid with large amounts of water If the battery fluid enters the eyes flush immediately with water for 10 min and consult a physician without delay CAUTION Malfunction due to discharged buffer battery The control unit s CMOS settings are buffered by a battery If this battery is discharged completely the CMOS settings are lost Malfunctions of the control unit may result For further information see Chapter 8 3 Troubleshooting chart on page 111 ul 06 02 2015 16 POWER AUTOMATION Safety Superior Control Units Safety Connector Software Additional Information PA 8000 LW CNC control unit 2 7 Safety devices DANGER Malfunctioning safety devices may pose a fatal risk Safety devices must be intact and properly integrated into the control unit s configuration and software in order to guarantee safety Before initial commissioning of the machine ensure that all safety devices are fully functional and correctly installed m Ensure that safety related inputs outputs of the PAMIO compo nents and the CNC control unit are fully functional and perform as intended W Never disable safety devices Heed regulations concerning hardwiring of safety circuits Superior CNC Control unit or PLC For information on required connections between the 5 PA control unit and safety devices integrated into the CNC machine see the documentation provided by the
81. s are conducted separately in a dis tance of at least 10 cm When using mechanical cable guides install additional metal shields Check if the CNC ready relay is properly integrated into the machine s emergency stop chain see Chapter 5 5 1 Wiring example for CNC ready relay on page 96 Skilled electrician 06 02 2015 112 POWER AUTOMATION Service At Power Automation Service Addresses PA 8000 LW CNC control unit Service and return process 9 Service and return process 9 1 Service By Phone PA s well educated service staff is available to answer your tech nical questions Due to the close co operation with our customers our engineers can solve problems often immediately by phone If on site support is necessary our service staff will diagnose the problem and will prepare our field service engineer beforehand This is to make on site service as much effective as possible By Remote Control Software Every PA CNC is equipped with an Ethernet interface If you have a network on site you only have to integrate the CNC system to your network for world wide web access Power Automation provides a remote control software which allows our service staff to log into your CNC This provides all the informa tion available on the machine They can check all the data like the PLC program machine parameters or the NC programs directly on the real system under real conditions This is the fastest and most
82. s 06 o o ojooeo eo eo AN NN Al N Fig 29 Power supply connector 24 VDC Each of the 2416 EL modules needs a separate 24 V DC power supply for its DC outputs connector X30 ll 06 02 2015 54 POWER AUTOMATION Pin Assignment Technical Data PA 8000 LW CNC control unit Design and function Fig 30 Power supply pins Each module has a 5 pin connector X30 with the following pin assignment Pin Fig 30 Assignment Pin 1 24 V power supply for output byte 1 Pin 2 24 V power supply for output byte 1 Pin 3 OV Pin 4 24 V power supply for output byte 2 Pin 5 24 V power supply for output byte 2 Property Value Unit Operating voltage 24 VDC Tolerance 15 0 12 5 Yo Effective range 10 4 27 0 V Current limitation 0 7 25 A Reference Pin 3 0 V ul 06 02 2015 55 POWER AUTOMAT PA 8000 LW CNC control unit Design and function Pin 1 and 2 are connected internally Pin 4 and 5 are connected internally Reference for all is pin 3 0 V With pins 1 and or 2 and pins 4 and or 5 the output bytes are supplied separately The two output bytes can be supplied independently from each other This allows for example power to be supplied independently to each byte in case of an emergency stop Notes For proper load balancing across pins connections to all available pins per output byte are recommended Establish wire conn
83. s properly All encoder signals of the axes are correct All axes position loops are under control The RMS power supply voltage is within operation range The operating temperature is below 55 C 131 F Logic Condition Result 5V RMS OK Ready relay 2 active AND Control unit ready AND T lt 55 C 131 F NOTICE M Damage to the machine If the CNC ready relay is not wired properly to the machine s emergency stop circuit the machine may be damaged upon operation W Ensure that the CNC ready relay is wired properly to the machine s emergency stop circuit ul 06 02 2015 70 POWER AUTOMATION PA 8000 LW CNC control unit Design and function 3 6 2 Safety connector schematic Relay passive Relay active N O N O COM COM N C N C COM Hu S 9 Jem a CH eZ 3 From supervisor CE 4 CH na H 6 From supervisor Fig 45 Safety connector equivalent schematic 3 7 X20 PA USB software dongle connector 3 42 ICH Dk f ei le Fig 46 PA USB software dongle connector An additional USB port is specially marked as PA dongle X20 port It is located on the bottom side of the control unit If the PA dongle is not connected to this port the PA software will not recog nize the dongle and in consequence will not start Always use the specially marked port to connect the PA USB
84. susceptible to electrostatic discharge Wear the ESD safety shoes to protect electrostatic discharge sen sitive devices due to inadequate derivative electrostatic energy ul 06 02 2015 14 POWER AUTOMATION PA 8000 LW CNC control unit Ear protection for protection of the ears during the work Wear the ear protection always until the work is finished Ground strap for protection of components susceptible to electrostatic discharge Wear the ground strap on your wrist and connect it to a suitable equipotential bonding Protective glasses for protection of the eyes during the work Always wear the protec tive glasses until the work is finished 2 6 Specific dangers The following section lists the residual risks W Observe the safety instructions listed here and the warnings in subsequent chapters of this installation manual to reduce health hazards and to avoid dangerous situations DANGER Danger to life caused by electric current Touching conductive parts causes a direct danger to life Damage to insulations or individual components can cause danger to life Inthe event of damage to insulation switch off the power supply immediately and have the defective parts repaired W Work on the electric system must be carried out only by skilled electricians Before maintenance cleaning or repair work switch off the power supply and secure it against being switched on again Do not bridge fuses or make them ineffecti
85. t Series PA 8000 LW xxx Manufacturer Power Automation GmbH Gottlieb Daimler Str 17 2 D 74385 Pleidelsheim The product described above in the form as delivered is in conformity with the provisions of the following European Directives e 2004 108 EC Electromagnetic compatibility e 2006 95 EG Low Voltage e 2011 65 EU RoHs Directive The following standards are fulfilled EN 60204 1 VDE 0113 1 Electrical equipment of machines EN 55011 2009 A1 2010 Class B Radio frequency disturbance characteristics EN 55022 2006 A1 2007 Class B Radio Disturbance Characteristics EN 61000 6 3 2007 Emission standard EN 61000 3 2 2006 A1 2009 A2 2009 Net harmonic components EN 61000 3 3 2008 Harmonic current emissions EN 61000 4 2 ESD 4KV Electrostatic discharge EN 61000 4 3 HF radiation 80 1000 MHz 10 V m EN 61000 4 4 Burst 2 KV power line 1 KV signal line data line EN 61000 4 5 Surge 1 KV symmetric 2 KV unsymmetric EN 61000 4 6 HF power input 10V into net signal line data line EN 61000 4 8 Magnetic field 50 Hz 30 A m EN 61000 4 11 Voltage dips and interruptions IEC EN 61000 6 2 2005 Immunity Pleidelsheim 24th June 2014 _ er Er General Manager Manager QA Specification of the control unit PA8000LW_EC_DECLARATION OF CONFORMITY EN REVO2 140624 Power Automation GmbH Phone 49 0 7144 899 0 Registration Banking account CNC Automatisierungstechnik Fax 49 0 7144 89
86. t Write the RMA number on the cardboard box clearly read able from outside The incoming goods department rejects all deliveries without a visible valid RMA number 3 Ship the goods FREE DOMICILE DDU Other deliveries will be rejected The goods have to arrive within 4 weeks after the date of the approved RMA form 9 4 Training Having the best CNCs is one thing to bring out the best of it is the other The PA training program comprises of a number of individually combinable training modules which offer you a well founded knowl edge for using PA CNCs At our training centers we bring your employees beginners and experts up to the scratch in CNC tech nology We also offer individual training courses at your site The contents of the courses will be customized to your requirements Fpr more information see Chapter 9 1 1 Service addresses on page 113 ul 06 02 2015 118 POWER AUTOMATION Dismounting Decommissioning PA 8000 LW CNC control unit Dismounting and decommissioning 10 Dismounting and decommissioning When the control unit has reached the end of its service life it must be dismounted and disposed of in an environmentally responsible manner Personnel Qualified personnel 1 Ensure that the machine connected to the control unit rests in ne 9 gt Gell lw a safe state Disable the external power supply Disconnect the power supply cable Disconnect all input output and inte
87. t re triggered The module is configured and the analog outputs are enabled 06 02 2015 110 PA 8000 LW CNC control unit Troubleshooting 8 3 Troubleshooting chart Notes Malfunctions or errors not listed in this chart require Power Automation to be contacted see Chapter 9 Service and return process on page 113 Do not attempt repairs not described in the troubleshooting chart or the following chapters Attempts at unauthorized repairs void the material warranty Ifin doubt regarding listed repairs contact Power Automation for help Return procedure In the event of an error that requires the control unit to 5 be sent to Power Automation follow the instructions given in amp Chapter 9 3 Return policy and procedure on page 115 General Procedure Personnel m Qualified personnel m Skilled electrician 1 Properly shut down the control unit and the tooling machine Ensure the tooling machine rests in a secured state 2 Ensure the power supply is deactivated and secured against inadvertent reactivation Follow the instructions given in the troubleshooting chart Restart the control unit and the tooling machine after termina tion of the work as described in the respective operating manuals vull 06 02 2015 111 POWER AUTOMATION Troubleshooting Chart No 001 002 003 004 005 Error Unscheduled shutdown Hardware failure Malfunction of the control unit
88. tch off the main power supply of the CNC control unit unit to avoid any unex pected damages to the control unit The contacts for CNC Ready and Power OK are available on connector X19 see Fig 60 vull 06 02 2015 97 POWER AUTOMATION PA 8000 LW CNC control unit BEIEN Schematic Suggested Wiring CNC ON Fig 60 Wiring example power ok relay 1 Connector X19 pin 1 3 Connector X19 pin 3 ul 06 02 2015 98 POWER AUTOMATION Inspection Improper Transport Concerning Packaging Handling Packaging Materials PA 8000 LW CNC control unit Transport packaging and storage 6 Transport packaging and storage 6 1 Transport Check the delivery immediately on receipt for completeness and transport damage Record the extent of transport damage in the transport documents or on the delivery note of the forwarding agent Complaint periods limited Claim any damage as soon as it is detected 5 Compensation claims can only be submitted within the applicable complaint periods CAUTION Improper transport can result in damage Improper transport can cause extensive material damage When unloading the packages upon delivery and during in house transport exercise caution and observe the symbols on the package Do not remove packaging material until control units are ready for assembly 6 2 Packaging The individual packages have been packed to match the transport conditions that
89. tem The module status is displayed via 4 LEDs 06 0 0 0 0 0 90 0e o jojo ojojJo nm un an un oo oo on an 00 un on uu on on un on e ojojo o YA DI 00 00 DI Hun un 00 dn DO OD un on 06 o oj oj o ojo o0 rm gu uu oo oo oo oo oo 10 00 uu Hu oo O0 O0 uuu 0 000 0 0 Illa Fig 17 Overview connectors module 2416 EL Output byte 2 X41 Output byte 1 X40 Status LEDs output byte 2 Status LEDs output byte 1 Power connector 24 V X30 Module status LEDs Status LEDs input byte 2 Status LEDs input byte 1 Status LEDs input byte 3 10 Input byte 2 X46 11 Input byte 1 X45 12 Input byte 3 X47 Qo JO Om P Go bh vull 06 02 2015 39 POWER AUTOMATION Overview PA 8000 LW CNC control unit Design and function 3 4 1 Digital inputs 3 4 1 1 Input interfaces oo 0860009060 0 0 eieiei eoloie D oo un oo oo du dn oo 00 00 00 on on on on on oi oi elei o DI 00 OD DI Hn 00 00 OD oo oo on on 0 0 e e 0 0 0e nu du un on oo on du oo jo om mm em e 0e 0e0 080j 0 0 oo 00 00 070 00 Fig 18 Input bytes 10 Input byte 2 X46 11 Input byte 1 X45 12 Input byte 3 X47 The inputs are grouped in bytes 8 signals ll 06 02 2015 40 POWER AUTOMATION PA 8000 LW CNC control unit Design and function Connection Teele Fr FF nu un on on on on on on Y nr 00 Hn u
90. terface panel Fig 32 13 and only intended for Ethernet connections The other RJ 45 connector Fig 32 9 is located next to the PAMIO superbus connector Inadvertent interchanging of the two connectors can cause control unit malfunctions and damages to the control unit and the attached drives When setting up the wiring carefully observe the connectors positions given in this installation manual as well as the labels on the control unit Property Value Pins 8 Connector type RJ 45 Max length 100 m 328 ft Pin Fig 32 Ethernet 10 100 BaseT 1 TX 2 TX 3 RX 4 5 6 RX 7 8 POWER AUTOMATION 06 02 2015 61 X2 Protective Earth Ground Screw 10 USB 2 0 Connectors 5 6 14 PA 8000 LW CNC control unit Design and function The protective ground screw X2 provides a means to ensure grounding connection of the control unit C 2 N A Fa NS Fig 36 Ground screw Use the ground screw M6 provided with the control unit m Use a wire of 6 mm 10 AWG cross section at minimum For standard conforming distinction use wire sheathed in yellow green The USB ports allow connection of USB peripherals The control unit includes 3 standard USB 2 0 type A ports M nn ID 1 23 4 Fig 37 USB connectors Type A Property Value Pins 4 Connector type USB 2 0 Type A Max length 5 m 16 5 ft Pin Fig 32 Assignment USB 1 VBUS 2 D 3 D 4 GND Shell Shiel
91. ternal electrical devices causing the noise Connect the shields to a PE rail Install noise suppression components for all coils relays valves switching units motor windings other operator display panels and other RF noise producing devices Connect noise suppression components directly at the noise Source If the distance to noise suppression components is several centimeters use twisted pair cables to connect m Make sure that noise suppressing capacitors have a low inductance and a good high frequency conductance Conduct power and signal lines separately in a distance of at least 10 cm amp When using mechanical cable guides install additional metal shields For all electrical installations follow the rules of VDE 0113 5 3 Installing analog axes The following chapters provide instructions and examples for analog axes installation Due to the versatility of the control unit not all possible configuration options can be covered in detail m If in doubt contact Power Automation s customer support For contact information see Chapter 9 Service and return process on page 113 5 3 1 Analog axes wiring example The following schematics demonstrate the recommended way of connecting the CNC analog outputs to the analog inputs of the drives depending on the analog input type of the drive vull 06 02 2015 89 POWER AUTOMATION PA 8000 LW CNC control unit Installation Drives With Non Differential I
92. tton NC Stop Numerical Control Stop Button PA Power Automation PAMIO Power Automation Modular Input Output Extendable Superbus based interface allowing connection of additional UO modules PC Personal Computer PCI Peripheral Component Interconnect Personal computer extension for periphery devices connected to the motherboard PLC Programmable Logic Controller POU Program Organization Unit PLC functions function blocks and programs are POUs RMS Rotating Measuring Systems Encoder ul 06 02 2015 10 POWER AUTOMATION PA 8000 LW CNC control unit 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 W The 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 Throughout the time of use of the control unit the customer must check whether the operating instructions cre
93. ve When changing fuses make sure you use the correct amperage W Keep moisture away from conductive parts This can cause short circuits De energize the machine for all work on the electrical system DANGER Uncontrolled operation due to improper installa tion and configuration The control unit s safety relay must be properly inte grated into the CNC machine emergency stop chain Improper wiring and configuration of the safety relay may result in uncontrolled operation of the CNC machine and in consequence may lead to irreversible personal injuries or death vull 06 02 2015 15 POWER AUTOMATION PA 8000 LW CNC control unit Only operate the CNC machine when the safety relay has been properly integrated into the machine emergency stop chain Only let qualified personnel Chapter 2 2 1 Qualifications on page 12 set up the emergency stop chain For information on safety devices integrated into the machine see the manual supplied by the machine s manufacturer If in doubt regarding the configuration contact the manufac turers of the CNC machine and the control unit WARNING Risk of injury due to improper handling of bat teries Batteries must be handled with special care Do not throw batteries into fire or expose to high temperature Explosion hazard Do not charge batteries Explosion hazard m Battery fluid leaking due to wrong usage may cause skin irrita tion Avoid contact with the batte
94. view The labels listed hereunder are located at the positions shown in Fig 1 Fig 1 Label positions 1 Material Warranty seal 2 Type Plate 3 License Operating system Type Plate The type plate includes the following information Manufacturer address CE sign Control unit model Serial number Article number Connection values Power Automation GmbH Gottlieb Daimler Str 17 2 C D 74385 Pleidelsheim Type pa 8000E LW STD SDI AN SNo oJJMMXXXXX ArtNo oo 100 240V AC Iph 50 60 Hz max 4A Made in Germany Fig 2 Type Plate Example vull 06 02 2015 23 POWER AUTOMATION Operating System Product Key Material Warranty Seals SEAL If this seal is broken you lose your warranty PA 8000 LW CNC control unit The label affixed to the side of the control unit next to the type plate provides the operating system s product key Windows XP Pro for Embedded Systems OEM Software Gl 1 F Product XXXXX XXXXX XXXXXKXXXX XXXXX UELLE TEE HI 79 Fig 3 Windows XP for Embedded Systems operating system license 1 Product key Serial number The material warranty seals affixed to the control unit at various positions ensure that the control unit s casing is not opened by unauthorized persons S Broken or removed seals void all material warranty 3 provided by Power Automation Never open the control unit or you will lose your material w
95. y 50 60 Hz Maximum current at 115 V 4A Maximum current at 230 V 2A Maximum power consumption 180 W NOTICE Damage to the control unit e Supply voltages not supported can cause damage to the control unit ul 06 02 2015 59 POWER AUTOMAT X3 CNC Operator s keyboard 4 Optional PA 8000 LW CNC control unit Design and function The CNC operator s keyboard connector is intended for use with a PA operator s panel with keyboard Alternatively a standard PC keyboard may be connected Supported panels m CP 121 m CP 121 T O50 Fig 34 Connector CNC operator s keyboard Keyboard power supply The listed operator s panels include their own key 5 board controller mounted on the rear side of the panel This keyboard controller requires 12 V power supply Therefore on pin 3 of the CNC keyboard con nector an additional 12 V is supplied unlike on standard keyboard connectors Note that the connector is only compatible with the listed panels Pin Fig 32 Assignment 1 keyboard clock 2 keyboard data 3 12V 4 GND 5 5V ul 06 02 2015 60 Ethernet Connector 13 PA 8000 LW CNC control unit Design and function The Ethernet connector allows connection of the control unit to local area networks all Fig 35 Ethernet connector RJ 45 NOTICE Malfunctions and damage to the control unit The control unit provides two RJ 45 connectors One is located on the PC in

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